ABB ACS 160 User Manual
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ABB ACS 160 User Manual

ABB ACS 160 User Manual

Driveit low voltage ac drives
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User's Manual
IT
Drive
for type ACS 160 frequency
Low Voltage
converters from 0.55 to 2.2 kW
AC Drives
(0.74 to 3 Hp)

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Summary of Contents for ABB ACS 160

  • Page 1 User’s Manual Drive for type ACS 160 frequency Low Voltage converters from 0.55 to 2.2 kW AC Drives (0.74 to 3 Hp)
  • Page 3 ACS 160 Frequency Converter User’s Manual 3BFE 64364120 REV C Effective: 17. 5. 2002  2002 copyright ABB Oy.

  • Page 5: Safety

    Warning! The ACS 160 must not be powered up more than 3 times in 5 minutes to avoid overheating the charging resistors.
  • Page 6 Note about compatibility! The supplied ACS 160 frequency converter and this manual are compatible with the software revision 1.0.0.E and later. Positioning macro is documented as it is in software revision 1.0.0.F and later. ACS 160 User’s Manual...

  • Page 7: Table Of Contents

    D Floating Network ............... 8 E Mounting the Options ..............8 F Mounting the ACS 160 on the Wall..........9 G Mounting the ACS 160 on Top of the Motor......10 H Terminal Interface ..............11 I Cable Entries ................12 J Routing the Motor Cables ............
  • Page 8 Application Macro PID Control ............ 41 Application Macro Premagnetise ..........42 Application Macro Positioning ............. 43 Parameter Guide ............45 ACS 160 Complete Parameter List ......47 Group 99: Start-up Data.............. 55 Group 01: Operating Data............56 Group 10: Command Inputs............58 Group 11: Reference Select ............
  • Page 9 Fault Resetting................107 Appendix A ..............113 Control signals ................113 Appendix B ..............117 Dimensions ..............117 Motor Mounted................117 Wall mounted ................118 Appendix C ..............119 EMC Instructions and Maximum Cable Lengths ..119 ACS 160 User’s Manual...
  • Page 10 ACS 160 User’s Manual...

  • Page 11: Introduction

    • The ACS 160 can be mounted on a wall nearby the motor. In this case, an external fan unit is needed. The fan unit provides the necessary cooling for the converter. The control panel is provided with the wall mounted unit.
  • Page 12 ACS 160 User’s Manual...

  • Page 13: Installation

    Step by step instructions The installation of the ACS 160 has been broken down into a number of steps that are listed on page 4 and page 5. The steps must be carried out in the order shown. To the right of each step reference is made to one or more Reference Sections on the following pages of this User’s Manual.

  • Page 14: Step By Step Instructions For Installing The Acs 160

    Step by Step Instructions for Installing the ACS 160 Mounting on the Wall (ACS 163-xKx-3-D, -E, -U, -V) See A CHECK the environment. CHECK voltage supply and fuses. See B, Q See C CHECK the motor. See E MOUNT the options, if necessary.

  • Page 15: Mounting On The Motor (Acs 163-Xkx-3-A, -B, -R, -S)

    See B, Q See C CHECK the motor. MOUNT the options, if necessary. See E See G INSTALL the ACS 160 on the motor. See H IDENTIFY power and control terminals. CHECK DIP switches. See K CONNECT power terminals. See H, I CONNECT control wires.

  • Page 16: Reference Sections

    • max 250 m/s (820 ft/s ), 6 ms (IEC-721-3-3, 2 edition In wall mounting: 1994-12) • max 70 m/s (230 ft/s ), 11 ms Free Fall not allowed • 76 cm (30 in.), according to ISTA 1A ACS 160 User’s Manual...

  • Page 17: B Type Designation Label And Code Key

    S = Standard product ACS 160 Product Family Input Supply 3 = 3~ Power supply input Rated Output Power in kVA See ACS 160 rating table, Section Q Voltage Rating 3 = 380 ... 500 V AC Accessories A = Motor mounting...

  • Page 18: C Motor

    ) of the ACS 160. See Q. Warning! Ensure the motor is suitable for use with the ACS 160. The ACS 160 must be installed by a competent person. If in doubt, contact your local ABB supplier. D Floating Network In IT networks do not use units which are equipped with built-in RFI filter.

  • Page 19: F Mounting The Acs 160 On The Wall

    3. Screw in the four screws or affix the nuts and bolts (depending on the mounting surface). 4. Position the ACS 160 onto the fixings and securely tighten all four corners. Note! Only lift the ACS 160 by its metal chassis.

  • Page 20: G Mounting The Acs 160 On Top Of The Motor

    Important! The correct mounting is shown in the figure above. The cooling ribs of the ACS 160 must be located at the N-end. This is because the converter is cooled by the air flow caused by the axial fan of the motor.

  • Page 21: H Terminal Interface

    In units with built-in RFI filter, earthing wire (PE) connectors for motor and mains are located on the filter baseplate. PE, motor Mains cable connector cable earthing wire connector PE, mains cable earthing wire connector Motor cable connector ACS 160 User’s Manual...

  • Page 22: I Cable Entries

    Small signal I/O cable entry 1/2” NPT plug Mains cable entry 3/4” NPT plug Motor cable entry Relay output cable entry Small signal I/O cable entry Control panel / Serial link connector Mains cable entry Motor cable entry (motor mounting) ACS 160 User’s Manual...

  • Page 23: J Routing The Motor Cables

    Wall mounting U2, V2, W2 Note! For cable selection and ensuring installation compatibility with the EMC instructions, see Appendix C for EMC Instructions and Maximum Cable Lengths. Motor mounting U2, V2, W2 ACS 160 User’s Manual...

  • Page 24: K Control Terminals

    Digital input common. To activate a digital input, there must be + 24 V (or -24 V) between that DCOM input and DCOM. The 24 V may be provided by the ACS 160 (X1:9) or by an external 12- 24 V source of either polarity.

  • Page 25: L Connection Examples

    +24V +24V DCOM DCOM ± 0 V DI configuration NPN connected RO1A RO1A DI configuration RO1B RO1B PNP connected RO2A RO2A with external RO2B RO2B power supply Note! These are connection examples only. ACS 160 User’s Manual...

  • Page 26: M Replacing The Cover

    Note! Whenever the ACS 160 detects a fault condition, the fault relay opens. The motor stops and the ACS 160 will wait to be reset. If the fault persists and no external cause has been identified, contact your ACS 160 supplier.

  • Page 27: O Motor Overload Protection

    O Motor Overload Protection ACS 160 provides two ways for motor overload protection in accordance with the National Electric Code (US): software I t model, which is the default setting, and PTC input. For more information see Group 30: Fault Functions parameters.

  • Page 28: P Loadability Of Acs 160

    P Loadability of ACS 160 Motor mounted ACS 160 types are primarily cooled by the air flow caused by the axial fan of the motor. Cooling performance of the ACS 160 is therefore dependent on the motor type and the speed at which the motor is rotating.

  • Page 29: Q Type Series And Technical Data

    * 180 % of nominal current I **150 % of nominal current I *** No overloadability! Derate to 90 % when using 8 kHz switching frequency. Rating is not valid if the ACS 160 is installed on top of a non ABB motor.

  • Page 30: R Product Conformity

    R Product Conformity CE Marking A CE mark is attached to the ACS 160 frequency converters to verity that the unit complies with the requirements of the European • Low Voltage Directive 73/23/EEC with amendments • EMC Directive 89/336/EEC with amendments Corresponding declarations and a list of main standards are available on request.

  • Page 31: T Options

    T Options Brake Resistors CA-BRK-R1-1 Integral brake resistor for ACS 160 (0.55- 0.75 kW / 0.74-1 Hp) CA-BRK-R1-2 Integral brake resistor for ACS 160 (1.1-1.5 kW / 1.5 Hp) CA-BRK-R2 Integral brake resistor for ACS 160 (2.2 kW / 3 Hp)
  • Page 32 ACS 160 User’s Manual...

  • Page 33: Start-Up

    MOTOR NOM VOLT 380-420 Y 1420 0.55 0.74 9906 220-240 D 1420 0.55 0.74 MOTOR NOM CURR 440-480 Y 1700 0.65 0.73 9907 MOTOR NOM FREQ 9908 MOTOR NOM SPEED 9909 MOTOR NOM POWER 9910 MOTOR COS PHI ACS 160 User’s Manual...
  • Page 34 After entering the required motor data, it would be a good idea to MENU check the other basic parameter settings. To see basic parameters refer to section ACS 160 Complete Parameter List (basic parameters are shaded grey in the table). OUTPUT Note! Check that starting the motor does not cause any danger.
  • Page 35 REVERSE button (parameter 1003 must be set to REQUEST 5. Connect the I/O Control Signals Disconnect the mains supply of the ACS 160, and wait 5 minutes for the intermediate circuit capacitors to discharge. Note! The unit is delivered with Factory macro 0 pre-set.
  • Page 36 Output frequency is controlled by analogue input AI 1. For further information on I/O settings, refer to the section on Application Macros. 7. Stop the drive from I/O To stop the drive deactivate digital input DI 1 (Factory macro 0). ACS 160 User’s Manual...

  • Page 37: Programming

    Programming Local and Remote Control The ACS 160 drive can be in two alternative control modes: • In remote control mode the drive is controlled externally through the digital and analogue inputs or through serial communication. This mode is active when REM is visible on the control panel display.

  • Page 38: Control Panel

    The control panel can be connected to and detached from the converter at any time. Units Control modes mAVs Crpm Active fault indicator FAULT Shaft direction OUTPUTPAR MENU FWDREV Display modes MENU START/STOP MENU LOC REM ENTER ENTER REVERSE UP/DOWN ACS 160 User’s Manual...

  • Page 39: Control Modes

    The very first time the drive is powered up, it is controlled from the Control Terminals (remote control, REM). The ACS 160 is controlled from the control panel when the drive is in local control (LOC). Switch to local control (LOC) by pressing and holding the MENU and ENTER buttons down simultaneously until first Loc or later LCr is displayed: •...

  • Page 40: Menu Structure

    Menu Structure ACS 160 has a large number of parameters. Of these, only the so-called basic parameters are initially visible. The menu function -LG- is used to make the full parameter set visible. OUTPUT display Parameter groups Parameters Setting Parameter Value Press ENTER to view the parameter value.

  • Page 41: Diagnostic Displays

    Caution! Resetting the fault may start the drive when in remote control. Some faults can only be reset by turning power off. Refer to section on Diagnostics Caution! Turning the power on again may start the drive immediately. ACS 160 User’s Manual...
  • Page 42 ACS 160 User’s Manual...

  • Page 43: Application Macros

    1602, and groups 51 - 52 serial communication parameters. Default values of certain parameters depend on the selected macro. These are listed with the description of each macro. Default values for other parameters are given in ACS 160 Complete Parameter List.

  • Page 44: Application Macro Factory (0)

    RO2A Default operation: Running =>closed RO2B *Note! DI 4 is used to configure ACS 160. It is read only once when power is connected. All parameters marked with * are determined by the DI4 input. Factory (0) default parameter values:...

  • Page 45: Application Macro Factory (1)

    RO2A Default operation: Running => closed RO2B *Note! DI 4 is used to configure ACS 160. It is read only once when power is connected. All parameters marked with * are determined by the DI4 input. Note! Stop input ( 2) deactivated: panel START/STOP button interlocked (local).

  • Page 46: Application Macro Abb Standard

    RO2B *Constant speed selection: 0 = open, 1 = connected Output Reference through AI1 Const speed 1 (1202) Const speed 2 (1203) Const speed 3 (1204) ABB Standard default parameter values: 1001 1,2) 1201 3,4) COMMANDS CONST SPEED SEL 1002...

  • Page 47: Application Macro 3-Wire

    COMMANDS NOT SEL RELAY OUTPUT 1003 1601 DIRECTION REQUEST RUN ENABLE NOT SEL 1102 1604 FAULT RESET SEL KEYPAD 1103 2105 EXT REF SELECT PREMAGN SEL NOT SEL 1106 2201 EXT REF SELECT KEYPAD NOT SEL ACS 160 User’s Manual...

  • Page 48: Application Macro Alternate

    1002 1402 COMMANDS NOT SEL RELAY OUTPUT 1003 1601 DIRECTION REQUEST RUN ENABLE NOT SEL 1102 1604 FAULT RESET SEL KEYPAD 1103 2105 EXT REF SELECT PREMAGN SEL NOT SEL 1106 2201 EXT REF SELECT KEYPAD ACS 160 User’s Manual...

  • Page 49: Application Macro Motor Potentiometer

    COMMANDS NOT SEL RELAY OUTPUT 1003 1601 DIRECTION REQUEST RUN ENABLE NOT SEL 1102 1604 FAULT RESET SEL KEYPAD 1103 2105 EXT REF SELECT PREMAGN SEL NOT SEL 1106 2201 EXT REF SELECT KEYPAD NOT SEL ACS 160 User’s Manual...

  • Page 50: Application Macro Hand - Auto

    Output frequency 0...20 mA <=> 0...50 Hz AGND +24 VDC +24V DCOM Start/Stop: Activate to start ACS 160 (Hand). Forward/Reverse: Activate to reverse rotation direction (Hand) EXT1/EXT2 Selection: Activate to select auto control Forward/Reverse (Auto) Start/Stop: Activate to start ACS 160 (Auto)

  • Page 51: Application Macro Pid Control

    AGND +24V +24 VDC DCOM Start/Stop: Activate to start ACS 160 (Manual). EXT1/EXT2 Selection: Activate to select PID control Constant speed 1: not used if PID control* Run enable: deactivation always stops ACS 160 Start/Stop: Activate to start ACS 160 (PID)

  • Page 52: Application Macro Premagnetise

    AGND Output frequency 0...20 mA <=> 0...50 Hz AGND +24V +24 VDC DCOM Start/Stop: Active to start ACS 160 Fwd/Rev: Activate to reverse rotation Constant Speed selection* Constant Speed selection* Premagnetise: Activate to start premagnetising Relay output 1, programmable RO1A RO1B Default operation: Fault =>...

  • Page 53: Application Macro Positioning

    The encoder should be mounted on the axis of the motor. • Use parameters 8207 - 8210 to adjust the target positions according to the application. • Described default functionality is valid from ACS 160 SW version 1.0.0.F. Positioning default parameter values: 1001 1201...
  • Page 54 Default operation of the Positioning Macro when positioning is active. Operation Homing Target 1 Target 2 Home position Figure 3 Example of homing operation For separate documentation about macro positioning please contact your local ABB supplier. ACS 160 User’s Manual...

  • Page 55: Parameter Guide

    Ext Comm Module Parameter settings for external fieldbus communication modules. Fieldbus Standard Modbus Parameter settings for standard Modbus (serial communication). Braking Parameter settings for selecting additional braking Braking features. Positioning Parameter settings for positioning applications. Positioning ACS 160 User’s Manual...
  • Page 56 ACS 160 User’s Manual...

  • Page 57: Acs 160 Complete Parameter List

    ACS 160 Complete Parameter List Initially, only the so called basic parameters (shaded grey in the table below) are visible. Use the appropriate menu function of the control panel to make the full parameter set visible. Refer to Menu Functions.
  • Page 58 CONSTANT SPEEDS ü ü 1201 0 - 10 3 / 0 CONST SPEED SEL 1202 0 - 250 Hz 0.1 Hz 5 Hz CONST SPEED 1203 0 - 250 Hz 0.1 Hz 10 Hz CONST SPEED ACS 160 User’s Manual...
  • Page 59 OVERVOLT CTRL ENABLE 2006 0 - 2 UNDERVOLT CTRL ENABLE TIME 2007 0 - 250 Hz 1 Hz 0 Hz MINIMUM FREQ ü 2008 0 - 250 Hz 1 Hz 50 Hz / 60 Hz MAXIMUM FREQ ACS 160 User’s Manual...
  • Page 60 50 - 150 % 100 % MOT LOAD CURVE 3007 25 - 150 % 70 % ZERO SPEED LOAD 3008 1 - 250 Hz 1 Hz 35 Hz BREAK POINT 3009 0 - 2 STALL FUNCTION NOT SEL ACS 160 User’s Manual...
  • Page 61 P VAR DIVISOR 3405 0 - 3 P VAR SCALING 3407 102 - 137 P VAR 3408 1 - 9999 P VAR MULTIP 3409 1 - 9999 P VAR DIVISOR 3410 0 - 3 P VAR SCALING ACS 160 User’s Manual...
  • Page 62 0 - 1000 % 100 % MAXIMUM 4119 1 - 2 SET POINT SEL EXTERNAL 4120 0.0 - 100.0 % 0.1 % 40.0 % INTERNAL SETPNT Group 51 EXT COMM MODULE 5101- 1 - 15 1026- FIELDBUSPAR 5115 1040 ACS 160 User’s Manual...
  • Page 63 0 - 200 1610 SPEEDGAIN 8221 0 - 65535 1611 T WINDOW LO 8222 0 ... 16000 1612 T WINDOW HI 8223 0 - 65535 1613 MAX TARGET LO 8224 0 ... 16000 1000 1614 MAX TARGET HI ACS 160 User’s Manual...
  • Page 64 POS ACT HI 8229 0 - 200 1619 DELTA DISTANCE * The motor nominal power depends on the type of unit. ** The maximum factor depending on the type of the frequency converter at 4 kHz switching frequency. ACS 160 User’s Manual...

  • Page 65: Group 99: Start-Up Data

    Group 99: Start-up Data The Start-up Data parameters are a special set of parameters for setting up the ACS 160 and for entering motor information. Code Description 9902 APPLIC MACRO Application macro selection. This parameter is used to select the Application Macro which will configure the ACS 160 for a particular application.

  • Page 66: Group 01: Operating Data

    See chapters Local and Remote Control and Appendix A, for description of different control locations. 0114 RUN TIME (R) Shows the total running time of the ACS 160 in hours (h). Can be reset by pressing UP and DOWN buttons simultaneously when in parameter set mode.
  • Page 67 0135 PROCESS VAR 2 Process variable 2, as selected by the parameters in group 34. 0136 RUN TIME Shows the total running time of ACS 160 in thousands of hours (kh). 0137 MWh COUNTER Counts the megawatt hours of ACS 160 in operation.

  • Page 68: Group 10: Command Inputs

    *Note! In cases 1, 3, 6 direction is set with parameter 1003 . Selecting value 3 ( ) fixes DIRECTION REQUEST direction to Forward. **Note! Stop signal must be activated before Start command can be given. ACS 160 User’s Manual...
  • Page 69 Rotation direction lock. This parameter allows you to fix the direction of rotation of the motor to forward or reverse. If you select 3 ( ), the direction is set according to the given direction command. REQUEST ACS 160 User’s Manual...

  • Page 70: Group 11: Reference Select

    External control location 2 ( 2) is selected. The control signal sources for 2 are defined with parameter 1002 (Start/Stop/Direction commands) and parameter 1106 (reference). COMM External control location 1 or 2 is chosen through serial communication. ACS 160 User’s Manual...
  • Page 71 Minimum reference for joystick should be 0.3 V (0.6 mA) or higher. If a 0... 10 V signal is used, the ACS 160 will operate at maximum reference in the reverse direction if the control signal is lost. Set parameter 3022...
  • Page 72 Frequency reference step down. Given as Hz or percentage depending on the value of parameter 1117 STEP MODE 1120 STEP DLY ON Switch on delay for reference step. 1121 STEP DLY OFF Switch off delay for reference step ACS 160 User’s Manual...
  • Page 73 AI max Figure 6 Setting . The range of the analogue input signal is EXT REF MINIMUM EXT REF MAXIMUM set by parameters 1301 and 1302 or parameters 1304 and 1305, depending on the analogue input used. ACS 160 User’s Manual...

  • Page 74: Group 12: Constant Speeds

    Group 12: Constant Speeds The ACS 160 has 7 programmable constant speeds, ranging from 0 to 250 Hz. Negative speed values cannot be given for constant speeds. Constant speed selections are ignored if the process PID reference is followed, the drive is in local control mode.

  • Page 75: Group 13: Analogue Inputs

    Value (%) = Desired minimum value / Full range of the analogue input * 100% = 4 mA / 20 mA * 100% = 20%. Note! In addition to this parameter setting, the analog input must be configured for 0-20 mA current signal. Refer to Reference Section L. ACS 160 User’s Manual...

  • Page 76: Group 14: Relay Outputs

    Relay is not used and is de-energised. READY The ACS 160 is ready to function. The relay is energised unless no run enable signal is present or a fault exists and supply voltage is within range. Relay energised when the ACS 160 is running.
  • Page 77 Code Description 21 = ACS OVERLOAD Relay is energised when ACS 160 overload alarm or fault exists. 22 = UNDERVOLTAGE Relay is energised when undervoltage alarm or fault exists. 23 = AI1 LOSS Relay is energised when AI1 signal is lost.

  • Page 78: Group 15: Analogue Output

    Minimum output current. 1505 MAXIMUM AO Maximum output current. 1506 AO FILTER Filter time constant for AO. AO (mA) 1505 1504 AO content 1503 1502 AO (mA) 1505 1504 AO content 1503 1502 Figure 9 Analogue output scaling. ACS 160 User’s Manual...

  • Page 79: Group 16: System Controls

    1...5 = DI1 ... DI5 To activate the run enable signal, the selected digital input must be activated. If the voltage drops and deactivates the selected digital input, the ACS 160 will coast to stop and not start until the run enable signal resumes.

  • Page 80: Group 20: Limits

    Caution! If a braking resistor is connected to the ACS 160, this parameter value must be set to 0 to enable proper operation of the chopper. Do not set this parameter to 0 if braking resistor is not connected...

  • Page 81: Group 21: Start/Stop

    Group 21: Start/Stop ACS 160 supports several start and stop modes, including flying start and torque boosting at start. DC current can be injected either before the start command (premagnetising) or automatically right after the start command (starting with DC hold).
  • Page 82 Start inhibit control enabled. Drive will not start after fault is reset, Run Enable is activated or mode is changed. In order to start the drive again, give start command anew. ACS 160 User’s Manual...

  • Page 83: Group 22: Accel/Decel

    MAXIMUM FREQ 2206 RAMP SHAPE Acceleration/deceleration ramp shape selection LINEAR FAST S CURVE MEDIUM S CRV SLOW S CURVE Output frequency MAXIMUM FREQ Linear S curve Time Ramp time Figure 10 Definition of acceleration/deceleration ramp time. ACS 160 User’s Manual...

  • Page 84: Group 25: Critical Freq

    Group 25: Critical Freq In some mechanical systems, certain speed ranges can cause resonance problems. With this parameter group, it is possible to set up to two different speed ranges that the ACS 160 will skip over. Code Description 2501 CRIT FREQ SEL Critical frequencies activation.

  • Page 85: Group 26: Motor Control

    This parameter defines the gain for the slip. 100 % means full slip compensation; 0 % means no slip compensation. U (%) IR compensation IR compensation range No compensation f (Hz) Field weakening point Figure 12 Operation of IR compensation ACS 160 User’s Manual...

  • Page 86: Group 30: Fault Functions

    CONST SPEED LAST SPEED A warning indication is displayed and the speed is set to the level the ACS 160 was last operating at. This value is determined by the average speed over the last 10 seconds. Caution: If you select...
  • Page 87 FAULT Displays a warning indication at the warning level (97.5 % of the nominal value). Displays a fault indication when the motor temperature reaches the 100 % level. The ACS 160 coasts to stop. WARNING A warning indication is displayed when the motor temperature reaches the warning level (95 % of the nominal value).
  • Page 88 NOT SEL Stall protection is not used. FAULT When the protection is activated the ACS 160 coasts to stop. Fault indication is displayed. WARNING A warning indication is displayed. The indication disappears in half the time set by parameter 3012...
  • Page 89 = output frequency = break point frequency (parameter 3008 BREAK POINT Figure 16 Thermal protection trip times when parameters 3005 , 3006 MOT THERM TIME MOT LOAD and 3007 have default values. CURVE ZERO SPEED LOAD ACS 160 User’s Manual...
  • Page 90 70 % 50 % 30 % 2.4 * ƒ ƒ ƒ Figure 17 Underload curve types. T nominal torque of the motor, nominal frequency of the motor. ACS 160 User’s Manual...

  • Page 91: Group 31: Automatic Reset

    3101 NR OF TRIALS 3103 DELAY TIME This parameter sets the time that the ACS 160 will wait after a fault occurs before attempting to reset. If set to zero, the ACS 160 will reset immediately. 3104 AR OVERCURRENT...

  • Page 92: Group 32: Supervision

    3205 SUPERV 2 LIM LO Second supervision limit low. Display of this parameter depends on selected supervised parameter (3204). 3206 SUPERV 2 LIM HI Second supervision limit high. Display of this parameter depends on selected supervised parameter (3204). ACS 160 User’s Manual...
  • Page 93 Case A: Is for monitoring when/if the supervised signal exceeds a given limit. Case B: Is for monitoring when/if the supervised signal falls below a given limit. Figure 19 Operating data supervision using relay outputs, when LOW ≤ HIGH. ACS 160 User’s Manual...
  • Page 94 LOW. After this the limit used is LOW, until the signal goes back below value HIGH. A = Initially the relay is de-energised. B = Initially the relay is energised. Figure 20 Operating data supervision using relay outputs, when LOW>HIGH. ACS 160 User’s Manual...

  • Page 95: Group 33: Information

    Group 33: Information Code Description 3301 SW VERSION Software version. 3302 TEST DATE Displays the test date of the ACS 160 (yy.ww). ACS 160 User’s Manual...

  • Page 96: Group 34: Process Variables

    Check what is the decimal point location on variable selected with parameter 3402 P VAR In this case the chosen variable 0103 is displayed with 0.1 Hz resolution. Therefore OUTPUT FREQ 3405 = 1 must be selected. See Figure 21. ACS 160 User’s Manual...

  • Page 97: Group 40: Pid Control

    Group 40: PID Control The PID Control Macro allows the ACS 160 to take a reference signal (setpoint) and an actual signal (feedback), and automatically adjust the speed of the drive to match the actual signal to the reference. There exist two PID parameter sets (group 40 for set 1 parameters and group 41 for set 2 parameters).
  • Page 98 Greater of actual values 1 and 2. 8 = sqrt (A1-A2) Square root of difference of actual values 1 and 2. 9 = sqA1 + sqA2 Sum of square roots of actual values 1 and 2. ACS 160 User’s Manual...
  • Page 99 Analogue input signal AI min AI max Figure 22 Actual value scaling. The range of the analogue input signal is set by parameters 1301 and 1302 or parameters 1304 and 1305, depending on the analogue input used. ACS 160 User’s Manual...
  • Page 100 Code Description 4013 PID SLEEP DELAY Time delay for the sleep function, see Figure 23. If the ACS 160 output frequency is below a set level (parameter 4014 ) longer than , ACS 160 is stopped. SLEEP LEVEL PID SLEEP DELAY Alarm 28 is displayed when PID sleep is active.
  • Page 101 Process reference is a constant value set with parameter 4020 INTERNAL SETPNT EXTERNAL Process reference is read from a source defined with parameter 1106 . The ACS 160 must EXT REF SELECT be in remote mode (REM is shown on control panel display).* * Process reference to PID controller can also be given from the control panel in local mode (LOC is shown on control panel display) if the panel reference is given as percentage, i.e.
  • Page 102 APPLIED WAKE-UP LEVEL 100 % SETPOINT 1107 EXT REF Figure 25 Example of how applied wake-up level floats with the set point, here parameter 4015 WAKE equals to 60 %, PID control inverted case. UP LEVEL ACS 160 User’s Manual...
  • Page 103 APPLIED WAKE- UP LEVEL SLEEP DEACTIVATED TIME EXPIRES TIME Figure 26 Wake-up level operation with non-inverted error value. TIME EXPIRES APPLIED WAKE- UP LEVEL SLEEP DEACTIVATED ACT VALUE Figure 27 Wake-up level operation with inverted error value. ACS 160 User’s Manual...

  • Page 104: Group 41: Pid Control (2)

    Parameters of this group belong to PID parameter set 2. The operation of parameters 4101 - 4112, 4119 - 4120 is analogous with set 1 parameters 4001 - 4012, 4019 - 4020. PID parameter set 2 can be selected by parameter 4016 PID PARAM SET ACS 160 User’s Manual...

  • Page 105: Group 51: Ext Comm Module

    Interbus-S (CFB-IBS) CS31 bus * CANopen (CFB-CAN) DeviceNet (CFB-DEV) LONWORKS (CFB-LON) Modbus+ * Others * * Reserved 5102 - FIELDBUSPAR 2 - FIELDBUSPAR 15 5115 Refer to communication module documentation for more information on these parameters. ACS 160 User’s Manual...

  • Page 106: Group 52: Standard Modbus

    When standard Modbus communication is used parameters 5201 - 5203 are used to set up station number, communication speed and parity. An adapter is required to connect the ACS 160 either to RS232 or to RS485 type bus (type code CFB- RS).
  • Page 107 CONST SPEED LAST SPEED A warning indication is displayed and the speed is set to the level the ACS 160 was last operating at. This value is determined by the average speed over the last 10 seconds. Caution: If you select...

  • Page 108: Group 54: Braking (Electromechanical Brake Control)

    Group 54: Braking (Electromechanical Brake Control) The versatile braking features of the ACS 160 include capability to control electromechanical brake. Electromechanical brake can be controlled by using programmable relay outputs of the ACS 160. The brake is applied when the motor is in stop (the relay output is de-energised).
  • Page 109 Start frequency (internal parameter) Relay output: brake delay 5401 MBRK OPEN DLY Brake Released (open) Brake On Mechanical (closed) brake: Figure 28 Operation of the electromechanical brake control. Note! Described functionality is valid from ACS 160 SW version 1.0.0.F. ACS 160 User’s Manual...

  • Page 110: Group 82: Positioning

    Group 82: Positioning Built-in positioning features of the ACS 160 make it possible to use the drive in simple positioning applications, in many cases without an external PLC. Possible application examples are indexing systems and positioning systems with two absolute positions. Homing functions are also available.
  • Page 111 Code Description 8201 ENC PULSE NUM Number of encoder pulses per revolution. 8202 ENC ERROR Defines the action of the ACS 160 in encoder error situation. NOT SEL Encoder error supervision disabled. FAULT The drive is stopped with coast stop and fault indication is given when the following conditions are fulfilled: •...
  • Page 112 0 ( CONST SPEED SEL NOT SEL Parameter 2201 must be set to 0 ( SELECT NOT SEL Frequency reference, acceleration and deceleration times can be set only when the drive is stopped. ACS 160 User’s Manual...
  • Page 113 Selected target is absolute. Continuous move between home and target1 position. Used for example for spinning wires. A position time delay parameter 8213 and external frequency reference POS DELAY parameter 8217 can be defined. AUX POS CMD ACS 160 User’s Manual...
  • Page 114 NOT SEL Digital input 2 (DI2) is used to give auxiliary positioning start/stop commands. This command does not start or stop the ACS 160 modulation. During homing this command acts only as start enable. STOP Positioning frequency reference is set to 0 Hz when positioning target window has been reached.
  • Page 115 The purpose of parameters 8220 1 and 8229 is to make actual positioning speed SPEED GAIN DELTA DISTANCE near target depended on the load and to ensure that the target is reached. ACS 160 User’s Manual...
  • Page 116 ACS 160 User’s Manual...

  • Page 117: Diagnostics

    The ACS 160 can be configured to automatically reset certain faults. Refer to parameter group 31 AUTOMATIC RESET. Warning! If an external source for start command is selected and it is active, the ACS 160 may start immediately after fault reset.
  • Page 118 Exception response is sent through Standard Modbus channel. The bus master MODBUS EXCEPTION may be sending queries which cannot be processed by the ACS 160. Last three exception response codes are stored into parameters 5213 - 5215. Analogue input 1 loss. Analogue input 1 value is less than AI1 (1301).
  • Page 119 Inverter overload condition. The ACS 160 output current exceeds the ratings OUTPUT OVERLOAD given in Reference Section P. 27 * ACS 160 is about to perform automatic fault reset operation. As a result, the AUTOMATIC RESET drive may start after the reset operation. Refer to parameter group 31 AUTOMATIC RESET.
  • Page 120 DECELER 1 and 2204 TIME DECELER TIME • Brake chopper (if present) may be underdimensioned ACS 160 heat sink temperature is excessive. Temperature trip limit is OVERTEMP 105 °C. • Check air flow and fan operation. • Check motor power against unit power.
  • Page 121 Full display blinking Serial link failure. Bad connection between the control panel and the ACS 160. Note! Faults (**) are indicated by a red blinking LED and are reset by turning the power off for a while. ACS 160 User’s Manual...
  • Page 122 ACS 160 User’s Manual...

  • Page 123: Control Signals

    Start/Stop Local NOT SEL REQUEST EXT1 DI1-DI5 Direction Remote KEYPAD FORWARD NOT SEL EXT2 DI1-DI5 REVERSE KEYPAD Enabled, DI1-DI5 DIRECTION RUN ENABLE 1003 COMMANDS 1601 COMMANDS 1001 1002 Figure 29 Selecting control location and control source. ACS 160 User’s Manual...
  • Page 124 REQUEST DI1-DI5 Direction Remote FORWARD NOT SEL KEYPAD DI1-DI5 REVERSE Enabled, KEYPAD DI1-DI5 RUN ENABLE DIRECTION COMMANDS COMMANDS 1601 1003 1001 1002 Figure 30 The control signal connections of the ABB Standard, Alternate and Premagnetise macros. ACS 160 User’s Manual...
  • Page 125 Loc/Rem Start/Stop, Direction Start/Stop NOT SEL Local REQUEST Remote Direction KEYPAD FORWARD NOT SEL REVERSE KEYPAD RUN ENABLE DIRECTION 1601 COMMANDS COMMANDS 1003 1001 1002 Figure 31 The control signal connections of the PID Control macro. ACS 160 User’s Manual...
  • Page 126 ACS 160 User’s Manual...

  • Page 127: Dimensions

    ACS 163- Size (mm) (mm) (mm) (mm) (mm) (kg) 1K1-3-A...2K7-3-A 4K1-3-A 1K1-3-B... 2K7-3-B 4K1-3-B Converter type Frame Weight ACS 163- Size (in) (in) (in) (in) (in) (lb) 1K1-3-R...2K1-3-R 4K1-3-R 10.3 10.14 1K1-3-S... 2K1-3-S 12.13 4K1-3-S 10.3 13.89 ACS 160 User’s Manual...

  • Page 128: Wall Mounted

    11.4 5.28 6.18 6.73 11.24 4K1-3-U 14.1 5.87 13.5 3.86 13.0 5.28 6.18 6.73 12.79 1K1-3-V... 2K1-3-V 12.5 5.87 11.93 3.86 11.4 6.73 6.18 6.73 14.77 4K1-3-V 14.1 5.87 13.5 3.86 13.0 6.73 6.18 6.73 16.53 ACS 160 User’s Manual...

  • Page 129: Emc Instructions And Maximum Cable Lengths

    CE Marking A CE mark is attached to ACS 160 frequency converters to verify that the unit follows the provisions of the European Low Voltage and EMC Directives (Directive 73/23/EEC, as amended by 93/68/ EEC and Directive 89/336/EEC, as amended by 93/68/EEC).
  • Page 130 Minimum requirement for the motor cable screen is presented in Figure 32. Copper wire screen Helix of copper tape Inner insulation Insulation jacket Cable core Figure 32 Minimum requirement for motor cable screen (e.g. MCMK, NK Cables). ACS 160 User’s Manual...
  • Page 131 At the motor end the motor cable screen must be earthed 360 degrees with an EMC cable gland (e.g. ZEMREX SCG Screened cable glands) or the screen wires must be twisted together into a bundle not longer than five times its width and connected to the PE terminal of the motor. ACS 160 User’s Manual...
  • Page 132 Never mix 24 VDC and 115/230 VAC signals in the same cable. Note! When the overriding control equipment and the ACS 160 are installed inside the same cabinet, these recommendations might be overly cautious. If the customer plans to test the entire installation, there is an opportunity to save some costs by relaxing these recommendations, for example by using unshielded cable for the digital inputs.
  • Page 133 5 / 16 5 / 16 5 / 16 ACS 163-4K1-3-E /-V 10 / 33 10 / 33 10 / 33 10 / 33 5 / 16 5 / 16 5 / 16 5 / 16 ACS 160 User’s Manual...
  • Page 134 Compliance with EN61800-3 EMC Standard Second Environment ACS 160 types ACS 163-xKx-3-B, -S comply with the requirements of EN 61800-3 Second Environment, Unrestricted and Restricted Distribution, with switching frequency of 4 kHz or 8 kHz, when mounted on the top of the motor.
  • Page 135 The ACS 160 with a total rated power greater than 1 kW conforms with EN 61000-3-2. Below 1 kW, use the following units to comply with class A limits of EN 61000-3-2: ACS163-1K1-3-B, -S, -E, -V and ACS163-1K6-3-B, -S, -E, -V.
  • Page 136 ACS 160 User’s Manual...
  • Page 138 ABB Inc. ABB Oy Drives & Power Electronics BAU Drives 16250 W. Glendale Drive P.O. Box 184 New Berlin, WI 53151 00381 Helsinki FINLAND Telephone (262) 785-3200 Telephone +358-10-2211 (800) 243-4384 Telefax +358-10-222 2681 Telefax (262) 780-5135...

This manual is also suitable for:

Acs 163-1k1-3-aAcs 163-1k1-3-rAcs 163-1k6-3-aAcs 163-1k6-3-rAcs 163-2k1-3-aAcs 163-2k1-3-r ... Show all

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