ABB ACS 400 User Manual
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ABB ACS 400 User Manual

Ac drives for speed control
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ACS 400
User's Manual
ACS 400 AC Drives for Speed Control
of 3 to 40 Hp, 230 Volt and
3 to 50 Hp, 460 Volt
AC Induction Motors
ABB Automation Inc.
http://nicontrols.com

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  • Page 1 ACS 400 User’s Manual ACS 400 AC Drives for Speed Control of 3 to 40 Hp, 230 Volt and 3 to 50 Hp, 460 Volt AC Induction Motors ABB Automation Inc. http://nicontrols.com...
  • Page 2 N O R T H E R N INDUSTRIAL W W W . N I C O N T R O L S . C O M ESTABLISHED IN 1978 Northern Industrial Thwaites Close Blackburn Lancashire BB1 2QQ United Kingdom Cert No.
  • Page 3 http://nicontrols.com...
  • Page 4 ACS 400 AC Drives for Speed Control of AC Induction Motors User’s Manual ACS400-US-04 3AUA489002B5310 R0101 Rev B Effective: 01/16/01 Supersedes: 2/1/99 Copyright © 2001 ABB Automation Inc. All Rights Reserved. http://nicontrols.com...
  • Page 5 http://nicontrols.com...

  • Page 6: Safety

    Warning! Even when the motor is stopped there are dangerous voltages present at Power Circuit terminals U1, V1, W1 and U2, V2, W2 and U Warning! Even when power is removed from the input terminals of the ACS 400, there may be dangerous external voltages at relay terminals RO1A, RO1B, RO1C, RO2A, RO2B, RO2C.
  • Page 7 ACS 400 User’s Manual http://nicontrols.com...

  • Page 8: Table Of Contents

    Dimensions (in/mm) ........4 Mounting the ACS 400 on a Wall ......6 Removing the Cover .
  • Page 9 Application Macro Factory (1) ......55 Application Macro ABB Standard ......56 Application Macro 3-wire .
  • Page 10 Application Macro PFC Control ......63 ACS 400 Complete Parameter List ....65 Group 99: Start-up Data .
  • Page 11 Relay Outputs ........160 Adding More I/O to ACS 400 ......160 Setting up NDIO modules .

  • Page 12: Installation

    Step by step instructions The installation of the ACS 400 has been broken down in a number of steps that are listed on page 2. The steps must be carried out in the order shown. At the right of each step, reference is made to one or more Reference Sections on the following pages of this User’s Manual.
  • Page 13 TURN the power on. See O Figure 1 Step by step instructions for installing the ACS 400. The references after each step refer to one or more of the Reference Sections on the following pages in this manual. ACS 400 User’s Manual...

  • Page 14: Reference Sections

    • Relative humidity less than 95% (non-condensing) The ACS 400 must be installed in a heated, indoor controlled environment that is suitable for the selected enclosure. Drives are available in either an IP21/NEMA Type 1 or an IP54/NEMA Type 12 enclosure.

  • Page 15: Dimensions (In/Mm)

    40.8 / 18.5 59.5 / 27 Figure 2 IP 21/NEMA Type 1 enclosures A complete set of dimensional drawings for the NEMA Type 1 ACS 400 drives is located in “Appendix D” on page 167. ACS 400 User’s Manual http://nicontrols.com...
  • Page 16 59.5 / 27 Figure 3 IP 54/NEMA Type 12 & 4 enclosures A complete set of dimensional drawings for the NEMA Type 12 & 4 ACS 400 drives is located in “Appendix D” on page 167. ACS 400 User’s Manual...

  • Page 17: Mounting The Acs 400 On A Wall

    C Mounting the ACS 400 on a Wall Warning! Before installing the ACS 400, ensure the input power supply to the drive is off. The lid of the packing-box provides a Wall Mounting Template. Remove the lid from the box.

  • Page 18: Removing The Cover

    4 Open the upper part of the front cover and remove it. 5 Press the retaining lever and pull. 6 Remove the lower part of the front cover. Figure 9 Opening the frame size R3 and R4 of type IP 21/NEMA Type 1. ACS 400 User’s Manual http://nicontrols.com...
  • Page 19 IP 54/NEMA Type 12 & 4 1 Take the screws off. 2 Remove the front cover. 3 Remove panel if needed. Figure 10 Opening type IP 54/NEMA Type 12 & 4 drives. ACS 400 User’s Manual http://nicontrols.com...

  • Page 20: Terminal Interface

    F Attaching a Warning Sticker The contents of the packing box include warning stickers in different languages. Attach a warning sticker in the language of your choice on the inside plastic shell as indicated above. ACS 400 User’s Manual http://nicontrols.com...

  • Page 21: Type Code And Model Designation

    48...63 Hz Ser.no. *1982800001* For more information see ACS400 User’s Manual 0...250Hz (EXCEPT 230 V) Figure 12 ACS 400 type designation label. AC S 4 0 1 AC Drive Product Type S = Standard drive ACS 400 Product Family Input Bridge...

  • Page 22: Floating Network

    GND 1 GND 2 Figure 15 Removing the grounding screws from frame size R1 and R2 frequency converters. GND 1 GND 2 Figure 16 Removing the grounding screws from frame size R3 and R4 frequency converters. ACS 400 User’s Manual http://nicontrols.com...

  • Page 23: Installation Of Acs 400 Conduit Box

    Variable Speed Drives.” Contact your local ABB representative for specific IEC installation instructions. Figure 17 US conduit box installation kit. Your ACS 400 should include the parts shown above, the two (2) halves of the conduit box, four (4) screws with captive washers and two (2) self tapping screws.
  • Page 24 Take care not to overtighten. Tighten the top two screws and use the supplied knockouts to route the appropriate cables. Figure 21 Conduit box with all screws inserted in the proper holes. ACS 400 User’s Manual http://nicontrols.com...

  • Page 25: Cable Connections

    Refer to Section T “Specifications” on page 21 for current, ratings, fuse recommendations and the maximum wire size capacities and tightening torques for the terminals. The ACS 400 is suitable for use on a circuit capable of delivering not more than 65,000 RMS symmetrical amperes, 480 V maximum.

  • Page 26: Control Terminals

    To activate a digital input, there must be ≥+10 V (or ≤-10 V) between that input and DI Configuration DCOM1. The 24 V may be provided by the ACS 400 (X1:9) using the connection examples (see Section M) or by an external 12-24 V source of either polarity.

  • Page 27: Motor

    50 Hz or 60 Hz. The motor nominal current must be less than the nominal output current of the ACS 400 (See Sections G and T). Warning! Ensure the motor is compatible for use with the ACS 400. The ACS 400 must be installed by a competent person.

  • Page 28: Connection Examples

    +24V +24V DCOM1 DCOM1 DCOM2 DCOM2 RO1C RO1C RO1A RO1A RO1B RO1B RO2C RO2C RO2A RO2A RO2B RO2B J1 Analog inputs J1 Analog inputs RS485 Multidrop application Other Modbus Devices ACS 400 RS485 interf. AGND ACS 400 User’s Manual http://nicontrols.com...

  • Page 29: Replacing The Cover

    2. Replace the front cover. 3. Carefully tighten the screws. O Applying Power When power is applied to the ACS 400, the green LED comes on. Note! Before increasing motor speed, check that the motor is running in desired direction. P Environmental Information The package is made of corrugated cardboard and can be recycled.

  • Page 30: Protection Features

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

  • Page 31: Motor Overload Protection

    If the motor current I exceeds nominal current I of the motor for a prolonged period, the ACS 400 automatically protects the motor from overheating by tripping. The trip time depends on the extent of the overload (I ), the output frequency and f .

  • Page 32: Specifications

    13 lb/in. 16 lb/in. 32 lb/in. Control Terminals 0.5 - 1.5 (AWG22...AWG16) / Torque 0.4 Nm Line Fuse 3~ Bussmann Type KTK-15 KTK-25 KTK-25 KTK-35 JJS-50 JJS-80 JJS-80 JJS-100 JJS-125 Power Losses Power Circuit Control Circuit ACS 400 User’s Manual http://nicontrols.com...
  • Page 33 13 - 16 lb/in. Control terminals 0.5 - 1.5 (AWG22...AWG16) / Torque 0.4 Nm **** Line fuse 3~ Bussman Fuse Type KTK-10 KTK-15 KTK-15 KTK-20 KTK-30 JJS-40 JJS-50 JJS-60 JJS-80 JJS-100 Power losses Power circuit 1100 Control circuit ACS 400 User’s Manual http://nicontrols.com...

  • Page 34: Product Conformity

    It may also be necessary to consider motor insulation requirements related to drive output dv/dt. U Product Conformity The ACS 400 complies with North American standard UL508C. The ACS 400 (400V Series) complies with European requirements: •...

  • Page 35: Accessories

    V Accessories ACS-100/140/400-EXT Extension cable kit for use with the control panel. ACS400-IF11-3 through ACS400-IF41-3 RFI input filters. RS485/232 Adapter DDCS Communication Module ACS 400 User’s Manual http://nicontrols.com...

  • Page 36: Programming

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

  • Page 37: Output Display

    ACS 400 is programmed for that type of operation. Menu Structure ACS 400 has a large number of parameters. Of these, only the so-called basic parameters are initially visible. See “Selecting Full Parameter Set” on page 28 for details on specifying the full parameter set.

  • Page 38: Setting Parameter Value

    Note! Parameter copying does not affect all parameters. The excluded parameters are: 9901, 9905-9910, 1605, 1607, 5002, 5201 and all Group 51 parameters. See “ACS 400 Complete Parameter List” on page 65 for a description of these parameters.

  • Page 39: Led Indicators

    The alarm and fault messages disappear when MENU, ENTER or the arrow buttons on the control panel are pressed. The message will reappear after a few seconds if the keypad is not touched and alarm or fault is still active. ACS 400 User’s Manual http://nicontrols.com...

  • Page 40: Resetting The Drive From The Control Panel

    Display contrast can be adjusted any time. Increase contrast by pressing and holding the ENTER and UP buttons. Decrease contrast by pressing and holding the ENTER and DOWN buttons. The buttons must be pressed simultaneously. ACS 400 User’s Manual http://nicontrols.com...

  • Page 41: Acs100-Pan Control Panel

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

  • Page 42: Output Display

    ENTER ENTER OUTPUT Menu Structure ACS 400 has a large number of parameters. Of these, only the so-called basic parameters are initially visible. The menu function -LG- is used to make the full parameter set visible. OUTPUT display Parameter groups...

  • Page 43: Menu Functions

    Note! Parameter copying does not affect all parameters. The excluded parameters are: 9901, 9905-9910, 1605, 1607, 5002, 5201 and all Group 51 parameters. See “ACS 400 Complete Parameter List” on page 65 for a description of these parameters.

  • Page 44: Diagnostic Displays

    Diagnostic Displays When the red LED of the ACS 400 is on or blinking, a fault is active. The relevant fault message flashes in the panel display. When the green LED of the ACS 400 is blinking, an alarm is active. The relevant alarm message is shown in the panel display.
  • Page 45 ACS 400 User’s Manual http://nicontrols.com...

  • Page 46: Diagnostics

    The ACS 400 can be configured to automatically reset certain faults. Refer to parameter group 31 AUTOMATIC RESET. Warning! If an external source for start command is selected and it is active, the ACS 400 may start immediately after fault reset.
  • Page 47 Exception response is sent through Standard Modbus channel. The bus master MODBUS EXCEPTION may be sending queries which cannot be processed by the ACS 400. Refer to “Standard Serial Communication” section. Last three exception response codes are stored into parameters 5213 - 5215.
  • Page 48 OUTPUT OVERLOAD given in “Specifications” on page 21 of this manual. 27 * ACS 400 is about to perform automatic fault reset operation. As a result, the AUTOMATIC RESET drive may start after the reset operation. Refer to parameter group 31 AUTOMATIC RESET.
  • Page 49 DECELER 1 and 2204 TIME DECELER TIME • Brake chopper (if present) may be underdimensioned ACS 400 heat sink temperature is excessive. Temperature trip limit is OVERTEMP 95 °C. • Check air flow and fan operation. • Check motor power against unit power.
  • Page 50 Serial link failure. Bad connection between the control panel and the “COMM LOSS” (ACS-PAN) ACS 400. Note! These faults (**) are indicated by a red blinking LED and are reset by turning the power off for a while. ACS 400 User’s Manual http://nicontrols.com...

  • Page 51: Troubleshooting Guide

    Troubleshooting Guide This section consists of a series of flowcharts to help determine the necessary corrective action for eight common problems that may occur during start-up of your ACS 400 drive. • motor will not run, see page 41 •...

  • Page 52: Motor Will Not Run

    Motor Will Not Run ACS 400 User’s Manual http://nicontrols.com...

  • Page 53: Motor Stalls During Acceleration

    Motor Stalls during Acceleration ACS 400 User’s Manual http://nicontrols.com...

  • Page 54: Overvoltage Fault Indication

    Overvoltage Fault Indication ACS 400 User’s Manual http://nicontrols.com...

  • Page 55: Overcurrent Fault Indication

    Overcurrent Fault Indication ACS 400 User’s Manual http://nicontrols.com...

  • Page 56: Overload Fault Indication

    Overload Fault Indication ACS 400 User’s Manual http://nicontrols.com...

  • Page 57: Undervoltage Fault Indication

    Undervoltage Fault Indication ACS 400 User’s Manual http://nicontrols.com...

  • Page 58: External Fault Indication

    External Fault Indication ACS 400 User’s Manual http://nicontrols.com...

  • Page 59: No Operator Display

    No Operator Display ACS 400 User’s Manual http://nicontrols.com...

  • Page 60: Acs 400 Basic Parameters

    ACS 400 Basic Parameters The ACS 400 has a large number of parameters. Of these, only the so-called basic parameters are initially visible. Setting up only a few basic parameters is sufficient in applications where the preprogrammed application macros of the ACS 400 can provide all desired functionality. For a full description of the programmable features provided by the ACS 400, see “ACS 400 Complete Parameter List”...
  • Page 61 CONSTANT SPEEDS 1202 CONST SPEED 1 Range for all constant speeds: 0 - 250.0 Hz Default value: 5.0 Hz 1203 CONST SPEED 2 Default value: 10.0 Hz 1204 CONST SPEED 3 Default value: 15.0 Hz ACS 400 User’s Manual http://nicontrols.com...
  • Page 62 Note! Analog output content is programmable. Values given here are valid only if other analog output configuration parameters have not been modified. Description of all parameters is given in “ACS 400 Complete Parameter List” on page 65. Group 20 LIMITS 2003 MAX CURRENT Maximum output current.
  • Page 63 Default value: 1 ( LINEAR Group 33 INFORMATION 3301 SW VERSION Software version code. S = Parameters can be modified only when the drive is stopped. ACS 400 User’s Manual http://nicontrols.com...

  • Page 64: Application Macros

    50 - 52 serial communication parameters) to their default values. Default values of certain parameters depend on the selected macro. These are listed with the description of each macro. Default values for other parameters are given in “ACS 400 Complete Parameter List” on page 65.

  • Page 65: Application Macro Factory (0)

    Relay output 2, programmable Default operation: Running =>20 connected to 22 *Note! DI 4 is used to configure ACS 400. It is read only once when power is connected. All parameters marked with * are determined by the DI4 input.

  • Page 66: Application Macro Factory (1)

    Relay output 2, programmable Default operation: Running => 20 connected to 22 *Note! DI 4 is used to configure ACS 400. It is read only once when power is connected. All parameters marked with * are determined by the DI4 input.

  • Page 67: Application Macro Abb Standard

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

  • Page 68: Application Macro 3-Wire

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

  • Page 69: Application Macro Alternate

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

  • Page 70: Application Macro Motor Potentiometer

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

  • Page 71: Application Macro Hand - Auto

    External reference 2: 0...20 mA <=> 0...50 Hz (Auto Control) Output frequency 0...20 mA <=> 0...50 Hz +24 VDC Start/Stop: Activate to start ACS 400 (Hand). Forward/Reverse: Activate to reverse rotation direction (Hand) EXT1/EXT2 Selection: Activate to select auto control...

  • Page 72: Application Macro Pid Control

    Actual signal; 0...20 mA (PID) Output frequency 0...20 mA <=> 0...50 Hz +24 VDC Start/Stop: Activate to start ACS 400 (Manual). EXT1/EXT2 Selection: Activate to select PID control Constant speed 1: not used if PID control* Run enable: deactivation always stops ACS 400...

  • Page 73: Application Macro Premagnetize

    External Reference 1: 0...10 V <=> 0...50 Hz Reference voltage 10 VDC Not used Output frequency 0...20 mA <=> 0...50 Hz +24 VDC Start/Stop: Active to start ACS 400 Fwd/Rev: Activate to reverse rotation Constant Speed selection* Constant Speed selection* Premagnetise: Activate to start premagnetising Relay output 1, programmable Default operation: Fault =>...

  • Page 74: Application Macro Pfc Control

    Output frequency 0...20 mA <=> 0...52 Hz +24 VDC Start/Stop: Activate to start ACS 400. Run enable: Deactivation always stops ACS 400 EXT1/EXT2 Selection: Activate to select PFC control Interlock: Deactivation stops ACS 400 Interlock: Deactivation stops constant speed motor...
  • Page 75 ACS 400 User’s Manual http://nicontrols.com...

  • Page 76: Acs 400 Complete Parameter List

    ACS 400 Complete Parameter List Initially, only the so called basic parameters (shaded grey in Table 7) are visible. Use the appropriate menu function of the control panel to make the full parameter set visible. S = Parameters can be modified only when the drive is stopped.
  • Page 77 ANALOG INPUTS 1301 0 - 100 % MINIMUM AI 1302 0 - 100 % 100 % MAXIMUM AI 1303 0 - 10 s 0.1 s 0.1 s FILTER AI 1304 0 - 100 % MINIMUM AI ACS 400 User’s Manual http://nicontrols.com...
  • Page 78 0 - 250 s 0.1 s STOP DC INJ TIME á á 2105 0 - 6 PREMAGN SEL 2106 0.0 - 130.0 s 0.1 s 2.0 s PREMAGN MAX TIME 2107 0 - 1 START INHIBIT ACS 400 User’s Manual http://nicontrols.com...
  • Page 79 NOT SEL 3014 10...400 s 20 s UNDERLOAD TIME 3015 1 - 5 UNDERLOAD CURVE 3017 1 - 2 GROUND FAULT FAULT 3022 0 - 100 % FLT LIMIT 3023 0 - 100 % FLT LIMIT ACS 400 User’s Manual http://nicontrols.com...
  • Page 80 102 - 137 P VAR 3408 1 - 9999 P VAR MULTIP 3409 1 - 9999 P VAR DIVISOR 3410 0 - 3 P VAR SCALING 3411 0 - 31 3 (Hz) P VAR UNIT ACS 400 User’s Manual http://nicontrols.com...
  • Page 81 100 % MAXIMUM 4111 0 - 1000 % MINIMUM 4112 0 - 1000 % 100 % MAXIMUM 4119 1 - 2 SET POINT SEL EXTERNAL 4120 0.0 - 100.0 % 0.1 % 40.0 % INTERNAL SETPNT ACS 400 User’s Manual http://nicontrols.com...
  • Page 82 LOW FREQ 8115 0.0 - 3600 s 0.1 s; 1 s AUX MOT START D 8116 0.0 - 3600 s 0.1 s; 1 s AUX MOT STOP D 8117 0 - 3 NR OF AUX MOT ACS 400 User’s Manual http://nicontrols.com...
  • Page 83 0 - 1 REG BYPASS CTRL 8122 0 - 10 s 0.01 s 0.5 s PFC START DELAY * The maximum factor depending on the type of the frequency converter at 4 kHz switching frequency. ACS 400 User’s Manual http://nicontrols.com...

  • Page 84: Group 99: Start-Up Data

    9902 APPLIC MACRO Application macro selection. This parameter is used to select the Application Macro which will configure the ACS 400 for a particular application. Refer to “Application Macros” on page 53, for a list and description of available Application Macros.

  • Page 85: Group 01: Operating Data

    See “Appendix A” on page 151, for description of different control locations. 0114 RUN TIME (R) Shows the total running time of the ACS 400 in hours (h). Can be reset by pressing UP and DOWN buttons simultaneously when in parameter set mode. 0115 kWh COUNTER (R) Shows the counted kilowatt hours of the ACS 400 in operation.
  • Page 86 0135 PROCESS VAR 2 Process variable 2, as selected by the parameters in group 34. 0136 RUN TIME Shows the total running time of ACS 400 in thousands of hours (kh). 0137 MWh COUNTER Counts the megawatt hours of ACS 400 in operation.
  • Page 87 *Note! In cases 1, 3, 6 direction is set with parameter 1003 . Selecting value 3 ( ) fixes DIRECTION REQUEST the direction to Forward. **Note! The stop signal must be activated before a Start command can be given. ACS 400 User’s Manual http://nicontrols.com...
  • Page 88 Rotation direction lock. This parameter allows you to fix the direction of rotation of the motor to forward or reverse. If you select 3 ( ), the direction is set according to the given direction command. REQUEST ACS 400 User’s Manual http://nicontrols.com...
  • Page 89 External control location 2 ( 2) is selected. The control signal sources for 2 are defined with parameter 1002 (Start/Stop/Direction commands) and parameter 1106 (reference). COMM External control location 1 or 2 is chosen through serial communication. ACS 400 User’s Manual http://nicontrols.com...
  • Page 90 Minimum reference for joystick should be 0.3 V (0.6 mA) or higher. If a 0 ... 10 V signal is used, the ACS 400 will operate at maximum reference in the reverse direction if the control signal is lost. Set...
  • Page 91 Figure 27 Setting . The range of the analog input signal is EXT REF MINIMUM EXT REF MAXIMUM set by parameters 1301 and 1302 or parameters 1304 and 1305, depending on the analog input used. ACS 400 User’s Manual http://nicontrols.com...
  • Page 92 Group 12: Constant Speeds The ACS 400 has 7 programmable constant speeds, ranging from 0 to 250 Hz. Negative speed values cannot be given for constant speeds. Constant speed selections are ignored if the process PID reference is followed, the drive is in local control mode or PFC (Pump-Fan Control) is active.
  • Page 93 Value (%) = Desired minimum value / Full range of the analog 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 section CROSSREF. ACS 400 User’s Manual http://nicontrols.com...
  • Page 94 Relay is not used and is de-energized. READY The ACS 400 is ready to function. The relay is energized unless no run enable signal is present or a fault exists and supply voltage is within range. Relay energized when the ACS 400 is running.
  • Page 95 Code Description 21 = ACS OVERLOAD Relay is energized when ACS 400 overload alarm or fault exists. 22 = UNDERVOLTAGE Relay is energized when undervoltage alarm or fault exists. 23 = AI1 LOSS Relay is energized when AI1 signal is lost.
  • Page 96 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 30 Analog output scaling. ACS 400 User’s Manual http://nicontrols.com...
  • Page 97 1...5 = DI1 ... DI5 To activate the run enable signal, the selected digital input must be activated. If the voltage drops and deactivates the selected digital input, the ACS 400 will coast to stop and not start until the run enable signal resumes.
  • Page 98 1607 is used. 1608 DISPLAY ALARMS Controls the visibility of some of the alarms, see “Diagnostics” on page 35. Some of the alarms are suppressed. All of the alarms are enabled. ACS 400 User’s Manual http://nicontrols.com...
  • Page 99 DC bus voltage above the lower limit. By decreasing the output frequency, the inertia of the load will cause regeneration back into the ACS 400, thus keeping the DC bus charged, and preventing an undervoltage trip. This will increase power loss ride-through on systems with a high inertia, such as a centrifuge or a fan.
  • Page 100 Group 21: Start/Stop ACS 400 supports several start and stop modes, including flying start and torque boosting at start. DC current can be injected either before the start command (premagnetizing) or automatically right after the start command (starting with DC hold).
  • Page 101 Start inhibit control enabled. Drive will not start after fault is reset, Run Enable is activated or mode is changed. In order to start the drive again, give start command anew. ACS 400 User’s Manual http://nicontrols.com...
  • Page 102 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 31 Definition of acceleration/deceleration ramp time. ACS 400 User’s Manual http://nicontrols.com...
  • Page 103 Group 25: Critical Freq In some mechanical systems, certain speed ranges can cause resonance problems. With this parameter group, it is possible to set up to two different speed ranges that the ACS 400 will skip over. Code Description 2501 CRIT FREQ SEL Critical frequencies activation.
  • Page 104 Standard (switching frequency 4 kHz). Low noise (switching frequency 8 kHz). at 30 ° C ambient Note! When the low noise setting is used, the maximum loadability of the ACS 400 is I at 40 ° C. temperature or 0.8 * I 2606 U/f RATIO U/f ratio below field weakening point.
  • Page 105 CONST SPEED LAST SPEED A warning indication is displayed and the speed is set to the level at which the ACS 400 was last operating. This value is determined by the average speed over the last 10 seconds. Caution: If you select...
  • Page 106 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 400 coasts to stop. WARNING A warning indication is displayed when the motor temperature reaches the warning level (95 % of the nominal value).
  • Page 107 NOT SEL Stall protection is not used. FAULT When the protection is activated the ACS 400 coasts to stop. Fault indication is displayed. WARNING A warning indication is displayed. The indication disappears in half the time set by parameter 3012...
  • Page 108 This parameter defines operation in case of ground fault is detected in the motor or in the motor cable. FAULT A fault indication is displayed and the ACS 400 coasts to stop. The fault indicator is suppressed and the ACS 400 continues operation normally.
  • Page 109 ƒ Figure 38 Underload curve types. T nominal torque of the motor, nominal frequency of the motor. ACS 400 User’s Manual http://nicontrols.com...
  • Page 110 3101 NR OF TRIALS 3103 DELAY TIME This parameter sets the time that the ACS 400 will wait after a fault occurs before attempting to reset. If set to zero, the ACS 400 will reset immediately. 3104 AR OVERCURRENT...
  • Page 111 Second supervision limit low. Display of this parameter depends on the selected supervised parameter (3204). 3206 SUPERV 2 LIM HI Second supervision limit high. Display of this parameter depends on the selected supervised parameter (3204). ACS 400 User’s Manual http://nicontrols.com...
  • Page 112 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 40 Operating data supervision using relay outputs, when LOW ≤ HIGH. ACS 400 User’s Manual http://nicontrols.com...
  • Page 113 LOW, until the signal goes back below value HIGH. A = Initially the relay is de-energized. B = Initially the relay is energized. Figure 41 Operating data supervision using relay outputs, when LOW>HIGH. ACS 400 User’s Manual http://nicontrols.com...
  • Page 114 Group 33: Information Code Description 3301 SW VERSION Software version. 3302 TEST DATE Displays the test date of the ACS 400 (yy.ww). ACS 400 User’s Manual http://nicontrols.com...
  • Page 115 18 = MWh 22 = bar 26 = CFM 30 = FPM 3 = Hz 7 = rpm 11 = mA 15 = kWh 19 = m/s 23 = kPa 27 = ft 31 = Cst ACS 400 User’s Manual http://nicontrols.com...
  • Page 116 P VAR DIVISOR Since variable 0103 is displayed with 0.1 Hz resolution, it is internally scaled so that OUTPUT FREQ value 10 represents 1 Hz. Therefore 3405 = 1 must be selected. P VAR SCALING ACS 400 User’s Manual http://nicontrols.com...
  • Page 117 Group 40: PID Control The PID Control Macro allows the ACS 400 to take a reference signal (setpoint) and an actual signal (feedback), and automatically adjust the speed of the drive to match the actual signal to the reference. There exist two PID parameter sets (group 40 for set 1 parameters and group 41 for set 2 parameters).
  • Page 118 4008 ACT2 INPUT SEL Source for actual value 2 ( 1 = AI 1 Analog input 1 is used as actual value 2. 2 = AI 2 Analog input 2 is used as actual value 2. ACS 400 User’s Manual http://nicontrols.com...
  • Page 119 Analog input signal AI min AI max Figure 44 Actual value scaling. The range of the analog input signal is set by parameters 1301 and 1302 or parameters 1304 and 1305, depending on the analog input used. ACS 400 User’s Manual http://nicontrols.com...
  • Page 120 Code Description 4013 PID SLEEP DELAY Time delay for the sleep function, see Figure 45. If the ACS 400 output frequency is below a set level (parameter 4014 ) longer than , ACS 400 is stopped. SLEEP LEVEL PID SLEEP DELAY Alarm 28 is displayed when PID sleep is active.
  • Page 121 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 400 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 122 APPLIED WAKE-UP LEVEL 100 % SETPOINT 1107 EXT REF Figure 47 Example of how applied wake-up level floats with the set point, here parameter 4015 equals to 60 %, PID control inverted case. WAKE UP LEVEL ACS 400 User’s Manual http://nicontrols.com...
  • Page 123 UP LEVEL SLEEP DEACTIVATED TIME EXPIRES TIME Figure 48 Wake-up level operation with non-inverted error value. TIME EXPIRES APPLIED WAKE- UP LEVEL SLEEP DEACTIVATED ACT VALUE Figure 49 Wake-up level operation with inverted error value. ACS 400 User’s Manual http://nicontrols.com...
  • Page 124 Parameters of this group belong to PID parameter set 2. The operation of parameters 4101 - 4112, 4119 - 4120 is analogous with set 1 parameters 4001 - 4012, 4019 - 4020. PID parameter set 2 can be selected by parameter 4016 PID PARAM SET ACS 400 User’s Manual http://nicontrols.com...
  • Page 125 CONST SPEED LAST SPEED A warning indication is displayed and the speed is set to the level at which the ACS 400 was last operating. This value is determined by the average speed over the last 10 seconds. Caution: If you select...
  • Page 126 Sets the operation mode of the DDCS link. FIELDBUS Fieldbus adapter is used in DDCS link. (The ACS 400 acts as the slave station on the DDCS link). IO EXTENSION Input/output extension module (type name NDIO) is used on DDCS link. The ACS 400 acts as the master station on the DDCS link, and is capable of controlling the digital inputs and outputs of the extension module.
  • Page 127 NMBA Modbus NIBA Interbus-S NCSA CS31 bus NCAN CANopen NDNA DeviceNet NLON LONWORKS NMBP Modbus+ Others 5102 - FIELDBUSPAR 2 - FIELDBUSPAR 15 5115 Refer to communication module documentation for more information on these parameters. ACS 400 User’s Manual http://nicontrols.com...
  • Page 128 5208 BUFFER OVERRUNS Longest possible message length for the ACS 400 is 32 bytes. If a message exceeding 32 bytes is received, this diagnostic counter increases by one every time a character which cannot be placed in the buffer is received.
  • Page 129 • CRC calculation is not performed correctly. 5212 BUSY ERRORS This diagnostic counter increases by one every time the ACS 400 receives a character from the bus while it is still processing the previous message. • There might be two stations with the same station number.
  • Page 130 Sets a percentage value that is added to the process reference when at least one auxiliary (constant speed) motor is running. Default value is 0 %. Example: An ACS 400 operates three parallel pumps that pump water to a pipe. The pressure in the pipe is controlled. The constant pressure reference is set by parameter 4020 INTERNAL SETPNT At low water consumption levels, only the speed regulated pump is run.
  • Page 131 8112 LOW FREQ 1 Sets a frequency limit (see Figure 50). When the ACS 400’s output frequency falls below the value (8112 1 - 1 Hz) and one auxiliary motor is running, the Stop Delay counter is started. When the time set...
  • Page 132 ACS 400. ACS 400 relay outputs RO1 and RO2 can be used to control the motors. It is also possible to use up to two optional external digital input/output modules (NDIO).
  • Page 133 The purpose of the Autochange operation is to ensure equal duty time for all the motors. Each motor in the system will in its turn be connected to the ACS 400 as well as direct on line. The starting order of the motors is changed when Autochange is done.
  • Page 134 DI2: Motor 1 DI3: Motor 2 DI4-DI5 free DI1: free DI2: Motor 1 DI3: Motor 2 DI4: Motor 3 DI5: free DI1: free DI2: Motor 1 DI3: Motor 2 DI4: Motor 3 DI5: Motor 4 ACS 400 User’s Manual http://nicontrols.com...
  • Page 135 DI4: Motor 1 DI5: Motor 2 DI1-DI3: free DI1: Motor 3 DI4: Motor 1 DI2: unused DI5: Motor 2 DI1-DI3: free DI1: Motor 3 Not used DI4: Motor 1 DI2: Motor 4 DI5: Motor 2 ACS 400 User’s Manual http://nicontrols.com...
  • Page 136 Interlock signals are active low, i.e. an interlock is active when the corresponding interlock signal is absent. If a start command is given when the interlock signal of the speed regulated motor is active, the ACS 400 will not start, and will show alarm 30 (INTERLOCK) on the control panel.
  • Page 137 Code Description ACS 400 ~230 VAC ~230 VAC On/Off On/Off K2.1 Figure 52 Wiring the interlocks of a PFC system with two motors. There is a thermal relay in the supply circuit of M2. ACS 400 User’s Manual http://nicontrols.com...
  • Page 138 No auxiliary motors running b: One auxiliary motor running c: Two auxiliary motors running Figure 54 The relation between the control signal and the frequency of the controlled motor in a three- motor system. ACS 400 User’s Manual http://nicontrols.com...
  • Page 139 The PFC Start Delay must be set longer than the time setting of the star-delta starter: After the motor is switched on by the relay output of the ACS 400 there must be enough time for the star-delta starter to first switch to star-connection and then back to delta-connection before the ACS 400 inverter starts switching.

  • Page 140: Standard Serial Communication

    Channel 1 is the standard Modbus fieldbus connection. Communication settings of Channel 1 can be configured by the user. To control the ACS 400 via Modbus, the ACS 400 must be programmed to accept control commands and/or frequency references from Channel 1. Channel 0 is reserved for drive control panels ACS-PAN and ACS100-PAN, and for the DriveWindow PC tool.
  • Page 141 Data Flow Fieldbus Master (PLC) Fieldbus Figure 56 Structure of a fieldbus system. ACS 400 User’s Manual http://nicontrols.com...

  • Page 142: Grounding And Termination

    The termination should not be done on the intermediate stations on the network as shown in Figure Terminated Terminated Figure 57 Termination for the RS485 link. The connections may only be made with the drive disconnected from the power source. ACS 400 User’s Manual http://nicontrols.com...

  • Page 143: Activating Modbus Protocol

    PROTOCOL SEL STD MODBUS After this single modification, the ACS 400 is ready to communicate via Channel 1 using the default communication settings (given in Table 13), making parameter read and write possible. The following sections describe how to configure the ACS 400 for more sophisticated communication and control.

  • Page 144: Communication Settings

    COMMUNICATION and 52 STANDARD MODBUS. The default communication settings for Channel 1 are listed in Table 13. To be able to communicate with the master device, the ACS 400 must use the same communication speed and parity settings as the master.

  • Page 145: Control Locations

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

  • Page 146: Output Signal Source Selection

    It is possible to control both the relay outputs 1 and 2, as well as the analog output from serial communication channel 1. Relay outputs can be controlled in the following way: Step 1: Configure the ACS 400 to supervise the value of any of the parameters 131-133 using the parameters in group 32 SUPERVISION Step 2: Configure a relay output 1 or 2 to respond to the status of one of the supervised parameters.
  • Page 147 102 - 137 e.g. 133 Directs the contents of parameter 133 to AO CONTENT the analog output. 1503 Analog output scaling: upper limit (20 mA) AO CONTENT MAX reached when value 255 is written to parameter 133. ACS 400 User’s Manual http://nicontrols.com...

  • Page 148: Diagnostic Counters

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

  • Page 149: Communication

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

  • Page 150: Register Mapping

    The register addresses between the groups are invalid. No reads or writes are allowed for these addresses. If there is an attempt to read or write outside the parameter addresses, the Modbus interface will return an exception code to the controller. ACS 400 User’s Manual http://nicontrols.com...

  • Page 151: Exception Codes

    Function Codes The ACS 400 supports the Modbus function codes given in Table 21. If any other function codes are used, the ACS 400 returns an exception response with error code 01 (illegal function). Table 21 Function codes.

  • Page 152: The Control Word And The Status Word

    Note! Operation of Control Word and Status Word conforms to ABB Drives Profile with the exception of Control Word bit #10 (REMOTE_CMD), which is not used by the ACS 400. Table 22 The Control Word. See also the state machine in Figure 58 on page 147.
  • Page 153 This example assumes that the ACS 400 is in remote control, that external control place 1 (EXT1) is the active control place (as selected by parameter 1102), and that EXT1 start and stop commands are received through serial communication (parameter 1001).
  • Page 154 The value of first supervised parameter is below supervision limit External control location 2 ( 2) selected External control location 1 ( 1) selected Run Enable signal received No Run Enable signal received 13 to Unused ACS 400 User’s Manual http://nicontrols.com...

  • Page 155: References

    Reference 1 Holding Register: 40002 Reference 1 can be used as the frequency reference 1 for the ACS 400. The signal source of external reference 1 ( 1) must be set to and external control location 1 (...
  • Page 156 2. If setting 1 is used, then the corrected fieldbus reference is 25 % * 30 % / 50 % = 15 % COMM or 7.5 Hz. 100 % 50 % FIELDBUS REFERENCE 100 % 50 % ACS 400 User’s Manual http://nicontrols.com...

  • Page 157: Actual Values

    16-bit words containing a sign bit and a 15-bit integer. A negative value is given as two’s complement of the corresponding positive value. Actual Value 1 Holding Register: 40005 Actual output frequency. Scaling: 5000 50 Hz. Actual Value 2 Holding Register: 40006 Actual output current. Scaling: 10 1 A. ACS 400 User’s Manual http://nicontrols.com...
  • Page 158 (e.g. digital input). State I = Output current CW = Control Word f = Output frequency SW = Status Word RFG = Ramp Function Generator Figure 58 The state machine for evaluation of start and stop signals. ACS 400 User’s Manual http://nicontrols.com...

  • Page 159: Fault And Alarm Status

    Fault and Alarm Status The ACS 400 provides fault and alarm status words for the external control system. These data words are accessible only through the serial communication link but not from the control panel. Fault and alarm status words are located in parameter group 3. The group also contains copies of the Control Word and Status Word.
  • Page 160 PFC autochange alarm Serial communication loss PFC interlock alarm Modbus exception Reserved Analog input 1 loss Analog input 2 loss Panel loss ACS 400 overtemperature Motor overtemperature Underload Motor stall alarm DDCS link Reserved Reserved ACS 400 User’s Manual http://nicontrols.com...
  • Page 161 ACS 400 User’s Manual http://nicontrols.com...

  • Page 162: Local Control Vs. Remote Control

    Appendix A Local Control vs. Remote Control The ACS 400 can be controlled from two remote control locations or from the control panel. Figure 59 below shows the ACS 400 control locations. The selection between local control (LOC) and remote control (REM) is accomplished by pushing the MENU and ENTER buttons simultaneously when the ACS100-PAN is used, and by pushing the LOC/REM button when the ACS-PAN is used.

  • Page 163: Remote Control

    Remote Control When the ACS 400 is in remote control (REM), the commands are given primarily through digital and analog inputs, although commands can also be given through the control panel or serial communication. Parameter 1102 selects between the two external control locations...
  • Page 164 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 1601 COMMANDS COMMANDS 1001 1002 Figure 60 Selecting control location and control source. ACS 400 User’s Manual http://nicontrols.com...

  • Page 165: Internal Signal Connections For The Macros

    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 61 The control signal connections of the ABB Standard, Alternate and Premagnetize macros. ACS 400 User’s Manual http://nicontrols.com...
  • Page 166 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 62 The control signal connections of the PID Control macro. ACS 400 User’s Manual http://nicontrols.com...
  • Page 167 ACS 400 User’s Manual http://nicontrols.com...

  • Page 168: Acs 400 Pump And Fan Control (Pfc) Macro

    The control principle of a two-pump station is as follows: • The motor of pump no. 1 is connected to the ACS 400. The capacity of the pump is controlled by varying the motor speed.
  • Page 169 Process Act. Value Process Ref. Value +24 V supply DI5 (Interlock 2) DI4 (Interlock 1) ~230VAC ~230VAC Pump 1 On/Off Pump 2 On/Off Alternation Switchgear Figure 64 In this example the automatic pump alternation is in use. ACS 400 User’s Manual http://nicontrols.com...

  • Page 170: Pid Controller

    Figure 65 The control signal connections of the Pump and Fan Control (PFC) macro. PID Controller The ACS 400 has an internal PID controller which is in use when the PFC Control Macro is selected. Key features of the PID controller are: •...

  • Page 171: Relay Outputs

    • When the standard digital inputs of the ACS 400 (DI1 - DI5) are needed for other purposes and/ or number of interlock signals (auxiliary motors) is large. I/O extension modules are connected to the ACS 400 via a DDCS fiber optic link. An optional DDCS communication module is needed to use DDCS.

  • Page 172: Appendix C

    CE Marking A CE mark is attached to ACS 400 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 173 Minimum requirement for the motor cable screen is presented in Figure 66. Copper wire screen Helix of copper tape Inner insulation Insulation jacket Cable core Figure 66 Minimum requirement for motor cable screen (e.g. MCMK, NK Cables). ACS 400 User’s Manual http://nicontrols.com...
  • Page 174 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 400 User’s Manual http://nicontrols.com...
  • Page 175 Never mix 24 VDC and 115/230 VAC signals in the same cable. Note! When the overriding control equipment and the ACS 400 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 176 The current harmonic levels under rated load conditions are available on request. Distribution Networks Isolated from Earth Input filters designed for ACS 400 cannot be used in an isolated, or high impedance earthed industrial distribution networks. ACS 400 User’s Manual...
  • Page 177 ACS 400 User’s Manual http://nicontrols.com...

  • Page 178: Appendix D

    Appendix D ACS 400 Dimensional Drawings ACS 400 NEMA Type 1 Enclosure, R1 Frame Size ACS 400 User’s Manual http://nicontrols.com...
  • Page 179 ACS 400 NEMA Type 1 Enclosure, R2 Frame Size ACS 400 User’s Manual http://nicontrols.com...
  • Page 180 ACS 400 NEMA Type 1 Enclosure, R3 Frame Size ACS 400 User’s Manual http://nicontrols.com...
  • Page 181 ACS 400 NEMA Type 1 Enclosure, R4 Frame Size ACS 400 User’s Manual http://nicontrols.com...
  • Page 182 ACS 400 NEMA Type 12 & 4 Enclosure, R1 Frame Size ACS 400 User’s Manual http://nicontrols.com...
  • Page 183 ACS 400 NEMA 12 & 4 Enclosure, R2 Frame Size ACS 400 User’s Manual http://nicontrols.com...
  • Page 184 ACS 400 NEMA Type 12 & 4, R3 Frame Size ACS 400 User’s Manual http://nicontrols.com...
  • Page 185 ACS 400 NEMA Type 12 & 4, R4 Frame Size ACS 400 User’s Manual http://nicontrols.com...
  • Page 186 http://nicontrols.com...
  • Page 187 ABB Automation Inc. Drives & Power Products Group 16250 W. Glendale Drive New Berlin, WI 53151 Telephone (262) 785-8378 (800) 243-4384 (262) 780-5135 http://nicontrols.com...

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