ABB ACS 502 Series Page 43 Installation & Start-Up Manual Download

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Chapter 3 – ACS 502 Installation Instructions

ACS 502 Installation & Start-up Manual

3-5

Output Power Wiring

Table 3-3 shows the output wire sizes for the ACS 502.

Table 3-3

ACS 502 Output Wire Sizes

* Indicates 2 pole per phase for terminal information and 2 conductor for wire

size information.

Table 3-4 shows ground lug wire sizes for the ACS 502.

Table 3-4

ACS 502 Ground Lug Wire Sizes

Amp Range

Overload

Terminal Block

29.3 – 60.0

#12 – #2

#6-250MCM

57.1 – 100.0

#10 – 2/0

#6-250MCM

98.0 – 180.0

#6 – 250MCM

#6-250MCM

175.0 – 220.0

* #6 – 4/0

* #6-4/0

221.0 – 465.0

* #6 – 4/0

* #6-4/0

Drive Type

Ground Lug

ACS 502-050 to ACS 502-350

#6-350MCM

Summary of Contents for ACS 502 Series

Page 1: ...ACS 502 ABB Drives Installation Start up Manual ASEA BROWN BOVERI ACS 502 504 Adjustable Frequency AC Drives 50 to 400 HP Series B ACS 502 04F EFFECTIVE 8 31 95 SUPERSEDES 9 1 94 ...

Page 2: ......

Page 3: ... 1995 ABB Industrial Systems Inc All Rights Reserved ACS 502 504 Adjustable Frequency AC Drives 50 to 400 HP Series B Installation Start up Manual ACS 502 04F EFFECTIVE 1995 08 30 SUPERSEDES 1994 09 01 ...

Page 4: ......

Page 5: ...s or conditions which will damage machinery or cause additional motor operation down time if you do not take suggested steps to correct or address such situations or conditions Note Notes provide you with additional and useful information Although less urgent than cautions and warnings notes are important and should not be ignored Warning Symbols For your own safety please pay special attention to...

Page 6: ...ry out the electrical installation Note that the Motor Control Card of the ACS 502 504 is at DC bus voltage potential The DC bus capacitors contain dangerous DC voltage levels 1 35 x VIN After disconnecting the supply wait at least five minutes after the display readout on the control panel has disappeared before taking any measurements Dangerous external control voltages may be present on the rel...

Page 7: ... ACS 502 504 2 3 ACS 502 Control Identification 2 4 General Information About Your ACS 502 504 2 6 Functional Description 2 6 Control Panel Operation 2 8 Control Panel Display 2 8 Control Panel Keys 2 9 Application Macros Overview 2 11 Hardware Description 2 11 Inverter Module 2 11 Features and Functions 2 14 Custom Options 2 17 Control Options 2 17 Disconnect Options 2 17 Bypass Options 2 18 Mete...

Page 8: ...X50 4 14 Control Interface Card Connections 4 16 Chapter 5 Start up Procedure Safety Precautions 5 1 Installation Inspection 5 2 Start up Data Parameters 5 3 Keypad Control Tests 5 4 Motor Disconnected from the ACS 502 5 4 Motor Connected to the ACS 502 5 5 Keypad Control vs External Control 5 6 Default Drive Parameters 5 7 Customizing Application Macro Parameters 5 7 Password Protection Parameter...

Page 9: ...Table of Contents ACS 502 Installation Start up Manual vii Digital Relay Outputs A 2 Environmental Limits A 2 Enclosures A 2 Glossary G 1 Index I 1 ...

Page 10: ...Table of Contents viii ACS 502 Installation Start up Manual This page intentionally left blank ...

Page 11: ...troduction to Control Panel operation the drive parameter menu system and drive Application macros Chapter 3 ACS 502 Installation Instructions describes planning for ACS 502 drive installation new drive inspection and drive installation This chapter also includes requirements and connections for input and output wiring and external control wiring Chapter 4 ACS 504 Installation Instructions describ...

Page 12: ...e Parameters into four main functional groups A Main in this manual is the number corresponding to Group access All Groups in the 10s range are accessed on the Control Panel through CONTROL CONNECTIONS MAIN 10 Access Groups in the 20s range through DRIVE PARAMETERS MAIN 20 Access Groups in the 30s range through PROTECTION PARAMETER MAIN 30 and access Groups in the 40 s range through APPLIC PARAMET...

Page 13: ... be liable for damages and failures due to misuse abuse improper installation or abnormal conditions of temperature dust or corrosives or failures due to operation above rated capacities Nor shall the manufacturer ever be liable for consequential and incidental damages The period of manufacturer s warranty is 12 months and not more than 18 months from the date of delivery Extended warranty may be ...

Page 14: ...Chapter 1 Introduction 1 4 ACS 502 Installation Start up Manual This page intentionally left blank ...

Page 15: ...closed assembly including the ACS 504 module ready for operation This chapter describes the features and functions of the ACS 502 and includes illustrations and block diagrams It also describes the ACS 502 hardware components and the Control Panel displays and keys This chapter also presents an overview of the Parameters menu system and Application macros Nameplate Identification Figure 2 1 explai...

Page 16: ...ternal Option 2 0 No Option Internal Option 1 2 I O Extension Board SNAT 7520 IOE 8 5 Isolated Digital Inputs SNAT 763 DII 9 3 15 PSI and 2 Isolated Digital Inputs SNAT 762 PSI 0 No Option Control Panel P Internal Control Panel Keypad and Display 0 No Panel Protection Class of Enclosure 0 Chassis IP 00 2 NEMA 1 IP 21 3 NEMA 1 w Air Filters 5 NEMA 12 IP 54 Not all Protection Classes are available f...

Page 17: ...X 050 4 50 65 62 60 77 69 65 R6 ACS50X 060 4 60 77 71 75 96 87 84 ACS50X 075 4 75 96 87 100 124 111 112 ACS50X 100 4 100 124 113 125 156 141 135 R7 ACS50X 125 4 125 156 143 150 180 159 164 ACS50X 150 4 150 180 161 200 240 214 200 R8 ACS50X 200 4 200 240 218 250 302 269 240 ACS50X 250 4 250 302 273 300 361 328 300 R9 ACS50X 300 4 300 361 333 350 414 376 365 ACS50X 350 4 300 361 333 400 460 418 365 ...

Page 18: ... and the dashes Symbol Definition VIN Rated supply voltage V The actual voltage is set by a parameter IIN Approximate input current rms when shaft power is PR line voltage is 480 V and the motor is a standard NEMA motor Amps IR Rated output current in constant torque applications Amps PR Maximum motor nominal shaft power in constant torque applications for 2 4 and 6 pole standard motors hp IINSQ A...

Page 19: ...mer Terminal Board 1 Internal Brake Chopper M A 1 N B 1 P C 1 0 None Input Options A Door Interlocked Disconnect Switch B Door Interlocked Circuit Breaker C Disconnect w 3 Line Reactor D Circuit Breaker w 3 Line Reactor E Input Terminal Block w 3 Line Reactor F Disconnect w 5 Line Reactor G Circuit Breaker w 5 Line Reactor H Input Terminal Block w 5 Line Reactor 0 Extended Enclosure w Input Termin...

Page 20: ...se diode bridge The cooling fan turns on at initial power on To prolong the useful life of the fan bearings the fan is automatically turned off after one minute unless The drive has a RUN command or Heatsink temperature is above 113 F 45 C Control In normal duty the drive follows commands and references either from the keypad or the terminal block on the Control Interface Card The control signal s...

Page 21: ...vercurrent two current limits and trip Input line phase loss unbalance trip Overvoltage trip at 130 nominal DC voltage Undervoltage trip at 60 nominal DC voltage Starting at overvoltage 117 of nominal DC voltage inhibits start Ground fault 2 5 amps In addition the drive identifies various internal and external hardware faults and displays a diagnostic message The ACS 504 also has a variety of prot...

Page 22: ...splayed in nine languages English German Italian Spanish Dutch French Danish Finnish and Swedish The language selection is made in Start up Data Parameter A Language Figure 2 3 shows control panel display indications Figure 2 3 Control Panel Displays Main Name Rotation Direction Forward Reverse Main Number Control Location Keypad Control No Brackets External Run Status I Run O Stop Parameter Numbe...

Page 23: ...xt Reference Function Selects the Setting mode and saves the selected parameter value Right Arrow Left Arrow Steps between levels Selects between Operating Data Main Group and Parameter levels and In Setting Mode returns to the Display mode without changing the Parameter value Up Arrow Down Arrow Steps through choices within a level In Display mode selects the next previous Main Group or Parameter...

Page 24: ...r by Up Arrow and Down Arrow key Change to Setting mode Brackets indicate that the parameter value now can be changed Set the parameter value If you want to cancel the change and return to Display mode press Right Arrow or Left Arrow otherwise Save the selected value to parameter memory Brackets disappear indicating that the parameter value is stored in memory Return to Operating Data parameter 1 ...

Page 25: ...he parameters to be set with the touch of a button When you select an Application macro the parameters listed in the ACS 500 Adjustable Frequency AC Drives 2 to 350 HP Programming Manual Including Application Macros are set to a value suitable for a particular application The parameters which are not included in the Application macro retain the factory settings If you must adjust the parameter val...

Page 26: ...AAAAAAA AAAAAAAA AAAAAAAA AAAAAAAA AAAAAAAA AAAAAAAA AAAAAAAA AAAAAAAA AAAAAAAA AAAAAAAA AAAAAAAA AAAAAAAA AAAAAAAA AAAAAAAA AAAAAAAA AAAAAAAA AAAAAAAA AAAAAAAA AAAAAAAA AAAAAAAA AAAAAAAA AAAAAAAA AAAAAAAA AAAAAAAA AAAAAAAA AAAAAAAA AAAA AA AA AA AA AA AA AA AA AA AA AA AA AA AA AA AA AA AA AA AA AA AA AA AA AA AA AA AA AA AA AA AA AA AA AA AA AA AA AA AA AA AA AA AA AA AA AA AA AA AA AA AA AA AA ...

Page 27: ...t choke at T1 T2 and T3 V1 V6 Inverter insulated gate bipolar transistors IGBT and clamp circuits A3 Main Circuit Interface Card SNAT 7261 INT This card contains the power supply transistor gate trigger cir cuits and DC voltage and motor current measurement circuits A7 Small card on top of SNAT 7261 INT This contains the power range programming information for the ACS 504 hardware SNAT xyz5 SCL wh...

Page 28: ... on the options chosen the ACS 502 provides motor overload protection disconnect switch or circuit breaker bypass analog meters indicator lights and external control connections Figure 2 6 shows the door of the ACS 502 and indicates all possible options Your drive may not look exactly like the illustration Figure 2 6 ACS 502 Front Door VM AM1 AM2 SPM W Y POT SS1 OPL SS2 BPL FPL RESET R ABB Drives ...

Page 29: ...tion Figure 2 7 ACS 502 R6 and R7 with Bypass Interior FU5 FU 6 O F F O N Ground Lug Circuit Breaker Disconnect Switch or Input Terminal Fuses for Voltmeter MOL s or Output Terminal Block Current Transformers for Ammeter Control Transformer Control Relays Automatic Bypass Input Bypass Output Drive Fuses Inverter Module Service Switch Contactors Output Bypass Input a312 dxf FRONT VIEW Terminal Boar...

Page 30: ...k Current Transformers Tower Brackets MOL Wireduct Control Relays Output Bypass Input Automatic Bypass Contactors Output Bypass Input Busbar Jumper Circuit Breaker Disconnect Switch or Input Terminal Terminal Board Fuses for Voltmeter Control Transformer Current Transformers for Ammeter Drive Fuses Inverter Module Service Switch a302 dxf Line Reactor not shown ...

Page 31: ...ntrols the speed In the Off mode the drive is disabled even if you use an external speed reference or if you attempt to start the drive via the keypad In the Auto mode a remote contact closure starts the drive provided you have connected a remote contact A remote signal voltage or current controls speed The remote signal controlling speed can also be pneumatic but requires an option board The 115 ...

Page 32: ...ass mode An External Fault indicator light is included The External Fault indicator light illuminates if any of the safety interlocks FREEZE FIRE SMOKE open or if the Thermal Motor Overload Relay trips CAUTION When changing from Bypass to Normal place the Bypass Switch in the TEST position for five seconds before selecting Normal Failure to do so could result in damage to the ACS 502 Note The ACS ...

Page 33: ...ut contactor opens when BYPASS is selected removing power from the drive The service switch will energize the input contactor in the TEST position to allow the drive to be powered while in BYPASS for servicing Note The ACS 502 is disabled when BYPASS is selected If the drive is to be run while in BYPASS a connection must be made between TB1 42 and TB1 43 This should be done by a qualified service ...

Page 34: ...bimetallic motor overload relays with a Class 20 trip curve The relays provide thermal motor protection when operating a motor from the drive If a Bypass Option is included the relays also provide thermal motor protection across the line power If the overload trips power is removed from the motor whether in Normal or Bypass mode When the drive has the Bypass option an external fault indicator is i...

Page 35: ...E16 E17 E18 E19 68 73 74 81 82 87 88 94 95 1 00 E23 E24 E26 E27 E28 1 10 1 10 1 11 1 26 1 27 1 40 1 41 1 58 1 59 1 74 E29 E31 E32 E33 E34 1 75 1 85 1 86 1 99 2 00 2 11 2 12 2 31 2 32 2 59 E36 E37 E38 E39 E41 2 60 2 75 2 76 2 95 2 96 3 21 3 22 3 48 3 49 3 89 E42 E44 E46 E47 E48 3 90 4 35 4 36 4 73 4 74 5 21 5 22 5 74 5 75 6 05 E49 E50 E51 E52 E53 6 06 6 46 6 47 6 95 6 96 8 09 8 10 9 29 9 30 10 4 E5...

Page 36: ... 33 2 33 3 35 7 35 8 39 4 39 5 43 4 43 5 46 9 E73A E74 E76 E77 E78 37 9 41 7 41 8 45 9 46 0 49 0 49 1 54 2 54 3 60 0 47 0 51 5 51 6 57 0 57 1 62 8 62 9 69 1 E79 E80 E88 E89 E91 69 2 75 0 75 1 83 3 50 0 55 9 56 0 60 9 61 0 65 9 E92 E93 E94 E96 E97 83 4 86 9 87 0 92 9 66 0 69 9 70 0 75 9 76 0 81 9 82 0 86 9 87 0 92 9 E98 E99 E101 E102 E103 93 0 100 0 93 0 97 9 98 0 107 9 108 0 113 9 114 0 125 9 126 ...

Page 37: ...7 0 50 0 AR 86 51 0 52 0 AR 95 53 0 56 0 AR 1 05 57 0 60 0 AR 1 15 61 0 66 0 AR 1 26 67 0 73 0 AR 1 39 74 0 81 0 AR 1 53 82 0 90 0 AR 1 68 91 0 105 0 AR 1 85 106 0 115 0 AR 2 04 116 0 125 0 AR 2 24 126 0 135 0 AR 2 46 136 0 147 0 AR 2 71 148 0 158 0 AR 2 98 159 0 174 0 AR 3 28 175 0 194 0 AR 3 62 195 0 220 0 AR 3 98 221 0 247 0 AR 4 37 248 0 276 0 AR 4 80 277 0 307 0 AR 5 3 308 0 345 0 AR 5 8 346 ...

Page 38: ...of maximum speed with a 0 100 percent scale connected to one of the analog outputs Note This option uses one of the analog outputs on the ACS 502 Output Ammeters The Ammeters have six calibration sizes ranging from 100 to 500 amps Depending on the number of motors driven one or two Output Ammeters can be installed in the ACS 502 If two ammeters are ordered two Thermal Motor Overload Relays must be...

Page 39: ...mperes for the 50 60 HP units 25 000 for the 75 125 HP units and 30 000 for the 150 400 HP units 600 VAC units are suitable for use on a circuit capable of delivering not more than 42 000 rms Amperes 600 Volts When circuit breakers are supplied the drive package is limited to the rating of the circuit breaker which is 14 000 rms Amperes When output chokes are supplied 480 and 600 VAC units are sui...

Page 40: ...o exceed the ambient temperature as stated in Environment above At least three 3 separate grounded conduits are required One each for input output and control wiring NEMA 12 units require side clearance of 3 for replacing air filters Figure 3 1 shows the dimensions of the ACS 502 Figure 3 1 ACS 502 Dimensions Installation Site Power The ACS 502 is designed for use on a three phase system Four wire...

Page 41: ...o prevent metal particles from falling into the drive Figure 3 2 ACS 502 Conduit Entry Area for One Door Enclosure Figure 3 3 ACS 502 Conduit Entry Area for Two Door Enclosure Figure 3 3 shows the left bay at the enclosure only TOP VIEW 5 906 in 150 0 mm 27 559 in 700 0 mm 23 622 in 600 0 mm 24 516 in 622 7 mm 12 113 in 307 7 mm Recommended area for entry exit 150 00 mm 5 906 600 00 mm 23 622 480 ...

Page 42: ... the fuse ratings UL R C JFH R2 for the ACS 502 Table 3 2 ACS 502 Fuse Ratings Drive Type Terminal Block Disconnect Circuit Breaker ACS 502 050 4 ACS 502 125 4 ACS 502 060 6 ACS 502 125 6 6 4 0 6 4 0 2 4 0 ACS 502 150 6 6 4 0 2 4 0 2 4 0 ACS 502 150 4 ACS 502 200 4 6 4 0 2 4 0 3 0 4 0 ACS 502 250 ACS 502 350 6 500MCM 2 500MCM 250MCM 500MCM Drive Type Fuse Ratings Bussmann Type A kA2 s V ACS 502 05...

Page 43: ...ates 2 pole per phase for terminal information and 2 conductor for wire size information Table 3 4 shows ground lug wire sizes for the ACS 502 Table 3 4 ACS 502 Ground Lug Wire Sizes Amp Range Overload Terminal Block 29 3 60 0 12 2 6 250MCM 57 1 100 0 10 2 0 6 250MCM 98 0 180 0 6 250MCM 6 250MCM 175 0 220 0 6 4 0 6 4 0 221 0 465 0 6 4 0 6 4 0 Drive Type Ground Lug ACS 502 050 to ACS 502 350 6 350M...

Page 44: ...res when power is applied Never connect line voltage to drive output Terminals U2 V2 and W2 T1 T2 T3 Do not make any voltage tolerance tests Hi Pot or Meggar on any part of the unit Disconnect motor wires before taking any measurements in the motor or motor wires Make sure that power factor correction capacitors are not connected between the drive and the motor The terminal sizes and tightening to...

Page 45: ...Input Power Wiring Output Wiring Sizing is the same as for the input wiring Figure 3 5 shows output power wiring for the ACS 502 Figure 3 5 Output Power Wiring R8 w bypass and R9 all R6 R7 all and R8 w o bypass a317 dxf a318 dxf R8 w bypass and R9 all R6 R7 all and R8 w o bypass a317 dxf a318 dxf ...

Page 46: ...al braking chopper is not present DO NOT CONNECT LOAD BANK RESISTORS 2 External Dynamic Braking Device If the internal dynamic brake chopper was not supplied and dynamic braking is required for the application an external dynamic braking chopper and resistor load bank can be connected to the DC bus terminals WARNING The brake control terminals carry a dangerous DC voltage 1 35 x VIN No device othe...

Page 47: ... voltage terminals 24 VDC maximum Terminals TB1 21 through TB1 29 are relay output terminals Ground terminals are located next to TB1 17 and TB1 29 These are to be used to connect the shields of shielded cables Terminals TB1 30 through TB1 55 are 115 VAC control These terminals are not used when the 115 VAC Control Transformer is not supplied Connection to all of these terminals is described in th...

Page 48: ... the Manual Speed Potentiometer when it is supplied The analog inputs can accept a voltage signal 0 10 VDC or a current signal 0 20 mA Jumpers S1 and S2 located on the Control Interface Board in the ACS 502 S1 for AI1 and S2 for AI2 determine the signal type The jumper is placed in the V position for voltage and the I position for current Orientation may vary with different versions of the control...

Page 49: ...B1 21 TB1 22 and TB1 23 Relay RO2 is on Terminals TB1 24 TB1 25 and TB1 26 Relay RO3 is on Terminals TB1 27 TB1 28 and TB1 29 The first terminal for each relay is the normally closed NC terminal the second is the common and the third is the normally open NO terminal Maximum Switching Voltage 300 VDC 250 VAC Maximum Switching Current Power 8 A 24 VDC 0 4 A 250 VDC or 2000 VA 250 VAC Maximum Continu...

Page 50: ...5 VAC Start To start the ACS 502 by applying 115 VAC connect the 115 VAC signal to TB1 35 and TB1 36 Operation is the same as Two Wire Start Freeze Fire Smoke Protection Safety interlocks such as Freeze Fire and Smoke protection are normally closed dry contacts connected in series between TB1 38 TB1 39 and TB1 40 Remove the jumper wire before making your connection When the contact opens the motor...

Page 51: ... circuit capable of delivering not more than 42 000 rms Amperes 600 Volts When output chokes are supplied 480 and 600 VAC units are suitable for use on a circuit capable of delivering not more than 65 000 rms Amperes 500 Volts or 600 Volts Careful planning is required to insure proper operation of the ACS 504 The information provided in this chapter includes all dimensions cooling requirements and...

Page 52: ... 76 70 M10 30 44Nm M 6 6 9 Nm AIR A4 A5 A6 A7 TOP OF THE CABINET BOTTOM OF THE CABINET BACK FRONT LEFT WALL RIGHT WALL 15 67 398 16 85 428 W2 W1 W3 0 60 15 H2 H1 H3 H3 H5 H4 H6 PE 0 60 15 0 35 0 79 9 20 U1 V1 W1 AIR AIR COOLING AIR INLET CONTROL CIRCUIT TERMINAL X301 INSIDE TO BE CONNECTED TO TERMINAL X401 IN CONTROL UNIT CONTROL CIRCUIT TERMINAL X302 INSIDE TO BE CONNECTED TO TERMINAL X402 IN CON...

Page 53: ...8 07 265 10 43 H4 390 15 35 557 21 93 720 28 35 928 36 54 H5 101 3 98 101 3 98 101 3 98 99 3 90 H6 214 8 43 363 14 29 538 21 18 717 28 23 H7 350 13 78 535 21 06 775 30 51 1080 42 52 H8 570 22 44 755 29 72 994 39 13 1300 51 18 W1 451 17 76 451 17 76 482 18 98 482 18 98 W2 473 18 62 473 18 62 512 20 16 512 20 16 W3 50 1 97 64 2 52 50 1 97 50 1 97 D1 385 15 28 385 15 28 415 16 34 415 16 34 D2 228 8 9...

Page 54: ...d with two brackets to allow it to be mounted to the door of the enclosure Refer to Figure 4 4 for an example Figure 5 5 shows the dimensions of the window required and the dimensions required to mount the brackets in the correct location with respect to the window Figure 4 3 Control Unit Dimensions Front Top Side 24 in 4 13 in 24 in 7 mm 14 27 in 12 28 in 55 in 14 mm 5 9 in 150 mm 7 875 in 200 mm...

Page 55: ...AA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA A A A A A A A A A A A A A A AA AA AA AA AA A A A A A A A A A A A A AA AA AA A AA AA AA AA AA AA AA A AA AA A A A A A A A A A A A A A A A A A A A A A A A A A A A A A A A A A A A A A A A A A A A AA AA AA A AA AA AA AA A AA AA AA AA A A A A A AAAAAA AA AA A A A A AA AA AA AA A A A A A A A A A A A AA AA AA AA A AA AA AA A A A A A A A A A A...

Page 56: ...5 ACS 504 075 4 075 6 3000 m3 hr 570 mm 150 100 50 100 150 400 cm2 800 1000 CFM 335 in 6 4 2 4 6 16 sq in 124 155 ACS 504 100 4 3500 m3 hr 690 mm 150 50 100 50 150 400 cm2 1000 1500 CFM 406 in 6 2 4 2 6 16 sq in 155 233 ACS 504 125 4 100 6 4250 m3 hr 690 mm 150 50 100 50 150 400 cm2 1000 1500 CFM 406 in 6 2 4 2 6 16 sq in 155 233 ACS 504 150 4 5250 m3 hr 950 mm 150 50 100 50 150 400 cm2 1200 1800 ...

Page 57: ...be arranged by using specially filtered air The maximum total power losses of the modules and required cooling air volumes with free space requirements are shown in Table 4 3 For dimensional reference for the free space around the module see Figure 4 1 Included in Table 4 3 are recommendations for total open areas in the enclosure walls or door for cooling air inlet and outlet If the total open ar...

Page 58: ...ertemperature warning and eventual tripping The tripping temperature of the heatsink is 185 F 85 C The drive can be started again when the temperature of the heatsink is below 167 F 75 C A faster way to start would be to disconnect the power wait for the display to turn off and power up again The temperature of the heatsink can be read from the control panel display The temperature difference betw...

Page 59: ...nput or output power wiring or control wires when power is applied Never connect line voltage to drive output Terminals U2 V2 and W2 T1 T2 T3 Do not make any voltage tolerance tests Hi Pot or Meggar on any part of the unit Disconnect motor wires before taking any measurements in the motor or motor wires Make sure that power factor correction capacitors are not connected between the drive and the m...

Page 60: ...stallation Instructions 4 10 ACS 502 Installation Start up Manual Figure 4 7 ACS 504 Input and Output Power Connections Input Power Output Power Dynamic Brake Connections Caution High Voltage Covered with protective shield ...

Page 61: ...A AA AA AA AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA A A A A A A A A A A A A A A A A A A A A A A U V W ACS504 AA AA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA A A A A A A A A A A A A A A A A A A A A AAAAAAAAAAAAAAAAAAAAA AA AA AA AA AA AA AA AA AA AA AA AA AA AA AA AA AA AA AA AA AAAAAAAAAAA A A A A A A A A AAAAAAAAAAA AA AA AA AA AA AA AA AA INPUT DEVICES Control Inter...

Page 62: ...e provided is 6 feet long and should not be extended The yellow green grounding wire that is connected to one of the PE terminals on the left side of the Inverter Module is also to be connected to the Control Unit Chassis PE2 Connecting the Ground Fault Current Transformer The ACS 504 is supplied with a current transformer CT to provide the ground fault protection This CT should be installed on th...

Page 63: ... 504 is disconnected from the input line and then disconnect the output conductors from terminals U2 V2 and W2 Check that the motor cable is disconnected from the motor Measure the insulation resistance in the motor The voltage range of the insulation resistance meter must be at least equal to the input line voltage but not exceeding 1000 V The insulation resistance must be greater than 1 Mohm Mea...

Page 64: ...th shielded cables X50 2 4 6 8 18 and 20 are circuit common They are optically isolated from the power line potential and from chassis ground by a 10 megohm resistor The common points are not isolated from each other Potentiometer A manual speed potentiometer is connected to the reference at X50 1 10 VDC and X50 2 common and to one of the analog inputs Analog Inputs There are two analog inputs AI1...

Page 65: ...upression must be provided at the load This is to reduce the electrical noise that could interfere with the electronics in the drive as well as increase the life of the contacts in the relay AC coils should be supressed with an MOV metal oxide varistor or a Series Connected RC resistor capacitor network as illustrated below MOV should be rated 120 VAC 240 VAC for 115 VAC circuits 240 VAC 320 VAC f...

Page 66: ... Select Output frequency 0 20 mA corresponds to 0 60 Hz Motor current 0 20 mA corresponds to 0 IMAX Relay output 1 Ready indication Relay output 3 Fault Inv indication A AA AAAAAAAAAAAAAAAAAAAAAAAAAA A AA AAAAAAAAAAAAAAAAAAAAAAAAAA A A AA AA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAA AAA A A AA AA AAAA AAAAAAAA AAAAAAAA AAAAAAAA AAAAAAAA AAAAAAAA AAAAAA AA A A A A A A A A A A A A A A A A A A A A ...

Page 67: ... To ensure that the voltage level is safe measure the voltage between positive and negative DC Bus Terminals UDC and UDC refer to Figure 4 7 Meter must be rated for 1000 VDC Also measure between UDC and chassis ground The Control Interface Card and Option Cards are isolated from the main circuit but dangerous voltages may be present at relay contact terminals Always check for high voltage at Termi...

Page 68: ...onnections wire shields grounding location as far as possible from the power wires Quantity and quality of cooling air for the ACS 502 Verify that it is safe to run the motor Connect the ACS 502 to supply voltage Check that the voltage between L1 L2 L2 L3 and L1 L3 U1 V1 U1 W1 and V1 W1 is VN 10 PREPARATION SAFETY PRECAUTIONS Read and follow safety instructions INSTALLATION INSPECTION Check for pr...

Page 69: ...arameter values Set this to YES by pressing Up Arrow Press to confirm the selection and move to the next parameter D SUPPLY VOLTAGE This parameter offers choices of 440 460 480 and 500 VAC for 480 volt units or 380 400 and 415 VAC for 380 volt units Press Up Arrow or Down Arrow to select the voltage value matching line voltage providing power to your ACS 502 Press to confirm the selection and move...

Page 70: ...value for your motor Press to confirm the selection and move to the next parameter J MOTOR BASE R P M This parameter is used to set the nameplate speed of the motor and is adjustable from 200 to the maximum 2 pole motor speed based on Start up Data Parameter I Motor Base Frequency Press Up Arrow or Down Arrow to set the motor nameplate speed value for your motor Press to confirm the selection and ...

Page 71: ...g to these steps refer to Chapter 6 Fault Tracing in this manual for additional information Motor Connected to the ACS 502 After successfully testing the drive with the motor disconnected continue testing the drive as follows 1 Disconnect and lock out power from the ACS 502 Check for zero volts at Terminals X50 21 29 and X2 and before continuing If a Bypass option is supplied set the Drive Switch ...

Page 72: ...5 VAC control transformer is supplied the Option Pack macro must be selected Refer to Chapter 3 Installation Instructions in this manual for more information on specific external control wiring schemes Refer to the Chapter 2 Overview of the ACS 502 504 Control Panel Operation for more information on accessing and changing parameters Keypad Control vs External Control The ACS 502 can be controlled ...

Page 73: ... macro to custom fit your application For example if you select the Factory macro for your application the Factory macro default for Start up Data Parameter D Supply Voltage is 480 V If your supply voltage is 460 V you need to change this parameter in the macro accordingly To customize the macro for your application you must change certain parameter values In each macro certain parameters are more...

Page 74: ... 20 Parameter Lock to LOCKED xxx if the control location is the Keypad or activate the selected digital input if the control location is a DI setting The Parameter Lock control location is indicated in Operating Data Parameter 20 Parameter Lock Characters xxx after the parameter value OPEN xxx LOCKED xxx indicate that the current control location is Keypad To open the Parameter Lock you must enter...

Page 75: ...7 on the Main Circuit Interface Card is loose Check that ambient temperature is 104 F 40 C Check that the drive was not overloaded for a long time Check the fan and air flow Check the fuses on SNAT 7902 INP Check that T61 primary and secondary connections are OK Check the heatsink fins and remove any dust or dirt If the fault persists contact a service representative 2 MOT STALL Parameter 30 18 8 ...

Page 76: ...e is a high probability that the motor is overheated Because the temperature rise is calculated from the motor current and not measured directly the motor may be within temperature rise specification Check the motor temperature If it is within temperature rise specification increase Parameter 30 1 5 Motor Load Curve and or Parameter 30 1 4 Motor Therm Time and restart If the motor temperature is a...

Page 77: ...gly for the new Control Interface Card Remove power wait one minute then restore power If the fault persists contact ABB Technical support 19 IN COMMS Failure in serial communication within the Control Interface and or Motor Control Cards Check the cabling between the Control Interface and the Motor Control Cards If the fault persists contact ABB Technical Support 20 CON INT This fault is related ...

Page 78: ... below 60 and does not increase above 80 within 40 sec Check input line fuses and supply If they are OK an internal failure has occurred Contact ABB Technical Support 24 GND FAULT Current at start is more than 5 of the nominal current IN There may be a ground fault or a voltage source in the motor circuit This message may also appear if the motor is switched from bypass to ACS 502 504 too quickly ...

Page 79: ...e OK about 1 4 times input voltage Yes No Remove Power and check the fuses on the Main Circuit Interface Card SNAT 726x INT OK Remove power check the line fuses OK Check the charging resistor R14 and diode and associated wiring Check the flat cables between SNAT 726x INT and the Control Unit Measure the 24 V and 8 V aux voltages on flat cable terminal X401 See figure Replace the Control Unit Repla...

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Page 81: ...ontinuous Current variable torque 1 0 x IRSQ Maximum Current 1 min every 10 min 1 5 x IR Short Time Overload 2 sec every 1 min 2 0 x IR Overcurrent Trip 3 75 x IN instantaneous 2 65 x IN RMS Field Weakening Point 30 180 Hz Continuous Loadability of Motor 100 at rated speed for F class motor Modulation Frequency 3 kHz Analog Inputs Two programmable analog inputs Current Reference 0 20 mA RI 250 ohm...

Page 82: ...l to 500 ohms floating Digital Relay Outputs Three programmable relay outputs Form C contacts Maximum Switching Voltage 300 VDC 250 VAC Maximum Switching Current Power 8 A 24 VDC 0 4 A 250 VDC or 2000 VA 250 VAC Maximum Continuous Current 2 A rms Environmental Limits Ambient Operating Temperature Constant Torque 32 to 113 F 0 to 45 C NEMA 1 Variable Torque 32 to 104 F 0 to 40 C NEMA 1 Storage Temp...

Page 83: ...C Bus voltage is 1 35 x Supply Voltage VIN Default A default is a pre programmed value for a parameter When you first install and start your ACS 502 504 drive all application macro parameter values appearing on the Keypad Display are default settings You may change these default settings in the process of customizing your drive for your particular drive application Digital Input DI The Digital Inp...

Page 84: ...he drive trips and on which settings are based Inverter The inverter changes DC power to AC power for application to the motor windings Control of the inverter affords variable frequency and voltage to be applied to the motor for control of motor speed and direction IR Compensation IR Compensation is a parameter that provides the motor with extra torque at motor speeds between 0 1 Hz and the set F...

Page 85: ...citor and measures the resistance of the insulation system Meggar test results are usually expressed in megohms CAUTION The ACS 502 504 must not be subjected to testing of this type as damage could result Any wires connected to the ACS 502 504 MUST be disconnected from the ACS 502 504 before being subjected to this type of test Memory The ACS 502 504 memory provides computer storage for program da...

Page 86: ... these parameters are one time settings made only during the drive installation process Start up Data parameters are not accessed through the same display levels as Operating Data parameters Main level or Group level Instead you must first view Operating Data Parameter 1 Output Frequency press and hold on the Control Panel Keypad then press Right Arrow Only this procedure accesses Start up Data pa...

Page 87: ...d ESD warning iv Control panel display 1 2 2 8 keys 1 2 2 9 LCD display illustration 2 8 operation 2 8 table of keypad functions 2 9 using the keys 1 2 Conventions used in this manual 1 2 Cooling requirements for ACS 502 3 1 D DC bus capacitors iv Digital inputs ACS 502 connections 3 11 ACS 504 connections 4 14 Digital outputs ACS 502 connections 3 11 ACS 504 connections 4 15 Dimensions of ACS 502...

Page 88: ...nnections 4 14 Power requirement for ACS 502 3 2 Pre installation planning for ACS 502 environment 3 1 mounting 3 2 output wire length restrictions 3 5 power wiring table 3 4 Pre installation planning for ACS 504 environment 4 6 input wiring 4 9 mounting 4 2 4 3 output wiring 4 9 Programming example 2 10 Publications related to this manual 1 3 R Relay outputs ACS 502 connections 3 11 ACS 504 conne...

Page 89: ...al I 3 V Voltage tolerance tests hi pot warning 3 6 4 9 Meggar warning 3 6 4 9 W Warning messages 6 1 Warranty information 1 3 Wire sizes for ACS 502 power 3 4 Wire sizes for ACS 504 power 4 9 Wiring control 5 6 X X50 ACS 504 connections 4 14 ...

Page 90: ...Index I 4 ACS 502 Installation Start up Manual This page intentionally left blank ...

Page 91: ......

Page 92: ...ABB Industrial Systems Inc 16250 West Glendale Drive New Berlin WI 53151 Telephone 414 785 3416 Fax 414 785 0397 ASEA BROWN BOVERI ACS 502 04F EFFECTIVE 8 331 95 SUPERSEDES 3 1 94 ...

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ABB ACS 502 Series, Installation & Start-Up Manual

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Summary of Contents for ACS 502 Series

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