ABB ACS 400 User Manual
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ABB ACS 400 User Manual

Frequency converter from 2.2 to 37 kw
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converters from 2.2 to 37 kW

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  • Page 1 User’s Manual for type ACS 400 frequency converters from 2.2 to 37 kW...
  • Page 3 ACS 400 Frequency Converter User’s Manual 3AFY 64036947 R0125 REV A Effective: 25.5.1999 © copyright 1999 ABB Industry Oy.

  • Page 5: Safety

    RO1A, RO1B, RO1C, RO2A, RO2B, RO2C. Warning! Never attempt to repair a broken unit; contact the supplier. Warning! The ACS 400 will start up automatically after an input voltage interruption if the external run command is on.
  • Page 6 Note about compatibility: The supplied ACS 400 frequency converter and this manual are fully compatible with ACS-PAN-A Control Panel revision F and later. If you use a control panel with older revision code, certain new parameter names and alarms will not be displayed properly. In this case, refer to displayed numeric parameter values, parameter numbers and alarm codes instead.

  • Page 7: Table Of Contents

    Motor Overload Protection ......25 Loadability of ACS 400 ....... . 25 Type Series and Technical Data .
  • Page 8 Resetting the Drive from the Control Panel ....38 ACS 400 Basic Parameters ......39 Application Macros .
  • Page 9 ACS 400 Complete Parameter List ......55 Group 99: Start-up Data ....... 63 Group 01: Operating Data .
  • Page 10 Relay Outputs ........148 Adding More I/O to ACS 400 ......148 Setting up NDIO modules .

  • Page 11: Installation

    Unpacking the unit The ACS 400 comes in a box that in addition to the unit itself and this User’s Manual contains Cable Gland Plates, Warning Stickers, an EMC Instruction and a separate Installation Guide. The separate Installation Guide gives a summary of the installation instructions described here.
  • Page 12 TURN the power on. See N Figure 1 Step by step instructions for installing the ACS 400. The references after each step refer to one or more of the Reference Sections on the following pages in this User’s Manual. ACS 400 User’s Manual...

  • Page 13: Reference Sections

    The ACS 400 should be installed in clean air according to IP classification. Cooling air must be clean, free from corrosive materials and electrically conduc- tive dust. In UL installations the ACS 400 should be installed in clean and dry air, free from dripping water. • chemical gases: Class 3C2 Storage •...

  • Page 14: Dimensions (Mm)

    Figure 2 IP 21/NEMA1 enclosures. Table 2 Dimensions of units with IP 21/NEMA1 enclosures. Frame Size, IP 21/NEMA1 * Dimension Reference (mm) Mass (kg) 19.0 28.6 * See paragraph S for frame size assignments for type codes. ACS 400 User’s Manual...
  • Page 15 Figure 3 IP 54/NEMA12 enclosures. Table 3 Dimensions of units with IP 54/NEMA12 enclosures. Frame Size, IP 54/NEMA12 * Dimension Reference (mm) Mass (kg) 11.2 22.3 32.3 See paragraph S for frame size assignments for type codes. ACS 400 User’s Manual...

  • Page 16: Mounting The Acs 400 On The Wall

    Warning! Before installing the ACS 400 ensure the mains supply to the installation is off. Note! ACS 400 can be mounted onto an air duct when flange mounting option set is used. The lid of the packing-box shows the Wall Mounting Template.

  • Page 17: Removing The Cover

    3 Lift the other retaining lever e.g. with a screwdriver. 4 Open the upper part of the front cover and remove it. Figure 9 Opening the frame size R3 and R4 frequency converters of type IP 21 / NEMA1. ACS 400 User’s Manual...
  • Page 18 IP 54 / NEMA12 1 Take the screws off. 2 Remove the front cover. 3 Remove control panel if needed. Figure 10 Opening type IP 54 / NEMA1 frequency converters. ACS 400 User’s Manual...

  • Page 19: Terminal Interface

    The contents of the packing box includes warning stickers in different languages. Attach a warning sticker in the language of your choice to the place on the inside plastic skeleton as indicated above, in section E, ’Terminal Interface’. ACS 400 User’s Manual...

  • Page 20: Type Designation Label And Code Key

    0 = Standard unit x = Panel and manual options Rated Output Power in kVA See ACS 400 rating tables, section S, Table 11 Voltage Rating 1 = 200 ... 240 V AC 3 = 380 ... 480 V AC...

  • Page 21: Motor

    (See G and R). 2NSQ Warning! Ensure the motor is suitable for use with the ACS 400. The ACS 400 must be installed by a competent person. If in doubt, contact your supplier. I Floating Network Make sure that no excessive emission is propagated to neighbouring low voltage networks.

  • Page 22: Cable Connections

    IP 21 Units A package, containing three screws and two gland plates, is included with type IP 21 (NEMA1) ACS 400 frequency converters. Figure 17 Gland plate for power cables (A) and for control cables (B), type IP 21 / NEMA1 frequency converters.
  • Page 23 8F 8F 8 9 : M A I N S M O T O R Figure 19 Motor cable connection for frame sizes R1 and R2 (IP 21 / NEMA1). Note! See ACS 400 EMC instructions. ACS 400 User’s Manual...
  • Page 24 Figure 20 Motor cable connection for frame sizes R3 and R4 (IP 21 / NEMA1). ACS 400 User’s Manual...
  • Page 25 The gland plate for control cables (B), see Figure 17. Figure 21 Fixing the gland plate for control cables (B), type IP 21 / NEMA1 frequency converters. Control cables Figure 22 Control cable connections (IP 21 / NEMA1). Note! See ACS 400 EMC instructions. ACS 400 User’s Manual...
  • Page 26 A package, containing five screws and two gland plates, is included with the type IP 54 (NEMA12) ACS 400 frequency converters. Figure 23 Gland plate for power cables (A) and for control cables (B), type IP 54 / NEMA 12 frequency converters.
  • Page 27 8F 8F 8 9 : M A I N S M O T O R Figure 25 Motor cable connection for frame sizes R1 and R2 (IP 54 / NEMA12). Note! See ACS 400 EMC instructions. ACS 400 User’s Manual...
  • Page 28 Figure 26 Motor cable connection for frame sizes R3 and R4 (IP 54 / NEMA12). Note! See ACS 400 EMC instructions. Figure 27 Fixing the gland plate for control cables (B), type IP 54 / NEMA12 frequency converters. ACS 400 User’s Manual...
  • Page 29 Figure 28 Control cable connections (IP 54 / NEMA12). Note! See ACS 400 EMC instructions. ACS 400 User’s Manual...

  • Page 30: Control Terminals

    ≥+10 V (or ≤-10 V) between that input and DCOM1. The 24 V may be provided by the ACS 400 (X1:9) as in the connection examples (see L) or by an external 12 - 24 V source of either polarity.
  • Page 31 3. AI1 = I 0(4) - 20 mA $, $, AI2 = I 0(4) - 20 mA RS485 terminal X3 Table 7 Signal termination is selected Description by jumper J2. ST#'$Ãv‡r…s Screen I‚‡ Ur…€v ‡r…€v AGND 2ƒr Screen 2Ãpy‚†rq ACS 400 User’s Manual...

  • Page 32: Connection Examples

    RO2C RO2C RO2A RO2A RO2B RO2B Figure 29 I/O examples. ACS 400 Other Modbus devices 6&5 6&5 ST#'$Ãv‡r…s WHUPLQ $*1' 6&5 Signal termination is selected by jumper J2 6&5 not terminated. Figure 30 RS485 Multidrop application. ACS 400 User’s Manual...

  • Page 33: Replacing The Cover

    3. Tighten the screws (max. torque 1.5 Nm). N Power On When power is supplied to the ACS 400, the green LED comes on. Note! Only three power-ups in five minutes are allowed. Note! Before increasing motor speed, check that the motor is running in desired direction.

  • Page 34: Protection Features

    Note! Whenever the ACS 400 detects a fault condition, the fault relay activates. The motor stops and the ACS 400 will wait to be reset. If the fault still persists and no external cause has been identified, contact your ACS 400 supplier.

  • Page 35: Motor Overload Protection

    Output frequency 35 Hz Figure 31 R Loadability of ACS 400 In the event of an output overload, the ACS 400 will first show an alarm and then trip. duty cycle = t/T < 10 min time Constant torque rating Ambient temperature, θ...

  • Page 36: Type Series And Technical Data

    * Power stages are designed for the continuous I current. These values are valid when the 2NSQ altitude is less than 1000 m ASL. See Q. ** Low noise setting only available with optional control panel. Derate P and I to 80%. ACS 400 User’s Manual...

  • Page 37: Product Conformity

    Note! The output contactor can be used only as a safety device. Do not close the contactor when the ACS 400 is running. ACS 400 is suitable for use in a circuit capable of delivering not more than 65 kA rms symmetrical amperes, 480 V maximum.

  • Page 38: Accessories

    ACS 400-PAN-A Control panel for use with the ACS 400. ACS 100-PAN Control panel for use with the ACS 100 / ACS 140 / ACS 400. PEC-98-0008 Panel Extension Cable kit for use with the ACS 100 / ACS 140 / ACS 400.

  • Page 39: Programming

    Control Modes The very first time the drive is powered up, it is controlled from the Control Terminal Block X1 (remote control, REM). The ACS 400 is controlled from the control panel when the drive is in local control (LOC).

  • Page 40: Output Display

    The frequency reference can be modified using UP/DOWN buttons when it is underlined. Pressing UP or DOWN buttons changes the output immediately. The reference can be modified in local control mode, but also in remote control mode if the ACS 400 is parameterised in such a way.

  • Page 41: Setting Parameter Value

    MENU Note! In the parameter set mode the cursor blinks, when the parameter value is altered. Note! To view the parameter default value in the parameter set mode, press the UP/DOWN buttons simultaneously. ACS 400 User’s Manual...

  • Page 42: Menu Functions

    Normally only the basic parameters are visible. When full Menu is active, an asterisk appears on the second row of the panel display in Menu. Activate this function again to resume the short Menu. Press & hold FULL/SHORT MENU FULL/SHORT MENU ENTER MENU MENU Visible if full menu is active. ACS 400 User’s Manual...

  • Page 43: Led Indicators

    Red LED Green LED Power ON and drive is operating normally. BLINKS Alarm is active. Fault is active. Drive can be reset from the control panel. BLINKS Fault is active. Turn power off to reset the drive. ACS 400 User’s Manual...

  • Page 44: Diagnostic Displays

    Contrast Setting Display contrast can be adjusted any time. Increase contrast by pressing and holding ENTER and UP buttons. Decrease contrast by pressing and holding ENTER and DOWN buttons. The buttons must be pressed down simultaneously. ACS 400 User’s Manual...

  • Page 45: Acs100-Pan Control Panel

    The very first time the drive is powered up, it is controlled from the Control Terminals (remote control, REM). The ACS 400 is controlled from the control panel when the drive is in local control (LOC). Switch to local control (LOC) by pressing and holding the MENU and ENTER buttons down simultaneously until first Loc or later LCr is displayed: •...

  • Page 46: Output Display

    OUTPUT (17(5 OUTPUT Menu 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. OUTPUT display Parameter groups...

  • Page 47: Menu Functions

    Scroll the Parameter groups for the desired menu function. Press and hold ENTER until the display blinks to start the function. Note! ACS100-PAN upload and download functions are not operational with ACS 400. The relatively small permanent memory of the ACS100-PAN cannot store all the ACS 400 parameter values.

  • Page 48: Diagnostic Displays

    Diagnostic Displays When the red LED of the ACS 400 is on or blinking, a fault is active. The relevant fault message flashes in the panel display. When the green LED of the ACS 400 is blinking, an alarm is active. The relevant alarm message is shown in the panel display.

  • Page 49: Acs 400 Basic Parameters

    ACS 400 Basic Parameters ACS 400 has a large number of parameters. Of these, only the so called basic parameters are initially visible. Setting up only a few basic parameters is sufficient in applications where the preprogrammed application macros of the ACS 400 can provide all desired functionality. For a full description of programmable features provided by the ACS 400, see “ACS 400 Complete Parameter List”, starting...
  • Page 50 ) depending on the selected application macro. REQUEST FORWARD Group 11 REFERENCE SELECT 1105 EXT REF1 MAX Maximum frequency reference in Hz. Range: 0 - 250 Hz Default value: 50 Hz or 52 Hz depending on the selected application macro. ACS 400 User’s Manual...
  • Page 51 Note! Analogue output content is programmable. Values given here are valid only if other analogue output configuration parameters have not been modified. Description of all parameters is given in “ACS 400 Complete Parameter List” starting on page 55. Group 20...
  • Page 52 Default value: 1 ( LINEAR Group 33 INFORMATION 3301 SW VERSION Software version code. S = Parameters can be modified only when the drive is stopped. ACS 400 User’s Manual...

  • Page 53: Application Macros

    Default values of certain parameters depend on the selected macro. These are listed with the description of each macro. Default values for other parameters are given in “ACS 400 Complete Parameter List” starting on page 55.

  • Page 54: Application Macro Factory (0)

    Default: Running =>20 connected to 22 RO2B *Note! DI 4 is used to configure ACS 400. It is read only once when power is connected. All parameters marked with * are determined by the DI4 input. Factory (0) parameter values:...

  • Page 55: Application Macro Factory (1)

    Default: Running => 20 connected to 22 RO2B *Note! DI 4 is used to configure ACS 400. It is read only once when power is connected. All parameters marked with * are determined by the DI4 input. Note! Deactivation of stop signal interlocks panel START/STOP button in local control mode.

  • Page 56: Application Macro Abb Standard

    50 Hz 2105 EXT REF PREMAGN SEL NOT SEL 1106 2201 5 (DI5) EXT REF SELECT KEYPAD 1201 3,4) 4001 CONST SPEED SEL PID GAIN 1401 (-1)) 4002 60 s RELAY OUTPUT FAULT PID INTEG TIME ACS 400 User’s Manual...

  • Page 57: Application Macro 3-Wire

    50 Hz 2105 EXT REF PREMAGN SEL NOT SEL 1106 2201 EXT REF SELECT KEYPAD NOT SEL 1201 4,5) 4001 CONST SPEED SEL PID GAIN 1401 (-1)) 4002 60 s RELAY OUTPUT FAULT PID INTEG TIME ACS 400 User’s Manual...

  • Page 58: Application Macro Alternate

    MAXIMUM FREQ 1105 50 Hz 2105 EXT REF PREMAGN SEL NOT SEL 1106 2201 EXT REF SELECT KEYPAD 1201 3,4) 4001 CONST SPEED SEL PID GAIN 1401 (-1)) 4002 60 s RELAY OUTPUT FAULT PID INTEG TIME ACS 400 User’s Manual...

  • Page 59: Application Macro Motor Potentiometer

    1105 50 Hz 2105 EXT REF PREMAGN SEL NOT SEL 1106 2201 EXT REF SELECT KEYPAD NOT SEL 1201 4001 CONST SPEED SEL PID GAIN 1401 (-1)) 4002 60 s RELAY OUTPUT FAULT PID INTEG TIME ACS 400 User’s Manual...

  • Page 60: Application Macro Hand - Auto

    Output frequency 0...20 mA <=> 0...50 Hz AGND +24 VDC +24V DCOM1 Start/Stop: Activate to start ACS 400 (Hand). Forward/Reverse: Activate to reverse rotation direction (Hand) EXT1/EXT2 Selection: Activate to select auto control Forward/Reverse (Auto) Start/Stop: Activate to start ACS 400 (Auto)

  • Page 61: Application Macro Pid Control

    AGND +24 VDC +24V DCOM1 Start/Stop: Activate to start ACS 400 (Manual). EXT1/EXT2 Selection: Activate to select PID control Constant speed 1: not used if PID control* Run enable: deactivation always stops ACS 400 Start/Stop: Activate to start ACS 400 (PID)

  • Page 62: Application Macro Premagnetise

    AGND Output frequency 0...20 mA <=> 0...50 Hz AGND +24 VDC +24V DCOM1 Start/Stop: Active to start ACS 400 Fwd/Rev: Activate to reverse rotation Constant Speed selection* Constant Speed selection* Premagnetise: Activate to start premagnetising DCOM2 Relay output 1, programmable...

  • Page 63: Application Macro Pfc Control

    AGND +24 VDC +24V DCOM1 Start/Stop: Activate to start ACS 400. Run enable: Deactivation always stops ACS 400 EXT1/EXT2 Selection: Activate to select PFC control Interlock: Deactivation stops ACS 400 Interlock: Deactivation stops constant speed motor DCOM2 Relay output 1, programmable...
  • Page 64 ACS 400 User’s Manual...

  • Page 65: Acs 400 Complete Parameter List

    ACS 400 Complete Parameter List Initially, only the so called basic parameters (shaded grey in Table 12) are visible. Use the appropriate menu function of the control panel to make the full parameter set visible. S = Parameters can be modified only when the drive is stopped.
  • Page 66 ANALOGUE INPUTS 1301 0 - 100 % MINIMUM AI 1302 0 - 100 % 100 % MAXIMUM AI 1303 0 - 10 s 0.1 s 0.1 s FILTER AI 1304 0 - 100 % MINIMUM AI ACS 400 User’s Manual...
  • Page 67 0 - 250 s 0.1 s STOP DC INJ TIME á á 2105 0 - 6 PREMAGN SEL 2106 0.0 - 25.0 s 0.1 s 2.0 s PREMAGN MAX TIME 2107 0 - 1 START INHIBIT ACS 400 User’s Manual...
  • Page 68 0.5 - 50 Hz 0.1 Hz 20 Hz STALL FREQ HI 3012 10...400 s 20 s STALL TIME 3013 0 - 2 UNDERLOAD FUNC NOT SEL 3014 10...400 s 20 s UNDERLOAD TIME 3015 1 - 5 UNDERLOAD CURVE ACS 400 User’s Manual...
  • Page 69 3407 102 - 137 P VAR 3408 1 - 9999 P VAR MULTIP 3409 1 - 9999 P VAR DIVISOR 3410 0 - 3 P VAR SCALING 3411 0 - 31 3 (Hz) P VAR UNIT ACS 400 User’s Manual...
  • Page 70 100 % MAXIMUM 4111 0 - 1000 % MINIMUM 4112 0 - 1000 % 100 % MAXIMUM 4119 1 - 2 SET POINT SEL EXTERNAL 4120 0.0 - 100.0 % 0.1 % 40.0 % INTERNAL SETPNT ACS 400 User’s Manual...
  • Page 71 AUX MOT STOP D 8117 0 - 3 NR OF AUX MOT 8118 0.0 - 336 h 0.1 h 0.0 h ( AUTOCHNG INTERV NOT SEL 8119 0.0 - 100.0 % 0.1 % 50 % AUTOCHNG LEVEL ACS 400 User’s Manual...
  • Page 72 8121 0 - 1 REG BYPASS CTRL 8122 0 - 10 s 0.01 s 0.5 s PFC START DELAY * The maximum factor depending on the type of the frequency converter at 4 kHz switching frequency. ACS 400 User’s Manual...

  • Page 73: Group 99: Start-Up Data

    Group 99: Start-up Data The Start-up Data parameters are a special set of parameters for setting up the ACS 400 and for entering motor information. Code Description 9901 LANGUAGE Language selection for the ACS-PAN-A control panel. 12 = (reserved) ENGLISH...

  • Page 74: Group 01: Operating Data

    See “Appendix A”, starting page 141 , for description of different control locations. 0114 RUN TIME (R) Shows the total running time of the ACS 400 in hours (h). Can be reset by pressing UP and DOWN buttons simultaneously when in parameter set mode. 0115 kWh COUNTER (R) Shows the counted the kilowatt hours of ACS 400 in operation.
  • Page 75 0135 PROCESS VAR 2 Process variable 2, as selected by the parameters in group 34. 0136 RUN TIME Shows the total running time of ACS 400 in thousands of hours (kh). 0137 MWh COUNTER Counts the megawatt hours of ACS 400 in operation.

  • Page 76: Group 10: Command Inputs

    *Note! In cases 1, 3, 6 direction is set with parameter 1003 . Selecting value 3 ( ) fixes DIRECTION REQUEST direction to Forward. **Note! Stop signal must be activated before Start command can be given. ACS 400 User’s Manual...
  • Page 77 Rotation direction lock. This parameter allows you to fix the direction of rotation of the motor to forward or reverse. If you select 3 ( ), the direction is set according to the given direction command. REQUEST ACS 400 User’s Manual...

  • Page 78: Group 11: Reference Select

    External control location 2 ( 2) is selected. The control signal sources for 2 are defined with parameter 1002 (Start/Stop/Direction commands) and parameter 1106 (reference). COMM External control location 1 or 2 is chosen through serial communication. ACS 400 User’s Manual...
  • Page 79 Minimum reference for joystick should be 0.3 V (0.6 mA) or higher. If a 0 ... 10 V signal is used, the ACS 400 will operate at maximum reference in the reverse direction if the control signal is lost. Set parameter 1301 AI1 to a value 3 % (corresponding 0.3 V) or higher, and parameter 3001...
  • Page 80 • If the PID Control or PFC macro is selected, this parameter sets the maximum process reference. • If any other macro than PID Control is selected, this parameter sets the maximum frequency reference. This value is given as percentage of maximum frequency. ACS 400 User’s Manual...
  • Page 81 AI max Figure 38 Setting . The range of the analogue input signal is EXT REF MINIMUM EXT REF MAXIMUM set by parameters 1301 and 1302 or parameters 1304 and 1305, depending on the analogue input used. ACS 400 User’s Manual...

  • Page 82: Group 12: Constant Speeds

    Group 12: Constant Speeds The ACS 400 has 7 programmable constant speeds, ranging from 0 to 250 Hz. Negative speed values cannot be given for constant speeds. Constant speed selections are ignored if the process PID reference is followed, the drive is in local control mode or PFC (Pump-Fan Control) is active.

  • Page 83: Group 13: Analogue Inputs

    = 4 mA / 20 mA * 100% = 20%. Note! In addition to this parameter setting, the analog input must be configured for 0-20 mA current signal. Refer to section “Connection Examples” on page 22. ACS 400 User’s Manual...

  • Page 84: Group 14: Relay Outputs

    Relay is not used and is de-energised. READY The ACS 400 is ready to function. The relay is energised unless no run enable signal is present or a fault exists and supply voltage is within range. Relay energised when the ACS 400 is running.
  • Page 85 Code Description 21 = ACS OVERLOAD Relay is energised when ACS 400 overload alarm or fault exists. 22 = UNDERVOLTAGE Relay is energised when undervoltage alarm or fault exists. 23 = AI1 LOSS Relay is energised when AI1 signal is lost.

  • Page 86: Group 15: Analogue Output

    Minimum output current. 1505 MAXIMUM AO Maximum output current. 1506 AO FILTER Filter time constant for AO. AO (mA) 1505 1504 AO content 1503 1502 AO (mA) 1505 1504 AO content 1503 1502 Figure 41 Analogue output scaling. ACS 400 User’s Manual...

  • Page 87: Group 16: System Controls

    1...5 = DI1 ... DI5 To activate the run enable signal, the selected digital input must be activated. If the voltage drops and deactivates the selected digital input, the ACS 400 will coast to stop and not start until the run enable signal resumes.
  • Page 88 Note! Parameter modifications done from the control panel are normally stored immediately to permanent memory. However, if 1602 PARAMETER LOCK is set to 2 ( ), modifications done from the control NOT SAVED panel are saved only if this parameter 1607 is used. ACS 400 User’s Manual...

  • Page 89: Group 20: Limits

    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 preventing an undervoltage trip. This will increase power loss ride-through on systems with a high inertia, such as a centrifuge or fan.

  • Page 90: Group 21: Start/Stop

    Group 21: Start/Stop ACS 400 supports several start and stop modes, including flying start and torque boosting at start. DC current can be injected either before the start command (premagnetising) or automatically right after the start command (starting with DC hold).
  • Page 91 Start inhibit control enabled. Drive will not start after fault is reset, Run Enable is activated or mode is changed. In order to start the drive again, give start command anew. ACS 400 User’s Manual...

  • Page 92: Group 22: Accel/Decel

    MAXIMUM FREQ 2206 RAMP SHAPE Acceleration/deceleration ramp shape selection LINEAR FAST S CURVE MEDIUM S CRV SLOW S CURVE Output frequency MAXIMUM FREQ Linear S curve Time Ramp time Figure 42 Definition of acceleration/deceleration ramp time. ACS 400 User’s Manual...

  • Page 93: Group 25: Critical Freq

    Group 25: Critical Freq In some mechanical systems, certain speed ranges can cause resonance problems. With this parameter group, it is possible to set up to two different speed ranges that the ACS 400 will skip over. Code Description 2501 CRIT FREQ SEL Critical frequencies activation.

  • Page 94: Group 26: Motor Control

    Standard (switching frequency 4 kHz). Low noise (switching frequency 8 kHz). at 30 °C ambient Note! When the low noise setting is used, the maximum loadability of the ACS 400 is I at 40 °C. temperature or 0.8 * I 2606 U/f RATIO U/f ratio below field weakening point.

  • Page 95: Group 30: Fault Functions

    CONST SPEED LAST SPEED A warning indication is displayed and the speed is set to the level the ACS 400 was last operating at. This value is determined by the average speed over the last 10 seconds. Caution: If you select...
  • Page 96 FAULT Displays a warning indication at the warning level (95 % of the nominal value). Displays a fault indication when the motor temperature reaches the 100 % level. The ACS 400 coasts to stop. WARNING A warning indication is displayed when the motor temperature reaches the warning level (95 % of the nominal value).
  • Page 97 NOT SEL Stall protection is not used. FAULT When the protection is activated the ACS 400 coasts to stop. Fault indication is displayed. WARNING A warning indication is displayed. The indication disappears in half the time set by parameter 3012...
  • Page 98 3007 have default values. CURVE ZERO SPEED LOAD 70 % 50 % 30 % 2.4 * ƒ ƒ ƒ Figure 49 Underload curve types. T nominal torque of the motor, nominal frequency of the motor. ACS 400 User’s Manual...

  • Page 99: Group 31: Automatic Reset

    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...

  • Page 100: Group 32: Supervision

    1 (1402 RELAY OUTPUT RELAY OUTPUT value is SUPRV OVER SUPRV OVER B = Parameter 1401 1 (1402 RELAY OUTPUT RELAY OUTPUT value is SUPRV UNDER SUPRV UNDER Figure 51 Operating data supervision using relay outputs. ACS 400 User’s Manual...

  • Page 101: Group 33: Information

    Group 33: Information Code Description 3301 SW VERSION Software version. 3302 TEST DATE Displays the test date of the ACS 400 (yy.ww). ACS 400 User’s Manual...

  • Page 102: Group 34: Process Variables

    18 = MWh 22 = bar 26 = CFM 30 = FPM 3 = Hz 7 = rpm 11 = mA 15 = kWh 19 = m/s 23 = kPa 27 = ft 31 = Cst ACS 400 User’s Manual...
  • Page 103 = 1000 P VAR DIVISOR Since variable 0103 is displayed with 0.1 Hz resolution, it is internally scaled so that OUTPUT FREQ value 10 represents 1 Hz. Therefore 3405 = 1 must be selected. P VAR SCALING ACS 400 User’s Manual...

  • Page 104: Group 40: Pid Control

    Group 40: PID Control The PID Control Macro allows the ACS 400 to take a reference signal (setpoint) and an actual signal (feedback), and automatically adjust the speed of the drive to match the actual signal to the reference. There exist two PID parameter sets (group 40 for set 1 parameters and group 41 for set 2 parameters).
  • Page 105 Greater of actual values 1 and 2. 8 = sqrt (A1-A2) Square root of difference of actual values 1 and 2. 9 = sqA1 + sqA2 Sum of square roots of actual values 1 and 2. ACS 400 User’s Manual...
  • Page 106 Analogue input signal AI min AI max Figure 54 Actual value scaling. The range of the analogue input signal is set by parameters 1301 and 1302 or parameters 1304 and 1305, depending on the analogue input used. ACS 400 User’s Manual...
  • Page 107 Code Description 4013 PID SLEEP DELAY Time delay for the sleep function, see Figure 55. If the ACS 400 output frequency is below a set level (parameter 4014 ) longer than , ACS 400 is stopped. SLEEP LEVEL PID SLEEP DELAY Alarm 28 is displayed when PID sleep is active.
  • Page 108 PID input (Process actual value) WAKE UP DELAY parameter 4017 Wake-up level Time PID Output (Output frequency) , parameter 4013 SLEEP DELAY t < t SLEEP LEVEL parameter 4014 Time STOP START Figure 55 Sleep function operation. ACS 400 User’s Manual...

  • Page 109: Group 41: Pid Control (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 ACS 400 User’s Manual...

  • Page 110: Group 50: Communication

    CONST SPEED LAST SPEED A warning indication is displayed and the speed is set to the level the ACS 400 was last operating at. This value is determined by the average speed over the last 10 seconds. Caution: If you select...
  • Page 111 Sets the operation mode of the DDCS link. FIELDBUS Fieldbus adapter is used in DDCS link. (The ACS 400 acts as the slave station on the DDCS link). IO EXTENSION Input/output extension module (type name NDIO) is used on DDCS link. The ACS 400 acts as the master station on the DDCS link, and is capable to control the digital inputs and outputs of the extension module.

  • Page 112: Group 51: Ext Comm Module

    NPBA Profibus NMBA Modbus NIBA Interbus-S NCSA CS31 bus NCAN CANopen NDNA DeviceNet NLON LONWORKS NMBP Modbus+ Others 5102 - FIELDBUSPAR 2 - FIELDBUSPAR 15 5115 Refer to communication module documentation for more information on these parameters. ACS 400 User’s Manual...

  • Page 113: Group 52: Standard Modbus

    5208 BUFFER OVERRUNS Longest possible message length for the ACS 400 is 32 bytes. If a message exceeding 32 bytes is received, this diagnostic counter increases by one every time a character which cannot be placed in the buffer is received.
  • Page 114 • CRC calculation is not performed correctly. 5212 BUSY ERRORS This diagnostic counter increases by one every time the ACS 400 receives a character from the bus while it is still processing the previous message. • There might be two stations with the same station number.

  • Page 115: Group 81: Pfc Control

    Sets a percentage value that is added to the process reference when at least one auxiliary (constant speed) motor is running. Default value is 0 %. Example: An ACS 400 operates three parallel pumps that pump water to a pipe. The pressure in the pipe is controlled. The constant pressure reference is set by parameter 4020 INTERNAL SETPNT At low water consumption level only the speed regulated pump is run.
  • Page 116 Code Description 8113 LOW FREQ 2 Sets a frequency limit (see Figure 56). When ACS 400 output frequency falls below value (8113 LOW FREQ - 1 Hz) and two auxiliary motors are running, the Stop Delay counter is started. When the time set with parameter 8116 .
  • Page 117 ACS 400. ACS 400 relay outputs RO1 and RO2 can be used to control the motors. It is also possible to use up to two optional external digital input/output modules (NDIO).
  • Page 118 The purpose of the Autochange operation is to ensure equal duty time for all the motors. Each motor in the system will in its turn be connected to the ACS 400 as well as direct on line. Starting order of the motors is changed when Autochange is done.
  • Page 119 DI1: free DI2: Motor 1 DI3: Motor 2 DI4-DI5 free DI1: free DI2: Motor 1 DI3: Motor 2 DI4: Motor 3 DI5: free DI1: free DI2: Motor 1 DI3: Motor 2 DI4: Motor 3 DI5: Motor 4 ACS 400 User’s Manual...
  • Page 120 DI1-DI3: free DI4: Motor 1 DI5: Motor 2 DI1-DI3: free DI1: Motor 3 DI4: Motor 1 DI2: unused DI5: Motor 2 DI1-DI3: free DI1: Motor 3 Not used DI4: Motor 1 DI2: Motor 4 DI5: Motor 2 ACS 400 User’s Manual...
  • Page 121 Interlock signals are active low, i.e. interlock is active when corresponding interlock signal is absent. If start command is given when the interlock signal of the speed regulated motor is active, the ACS 400 will not start, and will show alarm 30 (INTERLOCK) on the control panel.
  • Page 122 Code Description ACS 400 ~230 V a.c. ~230 V a.c. On/Off On/Off K2.1 Figure 58 Wiring the interlocks of a PFC system with two motors. There is a thermal relay in the supply circuit of M2. ACS 400 User’s Manual...
  • Page 123 No auxiliary motors running b: One auxiliary motor running c: Two auxiliary motors running Figure 60 The relation between the control signal and the frequency of the controlled motor in a three- motor system. ACS 400 User’s Manual...
  • Page 124 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 and then back to delta-connection before the ACS 400 inverter starts switching.

  • Page 125: Standard Serial Communication

    Channel 1 is the standard Modbus fieldbus connection. Communication settings of Channel 1 can be configured by the user. To control the ACS 400 via Modbus, ACS 400 must be parameterised to accept control commands and/or frequency references from Channel 1. Channel 0 is reserved for drive control panels ACS-PAN and ACS100-PAN, and for the Drive Window PC tool.
  • Page 126 Data Flow Fieldbus Master (PLC) Fieldbus Figure 62 Structure of a fieldbus system. ACS 400 User’s Manual...

  • Page 127: Earthing And Termination

    The termination should not be done on the intermediate stations on the network as shown in Figure 63 . Terminated Terminated Figure 63 Termination for the RS485 link. The connections may only be made with the drive disconnected from the power source. ACS 400 User’s Manual...

  • Page 128: Activating Modbus Protocol

    PROTOCOL SEL STD MODBUS After this single modification, the ACS 400 is ready to communicate via Channel 1 using the default communication settings (given in Table 18), making parameter read and write possible. Following sections describe how to configure the ACS 400 for more sophisticated communication and control.

  • Page 129: Communication Settings

    COMMUNICATION and 52 STANDARD MODBUS. Default communication settings for Channel 1 are listed in Table 18. To be able to communicate with the master device, the ACS 400 must use the same communication speed and parity settings as the master.

  • Page 130: Control Locations

    The ACS 400 drive can receive control information from multiple sources, including digital I/O, analogue I/O, keypad, and Modbus fieldbus. To control the ACS 400 via the serial communication channel 1 (Modbus fieldbus), it must be parameterised to accept control commands and/or frequency references from this channel. In addition, ACS 400 must be in remote control.

  • Page 131: Output Signal Source Selection

    It is possible to control both the relay outputs 1 and 2, as well as the analogue output from the serial communication channel 1. Relay outputs can be controlled in the following way: Step 1: Configure the ACS 400 to supervise the value of any of the parameters 131-133 using parameters in group 32 SUPERVISION Step 2: Configure a relay output 1 or 2 to respond to the status of one of the supervised parameters.
  • Page 132 102 - 137 e.g. 133 Directs the contents of parameter 133 to AO CONTENT the analogue output. 1503 Analogue output scaling: upper limit (20 AO CONTENT MAX mA) reached when value 255 written to parameter 133. ACS 400 User’s Manual...

  • Page 133: Diagnostic Counters

    0 - 65535 PARITY ERRORS 5211 0 - 65535 CRC ERRORS 5212 0 - 65535 BUSY ERRORS 5213 0 - 3 SER FAULT MEM 5214 0 - 3 SER FAULT MEM 0 - 3 5215 SER FAULT MEM ACS 400 User’s Manual...

  • Page 134: Communication

    Typical physical interface is RS485. Modbus is designed for integration with Modicon PLCs or other automation devices, and the services closely correspond to the PLC architecture. The ACS 400 drive ‘looks like’ a Modicon PLC on the network. If detailed information regarding the Modicon Modbus protocol is required, contact your ABB supplier for a copy of Modbus Protocol Guide.

  • Page 135: Register 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. ACS 400 User’s Manual...

  • Page 136: Exception Codes

    ACS 400: Parameter write not allowed when factory macro is selected Function Codes The ACS 400 supports the Modbus function codes given in Table 26. If any other function codes are used ACS 400 returns an exception response with error code 01 (illegal function). Table 26 Function codes.

  • Page 137: The Control Word And The Status Word

    Note! Operation of Control Word and Status Word conforms to ABB Drives Profile with the exception of Control Word bit #10 (REMOTE_CMD), which is not used by the ACS 400. Table 27 The Control Word. See also the state machine on page 132.
  • Page 138 This example assumes that the ACS 400 is in remote control, that external control place 1 (EXT1) is the active control place (as selected by parameter 1102), and that EXT1 start and stop commands are received through serial communication (parameter 1001).
  • Page 139 The value of first supervised parameter is below supervision limit External control location 2 ( 2) selected External control location 1 ( 1) selected Run Enable signal received No Run Enable signal received 13 to Unused ACS 400 User’s Manual...

  • Page 140: References

    Reference 1 Holding Register: 40002 Reference 1 can be used as the frequency reference 1 for the ACS 400. The signal source of external reference 1 ( 1) must be set to and external control location 1 (...

  • Page 141: Actual Values

    16-bit words containing sign bit and a 15-bit integer. A negative value is given as two’s complement of the corresponding positive value. Actual Value 1 Holding Register: 40005 Actual output frequency. Scaling: 5000 50 Hz. Actual Value 2 Holding Register: 40006 Actual output current. Scaling: 10 1 A. ACS 400 User’s Manual...
  • Page 142 (e.g. digital input). State I = Output current CW = Control Word f = Output frequency SW = Status Word RFG = Ramp Function Generator Figure 64 The state machine for evaluation of start and stop signals. ACS 400 User’s Manual...

  • Page 143: Fault And Alarm Status

    Fault and Alarm Status The ACS 400 provides fault and alarm status words for the external control system. These data words are accessible only through the serial communication link but not from the control panel. Fault and alarm status words are located in parameter group 3. The group also contains copies of the Control Word and Status Word.
  • Page 144 Direction lock alarm PFC autochange alarm Serial communication loss PFC interlock alarm Modbus exception Reserved Analogue input 1 loss Analogue input 2 loss Panel loss ACS 400 overtemperature Motor overtemperature Underload Motor stall alarm DDCS link Reserved Reserved ACS 400 User’s Manual...

  • Page 145: Diagnostics

    The ACS 400 can be configured to automatically reset certain faults. Refer to parameter group 31 AUTOMATIC RESET. Warning! If an external source for start command is selected and it is active, the ACS 400 may start immediately after fault reset.
  • Page 146 Exception response is sent through Standard Modbus channel. The bus master MODBUS EXCEPTION may be sending queries which cannot be processed by the ACS 400. Refer to “Standard Serial Communication” section. Last three exception response codes are stored into parameters 5213 - 5215.
  • Page 147 OUTPUT OVERLOAD given on page 25 of this manual. 27 * ACS 400 is about to perform automatic fault reset operation. As a result, the AUTOMATIC RESET drive may start after the reset operation. Refer to parameter group 31 AUTOMATIC RESET.
  • Page 148 DECELER 1 and 2205 TIME DECELER TIME • Brake chopper (if present) may be underdimensioned ACS 400 heat sink temperature is excessive. Temperature trip limit is OVERTEMP 95 °C. • Check air flow and fan operation. • Check motor power against unit power.
  • Page 149 Serial link failure. Bad connection between the control panel and the “COMM LOSS” (ACS-PAN) ACS 400. ** Note! These faults are indicated by a red blinking LED and are reset by turning the power off for a while. ACS 400 User’s Manual...
  • Page 150 ACS 400 User’s Manual...

  • Page 151: Appendix A

    1 (Hz) or KEYPAD REF SEL 2 (%). If 1 (Hz) is selected, the type of reference is frequency and it is given to the ACS 400 in Hz. If 2 (%) is selected, the reference is given in per cent.

  • Page 152: Remote Control

    Remote Control When the ACS 400 is in remote control (REM), the commands are given primarily through digital and analogue inputs, although commands can be given also through the control panel or serial communication. Parameter 1102 selects between the two external control locations...

  • Page 153: Internal Signal Connections For The Macros

    REQUEST DI1-DI5 Direction Remote FORWARD NOT SEL KEYPAD DI1-DI5 REVERSE Enabled, KEYPAD DI1-DI5 RUN ENABLE DIRECTION COMMANDS COMMANDS 1601 1003 1001 1002 Figure 67 The control signal connections of the ABB Standard, Alternate and Premagnetise macros. ACS 400 User’s Manual...
  • Page 154 Loc/Rem Start/Stop, Direction Start/Stop NOT SEL Local REQUEST Remote Direction KEYPAD FORWARD NOT SEL REVERSE KEYPAD RUN ENABLE DIRECTION 1601 COMMANDS COMMANDS 1003 1001 1002 Figure 68 The control signal connections of the PID Control macro. ACS 400 User’s Manual...

  • Page 155: Acs 400 Pump And Fan Control (Pfc) Macro

    The control principle of a two-pump station is as follows: • The motor of the pump no. 1 is connected to the ACS 400. The capacity of the pump is controlled by varying the motor speed.
  • Page 156 Process Act. Value Process Ref. Value +24 V supply DI5 (Interlock 2) DI4 (Interlock 1) ~230VAC ~230VAC Pump 1 On/Off Pump 2 On/Off Alternation Switchgear Figure 70 In this example the automatic pump alternation is in use. ACS 400 User’s Manual...

  • Page 157: Pid Controller

    Figure 71 The control signal connections of the Pump and Fan Control (PFC) macro. PID Controller The ACS 400 has an internal PID controller which is in use when PFC control macro is selected. Key features of the PID controller are: •...

  • Page 158: Relay Outputs

    • When the standard digital inputs of the ACS 400 (DI1 - DI5) are needed for other purposes and/ or number of interlock signals (auxiliary motors) is large. I/O extension modules are connected to the ACS 400 via a DDCS fibre optic link. An optional DDCS communication module is needed to use DDCS.
  • Page 160 ABB Industry Oy P.O. Box 184 00381 Helsinki FINLAND Telephone +358-10-222 000 Telefax +358-10-222 2681...

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