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Operation principle and hardware description

Operation principle and hardware description

What this chapter contains

The chapter briefly describes the operation principle, layout, type designation label
and type designation information. It also shows a general diagram of power
connections and control interfaces.

Operation principle

The ACS150 is a wall or cabinet mountable drive for controlling AC induction motors.

The figure below shows the simplified main circuit diagram of the drive. The rectifier
converts three-phase AC voltage to DC voltage. The capacitor bank of the
intermediate circuit stabilizes the DC voltage. The inverter converts the DC voltage
back to AC voltage for the AC motor. The brake chopper connects the external brake
resistor to the intermediate DC circuit when the voltage in the circuit exceeds its
maximum limit.

Rectifier

Capacitor

Inverter

AC supply

U1

V1

W1

bank

U2

V2

W2

M

AC motor

3~

Brake chopper

BRK- BRK+

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Summary of Contents for ACS150 series

Page 1: ...บริษัท ที จี คอนโทรล จำกัด 1683 ทาวน อินทาวน ซอย 9 แขวงพลับพลา เขตวังทองหลาง กรุงเทพฯ 10310 โทร 02 530 9090 แฟกซ 02 530 9933 www tgcontrol com www facebook com tgcontrol ...

Page 2: ...FDT 01 FlashDrop user s manual 1 2 3AFE68591074 Maintenance manuals Guide for capacitor reforming in ACS50 ACS55 ACS150 ACS310 ACS350 ACS355 ACS550 ACH550 and R1 R4 OINT SINT boards 2 3AFE68735190 1 Delivered as a printed copy with the drive or optional equipment 2 Available in the Internet All manuals are available in PDF format on the Internet See section Further information on the inside of the...

Page 3: ...ACS150 drives 0 37 4 kW 0 5 5 hp User s manual 3AFE68576032 Rev C EN EFFECTIVE 2011 01 01 2010 ABB Oy All Rights Reserved ...

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Page 6: ...this manual 15 Related documents 16 Categorization according to the frame size 16 Quick installation and commissioning flowchart 17 Operation principle and hardware description What this chapter contains 19 Operation principle 19 Product overview 20 Layout 20 Power connections and control interfaces 21 Type designation label 22 Type designation key 22 Mechanical installation What this chapter cont...

Page 7: ... Control cable ducts 34 Protecting the drive input power cable motor and motor cable in short circuit situations and against thermal overload 35 Protecting the drive and input power cable in short circuit situations 35 Protecting the motor and motor cable in short circuit situations 35 Protecting the drive motor cable and input power cable against thermal overload 36 Protecting the motor against t...

Page 8: ...between local and remote control 61 How to change the direction of the motor rotation 61 How to set the frequency reference 62 Output mode 63 How to browse the monitored signals 63 Reference mode 64 How to view and set the frequency reference 64 Parameter modes 65 How to select a parameter and change its value 65 How to select the monitored signals 66 Changed parameters mode 67 How to view and edi...

Page 9: ...21 START STOP 82 22 ACCEL DECEL 83 Actual signals 84 01 OPERATING DATA 84 04 FAULT HISTORY 85 Parameters in the Long parameter mode 86 10 START STOP DIR 86 11 REFERENCE SELECT 89 12 CONSTANT SPEEDS 92 13 ANALOG INPUTS 94 14 RELAY OUTPUTS 94 16 SYSTEM CONTROLS 96 18 FREQ INPUT 98 20 LIMITS 98 21 START STOP 99 22 ACCEL DECEL 101 25 CRITICAL SPEEDS 104 26 MOTOR CONTROL 105 30 FAULT FUNCTIONS 107 31 A...

Page 10: ...38 Switching frequency derating I2N 139 Power cable sizes and fuses 140 Dimensions weights and free space requirements 141 Dimensions and weights 141 Symbols 141 Free space requirements 141 Losses cooling data and noise 142 Losses and cooling data 142 Noise 142 Terminal and lead through data for the power cables 143 Terminal data for the control cables 143 Electric power network specification 144 ...

Page 11: ...3 Electrical installation 153 Start up 154 Dimension drawings Frame sizes R0 and R1 IP20 cabinet installation UL open 156 Frame sizes R0 and R1 IP20 NEMA 1 157 Frame size R2 IP20 cabinet installation UL open 158 Frame size R2 IP20 NEMA 1 159 Appendix Process PID control What this chapter contains 161 Process PID control 161 Quick configuration of process PID control 161 Pressure boost pump 162 How...

Page 12: ...These warnings are intended for all who work on the drive motor cable or motor Electrical safety WARNING Ignoring the instructions can cause physical injury or death or damage to the equipment Only qualified electricians are allowed to install and maintain the drive Never work on the drive motor cable or motor when input power is applied After disconnecting the input power always wait for 5 minute...

Page 13: ... drive must be used within a zone of equipotential bonding ie within a zone where all simultaneously accessible conductive parts are electrically connected to prevent hazardous voltages appearing between them This is accomplished by a proper factory grounding Note Even when the motor is stopped dangerous voltage is present at the power circuit terminals U1 V1 W1 and U2 V2 W2 and BRK and BRK Genera...

Page 14: ... activated these functions reset the drive and resume operation after a fault Do not control the motor with an AC contactor or disconnecting device disconnecting means use instead the control panel start and stop keys and or external commands I O The maximum allowed number of charging cycles of the DC capacitors that is power ups by applying power is two per minute and the maximum total number of ...

Page 15: ...14 Safety ...

Page 16: ... given Purpose of the manual This manual provides information needed for planning the installation installing commissioning using and servicing the drive Contents of this manual The manual consists of the following chapters Safety page 11 gives safety instructions you must follow when installing commissioning operating and servicing the drive Introduction to the manual this chapter page 15 describ...

Page 17: ... tells how to reset faults and view fault history It lists all alarm and fault messages including the possible cause and corrective actions Maintenance page 133 contains preventive maintenance instructions Technical data page 137 contains technical specifications of the drive such as ratings sizes and technical requirements as well as provisions for fulfilling the requirements for CE and other mar...

Page 18: ...ot connected Operation principle and hardware description Type designation key on page 22 Electrical installation Checking the compatibility with IT ungrounded and corner grounded TN systems on page 40 Install the drive on a wall or in a cabinet Mechanical installation on page 23 Route the cables Planning the electrical installation Routing the cables on page 34 Check the insulation of the input c...

Page 19: ...18 Introduction to the manual ...

Page 20: ...untable drive for controlling AC induction motors The figure below shows the simplified main circuit diagram of the drive The rectifier converts three phase AC voltage to DC voltage The capacitor bank of the intermediate circuit stabilizes the DC voltage The inverter converts the DC voltage back to AC voltage for the AC motor The brake chopper connects the external brake resistor to the intermedia...

Page 21: ...nection BRK BRK and motor connection U2 V2 W2 10 I O clamping plate 11 Clamping plate 12 Clamps Product overview Layout The layout of the drive is presented below The construction of frame sizes R0 R2 varies to some extent 1 2 3 4 5 6 7 8 9 2 12 10 12 11 Without plates R0 and R1 With plates R0 and R1 1 Cooling outlet through top cover 2 Mounting holes 3 Integrated control panel 4 Integrated potent...

Page 22: ...ence voltage 10 V DC max 10 mA Aux voltage output GND U AI 10V 24 V COM 24 V DC max 200 mA GND COM DI1 NC Relay output 250 V AC 30 V DC 6 A NO PROGRAMMABLE DIGITAL INPUTS DI5 can also be used as a frequency input DI2 DI3 DI4 DI5 EMC VAR EMC filter grounding screw Varistor grounding screw 6 FlashDrop PE PE L1 L2 U1 U2 V1 V2 M L3 W1 W2 3 phase Input EMC Brake chopper Output AC motor power supply 200...

Page 23: ...1111111111111111111111111111111 4 4 kW 5 HP S N MYYWWRXXXX U1 3 380 480 V 1111111111111111111111111111111111111111 11 3 13 6 A 68581818 5 f1 48 63 Hz RoHS U2 3 0 U1 V 6 12 8 8 A 150 1 10 min f2 0 500 Hz Type designation label Type designation key The type designation contains information on the specifications and configuration of the drive You find the type designation label attached to the drive ...

Page 24: ...o the requirements below Refer to chapter Dimension drawings on page 155 for frame details Requirements for the installation site Operation conditions See chapter Technical data on page 137 for the allowed operation conditions of the drive Wall The wall should be as close to vertical and even as possible of non flammable material and strong enough to carry the weight of the drive Floor The floor m...

Page 25: ...ws bolts mounting hardware screws or bolts if the drive is installed with screws bolts For the number of screws bolts see section With screws on page 25 Unpacking The drive 1 is delivered in a package that also contains the following items frame size R0 shown in the figure plastic bag 2 including clamping plate I O clamping plate clamps and screws mounting template integrated into the package 3 us...

Page 26: ...l installation instructions 3AFE68642868 Install the drive Install the drive with screws or on a DIN rail as appropriate Note Make sure that dust from drilling does not enter the drive during the installation With screws For installing the drive horizontally see section Horizontally on page 27 1 Mark the hole locations using for example the mounting template cut out from the package The locations ...

Page 27: ... 3 Position the drive onto the screws on the wall 4 Tighten the screws in the wall securely 3 4 On DIN rail 1 Click the drive to the rail To detach the drive press the release lever on top of the drive as shown in Figure 1b 1 1b ...

Page 28: ...e 25 Note For the required free space see the following figure WARNING Horizontal mounting is permitted only for frame sizes R1 and R2 because they include a cooling fan Position the drive so that the connectors at the bottom of the drive are situated to the right and the fan to the left as shown in the following figure Do not install frame size R0 horizontally 25 cm 75 cm 75 cm 25 cm ...

Page 29: ... throw the clamping plates away as they are required for proper grounding of the power and control cables 1 Fasten the clamping plate to the plate at the bottom of the drive with the provided screws 2 Fasten the I O clamping plate to the clamping plate with the provided screws 1 2 ...

Page 30: ...he AC power line WARNING As the leakage current of the device typically exceeds 3 5 mA a fixed installation is required according to IEC 61800 5 1 Selecting the supply disconnecting device disconnecting means Install a hand operated supply disconnecting device disconnecting means between the AC power source and the drive The disconnecting device must be of a type that can be locked to the open pos...

Page 31: ...r at least 70 C maximum permissible temperature of the conductor in continuous use For US see section Additional US requirements on page 32 The conductivity of the PE conductor must be equal to that of the phase conductor same cross sectional area 600 V AC cable is accepted for up to 500 V AC Refer to chapter Technical data on page 137 for the EMC requirements A symmetrical shielded motor cable se...

Page 32: ...a protective conductor PE Shield PE PE Not allowed for motor cabling Separate cables for each phase and PE PE Motor cable shield To function as a protective conductor the shield must have the same cross sectional area as the phase conductors when they are made of the same metal To effectively suppress radiated and conducted radio frequency emissions the shield conductivity must be at least 1 10 of...

Page 33: ... joint Bond the conduits also to the drive enclosure Use separate conduits for input power motor brake resistors and control wiring Do not run motor wiring from more than one drive in the same conduit Armored cable shielded power cable Six conductor three phases and three ground type MC continuous corrugated aluminium armor cable with symmetrical grounds is available from the following suppliers t...

Page 34: ... multipair cable Figure b is also usable However for frequency input always use a shielded cable a Double shielded twisted multipair cable b Single shielded twisted multipair cable Run the analog signal and digital signals in separate cables Relay controlled signals providing their voltage does not exceed 48 V can be run in the same cables as digital input signals It is recommended that the relay ...

Page 35: ...bles must cross power cables make sure that they are arranged at an angle as near to 90 degrees as possible The cable trays must have good electrical bonding to each other and to the grounding electrodes Aluminium tray systems can be used to improve local equalizing of potential A diagram of the cable routing is shown below Drive Motor cable Power cable min 300 mm 12 in Input power cable min 200 m...

Page 36: ...h the ACS150 can be used Fuses must be used with other circuit breakers Contact your local ABB representative for the approved breaker types and supply network characteristics The protective characteristics of circuit breakers depend on the type construction and settings of the breakers There are also limitations pertaining to the short circuit capacity of the supply network WARNING Due to the inh...

Page 37: ...otection function that protects the motor and switches off the current when necessary See parameter 3005 MOT THERM PROT for more information on the motor thermal protection Residual current device RCD compatibility ACS150 01x drives are suitable to be used with residual current devices of Type A ACS150 03x drives with residual current devices of Type B For ACS150 03x drives other measures for prot...

Page 38: ... to minimize the EMC emission at switch off If not suppressed the disturbances may connect capacitively or inductively to other conductors in the control cable and form a risk of malfunction in other parts of the system Install the protective component as close to the inductive load as possible Do not install protective components at the I O terminal block Varistor 230 V AC RC filter Drive relay o...

Page 39: ...38 Planning the electrical installation ...

Page 40: ...can damage the drive Every drive has been tested for insulation between the main circuit and the chassis at the factory Also there are voltage limiting circuits inside the drive which cut down the testing voltage automatically Input power cable Check the insulation of the input power cable according to local regulations before connecting to the drive Motor and motor cable Check the insulation of t...

Page 41: ...nected to ground potential through the EMC filter capacitors This may cause danger or damage the drive Disconnect the internal EMC filter when installing the drive on a corner grounded TN system otherwise the drive will be damaged 1 If you have an IT ungrounded system or corner grounded TN system disconnect the internal EMC filter by removing the EMC screw For 3 phase U type drives with type desig...

Page 42: ...ower cables on page 30 3 L and N are connection markings for 1 phase supply Note Do not use an asymmetrically constructed motor cable If there is a symmetrically constructed grounding conductor in the motor cable in addition to the conductive shield connect the grounding conductor to the grounding terminal at the drive and motor ends For the 1 phase power supply connect power to U1 L and V1 N term...

Page 43: ...a grounding clamp screw 2 Connect the phase conductors to the U1 V1 and W1 terminals Use a tightening torque of 0 8 N m 7 lbf in 2 1 3 Strip the motor cable and twist the shield to form as short a pigtail as possible Fasten the stripped motor cable under the grounding clamp Crimp a cable lug onto the pigtail and fasten the lug under a grounding clamp screw 3 Tightening torque 0 8 N m 7 lbf in ...

Page 44: ...nd W2 terminals Use a tightening torque of 0 8 N m 7 lbf in 5 Connect the optional brake resistor to the BRK and BRK terminals with a shielded cable using the same procedure as for the motor cable in the previous step 6 Secure the cables outside the drive mechanically 5 4 3 ...

Page 45: ... signals depends on the application macro in use which is selected with parameter 9902 APPLIC MACRO See chapter Application macros on page 69 for the connection diagrams Switch S1 selects voltage 0 2 10 V or current 0 4 20 mA as the signal type for analog input AI By default switch S1 is in the current position I Top position I 0 4 20 mA default for AI U Bottom position U 0 2 10 V If DI5 is used a...

Page 46: ...tion source X1 24V GND COM DI1 DI2 DI3 DI4 DI5 NPN connection sink X1 24V GND COM DI1 DI2 DI3 DI4 DI5 External power supply for digital inputs For using an external 24 V supply for the digital inputs see the figure below PNP connection source X1 24V NPN connection sink X1 24V 0 V DC 24 V DC GND COM DI1 DI2 DI3 DI4 DI5 24 V DC 0 V DC GND COM DI1 DI2 DI3 DI4 DI5 ...

Page 47: ...macro are given in the figure below 1 10 kohm Alternative connection for AI1 If used switch IU selector to U 0 10 V voltage signal 3 I O connection 4 SCR Signal cable shield screen AI Frequency reference 0 20 mA GND Analog input circuit common 10V Reference voltage 10 V DC max 10 mA 24V Auxiliary voltage output 24 V DC max 200 mA GND Auxiliary voltage output common COM Digital input common DI1 Sto...

Page 48: ...uter insulation of the analog signal cable 360 degrees and ground the bare shield under the clamp 2 Connect the conductors to the appropriate terminals 3 Twist the grounding conductors of the used pairs in the analog signal cable together and connect the bundle to the SCR terminal 1 2 3 1 ...

Page 49: ...nect the conductors of the cable to the appropriate terminals 6 Twist the grounding conductors of the used pairs in the digital signal cable together and connect the bundle to the SCR terminal 7 Secure all analog and digital signal cables outside the drive mechanically 5 6 Tightening torque for 4 input signals 0 22 N m 2 lbf in relay outputs 0 5 N m 4 4 lbf in ...

Page 50: ...ical installation Checking the compatibility of the motor and drive on page 30 as well as Technical data Motor connection data on page 144 ELECTRICAL INSTALLATION See Planning the electrical installation on page 29 and Electrical installation on page 39 For ungrounded and corner grounded systems The internal EMC filter is disconnected screw EMC removed The capacitors are reformed if the drive has ...

Page 51: ...50 Installation checklist ...

Page 52: ...t power up if the external run command is on and the drive is in the remote control mode Check that the starting of the motor does not cause any danger De couple the driven machine if there is a risk of damage in case of incorrect direction of rotation Check the installation See the checklist in chapter Installation checklist on page 49 Before you start ensure that you have the motor nameplate dat...

Page 53: ...7 s PAR FWD Enter the motor data from the motor nameplate Note Set the motor data to exactly the same value 3 motor ABB Motors M2AA 200 MLA 4 IEC 200 M L 55 No Ins cl F IP 55 as on the motor nameplate Wrong motor settings of parameter group 99 may result in V Hz kW r min A cos IA IN t E s 690 Y 400 D 660 Y 380 D 415 D 440 D 50 30 50 30 50 30 50 30 50 30 60 35 1475 1475 1470 1470 1475 1770 32 5 56 ...

Page 54: ... motor stop function parameter 2102 STOP FUNCTION LOC 9907 s PAR FWD LOC 1105 s PAR FWD LOC 1202 s PAR FWD LOC 1203 s PAR FWD LOC 1204 s PAR FWD LOC 1301 s PAR FWD LOC 2008 s PAR FWD LOC 2102 s PAR FWD DIRECTION OF THE MOTOR ROTATION Check the direction of the motor rotation Turn the potentiometer fully counterclockwise If the drive is in remote control REM shown on the left switch to local contro...

Page 55: ...our work by applying input power and repeating the check as described above forward direction reverse direction ACCELERATION DECELERATION TIMES Set the acceleration time 1 parameter 2202 ACCELER TIME 1 Note Set also acceleration time 2 parameter 2205 if two acceleration times will be used in the application Set the deceleration time 1 parameter 2203 DECELER TIME 1 Note Set also deceleration time 2...

Page 56: ... to switch REM between remote and local control See Default I O connection diagram on page 46 In remote control the panel display shows text REM STARTING AND CONTROLLING THE SPEED OF THE MOTOR Start by switching digital input DI1 on Text FWD starts flashing fast and stops after the setpoint is reached Regulate the drive output frequency motor speed by adjusting the voltage or current of the analog...

Page 57: ...56 Start up and control with I O ...

Page 58: ...scribes the control panel keys and display fields It also instructs in using the panel in control monitoring and changing the settings Integrated control panel The ACS150 works with an integrated control panel which provides basic tools for manual entry of parameter values ...

Page 59: ...value can be modified in the Parameter or Reference mode 2 RESET EXIT Exits to the next higher menu level without saving changed values Resets faults in the Output and Fault modes 3 MENU ENTER Enters deeper into menu level In the Parameter mode saves the displayed value as the new setting 4 Up Scrolls up through a menu or list Increases a value if a parameter is selected Holding the key down chang...

Page 60: ...r When a fault or alarm occurs the panel goes automatically to the Fault mode showing the fault or alarm code You can reset the fault or alarm in the Output or Fault mode see chapter Fault tracing on page 127 When the power is switched on the panel is in the Output mode where you can start stop change the direction switch between local and remote control monitor up to three actual values one at a ...

Page 61: ... start and stop the drive Any 61 How to change the direction of the motor rotation Any 61 How to set the frequency reference Any 62 How to view and set the frequency reference Reference 64 How to browse the monitored signals Output 63 How to change the value of a parameter Short Long Parameter 65 How to select the monitored signals Short Long Parameter 66 How to view and edit changed parameters Ch...

Page 62: ...splay changes from LoC to LoC r the drive continues as before except that the current position of the potentiometer determines the local reference if there is a great difference between the remote and local references the transfer from remote to local control is not smooth The drive copies the current remote value for run stop status and uses it as the initial local run stop setting To stop the dr...

Page 63: ...o view the current local reference you have to go to the Reference mode Step Action Display 1 If the drive is in remote control REM shown on the left switch to local control by pressing LOC The display briefly shows LoC before switching REM to local control Note With group 11 REFERENCE SELECT you can allow changing of the remote external reference in remote control REM for example using the integr...

Page 64: ...ntil the display shows text OUTPUT at the bottom The display shows the value of one group 01 OPERATING DATA signal The unit is shown on the REM 49 1 Hz right Page 66 tells how to select up to three signals to be monitored in the Output mode The table below shows how to view them one at a time How to browse the monitored signals OUTPUT FWD Step Action Display 1 66 you can browse them in the Output ...

Page 65: ...tegrated potentiometer clockwise To decrease the reference value rotate the integrated potentiometer counterclockwise The new value potentiometer setting is shown on the display To increase the reference value press To decrease the reference value press The new value is shown on the display LOC Reference mode In the Reference mode you can view and set the frequency reference start stop change dire...

Page 66: ...d to find the desired parameter LOC 1203 PAR FWD 5 Press and hold for about two seconds until the display shows the value of the parameter with SET underneath indicating that changing of the value is now possible Note When SET is visible pressing keys and simultaneously changes the displayed value to the default value of the parameter LOC 10 0 Hz PAR SET FWD Parameter modes There are two parameter...

Page 67: ... is no signals are selected for monitoring the panel displays text n A LOC LOC 2 Specify the decimal point location or use the decimal point location and unit of the source signal setting 9 DIRECT For details see parameter 3404 OUTPUT1 DSP FORM Signal 1 parameter 3404 OUTPUT1 DSP FORM Signal 2 parameter 3411 OUTPUT2 DSP FORM Signal 3 parameter 3418 OUTPUT3 DSP FORM LOC 9 PAR SET FWD 3 Select the u...

Page 68: ...r until you see PArCh and then press The display shows the number of the first changed parameter and PAR is flashing LOC PArCh MENU FWD LOC 1103 PAR FWD 3 Use keys and to find the desired changed parameter on the list LOC 1003 PAR FWD 4 Press and hold for about two seconds until the display shows the value of the parameter with SET underneath indicating that changing of the value is now possible N...

Page 69: ...68 Control panel ...

Page 70: ... and stopped with push buttons Alternate Speed control applications where no one two or three constant speeds are used Start stop and direction are controlled by two digital inputs combination of the input states determines the operation Motor potentiometer Speed control applications where no or one constant speed is used The speed is controlled by two digital inputs increase decrease keep unchang...

Page 71: ...Start Hand Stop Start Hand DI2 Forward Reverse Stop pulse Start reverse Forward Reverse Forward Reverse Hand Hand PID DI3 Constant speed input 1 Forward Reverse Constant speed input 1 Frequency reference up Hand Auto Constant speed 1 DI4 Constant speed input 2 Constant speed input 1 Constant speed input 2 Frequency reference down Forward Reverse Auto Run enable DI5 Ramp pair selection Constant spe...

Page 72: ...y reference 0 20 mA GND Analog input circuit common 10V Reference voltage 10 V DC max 10 mA Alternative connection for AI1 If used switch IU selector to U 0 10 V voltage signal 24V Auxiliary voltage output 24 V DC max 200 mA GND Auxiliary voltage output common COM Digital input common DI1 Stop 0 Start 1 DI2 Forward 0 Reverse 1 DI3 Constant speed selection 1 DI4 Constant speed selection 1 DI5 Accel...

Page 73: ...e stop input DI2 is deactivated no input the control panel start and stop buttons are disabled 1 10 kohm Default I O connections 2 I O connection 3 SCR Signal cable shield screen AI Frequency reference 0 20 mA GND Analog input circuit common 10V Reference voltage 10 V DC max 10 mA Alternative connection for AI1 If used switch IU selector to U 0 10 V voltage signal 24V Auxiliary voltage output 24 V...

Page 74: ...on 4 SCR Signal cable shield screen AI Frequency reference 0 20 mA GND Analog input circuit common 10V Reference voltage 10 V DC max 10 mA Alternative connection for AI1 If used switch IU selector to U 0 10 V voltage signal 24V Auxiliary voltage output 24 V DC max 200 mA GND Auxiliary voltage output common COM Digital input common DI1 Start forward If DI1 DI2 the drive stops DI2 Start reverse DI3 ...

Page 75: ...2 SCR Signal cable shield screen AI Not in use by default 0 20 mA GND Analog input circuit common 10V Reference voltage 10 V DC max 10 mA 24V Auxiliary voltage output 24 V DC max 200 mA GND Auxiliary voltage output common COM Digital input common DI1 Stop 0 Start 1 DI2 Forward 0 Reverse 1 DI3 Frequency reference up 1 DI4 Frequency reference down 1 DI5 Constant speed 1 parameter 1202 CONST SPEED 1 ...

Page 76: ... SCR Signal cable shield screen AI Frequency reference Auto 4 20 mA 1 GND Analog input circuit common 10V Reference voltage 10 V DC max 10 mA Alternative connection for AI1 If used switch IU selector to U 2 10 V voltage signal 24V Auxiliary voltage output 24 V DC max 200 mA GND Auxiliary voltage output common COM Digital input common DI1 Stop 0 Start 1 Hand DI2 Forward 0 Reverse 1 Hand DI3 Hand 0 ...

Page 77: ...ohm Default I O connections 2 I O connection 3 SCR Signal cable shield screen AI Process actual value 4 20 mA 1 GND Analog input circuit common 10V Reference voltage 10 V DC max 10 mA Alternative connection for AI1 If used switch IU selector to U 2 10 V voltage signal 24V Auxiliary voltage output 24 V DC max 200 mA GND Auxiliary voltage output common COM Digital input common DI1 Stop 0 Start 1 Han...

Page 78: ...O values are different To create User macro 1 Adjust the parameters Save the parameter settings to the permanent memory by changing parameter 9902 APPLIC MACRO to 1 USER S1 SAVE MENU Press ENTER to save To recall User macro 1 Change parameter 9902 APPLIC MACRO to 0 USER S1 LOAD MENU Press ENTER to load Note User macro load restores the parameter settings including group 99 START UP DATA Check that...

Page 79: ...78 Application macros ...

Page 80: ... following table includes the parameter default values for different macros For other parameters the default values are the same for all macros see section Actual signals on page 84 Index Name Selection ABB STANDARD 3 WIRE ALTERNATE MOTOR POT HAND AUTO PID CONTROL 1001 EXT1 COMMANDS 2 DI1 2 4 DI1P 2P 3 9 DI1F 2R 2 DI1 2 2 DI1 2 1 DI1 1002 EXT2 COMMANDS 0 NOT SEL 0 NOT SEL 0 NOT SEL 0 NOT SEL 21 DI...

Page 81: ...r EXT2 is active at a time Switching between EXT1 2 through digital input 6 PID CONTROL PID control For applications in which the drive controls a process value For example pressure control by the drive running the pressure boost pump Measured pressure and the pressure reference are connected to the drive 31 LOAD FD SET FlashDrop parameter values as defined by the FlashDrop file FlashDrop is an op...

Page 82: ...nsulations is always dependent on the drive supply voltage This also applies to the case where the motor voltage rating is lower than the rating of the drive and the supply of the drive 9906 MOTOR NOM CURR Defines the nominal motor current Must be equal to the value on the motor rating plate I2N 0 2 2 0 I2N Current 9907 MOTOR NOM FREQ Defines the nominal motor frequency that is the frequency at wh...

Page 83: ...stant speed 3 that is drive output frequency E 15 0 Hz U 18 0 Hz 0 0 500 0 Hz Output frequency 13 ANALOG INPUTS Analog input signal minimum 1301 MINIMUM AI1 Defines the minimum value that corresponds to minimum mA V signal for analog input AI1 0 20 mA 0 100 4 20 mA 20 100 When analog input AI1 is selected as the source for external reference REF1 the value corresponds to the minimum reference valu...

Page 84: ...t the drive automatically prolongs the acceleration in order not to exceed the drive operating limits 5 0 s 0 0 1800 0 s Time 2203 DECELER TIME 1 Defines the deceleration time 1 that is the time required for the speed to change from the value defined by parameter 2008 MAXIMUM FREQ to zero If the speed reference decreases slower than the set deceleration rate the motor speed follows the reference s...

Page 85: ...d DOWN keys simultaneously when the control panel is in the Parameter mode 0115 KWH COUNTER R kWh counter The counter value is accumulated till it reaches 65535 after which the counter rolls over and starts again from 0 The counter can be reset by pressing UP and DOWN keys simultaneously when the control panel is in the Parameter mode 0120 AI 1 Relative value of analog input AI1 in percent 0121 PO...

Page 86: ...umber of days elapsed after power on 0403 FAULT TIME 2 Time at which the latest fault occurred Format Time elapsed after power on in 2 second ticks minus the whole days stated by signal 0402 FAULT TIME 1 30 ticks 60 seconds For example value 514 equals 17 minutes and 8 seconds 514 30 0404 SPEED AT FLT Motor speed in rpm at the time the latest fault occurred 0405 FREQ AT FLT Frequency in Hz at the ...

Page 87: ...e control panel start and stop keys are disabled 4 DI1P 2P 3 Pulse start through digital input DI1 0 1 Start In order to start the drive digital input DI2 must be activated prior to the pulse fed to DI1 Pulse stop through digital input DI2 1 0 Stop Direction through digital input DI3 0 forward 1 reverse To control direction parameter 1003 DIRECTION setting must be 3 REQUEST Note When the stop inpu...

Page 88: ...tions and the source for the start stop and direction commands for external control location 2 EXT2 0 NOT SEL See parameter 1001 EXT1 COMMANDS 1003 DIRECTION Enables the control of rotation direction of the motor or fixes the direction 3 REQUEST 1 FORWARD Fixed to forward 2 REVERSE Fixed to reverse 3 REQUEST Control of rotation direction allowed ...

Page 89: ...is typically used to control a cyclical movement of a machine section One push button controls the drive through the whole cycle When it is on the drive starts accelerates to a preset speed at a preset rate When it is off the drive decelerates to zero speed at a preset rate The figure below describes the operation of the drive It also represent how the drive shifts to normal operation jogging inac...

Page 90: ...ossible to scale the external reference so that the signal minimum and maximum values correspond to a speed other than the minimum and maximum speed limits 1101 KEYPAD REF SEL Selects the type of the reference in the local control mode 1 REF1 1 REF1 Hz Frequency reference 2 REF2 reference 1102 EXT1 EXT2 SEL Defines the source from which the drive reads the signal that selects between two external ...

Page 91: ... 6 DI3U 4D Digital input DI3 Reference increase Digital input DI4 Reference decrease The program stores the active speed reference not reset by a stop command When the drive is restarted the motor ramps up with the selected acceleration rate to the stored reference Parameter 2205 ACCELER TIME2 defines the rate of the reference change 11 DI3U 4D RNC Digital input DI3 Reference increase Digital inpu...

Page 92: ...SELECT 3 AI1 JOYST See parameter 1103 REF1 SELECT 5 DI3U 4D R See parameter 1103 REF1 SELECT 6 DI3U 4D See parameter 1103 REF1 SELECT 11 DI3U 4D RNC See parameter 1103 REF1 SELECT 12 DI3U 4D NC See parameter 1103 REF1 SELECT 14 AI1 POT See parameter 1103 REF1 SELECT 16 AI1 POT See parameter 1103 REF1 SELECT 19 PID1OUT PID controller 1 output See parameter group 40 PROCESS PID SET 1 30 DI4U 5D See ...

Page 93: ... inactive 3 DI3 Speed defined by parameter 1202 CONST SPEED 1 is activated through digital input DI3 1 active 0 inactive 4 DI4 Speed defined by parameter 1202 CONST SPEED 1 is activated through digital input DI4 1 active 0 inactive 5 DI5 Speed defined by parameter 1202 CONST SPEED 1 is activated through digital input DI5 1 active 0 inactive 7 DI1 2 Constant speed selection through digital inputs D...

Page 94: ...SPEED 4 0 1 0 Speed defined by parameter 1206 CONST SPEED 5 1 0 0 Speed defined by parameter 1207 CONST SPEED 6 0 0 0 Speed defined by parameter 1208 CONST SPEED 7 13 DI3 4 5 INV See selection DI1 2 3 INV 1202 CONST SPEED 1 Defines constant speed 1 that is drive output frequency E 5 0 Hz U 6 0 Hz 0 0 500 0 Hz Output frequency 1203 CONST SPEED 2 Defines constant speed 2 that is drive output frequen...

Page 95: ...20 mA 20 100 Example If AI1 is selected as the source for external reference REF1 this value corresponds to the value of parameter 1105 REF1 MAX 100 0 0 0 100 0 Value in percent of the full signal range Example If the maximum value for analog input is 10 mA the percent value for 0 20 mA range is 10 mA 20 mA 100 50 1303 FILTER AI1 Defines the filter time constant for analog input AI1 that is the ti...

Page 96: ... REF2 is in use 19 CONST FREQ A constant speed is in use See parameter group 12 CONSTANT SPEEDS 20 REF LOSS Reference or active control location is lost 21 OVERCURRENT Alarm Fault by overcurrent protection function 22 OVERVOLTAGE Alarm Fault by overvoltage protection function 23 DRIVE TEMP Alarm Fault by drive overtemperature protection function 24 UNDERVOLTAGE Alarm Fault by undervoltage protecti...

Page 97: ...t be changed from the control panel The lock can be opened by entering the valid code to parameter 1603 PASS CODE The lock does not prevent parameter changes made by macros 1 OPEN The lock is open Parameter values can be changed 2 NOT SAVED Parameter changes from the control panel are not stored into the permanent memory To store changed parameter values set parameter 1607 PARAM SAVE value to 1 SA...

Page 98: ... DI1 INV 3 DI3 INV See selection DI1 INV 4 DI4 INV See selection DI1 INV 5 DI5 INV See selection DI1 INV 1607 PARAM SAVE Saves the valid parameter values into the permanent memory 0 DONE 0 DONE Saving completed 1 SAVE Saving in progress 1610 DISPLAY ALARMS Activates deactivates alarms OVERCURRENT code A2001 OVERVOLTAGE code A2002 UNDERVOLTAGE code A2003 and DEVICE OVERTEMP code A2006 For more info...

Page 99: ...rake chopper and resistor are connected to the drive the controller must be off selection DISABLE to allow chopper operation 0 DISABLE Overvoltage control deactivated 1 ENABLE Overvoltage control activated 2006 UNDERVOLT CTRL Activates or deactivates the undervoltage control of the intermediate DC link If the DC voltage drops due to input power cut off the undervoltage controller automatically dec...

Page 100: ...at the constant magnetizing time is long enough to allow generation of full magnetization and torque 4 TORQ BOOST Torque boost should be selected if a high break away torque is required The drive pre magnetizes the motor with DC current before the start The pre magnetizing time is defined by parameter 2103 DC MAGN TIME Torque boost is applied at start Torque boost is stopped when output frequency ...

Page 101: ...running the Start inhibit function ignores a pending start command in any of the following situations and a new start command is required a fault is reset Run enable signal activates while the start command is active See parameter 1601 RUN ENABLE the control mode changes from local to remote the external control mode switches from EXT1 to EXT2 or from EXT2 to EXT1 0 OFF 0 OFF Disabled 1 ON Enabled...

Page 102: ...inverter modulation is stopped and the motor coasts to standstill With Zero speed delay The drive receives a stop command and decelerates along a ramp When the actual motor speed falls below an internal limit called Zero speed the zero speed delay function activates During the delay the functions keeps the modulator live The inverter modulates motor is magnetized and the drive is ready for a quick...

Page 103: ...te the motor speed follows the reference signal If the reference changes faster than the set deceleration rate the motor speed follows the deceleration rate If the deceleration time is set too short the drive automatically prolongs the deceleration in order not to exceed drive operating limits If a short deceleration time is needed for a high inertia application the drive should be equipped with a...

Page 104: ... acceleration deceleration ramp 2 The function is deactivated during emergency stop 2109 EMERG STOP SEL Ramp shape 2 is used also as jogging ramp shape time See parameter 1010 JOGGING SEL 0 0 LINEAR 0 0 LINEAR 0 0 1000 0 s See parameter 2204 RAMP SHAPE 1 2208 EMERG DEC TIME Defines the time within which the drive is stopped if an emergency stop is activated See parameter 2109 EMERG STOP SEL 1 0 s ...

Page 105: ...vibration speed ranges Activate the critical speeds function Set the critical speed ranges as in the figure below foutput Hz 52 46 23 18 freference Hz 1 2 3 4 0 OFF 0 OFF Inactive 1 ON Active 2502 CRIT SPEED 1 LO Defines the minimum limit for critical speed frequency range 1 0 0 Hz 0 0 500 0 Hz Limit The value cannot be above the maximum parameter 2503 CRIT SPEED 1 HI 2503 CRIT SPEED 1 HI Defines ...

Page 106: ...R compensation voltage as low as possible The figure below illustrates the IR compensation Motor A IR compensated voltage B No compensation A Typical IR compensation values 2603 f Hz B 2604 Type dependent 0 0 100 0 V Voltage boost 2604 IR COMP FREQ Defines the frequency at which the IR compensation is 0 V See the figure for parameter 2603 IR COMP VOLT 80 0 100 Value in percent of the motor frequen...

Page 107: ...a static speed error is detected despite of the full slip compensation Example 35 Hz constant speed reference is given to the drive Despite of the full slip compensation SLIP COMP RATIO 100 a manual tachometer measurement from the motor axis gives a speed value of 34 Hz The static speed error is 35 Hz 34 Hz 1 Hz To compensate the error the slip gain should be increased 0 0 200 Slip gain 2609 NOISE...

Page 108: ...inue operation in case the analog input signal is lost 3 LAST SPEED The drive generates alarm AI1 LOSS code A2006 and freezes the speed to the level the drive was operating at The speed is determined by the average speed over the previous 10 seconds The alarm limit is defined by parameter 3021 AI1 FAULT LIMIT WARNING Make sure that it is safe to continue operation in case the analog input signal i...

Page 109: ...ds 30 C 1 FAULT 0 NOT SEL Protection is inactive 1 FAULT The drive trips on fault MOT OVERTEMP code F0009 when the temperature exceeds 110 C and the motor coasts to stop 2 ALARM The drive generates alarm MOTOR TEMP code A2010 when the motor temperature exceeds 90 C 3006 MOT THERM TIME Defines the thermal time constant for the motor thermal model that is the time within which the motor temperature ...

Page 110: ...ion level needs to be 115 of the motor nominal current set parameter 3007 value to 91 115 127 100 Output current relative to 150 9906 MOTOR NOM CURR Par 3007 100 127 Par 3008 50 f Par 3009 100 50 150 Allowed continuous motor load relative to the nominal motor current 3008 ZERO SPEED LOAD Defines the load curve together with parameters 3007 MOT LOAD CURVE and 3009 BREAK POINT FREQ 70 25 150 Allowed...

Page 111: ...tall function See parameter 3010 STALL FUNCTION 20 0 Hz 0 5 50 0 Hz Frequency 3012 STALL TIME Defines the time for the stall function See parameter 3010 STALL FUNCTION 20 s 10 400 s Time 3013 UNDERLOAD FUNC Selects how the drive reacts to underload The protection wakes up if the motor torque falls below the curve selected by parameter 3015 UNDERLOAD CURVE output frequency is higher than 10 of the ...

Page 112: ...0 s delay between the activation of the alarm and the output current limitation The current is limited until the ripple drops under the minimum limit 0 3 Ihd 2 ALARM The drive generates alarm INPUT PHASE LOSS code A2026 when the DC ripple exceeds 14 of the nominal DC voltage 3017 EARTH FAULT Selects how the drive reacts when an earth ground fault is detected in the motor or the motor cable The pro...

Page 113: ... by parameter 3102 TRIAL TIME Last fault is reset only if the number defined by parameter 3101 NR OF TRIALS is 3 or more Trial time t x Automatic reset X X X 0 0 5 Number of the automatic resets 3102 TRIAL TIME Defines the time for the automatic fault reset function See parameter 3101 NR OF TRIALS 30 0 s 1 0 600 0 s Time 3103 DELAY TIME Defines the time that the drive waits after a fault before at...

Page 114: ...t after the delay set by parameter 3103 DELAY TIME 0 DISABLE 0 DISABLE Inactive 1 ENABLE Active WARNING The drive may restart even after a long stop if the analog input signal is restored Ensure that the use of this feature will not cause danger 3108 AR EXTERNAL FLT Activates deactivates the automatic reset for faults EXT FAULT 1 EXT FAULT 2 code F0014 F0015 Automatically resets the fault after th...

Page 115: ...lue is set to SUPRV 1 UNDER Relay energizes when value of the signal selected with 3201 SUPERV 1 PARAM drops below the supervision limit defined by 3202 SUPERV 1 LIM LO The relay remains active until the supervised value rises above the high limit defined by 3203 SUPERV 1 LIM HI Value of supervised parameter HI par 3203 LO par 3202 t Case A Energized 1 t 0 Case B Energized 1 t 0 Example 2 If 3202 ...

Page 116: ...ERV 2 PARAM setting 3206 SUPERV 2 LIM HI Defines the high limit for the second supervised signal selected by parameter 3204 SUPERV 2 PARAM Supervision wakes up if the value is above the limit x x Setting range depends on parameter 3204 SUPERV 2 PARAM setting 3207 SUPERV 3 PARAM Selects the third supervised signal Supervision limits are defined by parameters 3208 SUPERV 3 LIM LO and 3209 SUPERV 3 L...

Page 117: ...UT FWD 103 0 101 162 Parameter index in group 01 OPERATING DATA For example 102 0102 SPEED If value is set to 0 no signal is selected If parameter 3401 SIGNAL1 PARAM 3408 SIGNAL2 PARAM and 3415 SIGNAL3 PARAM values are all set to 0 n A is displayed 3402 SIGNAL1 MIN Defines the minimum value for the signal selected by parameter 3401 SIGNAL1 PARAM Display value 3407 3406 Source value 3402 3403 Note ...

Page 118: ...e displayed signal selected by parameter 3401 SIGNAL1 PARAM Note Parameter is not effective if parameter 3404 OUTPUT1 DSP FORM setting is 9 DIRECT Note Unit selection does not convert values 0 NO UNIT No unit selected 1 A Ampere 2 V Volt 3 Hz Hertz 4 Percent 5 s Second 6 h Hour 7 rpm Revolutions per minute 8 kh Kilohour 9 C Celsius 11 mA Milliampere 12 mV Millivolt 3406 OUTPUT1 MIN Sets the minimu...

Page 119: ...depends on parameter 3408 SIGNAL2 PARAM setting 3414 OUTPUT2 MAX Sets the maximum display value for the signal selected by parameter 3408 SIGNAL2 PARAM See parameter 3402 SIGNAL1 MIN x x Setting range depends on parameter 3408 SIGNAL2 PARAM setting 3415 SIGNAL3 PARAM Selects the third signal to be displayed on the control panel in the Output mode See parameter 3401 SIGNAL1 PARAM 105 0 102 162 Para...

Page 120: ... time the faster the continuous error value is corrected Too short an integration time makes the control unstable A A Error B B Error value step C Controller output with gain 1 D 4001 10 D Controller output with gain 10 C 4001 1 t 4002 60 0 s 0 0 3600 0 s Integration time If parameter value is set to zero integration I part of the PID controller is disabled 4003 DERIVATION TIME Defines the derivat...

Page 121: ...ed drive output frequency Error Fbk Ref 4006 UNITS Selects the unit for PID controller actual values 4 0 12 See parameter 3405 OUTPUT1 UNIT selections 0 12 NO UNIT mV 4007 UNIT SCALE Defines the decimal point location for the display parameter selected by parameter 4006 UNITS 1 0 4 Example PI 3 14159 4008 0 VALUE Defines together with parameter 4009 100 VALUE the scaling applied to the PID control...

Page 122: ...tant value defined by parameter 4011 INTERNAL SETPNT 31 DI4U 5D NC See selection DI3U 4D NC 32 FREQ INPUT Frequency input 4011 INTERNAL SETPNT Selects a constant value as process PID controller reference when parameter 4010 SET POINT SEL value is set to 19 INTERNAL 40 x x Unit and range depend on the unit and scale defined by parameters 4006 UNITS and 4007 UNIT SCALE 4012 SETPOINT MIN Defines the ...

Page 123: ... defined by parameter 4014 FBK SEL Parameter is used mainly in applications where feedback value is calculated from an other variable for example flow from pressure difference 0 000 32 768 32 767 Multiplier If parameter value is set to zero no multiplier is used 4016 ACT1 INPUT Defines the source for actual value 1 ACT1 See also parameter 4018 ACT1 MINIMUM 1 AI1 1 AI1 Uses analog input 1 for ACT1 ...

Page 124: ...OT SEL 0 NOT SEL No sleep function selected 1 DI1 The function is activated deactivated through digital input DI1 1 activation 0 deactivation The internal sleep criteria set by parameters 4023 PID SLEEP LEVEL and 4025 WAKE UP DEV are not effective The sleep start and stop delay parameters 4024 PID SLEEP DELAY and 4026 WAKE UP DELAY are effective 2 DI2 See selection 1 DI1 3 DI3 See selection 1 DI1 ...

Page 125: ...leep function The drive wakes up if the process actual value deviation from the PID reference value exceeds the set wake up deviation 4025 longer than the wake up delay 4026 Wake up level depends on parameter 4005 ERROR VALUE INV settings If parameter 4005 ERROR VALUE INV is set to 0 Wake up level PID reference 4010 Wake up deviation 4025 If parameter 4005 ERROR VALUE INV is set to 1 Wake up level...

Page 126: ...T FlashDrop parameter values as defined by the FlashDrop file Parameter view is selected by parameter 1611 PARAMETER VIEW FlashDrop is an optional device for fast copying of parameters to unpowered drives FlashDrop allows easy customisation of the parameter list for example selected parameters can be hidden For more information see MFDT 01 FlashDrop user s manual 3AFE68591074 English 0 USER S1 LOA...

Page 127: ...nits 100 300 V 400 V E units 460 V U units 230 690 V Voltage Note The stress on the motor insulations is always dependent on the drive supply voltage This also applies to the case where the motor voltage rating is lower than the rating of the drive and the supply of the drive 9906 MOTOR NOM CURR Defines the nominal motor current Must be equal to the value on the motor rating plate I2N 0 2 2 0 I2N ...

Page 128: ...us Using the information given in this chapter most alarm and fault causes can be identified and corrected If not contact an ABB representative How to reset The drive can be reset either by pressing the keypad key on the control panel through digital input or by switching the supply voltage off for a while When the fault has been removed the motor can be restarted Fault history When a fault is det...

Page 129: ... AI1 FAULT LIMIT Check fault function parameter settings Check for proper analog control signal levels Check connections A2009 DEVICE OVERTEMP Drive IGBT temperature is excessive Alarm limit is 120 C Check ambient conditions See also section Derating on page 138 Check air flow and fan operation Check motor power against drive power A2010 MOTOR TEMP programmable fault function parameters 3005 3009 ...

Page 130: ...2 Direction of rotation is locked Enable change of direction See parameter 1003 DIRECTION A5013 Panel control is disabled because start inhibit is active Start from the panel is not possible Reset the emergency stop command or remove the 3 wire stop command before starting from the panel See section 3 wire macro on page 72 and parameters 1001 EXT1 COMMANDS 1002 EXT2 COMMANDS and 2109 EMERG STOP SE...

Page 131: ...heck air flow and fan operation Check motor power against drive power F0004 SHORT CIRC Short circuit in motor cable s or motor Check motor and motor cable F0006 DC UNDERVOLT Intermediate circuit DC voltage is not sufficient due to missing input power line phase blown fuse rectifier bridge internal fault or too low input power Check that undervoltage controller is on parameter 2006 UNDERVOLT CTRL C...

Page 132: ... local ABB representative F0021 CURR MEAS Drive internal fault Current measurement is out of range Contact your local ABB representative F0022 INPUT PHASE LOSS programmable fault function parameter 3016 SUPPLY PHASE Intermediate circuit DC voltage is oscillating due to missing input power line phase or blown fuse Fault trip occurs when DC voltage ripple exceeds 14 of nominal DC voltage Check input...

Page 133: ...Contact your local ABB representative F1000 PAR HZRPM Incorrect speed frequency limit parameter setting Check parameter settings Following must apply 2007 MINIMUM FREQ 2008 MAXIMUM FREQ 2007 MINIMUM FREQ 9907 MOTOR NOM FREQ and 2008 MAXIMUM FREQ 9907 MOTOR NOM FREQ are within range F1003 PAR AI SCALE Incorrect analog input AI signal scaling Check parameter group 13 ANALOG INPUTS settings Following...

Page 134: ...pacitors Every year when stored See section Capacitors on page 135 Check of dustiness corrosion and temperature Every year Cooling fan replacement frame sizes R1 R2 Every three years See section Cooling fan on page 134 Check and tightening of the power terminals Every six years Check that tightening torque values given in chapter Technical data are met Consult your local ABB Service representative...

Page 135: ...t use other than ABB specified spare parts Fan replacement R1 and R2 Only frame sizes R1 and R2 include a fan frame size R0 has natural cooling WARNING Read and follow the instructions in chapter Safety on page 11 Ignoring the instructions can cause physical injury or death or damage to the equipment 1 Stop the drive and disconnect it from the AC power source 2 Remove the hood if the drive has the...

Page 136: ...re power Capacitors Reforming the capacitors The capacitors must be reformed if the drive has been stored for a year See section Type designation label on page 22 for how to find out the manufacturing time from the serial number For information on reforming the capacitors refer to Guide for capacitor reforming in ACS50 ACS55 ACS150 ACS310 ACS320 ACS350 ACS550 and ACH550 3AFE68735190 English availa...

Page 137: ...ive minutes to let the drive DC capacitors discharge Ensure by measuring with a multimeter impedance at least 1 Mohm that there is no voltage present 2 Check the tightness of the power cable connections Use the tightening torques given in section Terminal and lead through data for the power cables on page 143 3 Restore power Control panel Cleaning Use a soft damp cloth to clean the control panel A...

Page 138: ... 1 1 5 2 R2 01x 09A8 2 21 0 9 8 14 7 17 2 2 2 3 R2 3 phase UN 200 240 V 200 208 220 230 240 V 03x 02A4 2 4 3 2 4 3 6 4 2 0 37 0 5 R0 03x 03A5 2 6 1 3 5 5 3 6 1 0 55 0 75 R0 03x 04A7 2 7 6 4 7 7 1 8 2 0 75 1 R1 03x 06A7 2 11 8 6 7 10 1 11 7 1 1 1 5 R1 03x 07A5 2 12 0 7 5 11 3 13 1 1 5 2 R1 03x 09A8 2 14 3 9 8 14 7 17 2 2 2 3 R2 3 phase UN 380 480 V 380 400 415 440 460 480 V 03x 01A2 4 2 2 1 8 1 2 1...

Page 139: ...me regardless of the supply voltage within one voltage range Note 1 The maximum allowed motor shaft power is limited to 1 5 PN If the limit is exceeded motor torque and current are automatically restricted The function protects the input bridge of the drive against overload Note 2 The ratings apply at ambient temperature of 40 C 104 F In multimotor systems the drive output current rating I2N must ...

Page 140: ...derated to 75 for R0 or to 80 for R1 and R2 12 kHz I2N derated to 80 I2N derated to 50 for R0 or to 65 for R1 and R2 and the maximum ambient temperature derated to 30 C 86 F 16 kHz I2N derated to 75 I2N derated to 50 and the maximum ambient temperature to 30 C 86 F When parameter 2607 SWITCH FREQ CTRL 2 ON LOAD the drive controls the switching frequency towards the selected switching frequency 260...

Page 141: ... x E U Fuses Size of CU conductor in cablings gG UL Class T 600 V Supply U1 V1 W1 Motor U2 V2 W2 PE Brake BRK and BRK A A mm2 AWG mm2 AWG mm2 AWG mm2 AWG 1 phase UN 200 240 V 200 208 220 230 240 V 01x 02A4 2 10 10 2 5 14 0 75 18 2 5 14 2 5 14 01x 04A7 2 16 20 2 5 14 0 75 18 2 5 14 2 5 14 01x 06A7 2 16 20 1 25 2 5 10 1 5 14 2 5 10 2 5 12 01x 07A5 2 20 25 1 30 2 5 10 1 5 14 2 5 10 2 5 12 01x 09A8 2 ...

Page 142: ...EMA 1 H4 H5 W D Weight mm in mm in mm in mm in kg lb R0 257 10 12 280 11 02 70 2 76 142 5 59 1 5 3 3 R1 257 10 12 280 11 02 70 2 76 142 5 59 1 7 1 6 2 3 7 3 5 2 R2 257 10 12 282 11 10 105 4 13 142 5 59 1 9 4 2 2 UN 200 240 V 1 7 kg 3 7 lb UN 380 480 V 1 6 kg 3 5 lb 00353783 xls J Symbols IP20 cabinet UL open H1 height without fastenings and clamping plate H2 height with fastenings without clamping...

Page 143: ... 230 240 V 01x 02A4 2 25 85 6 3 22 12 3 42 01x 04A7 2 46 157 9 6 33 16 0 55 24 14 01x 06A7 2 71 242 9 6 33 16 0 55 24 14 01x 07A5 2 73 249 10 6 36 17 1 58 21 12 01x 09A8 2 96 328 10 6 36 17 1 58 21 12 3 phase UN 200 240 V 200 208 220 230 240 V 03x 02A4 2 19 65 6 3 22 12 3 42 03x 03A5 2 31 106 6 3 22 12 3 42 03x 04A7 2 38 130 9 6 33 16 0 55 24 14 03x 06A7 2 60 205 9 6 33 16 0 55 24 14 03x 07A5 2 62...

Page 144: ...m2 AWG N m lbf in R0 16 0 63 4 0 6 0 10 0 8 7 25 3 1 2 11 R1 16 0 63 4 0 6 0 10 0 8 7 25 3 1 2 11 R2 16 0 63 4 0 6 0 10 0 8 7 25 3 1 2 11 00353783 xls J Terminal data for the control cables Conductor size Tightening torque Solid or stranded Stranded with ferrule without plastic sleeve Stranded with ferrule with plastic sleeve Min Max Min Max Min Max Min Max Min Max Min Max mm2 AWG mm2 AWG mm2 AWG ...

Page 145: ...o phase input voltage Motor connection data Motor type AC induction motor Voltage U2 0 to U1 3 phase symmetrical Umax at the field weakening point Short circuit protection IEC 61800 5 1 UL 508C The motor output is short circuit proof by IEC 61800 5 1 and UL 508C Frequency Scalar control 0 500 Hz Frequency resolution 0 01 Hz Current See section Ratings on page 137 Power limit 1 5 PN Field weakening...

Page 146: ... in section Definitions on page 148 2 Maximum motor cable length is determined by the drive s operational factors Contact your local ABB representative for the exact maximum lengths when using external EMC filters Note 1 In multimotor systems the calculated sum of all motor cable lengths must not exceed the maximum motor cable length given in the table Note 2 The internal EMC filter must be discon...

Page 147: ...230 V AC Max continuous current 2 A rms Wire size Relay connections I O connections Torque Relay connections I O connections 1 5 0 20 mm2 16 24 AWG 1 0 14mm2 16 26 AWG 0 5 N m 4 4 lbf in 0 22 N m 2 lbf in Brake resistor connection Short circuit protection IEC 61800 5 1 IEC 60439 1 UL 508C The brake resistor output is conditionally short circuit proof by IEC EN 61800 5 1 and UL 508C For correct fus...

Page 148: ...emical gases Class 3C2 solid particles Class 3S2 Note The drive must be installed in clean air according to enclosure classification Note Cooling air must be clean free from corrosive materials and electrically conductive dust According to IEC 60721 3 1 chemical gases Class 1C2 solid particles Class 1S2 According to IEC 60721 3 2 chemical gases Class 2C2 solid particles Class 2S2 Sinusoidal vibrat...

Page 149: ...C UL Standard for Safety Power Conversion Equipment third edition CE marking See the type designation label for the valid markings of your drive A CE mark is attached to the drive to verify that the drive follows the provisions of the European Low Voltage and EMC Directives Compliance with the European EMC Directive The EMC Directive defines the requirements for immunity and emissions of electrica...

Page 150: ...r manual 2 The motor and control cables are selected as specified in this manual 3 The drive is installed according to the instructions given in this manual 4 For the maximum motor cable length with 4 kHz switching frequency see section Motor connection data on page 144 WARNING In a domestic environment this product may cause radio inference in which case supplementary mitigation measures may be r...

Page 151: ...cables on page 41 Overload protection The drive provides overload protection in accordance with the National Electrical Code US Braking The drive has an internal brake chopper When applied with appropriately sized brake resistors the brake chopper allows the drive to dissipate regenerative energy normally associated with quickly decelerating a motor Brake resistor selection is discussed in section...

Page 152: ...in the table for the used drive type The resistor must be able to dissipate energy ERpulse during the braking cycle T Equations for selecting the resistor Eq 1 UN 200 240 V 150000 R PRmax 450000 ton PRmax PRave UN 380 415 V R UN 415 480 V R PRmax T 615000 PRmax Eq 2 ERpulse PRmax ton ton Eq 3 PRave PRmax T For conversion use 1 hp 746 W where R selected brake resistor value ohm PRmax maximum power ...

Page 153: ...x 08A8 4 70 110 4 0 5 20 1 E EMC filter connected metal EMC filter screw installed U EMC filter disconnected plastic EMC filter screw installed US parametrization 2 Braking time maximum allowed braking time in seconds at PBRmax every 120 seconds at 40 C ambient temperature 00353783 xls J Note The brake resistors listed in the table are available in Europe They do not apply to the USA Contact your ...

Page 154: ...the system in cable and brake resistor short circuit situations For short circuit protection of the brake resistor connection see Brake resistor connection on page 146 Alternatively a two conductor shielded cable with the same cross sectional area can be used Protection of the system in brake resistor overheating situations The following setup is essential for safety it interrupts the main supply ...

Page 155: ...Technical data 154 Start up To enable resistor braking switch off the drive s overvoltage control by setting parameter 2005 OVERVOLT CTRL to 0 DISABLE ...

Page 156: ...155 Dimension drawings Dimension drawings Dimensional drawings of the ACS150 are shown below The dimensions are given in millimeters and inches ...

Page 157: ...nsion drawings Frame sizes R0 and R1 IP20 cabinet installation UL open 3AFE68637902 A Frame sizes R0 and R1 IP20 cabinet installation UL open R1 and R0 are identical except for the fan at the top of R1 EMC VAR ...

Page 158: ...157 Dimension drawings Frame sizes R0 and R1 IP20 NEMA 1 3AFE68637929 A Frame sizes R0 and R1 IP20 NEMA 1 R1 and R0 are identical except for the fan at the top of R1 EMC VAR ...

Page 159: ...J Dl co 3 CD N CD o 1 0 J 11 111 A I I I 0 3 9 J 144 5 67 142 5 57 J A I u B I I 85 3 35 J C 1 0 0 Dl 2 I CD en 6t Dl 5 I c r Clll VG C0 en r0 en 0 C CD en 0C r0 0C u J uujLJ C Q 41 I 6 3 J II B 50 I 97J 3AFE68613264 A Frame size R2 IP20 cabinet installation IUL open ...

Page 160: ...L Q M 0 I II D I II I I ro I m D en m D D Q Q f 3AFE68633931 A 0 Frame size R2 IP20 INEMA 1 ...

Page 161: ...ji 4 I 5 I 6 4 J ...

Page 162: ......

Page 163: ...160 Dimension drawings ...

Page 164: ...he drive speed in order to keep the measured process quantity actual value at the desired level setpoint Quick configuration of process PID control 9902 APPLIC 1 MACRO 4010 SET 2 POINT SEL Process PID 4018 ACT1 MINUMUM 4016 ACT1 3 INPUT 4019 ACT1 MAXIMUM 4019 ACT1 MAXIMUM 4017 ACT2 4 INPUT 4018 ACT1 MINIMUM 4021 ACT2 MAXIMUM 4020 ACT2 MINUMUM 4001 GAIN 4014 FBK SEL PID output 6 4002 INTEGRATION TI...

Page 165: ...and error value inversion when needed 6 Activate PID output Check that 1106 REF2 SELECT is set to 19 PID1OUT Pressure boost pump The figure below shows an application example The controller adjusts the speed of a pressure boost pump according to the measured pressure and the set pressure reference Example PID control block diagram Pressure boost pump ref ACS150 Actual values 4014 4001 4002 4003 re...

Page 166: ...at 1106 REF2 SELECT is set to 19 PID1OUT 2 Set 3408 SIGNAL2 PARAM to 130 PID1 FBK 3 Set 3409 SIGNAL2 MIN to 0 4 Set 3410 SIGNAL2 MAX to 10 5 Set 3411 OUTPUT2 DSP FORM to 9 DIRECT 6 Set 3412 OUTPUT2 UNIT to 0 NO UNIT 7 Set 4006 UNITS to 0 NO UNIT 8 Set 4007 UNIT SCALE to 1 9 Set 4008 0 VALUE to 0 10 Set 4009 100 VALUE to 10 How to scale the PID setpoint signal 1 Set 4010 SET POINT SEL to 19 INTERNA...

Page 167: ...et S S R 1 R 0132 Compare 1 1 2 NOT SEL INTERNAL DI 1 Select Delay t 4025 2 4022 4026 1 1 Activate sleeping 0 Deactivate sleeping refActive The reference EXT REF2 is in use See parameter 1102 EXT1 EXT2 SEL PIDCtrlActive Parameter 9902 APPLIC MACRO 6 PID CONTROL modulating Drive IGBT control is operating Example The time scheme below visualizes the operation of the sleep function Motor speed td Sle...

Page 168: ...till monitoring the pressure The pumping restarts when the pressure falls under the allowed minimum level and the wake up delay has passed Settings Parameter Additional information 9902 APPLIC MACRO PID control activation 4022 SLEEP SELECTION Sleep function activation and source selection 4023 PID SLEEP LEVEL Definition of the start limit for the sleep function 4024 PID SLEEP DELAY Definition of t...

Page 169: ...166 Appendix Process PID control ...

Page 170: ...horized to compile the technical documentation Name Address Jukka Pari P O Box 184 FIN 00381 Helsinki The products referred in this Declaration of Incorporation are in conformity with Low voltage directive 2006 95 EC and EMC directive 2004 108 EC The Declaration of Conformity according to these directives is available from the manufacturer ABB Oy furthermore declares that it is not allowed to put ...

Page 171: ...168 ...

Page 172: ...uct training For information on ABB product training navigate to www abb com drives and select Training courses Providing feedback on ABB Drives manuals Your comments on our manuals are welcome Go to www abb com drives and select Document Library Manuals feedback form LV AC drives Document library on the Internet You can find manuals and other product documents in PDF format on the Internet Go to ...

Page 173: ...rlin WI 53151 USA Telephone 262 785 3200 1 800 HELP 365 Fax 262 780 5135 www abb com drives ABB Beijing Drive Systems Co Ltd No 1 Block D A 10 Jiuxianqiao Beilu Chaoyang District Beijing P R China 100015 Telephone 86 10 5821 7788 Fax 86 10 5821 7618 www abb com drives บริษัท ที จี คอนโทรล จำกัด 1683 ทาวน อินทาวน ซอย 9 แขวงพลับพลา เขตวังทองหลาง กรุงเทพฯ 10310 โทร 02 530 9090 แฟกซ 02 530 9933 www tg...

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