Abb Motor
Uploaded by
mohamad.algbaly1Abb Motor
Uploaded by
mohamad.algbaly1.
Motor & Drives
General documentation 1/2
Plant Name: Ramliya Cement Plant, Line 2, 6000 TPD
Contract Number: 0845194
Created by: DoS
Approved by: JESK
Approved date: 15-DEC-09
Doc. No.: 60073498 - 1.0
Hardware Manual
1
Ramliya 2
Egypt Firmware Manual 2
Frequency Converter
07-45194
Vendor
Documentation
Other Manuals 3
General Manual
Binder No. 1 / 2
ACS1000 Manual 4
Certificates 5
VFD Motor System
For Scope of Supply
see next page 8
English
ATAP8D11
ATAP8M11 9
3AEL000355
ABB DKABB
10
ABB
Scope of Supply
Ramliya 2 / Egypt
08-45194
Type Binders Numbers. ABB Doc ID ABB Order No.
General 1,2 3AEL000355 ATAP8D11
Specific 1,2,3,4 ATAP8M11
Equipment
Order Specific General
Equipment Description Type
No. Binder No. Binder No.
213.AF060 4-0845194-223047A Apron Feeder M3BP160 MLA4 1 2
213.AF060 4-0845194-223047A Apron Feeder ACS800-04-0011-3 1 1
213.AF060 4-0845194-223047A Apron Feeder M3BP160 MLA4 1 2
213.AF060 4-0845194-223047A Apron Feeder ACS800-04-0011-3 1 1
312.BC600 4-0845194-221986A Belt Conveyor M3ARF 180 M4 1 2
312.BC600 4-0845194-221986A Belt Conveyor ACS800-04-0023-3 1 1
312.BC620 4-0845194-222000A Belt Conveyor M3BP200 MLA 4 1 2
312.BC620 4-0845194-222000A Belt Conveyor ACS800-04-0030-3 1 1
312.BC630 4-0845194-222002A Belt Conveyor M2BAT 280 SMB 4 1 2
312.BC630 4-0845194-222002A Belt Conveyor ACS800-07-0100-3 1 1
312.BC640 4-0845194-222005A Belt Conveyor M3ARF 160 L4 1 2
312.BC640 4-0845194-222005A Belt Conveyor ACS800-04-0016-3 1 1
322.BC010 4-0845194-222007A Belt Conveyor M3ARF 180 M4 1 2
322.BC010 4-0845194-222007A Belt Conveyor ACS800-04-0023-3 1 1
322.MD152 4-0845194-214299A RM Separator M2BAT 355 S4 1 2
322.MD152 4-0845194-221225A RM Separator ACS800-07-0260-3 1 1
332.FN110 4-0845194-217750A ID Fan MF5800 1 2
332.FN110 4-0845194-217750A ID Fan AMI 630 L6A 1 2
332.FN110 4-085194-217750A ID Fan ACS1013-W3-Z0-00 1 1
332.FN400 4-0845194-217069A Filter Fan ACS800-07-1500-7 2 1
332.FN400 4-0845194-217069A Filter Fan AMA 450 L4A 2 2
332.FN400 4-0845194-217069A Filter Fan MF1600 2 2
432.MD140 4-0845194-217754A Kiln Drive MF1600 2 2
432.MD140 4-0845194-221820A Kiln Drive HXR 450LK6 2 2
432.MD140 4-0845194-221820A Kiln Drive ACS800-07-1160-7 2 1
432.MD140 4-0845194-221820A Kiln Drive HXR 450LK6 2 2
432.MD140 4-0845194-221820A Kiln Drive ACS800-07-1160-7 2 1
442.TA355 4-0845194-217756A Cooler Fan K11 MF3000 2 2
442.FN300 4-0845194-221842A Cooler Fan K11 M2BAT 315 SMC 4 2 2
442.FN300 4-0845194-221842A Cooler Fan K11 ACS800-02-0260-3 2 1
442.FN305 4-0845194-221863A Cooler Fan K21 M2BAT 315 MLA 4 2 2
442.FN305 4-0845194-221863A Cooler Fan K21 ACS800-02-0260-3 2 1
442.FN310 4-0845194-221864A Cooler Fan K22 M2BAT 315 MLA 4 2 2
442.FN310 4-0845194-221864A Cooler Fan K22 ACS800-02-0260-3 2 1
442.FN315 4-0845194-221959A Cooler Fan K31 M2BAT 315 MLA 4 2 2
442.FN315 4-0845194-221959A Cooler Fan K31 ACS800-02-0260-3 2 1
442.FN325 4-0845194-221963A Cooler Fan K32 M2BAT 315 MLA 4 2 2
442.FN325 4-0845194-221963A Cooler Fan K32 ACS800-02-0260-3 2 1
442.FN335 4-0845194-221968A Cooler Fan K41 M3BP 355 SMB 4 2 2
442.FN335 4-0845194-221968A Cooler Fan K41 ACS800-02-0440-3 2 1
442.FN340 4-0845194-221972A Cooler Fan K51 M3BP 355 SMB 4 3 2
442.FN340 4-0845194-221972A Cooler Fan K51 ACS800-02-0320-3 3 1
442.FN345 4-0845194-221978A Cooler Fan K61 M3BP 355 SMB 4 3 2
442.FN345 4-0845194-221978A Cooler Fan K61 ACS800-02-0320-3 3 1
442.FN350 4-0845194-221980A Cooler Fan K71 M2BAT 315 MLA 4 3 2
442.FN350 4-0845194-221980A Cooler Fan K71 ACS800-02-0260-3 3 1
442.FN590 4-0845194-223045A Cooler Filter Fan M3BP 400LKB4 3 2
1/4 27-11-2009
Ramliya 2 / Egypt
08-45194
Type Binders Numbers. ABB Doc ID ABB Order No.
General 1,2 3AEL000355 ATAP8D11
Specific 1,2,3,4 ATAP8M11
Equipment
Order Specific General
Equipment Description Type
No. Binder No. Binder No.
442.FN590 4-0845194-223045A Cooler Filter Fan ACS800-07-0770-3 3 1
452.FN240 4-0845194-221982A By-Pass Fan M3BP 355 LKB 8 3 2
452.FN240 4-0845194-221982A By-Pass Fan ACS800-02-0400-3 3 1
452.SC460 4-0845194-231516A Converter ACS800-04-0040-3 3 1
533.MD302 4-0845194-214362A CM Separator M2BAT 355 S4 3 2
533.MD302 4-0845194-223051A CM Separator ACS800-07-0260-3 3 1
534.MD302 4-0845194-214392A CM Separator M2BAT 355 S4 3 2
534.MD302 4-0845194-223052A CM Separator ACS800-07-0260-3 3 1
533.SC501 4-0845194-226409A Converter ACS800-04-0023-3 3 1
534.SC501 4-0845194-226409A Converter ACS800-04-0023-3 3 1
764.WP210 4-0845194-247407A Converter ACS800-04-0040-3 3 1
764.WP211 4-0845194-247407A Converter ACS800-04-0040-3 3 1
322.MD140 4-085194-213350A Raw Mill AML 630 L6A 4 2
322.FN400 4-085194-213350A Raw Mill AML 630 L6A 4 2
533.MD140 4-085194-213350A Cement Mill AML 710 L6A 4 2
534.MD140 4-085194-213350A Cement Mill AML 710 L6A 4 2
533.FN350 4-085194-213350A CM Fan HXR 450 LK6 4 2
534.FN350 4-085194-213350A CM Fan HXR 450 LK6 4 2
124.BC300 4-085194-219110A Standard Motor M3ARF 132 S4 2
124.BC600 4-085194-219110A Standard Motor M3ARF 132 S4 2
124.BC700 4-085194-219110A Standard Motor M3ARF 132 S4 2
131.BC600 4-085194-219110A Standard Motor M3ARF 160 L4 2
322.FN125 4-085194-219110A Standard Motor M2QA 132 S2B 2
322.BE220 4-085194-219110A Standard Motor M2BAT 280 SMA 4 2
342.BE050 4-085194-219110A Standard Motor M2BAT 315 SMC 4 2
342.BE050 4-085194-219110A Standard Motor M2BAT 315 SMC 4 2
342.FN315 4-085194-219110A Standard Motor M2QA 132 M4A 2
352.BE340 4-085194-219110A Standard Motor M2BAT 315 MLA 4 2
352.BE340 4-085194-219110A Standard Motor M2BAT 315 MLA 4 2
432.FN171 4-085194-219110A Standard Motor M2QA 200 L4A 2
342.BL300 4-085194-214822B Standard Motor M2QA160M2A 2
342.BL305 4-085194-214822B Standard Motor M2QA160M2A 2
342.BL310 4-085194-214822B Standard Motor M2QA160M2A 2
352.BL110 4-085194-214822B Standard Motor M2QA225M2A 2
352.BL115 4-085194-214822B Standard Motor M2QA225M2A 2
322.BC200 4-085194-216877A Standard Motor M2QA160M4A 2
442.CV600 4-085194-216877A Standard Motor M2QA100L4A 2
442.CV610 4-085194-216877A Standard Motor M2QA100L4A 2
442.CV620 4-085194-216877A Standard Motor M2QA100L4A 2
452.FN010 4-085194-216877A Standard Motor M3BP355 SMA 8 2
482.BC150 4-085194-216877A Standard Motor M2QA160M4A 2
482.BC160 4-085194-216877A Standard Motor M2QA160M4A 2
482.BC170 4-085194-216877A Standard Motor M2QA160M4A 2
213.HC100 4-085194-217015A Standard Motor M2BAT 315 SMC 4 2
442.CR400 4-085194-217015A Standard Motor M3BP355 SMA 6 2
472.AC100 4-085194-219059A Standard Motor M2BAT 280 SMA 4 2
533.FN364 4-085194-219059A Standard Motor M2QA 225 S4A 2
533.FN530 4-085194-219059A Standard Motor M2BAT 280 SMB 4 2
534.FN364 4-085194-219059A Standard Motor M2QA 225 S4A 2
534.FN530 4-085194-219059A Standard Motor M2BAT 280 SMB 4 2
432.FN176 4-085194-219147A Standard Motor M2QA 225 M4A 2
442.FN662 4-085194-219147A Standard Motor M2QA 180 M4A 2
452.FN612 4-085194-219147A Standard Motor M2QA 200 L4A 2
2/4 27-11-2009
Ramliya 2 / Egypt
08-45194
Type Binders Numbers. ABB Doc ID ABB Order No.
General 1,2 3AEL000355 ATAP8D11
Specific 1,2,3,4 ATAP8M11
Equipment
Order Specific General
Equipment Description Type
No. Binder No. Binder No.
452.FN652 4-085194-219147A Standard Motor M2QA160M2A 2
472.FN153 4-085194-219147A Standard Motor M2BAT 280 SMB 4 2
482.FN412 4-085194-219147A Standard Motor M2QA 200 L4A 2
543.BE180 4-085194-219147A Standard Motor M2BAT 280 SMA 4 2
544.BE180 4-085194-219147A Standard Motor M2BAT 280 SMA 4 2
613.BL300 4-085194-219555A Standard Motor M2QA 200 L2B 2
614.BL300 4-085194-219555A Standard Motor M2QA 200 L2B 2
213.BC200 4-085194-220186A Standard Motor M2QA180 L4A 2
213.BC320 4-085194-220186A Standard Motor M2QA160 L4A 2
213.BC360 4-085194-220186A Standard Motor M2QA225 M4A 2
482.BC600 4-0845194-221198A Standard Motor M2BAT 315 SMC 4 2
131.BC400 4-085194-221251A Standard Motor M2BAT 280 SMB 4 2
124.FN552 4-085194-221977A Standard Motor M2QA 200 L4A 2
213.FN312 4-085194-221977A Standard Motor M2QA180 M4A 2
213.FN402 4-085194-221977A Standard Motor M2QA180 M4A 2
622.FN092 4-085194-221977A Standard Motor M2QA132 S2B 2
622.FN192 4-085194-221977A Standard Motor M2QA132 S2B 2
622.FN292 4-085194-221977A Standard Motor M2QA132 S2B 2
644.FN922 4-085194-221977A Standard Motor M2QA 250 M4A 2
645.FN922 4-085194-221977A Standard Motor M2QA 250 M4A 2
646.FN922 4-085194-221977A Standard Motor M2QA 250 M4A 2
131.BC500 4-0845194-222001A Standard Motor M2BAT 315 SMB 4 2
131.BC500 4-0845194-222001A Standard Motor M2BAT 315 SMB 4 2
213.FN212 4-0845194-222001A Standard Motor M2QA 200 L4A 2
213.FN352 4-0845194-222001A Standard Motor M2QA160M2A 2
131.FN452 4-0845194-222206A Standard Motor M2QA 180 M4A 2
131.FN652 4-0845194-222206A Standard Motor M2QA180 M4A 2
213.FN332 4-0845194-222206A Standard Motor M2QA160M2A 2
312.FN613 4-0845194-222206A Standard Motor M2BAT 280 SMA 4 2
312.FN627 4-0845194-222206A Standard Motor M2QA160M2B 2
312.FN637 4-0845194-222206A Standard Motor M2QA160M2B 2
312.FN652 4-0845194-222206A Standard Motor M2QA160M2B 2
322.FN292 4-0845194-222206A Standard Motor M2QA160M2B 2
124.FN652 4-0845194-222035A Standard Motor M2QA 200 L4A 2
533.FN242 4-0845194-222035A Standard Motor M2QA160M2A 2
534.FN242 4-0845194-222035A Standard Motor M2QA160M2A 2
543.FN142 4-0845194-222035A Standard Motor M2QA160M2A 2
543.FN172 4-0845194-222035A Standard Motor M2QA132 S2B 2
544.FN142 4-0845194-222035A Standard Motor M2QA160M2A 2
544.FN172 4-0845194-222035A Standard Motor M2QA132 S2B 2
622.FN612 4-0845194-222035A Standard Motor M2QA132 S2B 2
622.FN622 4-0845194-222035A Standard Motor M2QA132 S2B 2
622.FN632 4-0845194-222035A Standard Motor M2QA132 S2B 2
213.BC380 4-085194-222753A Standard Motor M3ARF 160 M4 2
352.FN407 4-085194-222753A Standard Motor M2QA160M2A 2
213.FN442 4-085194-222802A Standard Motor M2QA180 M4A 2
322.FN022 4-085194-222802A Standard Motor M2QA 225 S4A 2
332.FN666 4-085194-222802A Standard Motor M2QA180 M4A 2
342.FN402 4-085194-222802A Standard Motor M2QA180 M4A 2
482.FN157 4-085194-222802A Standard Motor M2QA180 M4A 2
482.FN167 4-085194-222802A Standard Motor M2QA180 M4A 2
482.FN177 4-085194-222802A Standard Motor M2QA180 M4A 2
482.FN652 4-085194-222802A Standard Motor M2QA 225 S4A 2
3/4 27-11-2009
Ramliya 2 / Egypt
08-45194
Type Binders Numbers. ABB Doc ID ABB Order No.
General 1,2 3AEL000355 ATAP8D11
Specific 1,2,3,4 ATAP8M11
Equipment
Order Specific General
Equipment Description Type
No. Binder No. Binder No.
513.FN662 4-085194-222802A Standard Motor M2QA 225 S4A 2
513.BC600 4-085194-222852A Standard Motor M2QA 112 M4A 2
514.BC600 4-085194-222852A Standard Motor M2QA 112 M4A 2
533.BE220 4-085194-222852A Standard Motor M2BAT 280 SMA 4 2
534.BE220 4-085194-222852A Standard Motor M2BAT 280 SMA 4 2
213.FN372 4-085194-222891A Standard Motor M2QA180 M4A 2
322.FN552 4-085194-222891A Standard Motor M2QA132 S2A 2
332.FN662 4-085194-222891A Standard Motor M2QA 112 M2A 2
352.FN402 4-085194-222891A Standard Motor M2QA160M2B 2
514.FN662 4-085194-222891A Standard Motor M2QA 225 S4A 2
482.FN672 4-0845194-223285A Standard Motor M2QA 200 L4A 2
543.FN221 4-0845194-223285A Standard Motor M2QA132 S2B 2
213.BC420 4-085194-223784A Standard Motor M3ARF 132 S4 2
213.BC460 4-085194-223784A Standard Motor M3ARF 132 S4 2
352.FN402 4-085194-223784A Standard Motor M2QA160M2B 2
472.CV200 4-0845194-223791A Standard Motor M2QA 180 L4A 2
482.BC580 4-0845194-223791A Standard Motor M2QA 180 M4A 2
543.FN241 4-0845194-223791A Standard Motor M2QA160M2A 2
481.FN382 4-0845194-227187A Standard Motor M2QA 180 M4A 2
481.BC520 4-0845194-227952A Standard Motor M2QA 225 M4A 2
481.BC270 4-0845194-229683A Standard Motor M2QA160 L4A 2
4/4 27-11-2009
ACS800
Hardware Manual
ACS800-07 Drives (45 to 560 kW)
ACS800-U7 Drives (50 to 600 HP)
ACS800 Single Drive Manuals
HARDWARE MANUALS (appropriate manual is included in the
delivery)
ACS800-01/U1 Hardware Manual 0.55 to 160 kW (0.75 to 200 HP)
3AFE64382101 (English)
ACS800-01/U1/04/U4 Marine Supplement 0.55 to 160 kW (0.75 to
200 HP) 3AFE64291275 (English)
ACS800-11/U11 Hardware Manual 5.5 to 110 kW (7.5 to 125 HP)
3AFE68367883 (English)
ACS800-31/U31 Hardware Manual 5.5 to110 kW (7.5 to 125 HP)
3AFE68599954 (English)
ACS800-02/U2 Hardware Manual 90 to 500 kW (125 to 600 HP)
3AFE64567373 (English)
ACS800-04/U4 Hardware Manual 0.55 to 160 kW (0.75 to 200 HP)
3AFE68372984 (English)
ACS800-04/04M/U4 Hardware Manual 45 to 560 kW (60 to
600 HP) 3AFE64671006 (English)
ACS800-04/04M/U4 Cabinet Installation 45 to 560 kW (60 to
600 HP) 3AFE68360323 (English)
ACS800-07/U7 Hardware Manual 45 to 560 kW (50 to 600 HP)
3AFE64702165 (English)
ACS800-07/U7 Dimensional Drawings 45 to 560 kW (50 to
600 HP) 3AFE64775421
ACS800-07 Hardware Manual 500 to 2800 kW
3AFE64731165 (English)
ACS800-17 Hardware Manual 55 to 2500 kW (75 to 2800 HP)
3AFE68397260 (English)
ACS800-37 Hardware Manual 55 to 2700 kW (75 to 3000 HP)
3AFE68557925 (English)
• Safety instructions
• Electrical installation planning
• Mechanical and electrical installation
• Motor control and I/O board (RMIO)
• Maintenance
• Technical data
• Dimensional drawings
• Resistor braking
FIRMWARE MANUALS, SUPPLEMENTS AND GUIDES
(appropriate documents are included in the delivery)
Standard Control Program Firmware Manual
3AFE64527592 (English)
System Control Program Firmware Manual
3AFE64670646 (English)
Control Program Template Firmware Manual
3AFE64616340 (English)
Master/Follower 3AFE64590430 (English)
Pump Control Program Firmware Manual
3AFE68478952 (English)
Extruder Control Program Supplement 3AFE64648543 (English)
Centrifuge Control Program Supplement 3AFE64667246 (English)
Traverse Control Program Supplement 3AFE64618334 (English)
Crane Control Program Firmware Manual 3BSE11179 (English)
Adaptive Programming Application Guide
3AFE64527274 (English)
OPTION MANUALS (delivered with optional equipment)
Fieldbus Adapters, I/O Extension Modules etc.
ACS800-07 Drives
45 to 560 kW
ACS800-U7 Drives
50 to 600 HP
Hardware Manual
3AFE64702165 Rev G EN
EFFECTIVE: 19.1.2009
© 2009 ABB Oy. All Rights Reserved.
5
Safety instructions
What this chapter contains
This chapter contains the safety instructions which you must follow when installing,
operating and servicing the drive. If ignored, physical injury or death may follow, or
damage may occur to the drive, the motor or driven equipment. Read the safety
instructions before you work on the unit.
Use of warnings and notes
There are two types of safety instructions throughout this manual: warnings and
notes. Warnings caution you about conditions which can result in serious injury or
death and/or damage to the equipment. They also tell you how to avoid the danger.
Notes draw attention to a particular condition or fact, or give information on a
subject. The warning symbols are used as follows:
Dangerous voltage warning warns of high voltage which can cause
physical injury and/or damage to the equipment.
General warning warns about conditions, other than those caused by
electricity, which can result in physical injury and/or damage to the
equipment.
Electrostatic discharge warning warns of electrostatic discharge which
can damage the equipment.
Hot surface warning warns of hot surfaces which can cause physical
injury.
Safety instructions
6
Installation and maintenance work
These warnings are intended for all who work on the drive, motor cable or motor.
WARNING! Ignoring the following 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 main power is applied.
After switching off the power, always wait for 5 minutes to let the intermediate
circuit capacitors discharge before you start working on the drive, the motor or
the motor cable.
Always ensure by measuring with a multimeter (impedance at least 1 Mohm)
that:
1. Voltage between drive input phases L1, L2 and L3 and the frame is close to
0 V.
2. Voltage between terminals UDC+ and UDC- and the frame is close to 0 V.
• Do not work on the control cables when power is applied to the drive or to the
external control circuits. Externally supplied control circuits may cause
dangerous voltages inside the drive even when the main power on the drive is
switched off.
• Do not make any insulation or voltage withstand tests on the drive or drive
modules.
• When reconnecting the motor cable, always check that the phase order is
correct.
Note:
• The disconnecting device (means) of the drive does not isolate the input cables
and busbars from the main AC supply. Before working inside the cabinet,
isolate the input cables and busbars from the main supply with the
disconnecting device at the distribution board or with the disconnector of the
supply transformer.
• The motor cable terminals on the drive are at a dangerously high voltage when
the input power is on, regardless of whether the motor is running or not.
• The brake control terminals (UDC+, UDC-, R+ and R- terminals) carry a
dangerous DC voltage (over 500 V).
• Depending on the external wiring, dangerous voltages [115 V, 220 V or 230 V]
may be present on the terminals of relay outputs RO1 to RO3 or on the optional
AGPS board (Prevention of Unexpected Start).
• The Prevention of Unexpected Start function does not remove the voltage from
the main and auxiliary circuits.
Safety instructions
7
• At installation sites above 2000 m (6562 ft), the terminals of the RMIO board
and optional modules attached to the board do not fulfil the Protective Extra
Low Voltage (PELV) requirements stated in EN 50178.
Grounding
These instructions are intended for all who are responsible for the grounding of the
drive.
WARNING! Ignoring the following instructions can cause physical injury, death or
equipment malfunction and increase electromagnetic interference.
• Ground the drive, the motor and adjoining equipment to ensure personnel
safety in all circumstances, and to reduce electromagnetic emission and
interference.
• Make sure that grounding conductors are adequately sized as required by
safety regulations.
• In a multiple-drive installation, connect each drive separately to protective
earth (PE).
• Do not install a drive with EMC filter option +E202 on an ungrounded power
system or a high resistance-grounded (over 30 ohms) power system.
Note:
• Power cable shields are suitable for equipment grounding conductors only
when adequately sized to meet safety regulations.
• As the normal leakage current of the drive is higher than 3.5 mA AC or 10 mA
DC (stated by EN 50178, 5.2.11.1), a fixed protective earth connection is
required.
Safety instructions
8
Mechanical installation and maintenance
These instructions are intended for all who install and service the drive.
WARNING! Ignoring the following instructions can cause physical injury or death,
or damage to the equipment:
• Cover the drive when installing to ensure that dust from borings and grindings
or foreign objects do not enter the drive. Electrically conductive dust inside the
unit may cause damage or lead to malfunction.
• Ensure sufficient cooling.
• Welding of the cabinet frame is not recommended. However, if electric welding
is the only way to mount the cabinet, follow the instructions given in chapter
Mechanical installation. Ensure that welding fumes are not inhaled. If the
welding return wire is connected improperly, the welding circuit may damage
electronic circuits in the cabinet.
• When removing the module from the cabinet and manoeuvring it outside the
cabinet, prevent it from toppling over by securing it. The drive module is heavy
and has a high centre of gravity.
• Beware of hot surfaces. Some parts, such as heatsinks of power
semiconductors, remain hot for a while after disconnection of the electrical
supply.
Printed circuit boards
WARNING! Ignoring the following instructions can cause damage to the printed
circuit boards:
• The printed circuit boards contain components sensitive to electrostatic
discharge. Wear a grounding wrist band when handling the boards. Do not
touch the boards unnecessarily.
Fibre optic cables
WARNING! Ignoring the following instructions can cause equipment malfunction
and damage to the fibre optic cables:
• Handle the fibre optic cables with care. When unplugging optic cables, always
grab the connector, not the cable itself. Do not touch the ends of the fibres with
bare hands as the fibre is extremely sensitive to dirt. The minimum allowed
bend radius is 35 mm (1.4 in.).
Safety instructions
9
Operation
These warnings are intended for all who plan the operation of the drive or operate
the drive.
WARNING! Ignoring the instructions can cause physical injury or death or damage
to the equipment.
• Before adjusting the drive and putting it into service, make sure that the motor
and all driven equipment are suitable for operation throughout the speed range
provided by the drive. The drive can be adjusted to operate the motor at
speeds above and below the speed provided by connecting the motor directly
to the power line.
• Do not activate automatic fault reset functions of the Standard Control
Program if dangerous situations can occur. When activated, these functions
will reset the drive and resume operation after a fault.
• Do not control the motor with the disconnecting device (disconnecting means);
instead, use the control panel keys and , or commands via the I/O
board of the drive. The maximum allowed number of charging cycles of the DC
capacitors (i.e. power-ups by applying power) is five in ten minutes.
Note:
• If an external source for start command is selected and it is ON, the drive (with
Standard Control Program) will start immediately after fault reset unless the
drive is configured for 3-wire (a pulse) start/stop.
• When the control location is not set to Local (L not shown in the status row of
the display), the stop key on the control panel will not stop the drive. To stop
the drive using the control panel, press the LOC/REM key and then the stop
key .
Safety instructions
10
Permanent magnet motor
These are additional warnings concerning permanent magnet motor drives. Ignoring
the instructions can cause physical injury or death, or damage to the equipment.
Installation and maintenance work
WARNING! Do not work on the drive when the permanent magnet motor is rotating.
Also, when the supply power is switched off and the inverter is stopped, a rotating
permanent magnet motor feeds power to the intermediate circuit of the drive and the
supply connections become live.
Before installation and maintenance work on the drive:
• Stop the motor.
• Ensure that the motor cannot rotate during work. Prevent the start-up of any
drives in the same mechanical group by opening the “prevention of unexpected
start” switch and padlocking it. Make sure that no other system, like hydraulic
crawling drives, are able to rotate the motor directly or through any mechanical
connection like felt, nip, rope, etc.
• Ensure that there is no voltage on the drive power terminals:
Alternative 1) Disconnect the motor from the drive with a safety switch or by other
means. Measure that there is no voltage present on the drive input or output
terminals (L1, L2, L3, U2, V2, W2, UDC+, UDC-).
Alternative 2) Measure that there is no voltage present on the drive input or output
terminals (L1, L2, L3, U2, V2, W2, UDC+, UDC-). Ground the drive output
terminals temporarily by connecting them together as well as to the PE.
Alternative 3) If possible, both of the above.
Start-up and operation
WARNING! Do not run the motor over the rated speed. Motor overspeed leads to
overvoltage which may damage or explode the capacitors in the intermediate circuit
of the drive.
Controlling a permanent magnet motor is only allowed using the control program for
Permanent Magnet Synchronous Machine Drive, or other control programs in scalar
control mode.
Safety instructions
11
Table of contents
ACS800 Single Drive Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Safety instructions
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Use of warnings and notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Installation and maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Mechanical installation and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Printed circuit boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Fibre optic cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Permanent magnet motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Installation and maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Start-up and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Table of contents
About this manual
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Target audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Common chapter for four products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Categorization according to the frame size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Categorization according to the + code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Installation and commissioning flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Product and service inquiries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Product training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Providing feedback on ABB Drives manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Document library on the Internet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
The ACS800-07/U7
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
The ACS800-07/U7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Type code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Main circuit and control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Door switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Printed circuit boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Motor control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Table of contents
12
Mechanical installation
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Moving the unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Before installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Delivery check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Requirements for the installation site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Cooling air flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Cable channel in the floor below the cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Fastening the cabinet to the floor and wall (non-marine units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Fastening the cabinet with the outside brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Fastening the cabinet through the holes inside the cabinet . . . . . . . . . . . . . . . . . . . . . . . . . .34
Fastening the cabinet to the floor and roof/wall (marine units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Electric welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
Planning the electrical installation
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
To which products this chapter applies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
Motor selection and compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
Protecting the motor insulation and bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Requirements table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
Permanent magnet synchronous motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
Supply connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
Disconnecting device (disconnecting means) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
ACS800-01, ACS800-U1, ACS800-11, ACS800-U11, ACS800-31, ACS800-U31,
ACS800-02 and ACS800-U2 without enclosure extension, ACS800-04, ACS800-U4 .44
ACS800-02 and ACS800-U2 with enclosure extension, ACS800-07 and ACS800-U7 .44
EU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
US . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
Main contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
Thermal overload and short-circuit protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
Thermal overload protection of the drive and the input and motor cables . . . . . . . . . . . . . . .45
Thermal overload protection of the motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
Protection against short-circuit in the motor cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
Protection against short-circuit inside the drive or in the supply cable . . . . . . . . . . . . . . . . . .46
Ground fault protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
Emergency stop devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
ACS800-02/U2 with enclosure extension and ACS800-07/U7 . . . . . . . . . . . . . . . . . . . . . . . .47
Restarting after an emergency stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
Power-loss ride-through function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
ACS800-07/U7 units with line contactor (+F250) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
Prevention of Unexpected Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
Table of contents
13
Selecting the power cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
General rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Alternative power cable types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Motor cable shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Additional US requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Conduit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Armored cable / shielded power cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Power factor compensation capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Equipment connected to the motor cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Installation of safety switches, contactors, connection boxes, etc. . . . . . . . . . . . . . . . . . . . . 53
Bypass connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Before opening a contactor (DTC control mode selected) . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Protecting the relay output contacts and attenuating disturbances in case of inductive loads . . . . 54
Selecting the control cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Relay cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Control panel cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Connection of a motor temperature sensor to the drive I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Installation sites above 2000 metres (6562 feet) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Routing the cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Control cable ducts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Electrical installation
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Before installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
IT (ungrounded) systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Checking the insulation of the assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Input cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Motor and motor cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Brake resistor assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Warning sticker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Example wiring diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Power cable connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Connecting the power cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Additional instructions for frame size R6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Cable terminals R+ and R- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Cable lug installations to R+ and R- screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Connecting the control cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Routing the cables (frame sizes R5 and R6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Routing the cables (frame sizes R7 and R8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
360 degrees EMC grounding at the cable entry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Special for top entry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Connecting the cables to the I/O terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Settings of the cooling fan transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Installation of optional modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Cabling of I/O and fieldbus modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Pulse encoder module cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Fibre optic link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Table of contents
14
Layout drawing of factory installed optional equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72
Frame sizes R5 and R6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72
Additional terminal blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72
Frame size R7 and R8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73
Installation of brake resistors (units with brake chopper option) . . . . . . . . . . . . . . . . . . . . . . . . . . .73
Motor control and I/O board (RMIO)
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
Note for the ACS800-02 with enclosure extension and the ACS800-07 . . . . . . . . . . . . . . . . . . . . .75
Note on terminal labelling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
Note on external power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76
Parameter settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76
External control connections (non-US) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77
External control connections (US) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78
RMIO board specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79
Analogue inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79
Constant voltage output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79
Auxiliary power output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79
Analogue outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79
Digital inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79
Relay outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80
DDCS fibre optic link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80
24 V DC power input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80
Installation checklist and start-up
Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83
Start-up procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84
Checks with no voltage connected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84
Starting the drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84
Control program set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84
On-load checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84
Maintenance
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
Maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
Required tools for maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86
Cabinet layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87
Frame sizes R5 and R6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87
Frame sizes R7 and R8 without du/dt filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88
Frame sizes R7 and R8 with du/dt filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89
Designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90
Layout of the drive module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91
Checking and replacing the air filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92
Heatsink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92
Table of contents
15
Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Replacing the drive module fan (R5 and R6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Replacing the drive module fan (R7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Replacing the drive module fan (R8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Replacing the cabinet fans (R5 and R6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Replacing the fans at upper part of the cubicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Replacing the additional fan at the lower part of the cubicle (R6 with du/dt
filter, +E205) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Replacing the cabinet fans (frame size R8 only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Replacing the additional cabinet fan (frame sizes R7 and R8 only with IP 22 and IP 42
when cabling: bottom entry/exit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Replacing the additional cabinet fan (frame sizes R7 and R8 only with IP 22 and IP 42
when cabling: top entry and bottom exit, bottom entry and top exit or top entry/exit) . . . . . . 99
Replacing the IP 54 (UL type 12) fan in frame size R6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Replacing the IP 54 (UL type 12) fan in frame sizes R7 and R8 . . . . . . . . . . . . . . . . . . . . . 101
Capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Reforming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Replacing the capacitor pack (R7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Replacing the capacitor pack (R8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Replacing the drive module (R5 and R6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Replacing the drive module (R7 and R8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Technical data
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
IEC data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Temperature derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Altitude derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Calculation example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Notes concerning the fuse tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Ultrarapid (aR) fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Optional gG fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Quick guide for selecting between gG and aR fuses . . . . . . . . . . . . . . . . . . . . . . . . . 120
Cable types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Cable entries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Dimensions, weights and noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Table of contents
16
NEMA data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .124
Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .124
Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .125
Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .125
Derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .125
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .126
UL class T or L fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .127
Cable types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .128
Cable entries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .129
Dimensions, weights and noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .129
Free space around the unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .130
Input power connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .131
Motor connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .131
Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .131
Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .132
Degrees of protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .132
Ambient conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .132
Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .133
Applicable standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .133
US patents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .134
CE marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .135
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .135
Compliance with the EMC Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .135
Compliance with EN 61800-3 (2004) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .135
First environment (drive of category C2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .135
Second environment (drive of category C3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .136
Second environment (drive of category C4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .136
Machinery Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .136
“C-tick” marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .137
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .137
Compliance with IEC 61800-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .137
First environment (drive of category C2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .137
Second environment (drive of category C3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .138
Second environment (drive of category C4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .138
UL/CSA markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .139
Equipment warranty and liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .139
Dimensional drawings
Frame sizes R5 and R6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .142
Frame sizes R7 and R8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .143
IP 54 and IP 54R units of frame sizes R7 and R8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .144
Resistor braking
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .145
Availability of brake choppers and resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .145
How to select the correct drive/chopper/resistor combination . . . . . . . . . . . . . . . . . . . . . . . . . . . .145
Optional brake chopper and resistor(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .146
Resistor installation and wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .149
Table of contents
17
Protection of frame size R5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Protection of frame sizes R6, R7 and R8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Brake circuit commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Table of contents
18
Table of contents
17
About this manual
What this chapter contains
This chapter describes the intended audience and contents of the manual. It
contains a flowchart of steps in checking the delivery, installing and commissioning
the drive. The flowchart refers to chapters/sections in this manual and other
manuals.
Target audience
This manual is intended for people who plan the installation, install, commission, use
and service the drive. Read the manual before working on the drive. The reader is
expected to know the fundamentals of electricity, wiring, electrical components and
electrical schematic symbols.
The manual is written for readers worldwide. Both SI and imperial units are shown.
Special US instructions for installations within the United States that must be
performed per the National Electrical Code and local codes are marked with (US).
Common chapter for four products
Chapter Planning the electrical installation applies to the ACS800-01/U1, ACS800-
02/U2, ACS800-04/U4, and ACS800-07/U7.
Categorization according to the frame size
Some instructions, technical data and dimensional drawings which concern only
certain frame sizes are marked with the symbol of the frame size R2, R3... or R8.
The frame size is not marked on the drive designation label. To identify the frame
size of your drive, see the rating tables in chapter Technical data.
Categorization according to the + code
The instructions, technical data and dimensional drawings which concern only
certain optional selections are marked with + codes, e.g. +E205. The options
included in the drive can be identified from the + codes visible on the type
designation label of the drive. The + code selections are listed in chapter The
ACS800-07/U7 under Type code.
About this manual
18
Contents
The chapters of this manual are briefly described below.
Safety instructions give safety instructions for the installation, commissioning,
operation and maintenance of the drive.
About this manual introduces this manual.
The ACS800-07/U7 describes the drive.
Mechanical installation shows how to move and unpack the delivery and how to
fasten the cabinet to the floor.
Planning the electrical installation instructs on the motor and cable selection, the
protections and the cable routing.
Electrical installation instructs how to wire the drive.
Motor control and I/O board (RMIO) shows external control connections to the motor
control and I/O board and its specifications.
Installation checklist and start-up helps in checking the mechanical and electrical
installation of the drive.
Maintenance contains preventive maintenance instructions.
Technical data contains the technical specifications of the drive, e.g. the ratings,
sizes and technical requirements, provisions for fulfilling the requirements for CE
and other markings and warranty policy.
Dimensional drawings contains the dimensional drawings of the drive.
Resistor braking describes how to select, protect and wire optional brake choppers
and resistors. The chapter also contains technical data.
Installation and commissioning flowchart
Task See
Identify the frame size of your drive: R6, R7 or R8. Technical data / IEC data or NEMA data
Plan the installation. Technical data
Check the ambient conditions, ratings, required Planning the electrical installation
cooling air flow, input power connection, compatibility Option manual (if optional equipment is
of the motor, motor connection, and other technical included)
data.
Select the cables.
About this manual
19
Task See
Unpack and check the units. Mechanical installation: Moving the unit, Before
Check that all necessary optional modules and installation
equipment are present and correct. If the converter has been non-operational for
Only intact units may be started up. more than one year, the converter DC link
capacitors need to be reformed. Ask ABB for
instructions.
Check the installation site. Mechanical installation: Before installation
Technical data
If the drive is about to be connected to an IT The ACS800-07/U7: Type code. For
(ungrounded) system, check that the drive is not instructions on how to disconnect the EMC
equipped with EMC filter +E202. filtering, contact ABB.
Route the cables. Planning the electrical installation: Routing the
cables
Check the insulation of the motor and the motor Electrical installation: Checking the insulation of
cable. the assembly
Install the drive. Connect the power cables. Connect Mechanical installation, Electrical installation,
the control and the auxiliary control cables. Resistor braking (optional)
Check the installation. Installation checklist and start-up
Commission the drive. Installation checklist and start-up, appropriate
firmware manual
Commission the optional brake chopper (if present). Resistor braking
Product and service inquiries
Address any inquiries about the product to your local ABB representative, quoting
the type code and serial number of the unit in question. A listing of ABB sales,
support and service contacts can be found by navigating to www.abb.com/drives and
selecting Sales, Support and Service network.
About this manual
20
Product 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/drivesand 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 www.abb.com/drives and select Document Library. You can browse the library
or enter selection criteria, for example a document code, in the search field.
About this manual
21
The ACS800-07/U7
What this chapter contains
This chapter describes the construction and operating principle of the drive in short.
The ACS800-07/U7
The ACS800-07/U7 is a cabinet-installed drive for controlling AC motors.
IP 21/22 (UL type 1) *Line contactor
Control panel
Switch fuse (main Switch fuse handle
switch / disconnector)
*Emergency Stop and Start/Stop
switches
Auxiliary circuit fuses *Brake resistor cubicle with +D151
Drive
Drive control unit module
(RDCU, RMIO) Input Input Output
U1,V1,W1
Swing-out frame
For layout of optional
equipment on the
swing-out frame, see
Electrical installation /
Layout drawing of PE
factory installed optional
equipment Output
U2,V2,W2
Brake
*du/dt filter (+E205)
resistor
behind the swing-out
(R-, R+)
frame
Cable
entries
*EMC filter cubicle with +E202
+E205
Power and signal cable terminals, and du/dt
filter (+E205), behind the swing-out frame
* Denotes optional equipment not present on
all units.
Note: The input terminals are located in the
View of frame size R8 EMC filter cubicle with +E202.
The ACS800-07/U7
22
IP 21/22
See page
72.
Drive
module
RMIO
Additional
fan (not in
all types)
View of frame size R6 without shrouds Power cable terminals
See page
72.
Drive
module
RMIO
View of frame size R5 without shrouds Power cable terminals
The ACS800-07/U7
23
Type code
The type code contains information on the specifications and configuration of the
drive. The first digits from left express the basic configuration (e.g. ACS800-07-
0170-5). The optional selections are given thereafter, separated by + signs (e.g.
+E202). The main selections are described below. Not all selections are available for
all types. For more information, refer to ACS800 Ordering Information (EN code:
64556568, available on request).
Selection Alternatives
Product series ACS800 product series
Type 07 cabinet built. When no options are selected: 6-pulse diode input
bridge, IP 21, switch fuse with aR fuses, control panel CDP312R,
no EMC filter, Standard Control Program, bottom entry and exit of
cables, boards without coating, one set of manuals.
U7 cabinet built (USA). When no options are selected: 6-pulse diode
bridge, UL type 1, switch fuse with class T or L fuses, control
panel CDP312R, no EMC filter, US version of the Standard
Control Program (three-wire start/stop as default setting), cable
conduit entry, common mode filter in frame size R8, boards
without coating, one set of manuals.
Size See Technical data: IEC data or NEMA data.
Voltage range 3 380/400/415 VAC
(nominal rating in bold) 5 380/400/415/440/460/480/500 VAC
7 525/575/600/690 VAC
+ options
Degree of protection B053 IP 22 (UL type 1)
B054 IP 42 (UL type 2)
B055 IP 54 (UL type 12)
B059 IP 54R with connection to air outlet duct
Construction C121 marine construction (reinforced mechanics and fastening,
marking of conductors according to class A1, door handles, self-
extinctive materials)
C129 UL listed (for ACS800-07 units only): US type main switch fuse,
115 VAC control voltage, US cable conduit entry, all components
UL listed/recognized, max. supply voltage 600 V.
C134 CSA marked. US/CSA type main switch fuse, bottom entry and
exit, 115 VAC control voltage, all components UL/CSA listed/
recognized, max. supply voltage 600 V.
Resistor braking D150 brake chopper (external resistor)
D151 brake chopper and resistor
Filter E200 EMC/RFI filter for second environment TN (grounded) system
E202 EMC/RFI filter for first environment TN (grounded) system,
restricted (A limits)
E210 EMC/RFI filter for second environment TN/IT (grounded/
ungrounded) system
E205 du/dt filter
E206 sine filter
E208 common mode filter
Line options F250 line contactor
F251 gG line fuses
The ACS800-07/U7
24
Selection Alternatives
Cabinet options G300 cabinet heater (external supply)
G304 115 VAC control voltage
G307 terminals for external control voltage (UPS)
G313 output for motor heater (external supply)
G330 halogen-free materials and control wiring
Cabling H351 top entry
H353 top exit
H358 cable conduit entry (US and UK version)
Fieldbus K... Refer to ACS800 Ordering Information (EN code: 64556568).
I/O L504 additional terminal block X2
L505 thermistor relay (1 or 2 pcs)
L506 Pt100 relay (3, 5 or 8 pcs)
L... Refer to ACS800 Ordering Information (EN code: 64556568).
Starter for auxiliary motor M600 1...1.6 A
fan M601 1.6...2.5 A
M602 2.5...4 A
M603 4...6.3 A
M604 6.3...10 A
M605 10...16 A
Control program N... Refer to ACS800 Ordering Information (EN code: 64556568).
Language of manual R...
Specialities P901 coated boards
P902 customized
P904 extended warranty
P913 special colour
Safety features Q950 prevention of unexpected start
Q951 emergency stop of category 0 (+F250 required)
Q952 emergency stop of category 1 (+F250 required)
Q954 earth fault monitoring for IT (ungrounded) systems
The ACS800-07/U7
25
Main circuit and control
Door switches
The following switches are mounted on the cabinet door:
Operating switch (units with main Emergency stop button
contactor only) (optional)
“START” position closes the main
contactor; “ON” position keeps the main
contactor closed; “OFF” position opens
the main contactor.
The ACS800-07/U7
26
Diagram
This diagram shows the control interfaces and the main circuit of the drive.
Motor
control and Optional module 1: RMBA, RAIO,
I/O board RDIO, RDNA, RLON, RIBA, RPBA,
(RMIO) RCAN, RCNA, RMBP, RETA, RRIA or
RTAC
External control via Optional module 2: RTAC, RAIO, RRIA
analogue/digital or RDIO
inputs and outputs DDCS communication option module:
RDCO-01, RDCO-02 or RDCO-03
= ~
Input power
~ = Output power
Brake chopper (optional)
R- UDC+ UDC-
R+
Operation
This table describes the operation of the main circuit in short.
Component Description
six-pulse rectifier converts the three-phase AC voltage to DC voltage
capacitor bank energy storage which stabilizes the intermediate circuit DC voltage
six-pulse IGBT inverter converts the DC voltage to AC voltage and vice versa. The motor
operation is controlled by switching the IGBTs.
The ACS800-07/U7
27
Printed circuit boards
The drive contains the following printed circuit boards as standard:
• main circuit board (AINT)
• motor control and I/O board (RMIO) with a fibre optic link to the AINT board
• input bridge control board (AINP)
• input bridge protection board (AIBP) which includes varistors and snubbers for
the thyristors
• power supply board (APOW)
• gate driver control board (AGDR)
• diagnostics and panel interface board (ADPI)
• EMC filter boards (NRFC) with option +E202
• brake chopper control board (ABRC) with option +D150
Motor control
The motor control is based on the Direct Torque Control (DTC) method. Two phase
currents and DC link voltage are measured and used for the control. The third phase
current is measured for earth fault protection.
The ACS800-07/U7
28
The ACS800-07/U7
29
Mechanical installation
What this chapter contains
This chapter describes the mechanical installation procedure of the drive.
Moving the unit
Move the transport package by truck and pallet truck to the installation site.
Max 30°
Cabinet back panel
Support
View of cabinet laid on its back
It is allowed to tilt the drive if required, or move it on its back
when supported properly from below. Note: It is not allowed
to move a unit with sine filter (+E206) on its back.
WARNING! Lift the drive by the upper part only using the lifting lugs/bars attached to
the top of the unit.
Mechanical installation
30
Before installation
Delivery check
The drive delivery contains:
• drive cabinet including factory installed options such as optional modules
(inserted onto the RMIO board in the RDCU unit)
• residual voltage warning stickers
• hardware manual
• appropriate firmware manuals and guides
• appropriate optional module manuals
• delivery documents.
Check that there are no signs of damage. Before attempting installation and
operation, check the information on the type designation label of the drive to verify
that the unit is of the correct type. The label includes an IEC and NEMA rating, C-UL
US, and CSA markings, a type code and a serial number, which allow individual
recognition of each unit. The first digit of the serial number refers to the
manufacturing plant. The next four digits refer to the unit’s manufacturing year and
week respectively. The remaining digits complete the serial number so that there are
no two units with the same serial number.
The type designation label is located on the front cover and the serial number label
inside the unit. Example labels are shown below.
Type designation label
Serial number label
Requirements for the installation site
Check the installation site according to the requirements below. See ACS800-07/U7
Dimensional Drawings [3AFE64775421 (English)] for frame details. See Technical
data for the allowed operation conditions of the drive.
Mechanical installation
31
Cooling air flow
Provide the drive with the amount of clean cooling air given in Technical data / IEC
data or NEMA data.
Cable channel in the floor below the cabinet
A cable channel can be constructed below the 400 mm wide middle part of the
cabinet. The cabinet weight lies on the two 100 mm wide transverse sections which
the floor must carry.
Viewed from above Side view
With heavy
cabinets,
support the
structural C-
sections from This area can be used for a
cable channel
Prevent the cooling air flow from the cable channel to
Cables
the cabinet by bottom plates. To ensure the degree of
protection for the cabinet use the original bottom plates
delivered with the unit. With user-defined cable entries
take care of the degree of protection, fire protection and
EMC compliance.
Mechanical installation
32
Fastening the cabinet to the floor and wall (non-marine units)
Fasten the cabinet to the floor either with the outside fastening brackets from front
and back, or by the fastening holes inside the cabinet. When fastening at the back is
not possible, fasten the cabinet at the top using L-brackets bolted to the holes of the
lifting lugs (M16 bolt). The cabinet can be fastened against a wall or back to back
with another cabinet. See chapter Dimensional drawings for the horizontal and
vertical fastening points. Height adjustment can be done by using metal shims
between the bottom frame and floor.
Fastening points when installed
back against wall
Fastening points when installed
back against back
320 mm (12.28 in.) for fan replacement
in frame sizes R7 and R8
> 400 mm > 400 mm
(15.75 in.) IP 21/22/42 (15.75 in.) IP54
Top clearance
L-bracket
M16 bolt
Cabinet top
Fastening the cabinet at the top
by using L-brackets (side view)
Mechanical installation
33
Fastening the cabinet with the outside brackets
Insert the bracket into the longitudinal hole in the edge of the cabinet frame body and
fasten it with a bolt to the floor.
Dimensions of the fastening bracket:
Cabinet frame body
Cabinet frame body
Cubicle Fastening hole distance in mm [in.]
width
a b a
mm [in.]
200 [7.87]
46 [1.81]
400 [15.75] a: 250 [9.84]
600 [23.62] a: 450 [17.71]
800 [31.50] a: 650 [25.29]
1000 [39.37] a: 350 [13.78], b: 150 [5.91], a: 350 [13.78]
1200 [47.24] a: 450 [17.71], b: 150 [5.91], a: 450 [17.71]
Fastening bolt: M10 to M12 (3/8” to 1/2”).
Mechanical installation
34
Fastening the cabinet through the holes inside the cabinet
The cabinet can be fastened to the floor using the fastening holes inside the cabinet,
if they are available and accessible. The maximum allowed distance between the
fastening points is 800 mm (31.50 in.).
Side plates of the cabinet: 15 mm
Back plate of the cabinet: 10 mm
Gap between the 200 mm, 400 mm, 600 mm,
800 mm, 1000 mm and 1500 mm cubicles:
IP 20...42 IP 54
25 [0.98]
≈ 0.5 ≈1
Cubicle width Fastening hole distance in mm [in.]
∅ 31 mm [1.22]
a b a
mm [in.]
200 [7.87] a: 50 [1.97]
400 [15.75] a: 250 [9.84]
600 [23.62] a: 450 [17.71]
800 [31.50] a: 650 [25.29]
1000 [39.37] a: 350 [13.78], b: 150 [5.91], a: 350 [13.78]
1200 [47.24] a: 450 [17.71], b: 150 [5.91], a: 450 [17.71]
Fastening bolt: M10 to M12 (3/8” to 1/2”).
Mechanical installation
35
Fastening the cabinet to the floor and roof/wall (marine units)
See ACS800-07 Dimensional Drawings [3AFE64775421 (English)] for the locations
of the fastening holes in the flat bars below the cabinet and for fastening points at the
top of the cabinet. Top fastening brackets are included in the delivery.
Fasten the cabinet to the floor and roof (wall) as follows:
1. Bolt the unit to the floor through the holes in each flat bar at the base of the
cabinet using M10 or M12 screws.
2. If there is not enough room behind the cabinet for installation, clamp the rear ends
of the flat bars.
3. Remove the lifting lugs and bolt the fastening brackets into the lifting lug holes (a).
Fasten the top of the cabinet to the rear wall and/or roof with brackets (b).
IP 54 roof
3b
3a
3a 3a
Fastening bracket
M16 bolt
3a
Fastening bracket
Cabinet
Fastening the cabinet at the top with brackets (side view)
Back panel of
Clamps cabinet
1
1
1 Flat bars at base of cabinet
Clamping the cabinet to the floor at the back
Mechanical installation
36
Electric welding
It is not recommended to fasten the cabinet by welding.
Cabinets without flat bars at the base (non-marine versions)
If the preferred fastening methods (clamping or bolting through the holes inside the
cabinet) cannot be used, proceed as follows:
• Connect the return conductor of the welding equipment to the cabinet frame at
the bottom within 0.5 metres of the welding point.
Cabinets with flat bars at the base (marine versions)
If the fastening cannot be done using screws, proceed as follows:
• Weld only on the flat bar under the cabinet, not the cabinet frame itself.
• Clamp the welding electrode onto the flat bar about to be welded or onto the floor
within 0.5 metres of the welding point.
WARNING! If the welding return wire is connected improperly, the welding circuit
may damage electronic circuits in the cabinet. The thickness of the zinc coating of
the cabinet frame is 100 to 200 micrometres; on the flat bars the coating is
approximately 20 micrometres. Ensure that the welding fumes are not inhaled.
Mechanical installation
37
Planning the electrical installation
What this chapter contains
This chapter contains the instructions that you must follow when selecting the motor,
cables, protections, cable routing and way of operation for the drive system.
Note: The installation must always be designed and made according to applicable
local laws and regulations. ABB does not assume any liability whatsoever for any
installation which breaches the local laws and/or other regulations. Furthermore, if
the recommendations given by ABB are not followed, the drive may experience
problems that the warranty does not cover.
To which products this chapter applies
This chapter applies to the ACS800-01/U1, ACS800-11/U11, ACS800-31/U31,
ACS800-02/U2, ACS800-04/U4, and ACS800-07/U7 types up to -0610-x.
Note: All options described in this chapter are not available for all products. Check
the availability from section Type code on page 23.
Motor selection and compatibility
1. Select the motor according to the rating tables in chapter Technical Data. Use the
DriveSize PC tool if the default load cycles are not applicable.
2. Check that the motor ratings lie within the allowed ranges of the drive control
program:
• motor nominal voltage is 1/2 ... 2 · UN of the drive
• motor nominal current is 1/6 ... 2 · I2hd of the drive in DTC control and
0 ... 2 · I2hd in scalar control. The control mode is selected by a drive parameter.
Planning the electrical installation
38
3. Check that the motor voltage rating meets the application requirements:
If the drive is equipped … and … … then the motor voltage
with … rating should be …
diode supply no resistor braking is in use UN
ACS800-01, -U1, -02, -U2, frequent or long term brake cycles will UACeq1
-04, -04M, -U4 -07, -U7 be used
IGBT supply DC link voltage will not be increased UN
ACS800-11, -U11, -31, from nominal (parameter setting)
-U31, -17, -37 DC link voltage will be increased from UACeq2
nominal (parameter setting)
UN = rated input voltage of the drive
UACeq1 = UDC/1.35
UACeq2 = UDC/1.41
UACeq is the equivalent AC power source voltage of the drive in V AC.
UDC is the maximum DC link voltage of the drive in V DC.
For resistor braking: UDC= 1.21 × nominal DC link voltage.
For units with IGBT supply: See the parameter value.
(Note: Nominal DC link voltage is UN × 1.35 or UN × 1.41 in V DC.)
See notes 6 and 7 below the Requirements table, page 42.
4. Consult the motor manufacturer before using a motor in a drive system where the
motor nominal voltage differs from the AC power source voltage.
5. Ensure that the motor insulation system withstands the maximum peak voltage in
the motor terminals. See the Requirements table below for the required motor
insulation system and drive filtering.
Example 1: When the supply voltage is 440 V and a drive with a diode supply is
operating in motor mode only, the maximum peak voltage in the motor terminals
can be approximated as follows: 440 V · 1.35 · 2 = 1190 V. Check that the motor
insulation system withstands this voltage.
Example 2: When the supply voltage is 440 V and the drive is equipped with an
IGBT supply, the maximum peak voltage in the motor terminals can be
approximated as follows: 440 V · 1.41 · 2 = 1241 V. Check that the motor
insulation system withstands this voltage.
Planning the electrical installation
39
Protecting the motor insulation and bearings
The output of the drive comprises – regardless of output frequency – pulses of
approximately 1.35 times the equivalent mains network voltage with a very short rise
time. This is the case with all drives employing modern IGBT inverter technology.
The voltage of the pulses can be almost double at the motor terminals, depending on
the attenuation and reflection properties of the motor cable and the terminals. This in
turn can cause additional stress on the motor and motor cable insulation.
Modern variable speed drives with their fast rising voltage pulses and high switching
frequencies can generate current pulses that flow through the motor bearings, which
can gradually erode the bearing races and rolling elements.
The stress on motor insulation can be avoided by using optional ABB du/dt filters.
du/dt filters also reduce bearing currents.
To avoid damage to motor bearings, the cables must be selected and installed
according to the instructions given in the hardware manual. In addition, insulated N-
end (non-drive end) bearings and output filters from ABB must be used according to
the following table. Two types of filters are used individually or in combinations:
• optional du/dt filter (protects motor insulation system and reduces bearing
currents).
• common mode filter (mainly reduces bearing currents).
Planning the electrical installation
40
Requirements table
The following table shows how to select the motor insulation system and when an optional ABB du/dt
filter, insulated N-end (non-drive end) motor bearings and ABB common mode filters are required. The
motor manufacturer should be consulted regarding the construction of the motor insulation and
additional requirements for explosion-safe (EX) motors. Failure of the motor to fulfil the following
requirements or improper installation may shorten motor life or damage the motor bearings and voids
the warranty.
Motor type Nominal mains Requirement for
voltage (AC line
Motor insulation ABB du/dt filter, insulated N-end bearing and ABB common mode
voltage)
Manufacturer
system filter
PN < 100 kW 100 kW < PN < 350 kW PN > 350 kW
and or or
frame size < IEC 315 frame size > IEC 315 frame size > IEC 400
PN < 134 HP 134 HP < PN < 469 HP PN > 469 HP
and frame size < or frame size > or frame size >
NEMA 500 NEMA 500 NEMA 580
A Random- UN < 500 V Standard - +N + N + CMF
B wound M2_
500 V < UN < 600 V Standard + du/dt + du/dt + N + du/dt + N + CMF
and M3_
B or
Reinforced - +N + N + CMF
600 V < UN < 690 V Reinforced + du/dt + du/dt + N + du/dt + N + CMF
Form-wound 380 V < UN < 690 V Standard n.a. + N + CMF PN < 500 kW: + N +
HX_ and AM_ CMF
PN > 500 kW: + N +
CMF + du/dt
Old* form- 380 V < UN < 690 V Check with the + du/dt with voltages over 500 V + N + CMF
wound HX_ motor
and modular manufacturer.
Random- 0 V < UN < 500 V Enamelled wire + N + CMF
wound HX_ with fibre glass
500 V < UN < 690 V + du/dt + N + CMF
and AM_ ** taping
Planning the electrical installation
41
Motor type Nominal mains Requirement for
voltage (AC line
Motor insulation ABB du/dt filter, insulated N-end bearing and ABB common mode
voltage)
Manufacturer
system filter
PN < 100 kW 100 kW < PN < 350 kW PN > 350 kW
and or or
frame size < IEC 315 frame size > IEC 315 frame size > IEC 400
PN < 134 HP 134 HP < PN < 469 HP PN > 469 HP
and frame size < or frame size > or frame size >
NEMA 500 NEMA 500 NEMA 580
N Random- UN < 420 V Standard: ÛLL = - + N or CMF + N + CMF
O wound and 1300 V
form-wound
N 420 V < UN < 500 V Standard: ÛLL = + du/dt + du/dt + N + du/dt + N + CMF
- 1300 V or
A
+ du/dt + CMF
B
or
B
Reinforced: ÛLL = - + N or CMF + N + CMF
1600 V, 0.2
microsecond rise
time
500 V < UN < 600 V Reinforced: ÛLL = + du/dt + du/dt + N + du/dt + N + CMF
1600 V or
+ du/dt + CMF
or
Reinforced: ÛLL = - + N or CMF + N + CMF
1800 V
600 V < UN < 690 V Reinforced: ÛLL = + du/dt + du/dt + N + du/dt + N + CMF
1800 V
Reinforced: ÛLL = - N + CMF N + CMF
2000 V, 0.3
microsecond rise
time ***
* manufactured before 1.1.1998
** For motors manufactured before 1.1.1998, check for additional instructions with the motor manufacturer.
*** If the intermediate DC circuit voltage of the drive is increased from the nominal level by resistor braking or by the
IGBT Supply Control Program (parameter selectable function), check with the motor manufacturer if additional
output filters are needed in the applied drive operation range.
Note 1: The abbreviations used in the table are defined below.
Abbreviation Definition
UN nominal voltage of the supply network
ÛLL peak line-to-line voltage at motor terminals which the motor insulation must withstand
PN motor nominal power
du/dt du/dt filter at the output of the drive +E205
CMF common mode filter +E208
N N-end bearing: insulated motor non-drive end bearing
n.a. Motors of this power range are not available as standard units. Consult the motor manufacturer.
Planning the electrical installation
42
Note 2: Explosion-safe (EX) motors
The motor manufacturer should be consulted regarding the construction of the motor insulation and
additional requirements for explosion-safe (EX) motors.
Note 3: High-output motors and IP 23 motors
For motors with higher rated output than what is stated for the particular frame size in EN 50347 (2001)
and for IP 23 motors, the requirements of ABB random-wound motor series M3AA, M3AP, M3BP are
given below. For other motor types, see the Requirements table above. Apply the requirements of
range 100 kW < PN < 350 kW to motors with PN < 100 kW. Apply the requirements of range PN >
350 kW to motors within the range 100 kW < PN < 350 kW. In other cases, consult the motor
manufacturer.
Manufacturer
Motor type Nominal mains Requirement for
voltage (AC line
Motor insulation ABB du/dt filter, insulated N-end bearing and ABB common mode
voltage) system filter
PN < 55 kW 55 kW < PN < 200 kW PN > 200 kW
PN < 74 HP 74 HP < PN < 268 HP PN > 268 HP
A Random- UN < 500 V Standard - +N + N + CMF
B wound M3AA,
500 V < UN < 600 V Standard + du/dt + du/dt + N + du/dt + N + CMF
M3AP, M3BP
B or
Reinforced - +N + N + CMF
600 V < UN < 690 V Reinforced + du/dt + du/dt + N + du/dt + N + CMF
Note 4: HXR and AMA motors
All AMA machines (manufactured in Helsinki) for drive systems have form-wound windings. All HXR
machines manufactured in Helsinki starting 1.1.1998 have form-wound windings.
Note 5: ABB motors of types other than M2_, M3_, HX_ and AM_
Use the selection criteria given for non-ABB motors.
Note 6: Resistor braking of the drive
When the drive is in braking mode for a large part of its operation time, the intermediate circuit DC
voltage of the drive increases, the effect being similar to increasing the supply voltage by up to
20 percent. The voltage increase should be taken into consideration when determining the motor
insulation requirement.
Example: Motor insulation requirement for a 400 V application must be selected as if the drive were
supplied with 480 V.
Note 7: Drives with an IGBT supply unit
If voltage is raised by the drive (this is a parameter selectable function), select the motor insulation
system according to the increased intermediate circuit DC voltage level, especially in the 500 V supply
voltage range.
Planning the electrical installation
43
Note 8: Calculating the rise time and the peak line-to-line voltage
The peak line-to-line voltage at the motor terminals generated by the drive as well as the voltage rise
time depend on the cable length. The requirements for the motor insulation system given in the table
are “worst case” requirements covering installations with 30 metre and longer cables. The rise time can
be calculated as follows: t = 0.8 · ÛLL/(du/dt). Read ÛLL and du/dt from the diagrams below. Multiply
the values of the graph by the supply voltage (UN). In case of drives with an IGBT supply unit or resistor
braking, the ÛLL and du/dt values are approximately 20% higher.
3.0 5.5
ÛLL/UN 5.0
2.5 du/dt
------------- (1/μs)
4.5 UN
2.0 4.0
3.5
1.5
3.0
ÛLL/UN
1.0 2.5
du/dt
------------- (1/μs)
UN 2.0
0.5
1.5
0.0 1.0
100 200 300 100 200 300
Cable length (m) Cable length (m)
With du/dt Filter Without du/dt Filter
Note 9: Sine filters protect the motor insulation system. Therefore, du/dt filter can be replaced with a
sine filter. The peak phase-to-phase voltage with the sine filter is approximately 1.5 × UN.
Note 10: Common mode filter is available as a plus code option (+E208) or as a separate kit (one box
including three rings for one cable).
Permanent magnet synchronous motor
Only one permanent magnet motor can be connected to the inverter output.
It is recommended to install a safety switch between the permanent magnet
synchronous motor and the drive output. The switch is needed to isolate the motor
during any maintenance work on the drive.
Planning the electrical installation
44
Supply connection
Disconnecting device (disconnecting means)
ACS800-01, ACS800-U1, ACS800-11, ACS800-U11, ACS800-31, ACS800-U31,
ACS800-02 and ACS800-U2 without enclosure extension, ACS800-04, ACS800-U4
Install a hand-operated input 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 position for installation and maintenance work.
ACS800-02 and ACS800-U2 with enclosure extension, ACS800-07 and ACS800-U7
These units are equipped with a hand-operated input disconnecting device
(disconnecting means) which isolates the drive and the motor from the AC power as
standard. The disconnecting device does not, however, isolate the input busbars
from the AC power. Therefore, during installation and maintenance work on the
drive, the input cables and busbars must be isolated from the input power with a
disconnector at the distribution board or at the supplying transformer.
EU
To meet the European Union Directives, according to standard EN 60204-1, Safety
of Machinery, the disconnecting device must be one of the following types:
• switch-disconnector of utilization category AC-23B (EN 60947-3)
• disconnector that has an auxiliary contact that in all cases causes switching
devices to break the load circuit before the opening of the main contacts of the
disconnector (EN 60947-3)
• circuit breaker suitable for isolation in accordance with EN 60947-2.
US
The disconnecting means must conform to the applicable safety regulations.
Fuses
See section Thermal overload and short-circuit protection.
Main contactor
If used, dimension the contactor according to the nominal voltage and current of the
drive. The utilization category (IEC 947-4) is AC-1.
Planning the electrical installation
45
Thermal overload and short-circuit protection
Thermal overload protection of the drive and the input and motor cables
The drive protects itself and the input and motor cables against thermal overload
when the cables are dimensioned according to the nominal current of the drive. No
additional thermal protection devices are needed.
WARNING! If the drive is connected to multiple motors, a separate thermal overload
switch or a circuit breaker must be used for protecting each cable and motor. These
devices may require a separate fuse to cut off the short-circuit current.
Thermal overload protection of the motor
According to regulations, the motor must be protected against thermal overload and
the current must be switched off when overload is detected. The drive includes a
motor thermal protection function that protects the motor and switches off the current
when necessary. Depending on a drive parameter value, the function either monitors
a calculated temperature value (based on a motor thermal model) or an actual
temperature indication given by motor temperature sensors. The user can tune the
thermal model further by feeding in additional motor and load data.
The most common temperature sensors are:
• motor sizes IEC180…225: thermal switch (e.g. Klixon)
• motor sizes IEC200…250 and larger: PTC or Pt100.
See the firmware manual for more information on the motor thermal protection, and
the connection and use of the temperature sensors.
Protection against short-circuit in the motor cable
The drive protects the motor cable and motor in a short-circuit situation when the
motor cable is dimensioned according to the nominal current of the drive. No
additional protection devices are needed.
Planning the electrical installation
46
Protection against short-circuit inside the drive or in the supply cable
Arrange the protection according to the following guide lines.
Circuit diagram Drive type Short-circuit
protection
DRIVE IS NOT EQUIPPED WITH INPUT FUSES
ACS800-01 Protect the drive and
Distribution Drive or drive ACS800-U1 input cable with fuses
board Input cable module or a circuit breaker.
ACS800-02
See footnotes 1) and
1) ACS800-U2+0C111 2).
~ M
~ 3~ ACS800-11
ACS800-U11
ACS800-31
ACS800-U31
2) ACS800-04
~ M
I>
~ 3~ ACS800-U4
DRIVE IS EQUIPPED WITH INPUT FUSES
ACS800-02+C111 Protect the input cable
Distribution ACS800-U2 with fuses or a circuit
board Input cable Drive breaker according to
ACS800-07
local regulations. See
3) 4) ACS800-U7
~ M footnotes 3) and 4).
~ 3~
Drive
4)
~ M
I>
~ 3~
1) Size the fuses according to instructions given in chapter Technical data. The fuses will protect the input
cable in short-circuit situations, restrict drive damage and prevent damage to adjoining equipment in
case of a short-circuit inside the drive.
Planning the electrical installation
47
2) Circuit breakers which have been tested by ABB with the ACS800 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 inherent operating principle and construction of circuit breakers,
independent of the manufacturer, hot ionized gases may escape from the breaker
enclosure in case of a short-circuit. To ensure safe use, special attention must be paid to
the installation and placement of the breakers. Follow the manufacturer’s instructions.
Note: Circuit breakers must not be used without fuses in the USA.
3) Size the fuses according to local safety regulations, appropriate input voltage and the rated current of
the drive (see chapter Technical data).
4) ACS800-02 units and ACS800-07 units with enclosure extension are equipped with aR fuses as
standard. ACS800-U2 and ACS800-U7 units are equipped with T/L fuses as standard. The fuses
restrict drive damage and prevent damage to adjoining equipment in case of a short-circuit inside the
drive.
Ground fault protection
The drive is equipped with an internal ground fault protective function to protect the
unit against ground faults in the motor and motor cable. This is not a personal safety
or a fire protection feature. The ground fault protective function can be disabled with
a parameter, refer to the appropriate ACS800 Firmware Manual.
The EMC filter of the drive includes capacitors connected between the main circuit
and the frame. These capacitors and long motor cables increase the ground leakage
current and may cause fault current circuit breakers to function.
Emergency stop devices
For safety reasons, install the emergency stop devices at each operator control
station and at other operating stations where emergency stop may be needed.
Note: Pressing the stop key ( ) on the control panel of the drive does not generate
an emergency stop of the motor or separate the drive from dangerous potential.
ACS800-02/U2 with enclosure extension and ACS800-07/U7
An emergency stop function is optionally available for stopping and switching off the
whole drive. Two stop categories according to IEC/EN 60204-1 (1997) are available:
immediate removal of power (Category 0 for ACS800-02/U2 and ACS800-07/U7)
and controlled emergency stop (Category 1 for ACS800-07/U7).
Restarting after an emergency stop
After an emergency stop, the emergency stop button must be released and the drive
started by turning the operating switch of the drive from position “ON” to “START”.
Planning the electrical installation
48
Power-loss ride-through function
The power-loss ride-through function is activated when parameter
20.06 UNDERVOLTAGE CTRL is set to ON (default in Standard Control Program).
ACS800-07/U7 units with line contactor (+F250)
The power-loss ride-through funtion is enabled by connecting RMIO board terminals
X22:8 and X22:11 with a jumper.
X2 / RMIO board
X22
1
2
3
4
5
6
7
8
22 9
K13
10
21
11
Planning the electrical installation
49
Prevention of Unexpected Start
The ACS800-01/U1, ACS800-04/04M, ACS800-11/U11 and ACS800-07/U7 can be
equipped with an optional Prevention of Unexpected Start function according to
standards IEC/EN 60204-1: 1997; ISO/DIS 14118: 2000 and EN 1037: 1996.
The Prevention of Unexpected Start function disables the control voltage of the
power semiconductors, thus preventing the inverter from generating the AC voltage
required to rotate the motor. By using this function, short-time operations (like
cleaning) and/or maintenance work on non-electrical parts of the machinery can be
performed without switching off the AC power supply to the drive.
The operator activates the Prevention of Unexpected Start function by opening a
switch on a control desk. An indicating lamp on the control desk will light, signalling
that the prevention is active. The switch can be locked out.
The user must install on a control desk near the machinery:
• switching/disconnecting device for the circuitry. “Means shall be provided to
prevent inadvertent, and/or mistaken closure of the disconnecting device.”
EN 60204-1: 1997.
• indicating lamp; on = starting the drive is prevented, off = drive is operative.
• ACS800-01/U1, ACS800-04/U4, ACS800-11/U11: safety relay (type BD5935 has
been approved by ABB)
For connections to the drive, see chapter Installation of AGPS board (Prevention of
Unexpected Start, +Q950) or the circuit diagram delivered with the drive (ACS800-
07/U7). For ACS800-04 from 45 to 560 kW, refer to ACS800-04/04M/U4 Cabinet
Installation [3AFE68360323 (English)].
WARNING! The Prevention of Unexpected Start function does not disconnect the
voltage of the main and auxiliary circuits from the drive. Therefore maintenance work
on electrical parts of the drive or the motor can only be carried out after isolating the
drive system from the main supply.
Note: If a running drive is stopped by using the Prevention of Unexpected Start
function, the drive will cut off the motor supply voltage and the motor will coast to
stop.
Planning the electrical installation
50
Selecting the power cables
General rules
Dimension the mains (input power) and motor cables according to local
regulations:
• The cable must be able to carry the drive load current. See chapter Technical
data for the rated currents.
• The cable must be rated for at least 70 °C maximum permissible temperature of
conductor in continuous use. For US, see Additional US requirements.
• The inductance and impedance of the PE conductor/cable (grounding wire) must
be rated according to permissible touch voltage appearing under fault conditions
(so that the fault point voltage will not rise excessively when a ground fault
occurs).
• 600 V AC cable is accepted for up to 500 V AC. 750 V AC cable is accepted for
up to 600 V AC. For 690 V AC rated equipment, the rated voltage between the
conductors of the cable should be at least 1 kV.
For drive frame size R5 and larger, or motors larger than 30 kW (40 HP),
symmetrical shielded motor cable must be used (figure below). A four-conductor
system can be used up to frame size R4 with up to 30 kW (40 HP) motors, but
shielded symmetrical motor cable is always recommended. The shield(s) of motor
cable(s) must have 360° bonding at both ends.
Note: When continuous metal conduit is employed, shielded cable is not required.
The conduit must have bonding at both ends as with cable shield.
A four-conductor system is allowed for input cabling, but shielded symmetrical cable
is recommended. To operate as a protective conductor, the shield conductivity must
be as follows when the protective conductor is made of the same metal as the phase
conductors:
Cross-sectional area of the phase Minimum cross-sectional area of the
conductors corresponding protective conductor
S (mm2) Sp (mm2)
S < 16 S
16 < S < 35 16
35 < S S/2
Compared to a four-conductor system, the use of symmetrical shielded cable
reduces electromagnetic emission of the whole drive system as well as the stress on
motor insulation, bearing currents and wear.
The motor cable and its PE pigtail (twisted shield) should be kept as short as
possible in order to reduce high-frequency electromagnetic emission, as well as
stray currents outside the cable and capacitive current (relevant in power range
below 20 kW).
Planning the electrical installation
51
Alternative power cable types
Power cable types that can be used with the drive are represented below.
Recommended
Symmetrical shielded cable: three phase conductors A separate PE conductor is required if the conductivity
and a concentric or otherwise symmetrically of the cable shield is < 50% of the conductivity of the
constructed PE conductor, and a shield phase conductor.
PE conductor Shield
and shield Shield
PE
PE
PE Shield
A four-conductor system:
three phase conductors
and a protective
conductor
Not allowed for motor cables Not allowed for motor cables with phase
conductor cross section larger than 10 mm2
[motors > 30 kW (40 HP)].
Motor cable shield
To effectively suppress radiated and conducted radio-frequency emissions, the
shield conductivity must be at least 1/10 of the phase conductor conductivity. The
requirements are easily met with a copper or aluminium shield. The minimum
requirement of the motor cable shield of the drive is shown below. It consists of a
concentric layer of copper wires with an open helix of copper tape or copper wire.
The better and tighter the shield, the lower the emission level and bearing currents.
Copper wire screen Helix of copper tape Inner insulation
Insulation jacket
or copper wire
Cable core
Planning the electrical installation
52
Additional US requirements
Type MC continuous corrugated aluminum armor cable with symmetrical grounds or
shielded power cable must be used for the motor cables if metallic conduit is not
used. For the North American market, 600 V AC cable is accepted for up to
500 V AC. 1000 V AC cable is required above 500 V AC (below 600 V AC). For
drives rated over 100 amperes, the power cables must be rated for 75 °C (167 °F).
Conduit
Separate parts of a conduit must be coupled together, bridge the joints with a ground
conductor bonded to the conduit on each side of the joint. Bond the conduits also to
the drive enclosure and motor frame. Use separate conduits for input power, motor,
brake resistor, and control wiring. When conduit is employed, type MC continuous
corrugated aluminium armor cable or shielded cable is not required. A dedicated
ground cable is always required.
Note: Do not run motor wiring from more than one drive in the same conduit.
Armored cable / shielded power cable
Six conductor (3 phases and 3 ground) type MC continuous corrugated aluminum
armor cable with symmetrical grounds is available from the following suppliers (trade
names in parentheses):
• Anixter Wire & Cable (Philsheath)
• BICC General Corp (Philsheath)
• Rockbestos Co. (Gardex)
• Oaknite (CLX).
Shielded power cables are available from Belden, LAPPKABEL (ÖLFLEX) and
Pirelli.
Power factor compensation capacitors
Power factor compensation is not needed with AC drives. However, if a drive is to be
connected in a system with compensation capacitors installed, note the following
restrictions.
WARNING! Do not connect power factor compensation capacitors or harmonic
filters to the motor cables (between the drive and the motor). They are not meant to
be used with AC drives and can cause permanent damage to the drive or
themselves.
Planning the electrical installation
53
If there are power factor compensation capacitors in parallel with the three phase
input of the drive:
1. Do not connect a high-power capacitor to the power line while the drive is
connected. The connection will cause voltage transients that may trip or even
damage the drive.
2. If capacitor load is increased/decreased step by step when the AC drive is
connected to the power line: Ensure that the connection steps are low enough not
to cause voltage transients that would trip the drive.
3. Check that the power factor compensation unit is suitable for use in systems with
AC drives i.e. harmonic generating loads. In such systems, the compensation unit
should typically be equipped with a blocking reactor or harmonic filter.
Equipment connected to the motor cable
Installation of safety switches, contactors, connection boxes, etc.
To minimize the emission level when safety switches, contactors, connection boxes
or similar equipment are installed in the motor cable between the drive and the
motor:
• EU: Install the equipment in a metal enclosure with 360 degrees grounding for the
shields of both the incoming and outgoing cable, or connect the shields of the
cables otherwise together.
• US: Install the equipment in a metal enclosure in a way that the conduit or motor
cable shielding runs consistently without breaks from the drive to the motor.
Bypass connection
WARNING! Never connect the supply power to the drive output terminals U2, V2
and W2. If frequent bypassing is required, employ mechanically connected switches
or contactors. Mains (line) voltage applied to the output can result in permanent
damage to the unit.
Before opening a contactor (DTC control mode selected)
Stop the drive and wait for the motor to stop before opening a contactor between the
output of the drive and the motor when the DTC control mode is selected. See the
appropriate ACS800 control program firmware manual for the required parameter
settings. Otherwise, the contactor will be damaged. In scalar control, the contactor
can be opened with the drive running.
Planning the electrical installation
54
Protecting the relay output contacts and attenuating disturbances in case
of inductive loads
Inductive loads (relays, contactors, motors) cause voltage transients when switched
off.
The relay contacts on the RMIO board are protected with varistors (250 V) against
overvoltage peaks. In spite of this, it is highly recommended to equip inductive loads
with noise attenuating circuits [varistors, RC filters (AC) or diodes (DC)] in order 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 RMIO board terminal block.
RMIO
Relay outputs
Varistor X25
1 RO1
2 RO1
230 V AC
3 RO1
RC filter X26
1 RO2
2 RO2
230 V AC
3 RO2
Diode X27
1 RO3
2 RO3
24 V DC
3 RO3
Planning the electrical installation
55
Selecting the control cables
All control cables must be shielded.
Use a double-shielded twisted pair cable (Figure a, e.g. JAMAK by Draka NK
Cables, Finland) for analogue signals. This type of cable is recommended for the
pulse encoder signals also. Employ one individually shielded pair for each signal. Do
not use common return for different analogue signals.
A double-shielded cable is the best alternative for low-voltage digital signals but
single-shielded twisted pair cable (Figure b) is also usable.
a b
A double-shielded twisted A single-shielded twisted
pair cable pair cable
Run analogue and digital signals in separate, shielded 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-controlled
signals be run as twisted pairs.
Never mix 24 V DC and 115/230 V AC signals in the same cable.
Relay cable
The cable type with braided metallic screen (e.g. ÖLFLEX by LAPPKABEL,
Germany) has been tested and approved by ABB.
Control panel cable
In remote use, the cable connecting the control panel to the drive must not exceed 3
metres (10 ft). The cable type tested and approved by ABB is used in control panel
option kits.
Planning the electrical installation
56
Connection of a motor temperature sensor to the drive I/O
WARNING! IEC 60664 requires double or reinforced insulation between live parts
and the surface of accessible parts of electrical equipment which are either non-
conductive or conductive but not connected to the protective earth.
To fulfil this requirement, the connection of a thermistor (and other similar
components) to the digital inputs of the drive can be implemented in three alternate
ways:
1. There is double or reinforced insulation between the thermistor and live parts of
the motor.
2. Circuits connected to all digital and analogue inputs of the drive are protected
against contact and insulated with basic insulation (the same voltage level as the
drive main circuit) from other low voltage circuits.
3. An external thermistor relay is used. The insulation of the relay must be rated for
the same voltage level as the main circuit of the drive. For connection, see
ACS800 Firmware Manual.
Installation sites above 2000 metres (6562 feet)
WARNING! Protect against direct contact when installing, operating and servicing
the RMIO board wiring and optional modules attached to the board. The Protective
Extra Low Voltage (PELV) requirements stated in EN 50178 are not fulfilled at
altitudes above 2000 m (6562 ft).
Routing the cables
Route the motor cable away from other cable routes. Motor cables of several drives
can be run in parallel installed next to each other. It is recommended that the motor
cable, input power cable and control cables be installed on separate trays. Avoid
long parallel runs of motor cables with other cables in order to decrease
electromagnetic interference caused by the rapid changes in the drive output
voltage.
Where control cables must cross power cables make sure they are arranged at an
angle as near to 90 degrees as possible. Do not run extra cables through the drive.
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.
Planning the electrical installation
57
A diagram of the cable routing is shown below.
Motor cable
Drive
min 300 mm (12 in.)
Power cable
Input power cable Motor cable
min 200 mm (8 in.) 90 ° min 500 mm (20 in.)
Control cables
Control cable ducts
230 V 230 V
24 V (120 V) 24 V (120 V)
Not allowed unless the 24 V cable is Lead 24 V and 230 V (120 V) control
insulated for 230 V (120 V) or insulated cables in separate ducts inside the
with an insulation sleeving for 230 V cabinet.
(120 V).
Planning the electrical installation
58
Planning the electrical installation
59
Electrical installation
What this chapter contains
This chapter describes the electrical installation procedure of the drive.
WARNING! Only qualified electricians are allowed to carry out the work described in
this chapter. Follow the Safety instructions on the first pages of this manual. Ignoring
the safety instructions can cause injury or death.
Before installation
IT (ungrounded) systems
A drive equipped with no EMC filter or with EMC filter +E210 is suitable for IT
(ungrounded systems). If the drive is equipped with EMC filter +E202, disconnect
the filter before connecting the drive to an ungrounded system. For detailed
instructions on how to do this, please contact your local ABB representative.
WARNING! If a drive with EMC filter +E202 is installed on an IT system [an
ungrounded power system or a high resistance-grounded (over 30 ohms) power
system], the system will be connected to earth potential through the EMC filter
capacitors of the drive. This may cause danger or damage the unit.
Checking the insulation of the assembly
Drive
Every drive module has been tested for insulation between the main circuit and the
chassis (2500 V rms 50 Hz for 1 second) at the factory. Therefore, do not make any
voltage tolerance or insulation resistance tests (e.g. hi-pot or megger) on any part of
the drive.
Input cable
Check the insulation of the input cable according to local regulations before
connecting it to the drive.
Motor and motor cable
1. Check that the motor cable is disconnected from the drive output terminals U2,
V2 and W2.
Electrical installation
60
2. Measure the insulation resistance between each phase conductor and the
Protective Earth conductor using a measuring voltage of 500 V DC. The
insulation resistance of an ABB motor must exceed 10 Mohm (reference value at
25 °C or 77 °F). For the insulation resistance of other motors, please consult the
manufacturer’s instructions. Note: Moisture inside the motor casing will reduce
the insulation resistance. If moisture is suspected, dry the motor and repeat the
measurement.
U1
M
V1
3~
ohm W1
PE
Brake resistor assembly
Check the insulation of the brake resistor assembly (if present) as follows:
1. Check that the resistor cable is connected to the resistor, and disconnected from
the drive output terminals R+ and R-.
2. At the drive end, connect the R+ and R- conductors of the resistor cable together.
Measure the insulation resistance between the combined conductors and the PE
conductor by using a measuring voltage of 1 kV DC. The insulation resistance
must be higher than 1 Mohm.
R+
R-
ohm
PE
Warning sticker
A multi-language sticker is attached onto the drive module cover. Attach the warning
sticker in the local language onto the cover of the drive module.
Electrical installation
Cabinet
CDP312R control panel delivery.
RDCU
Example wiring diagram
RMIO *Main contactor
Switch fuse
*Motor temperature disconnector
supervision
*Common Drive module
mode filter
*Internal
*du/dt filter or brake
*sine filter resistor
Supply 3~ *External
Motor brake
resistor
Signal/ Alarm
Temperature sensors
includes optional components (marked *) which are not always included in the
control
for motor protection
The diagram below presents an example for the main wiring. Note that the diagram
360 degrees grounding
Electrical installation
61
62
Power cable connection diagram
Drive
PE
1) 2) INPUT OUTPUT
L1 L2 L3 R- R+ U2 V2 W2
3) 4) 4)
5)
(PE) PE (PE) L1 L2 L3
V1
External brake U1 W1
resistor
(optional)
3 ~
Motor
1), 2) Grounding of the motor cable shield at the motor end
If shielded cable is used (not required but For minimum radio frequency interference:
recommended), use a separate PE cable (1) or a • ground the cable shield 360 degrees at the lead-through of
cable with a grounding conductor (2) if the the motor terminal box
conductivity of the input cable shield is < 50% of the
conductivity of the phase conductor.
Ground the other end of the input cable shield or PE
conductor at the distribution board. 360 degrees grounding
3) 360 degrees grounding recommended if shielded
cable
Conductive gaskets
4) 360 degrees grounding required
5) Use a separate grounding cable if the conductivity of • or ground the cable by twisting the shield as follows:
the cable shield is < 50% of the conductivity of the flattened width > 1/5 · length.
phase conductor and there is no symmetrically
constructed grounding conductor in the cable (see
Planning the electrical installation / Selecting the
b > 1/5 · a
power cables).
Note:
b
If there is a symmetrically constructed grounding a
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.
Do not use an asymmetrically constructed motor cable.
Connecting its fourth conductor at the motor end
increases bearing currents and causes extra wear.
Electrical installation
63
Connecting the power cables
1. Open the swing-out frame.
2 Remove the additional cabinet cooling fan (if any). See Replacing the additional
fan at the lower part of the cubicle (R6 with du/dt filter, +E205) on page 96.
3. If fire insulation is used, make an opening in the mineral wool sheet according to
the diameter of the cable.
4. Cut adequate holes to the rubber grommet (if present) in the lead-through plate
and lead the cable through the grommet and the conductive sleeve (if present)
into the cabinet.
5. Strip the cable.
6. Connect the twisted shield of the cable to the PE terminal of the cabinet.
7. Connect the phase conductors of the input cable to the L1, L2 and L3 terminals
and the phase conductors of the motor cable to the U2, V2 and W2 terminals.
8. Peel off 3 to 5 cm of the outer insulation of the cable above the lead-through
plate for the 360° high-frequency earthing.
9. Fasten the conductive sleeve to the cable shield with cable ties.
10. Seal the slot between the cable and mineral wool sheet (if used) with sealing
compound (e.g. CSD-F, ABB brand name DXXT-11, code 35080082).
11. Tie up the unused conductive sleeves with cable ties.
Cable shield Strain relief
PE terminal
EMC sleeve
Strip this part of
the cable
For control cables
Base plate
Lead-through plate
Electrical installation
64
Additional instructions for frame size R6
Cable terminals R+ and R-
Power cable conductors of sizes 95 to 185 mm2 (3/0 to 350 AWG) are connected to
the cable terminals as follows:
• Undo the fastening screw of the terminal.
• Connect the conductor to the terminal.
• Screw the terminal to the original location.
WARNING! If the wire size is less than
95 mm2 (3/0 AWG), a cable lug must
Cable terminal
be used. A cable of wire size less than
95 mm2 (3/0 AWG) connected to this
terminal will loosen and may damage
the drive.
Cable lug installations to R+ and R- screws
Cables of sizes 16 to 70 mm2 (6 to 2/0 AWG) can be connected to the screws with
cable lugs. Isolate the ends of the cable lugs with insulating tape or shrink tubing. To
meet UL requirements, use UL listed cable lugs and tools given below or
corresponding.
Wire size Compression lug Crimping tool
kcmil/AWG Manufacturer Type Manufacturer Type No. of crimps
6 Burndy YAV6C-L2 Burndy MY29-3 1
Ilsco CCL-6-38 Ilsco ILC-10 2
4 Burndy YA4C-L4BOX Burndy MY29-3 1
Ilsco CCL-4-38 Ilsco MT-25 1
2 Burndy YA2C-L4BOX Burndy MY29-3 2
Ilsco CRC-2 Ilsco IDT-12 1
Ilsco CCL-2-38 Ilsco MT-25 1
1 Burndy YA1C-L4BOX Burndy MY29-3 2
Ilsco CRA-1-38 Ilsco IDT-12 1
Ilsco CCL-1-38 Ilsco MT-25 1
Thomas & Betts 54148 Thomas & Betts TBM-8 3
1/0 Burndy YA25-L4BOX Burndy MY29-3 2
Ilsco CRB-0 Ilsco IDT-12 1
Ilsco CCL-1/0-38 Ilsco MT-25 1
Thomas & Betts 54109 Thomas & Betts TBM-8 3
2/0 Burndy YAL26T38 Burndy MY29-3 2
Ilsco CRA-2/0 Ilsco IDT-12 1
Ilsco CCL-2/0-38 Ilsco MT-25 1
Thomas & Betts 54110 Thomas & Betts TBM-8 3
Electrical installation
65
Connecting the control cables
Routing the cables (frame sizes R5 and R6)
Run the cables to the inside of the cabinet through the grommets (1) and the EMI
conductive cushions (2) to the swing-out frame or the RMIO board as shown below.
Use sleeving wherever the cables are laid against sharp edges. Leave some slack in
the cable at the hinge (3) to allow the frame to open fully. Tie the cables to the
braces (4) to provide strain relief.
RMIO
4 Strain relief at the left
side of the cabinet
2
3
Electrical installation
66
Routing the cables (frame sizes R7 and R8)
Run the cables to the inside of the cabinet through the grommets (1) and the EMI
conductive cushions (2) to the swing-out frame as shown below.
Use sleeving wherever the cables are laid against sharp edges. Leave some slack in
the cable at the hinge (3) to allow the frame to open fully. Tie the cables to the
braces (4) to provide strain relief.
4
4
Electrical installation
67
360 degrees EMC grounding at the cable entry
1. Loosen the fastening screws of the EMI conductive cushions and pull the
cushions apart.
2. Cut adequate holes to the rubber grommets in the lead-through plate and lead the
cables through the grommets and the cushions into the cabinet.
Strain
relief
EMI conductive
cushion
1 1
Lead-through
plate
Grommet
Side view View from above
3. Strip off the cable plastic sheath above the lead-through plate just enough to
ensure proper connection of the bare shield and the EMI conductive cushions.
4. Tighten the two fastening screws (1) so that the EMI conductive cushions press
tightly round the bare shield.
Note: If the outer surface of the shield is non-conductive:
• Cut the shield at the midpoint of the bare part. Be careful not to cut the
conductors or the grounding wire (if present).
• Turn the shield inside out to expose its conductive surface.
• Cover the turned shield and the stripped cable with copper foil to keep the
shielding continuous.
Copper foil
Cable shield
Shielded twisted pair
Grounding wire
Stripped cable Conductive surface of Stripped part covered
the shield exposed with copper foil
Electrical installation
68
Special for top entry
When each cable has its own rubber grommet, sufficient IP and EMC protection can
be achieved. However, if very many control cables come to one cabinet, plan the
installation beforehand as follows:
1. Make a list of the cables coming to the cabinet.
2. Sort the cables going to the left into one group and the cables going to the right
into another group to avoid unnecessary crossing of cables inside the cabinet.
3. Sort the cables in each group according to size.
4. Group the cables for each grommet as follows ensuring that each cable has a
proper contact to the cushions on both sides.
Cable diameter in mm Max. number of cables per grommet
< 13 4
< 17 3
< 25 2
> 25 1
5. Divide the bunches so that cables will be arranged according to size between the
EMI conductive cushions.
View from above
Thickest cable Thinnest cable
6. If more than one cable go through a grommet, the grommet must be sealed by
Loctite 5221 (catalogue number 25551).
Apply Loctite
Side view 5221 inside the
grommet.
Attach control
cables to the
supporting plate.
Connect the earthing wire to
the PE busbar.
Electrical installation
69
Connecting the cables to the I/O terminals
Connect the conductors to the appropriate detachable terminals of the RMIO board
or optional terminal X2 [see chapter Motor control and I/O board (RMIO)]. Tighten
the screws to secure the connection.
Insulation
4
3
2
1
Double-shielded cable Single-shielded cable
Single-shielded cable: Twist the grounding wires of the outer shield and connect
them to the nearest grounding clamp. Double-shielded cable: Connect the inner
shields and the grounding wires of the outer shield to the nearest grounding clamp.
Do not connect shields of different cables to the same grounding clamp.
Leave the other end of the shield unconnected or ground it indirectly via a few
nanofarads high-frequency capacitor (e.g. 3.3 nF / 630 V). The shield can also be
grounded directly at both ends if they are in the same ground line with no significant
voltage drop between the end points.
Keep the signal wire pairs twisted as close to the terminals as possible. Twisting the
wire with its return wire reduces disturbances caused by inductive coupling.
Electrical installation
70
Settings of the cooling fan transformer
The voltage transformer of the cooling fan is located at the top right-hand corner of
the drive module. Remove the front cover for adjusting the settings and replace the
cover after setting.
Set to 220 V if the supply frequency is 60 Hz. Set to
230 V if the supply frequency is 50 Hz.
Set according to the supply voltage:
380 V, 400 V, 415 V, 440 V, 480 V or 500 V; or
525 V, 575 V, 600 V, 660 V or 690 V.
Installation of optional modules
The optional module (such as a fieldbus adapter, an I/O extension module and the
pulse encoder interface) is inserted in the optional module slot of the RMIO board in
the RDCU unit and fixed with two screws. See the appropriate optional module
manual for the cable connections.
Cabling of I/O and fieldbus modules
Grounding wire of the outer shield
Alternative to a)
As short as possible
1
2
3
4
a)
Shield
Module
Electrical installation
71
Pulse encoder module cabling
Clamp as close to the terminals as
possible.
Alternative to a)
As short as Note 1: If the encoder is of unisolated
possible type, ground the encoder cable at the
drive end only. If the encoder is
1 galvanically isolated from the motor
2
3 shaft and the stator frame, ground the
4
encoder cable shield at the drive and
a) the encoder end.
12345678 123456 Note 2: Twist the pair cable wires.
Note 3: The grounding wire of the outer
shield of the cable can alternatively be
PULSE ENCODER INTERFACE
+24V
V IN
+15V
V OUT
0V
0V
CHZ-
CHZ+
CHB-
CHB+
CHA-
CHA+
SHLD
SHLD
CHASSIS
X1
X2
connected to the SHLD terminal of the
RTAC-01
NODE ID
CHB
CHA
RTAC module.
WD/
INIT
GND
BCD
67 A
EF 2
89
01
345
Fibre optic link
A DDCS fibre optic link is provided via the RDCO optional module for PC tools,
master/follower link, NDIO, NTAC, NAIO, AIMA I/O module adapter and fieldbus
adapter modules of type Nxxx. See RDCO User’s Manual [3AFE64492209
(English)] for the connections. Observe colour coding when installing fibre optic
cables. Blue connectors go to blue terminals, and grey connectors to grey terminals.
When installing multiple modules on the same channel, connect them in a ring.
Electrical installation
72
Layout drawing of factory installed optional equipment
Frame sizes R5 and R6
* Main contactor control relays
*
* * Motor auxiliary fan circuit breaker
* * Motor auxiliary fan contactor
* *Thermistor/Pt100 relays
* *Thermistor/Pt100 control relays
* *Relay for Prevention of Unexpected Start
*Emergency stop of Category 1
*
*Earth fault *Circuit breakers for cabinet heaters
protection
device *Circuit breakers for motor heaters
68328861 B
Swing-out frame (front view)
* Denotes optional equipment not present on all units.
Additional terminal blocks
*X1 line contactor control and auxiliary voltage supply
*X2 RMIO/RDCU
*X4 temperature supervision
*X5 cabinet heaters
*X6 motor auxiliary fan supply
*X7 motor heater
*X8 emergency stop of Category 1
*X9 prevention of unexpected start
*X10 earth fault protection
Electrical installation
73
Frame size R7 and R8
Grounding clamps for
RMIO RDCU,
RMIO
*X2
Grounding clamps for
X2
*X5 * Main contactor
*X1 control relays
* Motor auxiliary fan
*X7 devices
*X8
*Thermistor/Pt100
*X4 relays
*X9
*X10
*Relay for Prevention of
Unexpected Start
*X6
*Emergency stop of
Category 1
*AIMA board
*Circuit breakers for motor
and cabinet heaters
*Earth fault protection device
+24 V external power
supply
* Denotes optional equipment not present on
all units.
Swing-out frame (front view)
64744291 A
For additional terminal blocks X1 to X10, see Additional terminal blocks.
Installation of brake resistors (units with brake chopper option)
See chapter Resistor braking. Connect the resistor as shown in section Power cable
connection diagram above.
Electrical installation
74
Electrical installation
75
Motor control and I/O board (RMIO)
What this chapter contains
This chapter shows
• external control connections to the RMIO board for the ACS800 Standard Control
Program (Factory Macro)
• specifications of the inputs and outputs of the board.
Note for the ACS800-02 with enclosure extension and the ACS800-07
The connections for the RMIO board shown below apply also to optional terminal
block X2 available for the ACS800-02 and ACS800-07. The terminals of the RMIO
board are wired to terminal block X2 internally.
Terminals of X2 accept cables from 0.5 to 4.0 mm2 (22 to 12 AWG). Tightening
torque for screw terminals is 0.4 to 0.8 Nm (0.3 to 0.6 lbf ft). For disconnecting wires
from spring terminals, use a screw driver with a blade thickness of 0.6 mm
(0.024 in.) and width of 3.5 mm (0.138 in.), e.g. PHOENIX CONTACT SZF 1-
0,6X3,5.
Note on terminal labelling
Optional modules (Rxxx) may have identical terminal designations with the RMIO
board.
Motor control and I/O board (RMIO)
76
Note on external power supply
External +24 V power supply for the RMIO board is recommended if
• the application requires a fast start after connecting the input power supply
• fieldbus communication is required when the input power supply is disconnected.
The RMIO board can be supplied from an external power source via terminal X23 or
X34 or via both X23 and X34. The internal power supply to terminal X34 can be left
connected when using terminal X23.
WARNING! If the RMIO board is supplied from an external power source via
terminal X34, the loose end of the cable removed from the RMIO board terminal
must be secured mechanically to a location where it cannot come into contact with
electrical parts. If the screw terminal plug of the cable is removed, the wire ends
must be individually insulated.
WARNING! If the RMIO board is powered from two power supplies (connected to
X23 and X34), and the external power supply connected to X23 is also used to
power external equipment, equip the RMIO branch of the circuit with a diode as
shown below. The diode ensures that the RMIO board will not be damaged by
overcurrent in case the external power supply fails.
X34
RMIO 2 + External or
internal power
3 - supply
X23
+ 1 +24V Auxiliary voltage output
+24 V DC and input, non-isolated,
- 2 GND 24 V DC 250 mA
Other
equipment
Parameter settings
In Standard Control Program, set parameter 16.09 CTRL BOARD SUPPLY to
EXTERNAL 24V if the RMIO board is powered from an external supply.
Motor control and I/O board (RMIO)
77
External control connections (non-US)
External control cable connections to the RMIO board for the ACS800 Standard
Control Program (Factory Macro) are shown below. For external control connections
of other control macros and programs, see the appropriate Firmware Manual.
X2* RMIO
X20 X20
RMIO 1 1 VREF- Reference voltage -10 V DC, 1 kohm < RL
Terminal block size: 2 2 AGND < 10 kohm
cables 0.3 to 3.3 mm2 (22 to 12 AWG) X21 X21
Tightening torque: 1 1 VREF+ Reference voltage 10 V DC, 1 kohm < RL <
0.2 to 0.4 Nm 2 2 AGND 10 kohm
(0.2 to 0.3 lbf ft) 3 3 AI1+ Speed reference 0(2) ... 10 V, Rin =
4 4 AI1- 200 kohm
5 5 AI2+ By default, not in use. 0(4) ... 20 mA, Rin =
6 6 AI2- 100 ohm
7 7 AI3+ By default, not in use. 0(4) ... 20 mA, Rin =
8 8 AI3- 100 ohm
rpm 9 9 AO1+ Motor speed 0(4)...20 mA = 0...motor nom.
10 10 AO1- speed, RL < 700 ohm
A 11 11 AO2+ Output current 0(4)...20 mA = 0...motor
12 12 AO2- nom. current, RL < 700 ohm
* optional terminal block in ACS800-02 X22 X22
and ACS800-07
1 1 DI1 Stop/Start
1) Only effective if par. 10.03 is set to
2 2 DI2 Forward/Reverse 1)
REQUEST by the user. 3 3 DI3 Not in use
4 4 DI4 Acceleration & deceleration select 2)
2) 0 = open, 1 = closed 5 5 DI5 Constant speed select 3)
DI4 Ramp times according to 6 6 DI6 Constant speed select 3)
0 parameters 22.02 and 22.03
7 7 +24VD +24 V DC max. 100 mA
1 parameters 22.04 and 22.05
8 8 +24VD
3)
9 9 DGND1 Digital ground
See par. group 12 CONSTANT
SPEEDS. 10 10 DGND2 Digital ground
DI5 DI6 Operation 11 11 DIIL Start interlock (0 = stop) 4)
0 0 Set speed through AI1 X23 X23
1 0 Constant speed 1 1 1 +24V Auxiliary voltage output and input, non-
0 1 Constant speed 2 2 2 GND isolated, 24 V DC 250 mA 5)
1 1 Constant speed 3 X25 X25
1 1 RO1 Relay output 1: ready
4) See parameter 21.09 START INTRL
2 2 RO1
FUNC.
5) Total maximum current shared
3 3 RO1
X26 X26
between this output and optional
modules installed on the board. 1 1 RO2 Relay output 2: running
2 2 RO2
3 3 RO2
X27 X27
1 1 RO3 Relay output 3: fault (-1)
Fault 2 2 RO3
3 3 RO3
Motor control and I/O board (RMIO)
78
External control connections (US)
External control cable connections to the RMIO board for the ACS800 Standard
Control Program (Factory Macro US version) are shown below. For external control
connections of other control macros and programs, see the appropriate Firmware
Manual.
X2* RMIO
RMIO X20 X20
Terminal block size: 1 1 VREF- Reference voltage -10 V DC, 1 kohm < RL
2 2 AGND < 10 kohm
cables 0.3 to 3.3 mm2 (22 to 12 AWG)
Tightening torque: X21 X21
1 1 VREF+ Reference voltage 10 V DC, 1 kohm < RL <
0.2 to 0.4 Nm (0.2 to 0.3 lbf ft)
2 2 AGND 10 kohm
3 3 AI1+ Speed reference 0(2) ... 10 V, Rin =
4 4 AI1- 200 kohm
5 5 AI2+ By default, not in use. 0(4) ... 20 mA, Rin =
6 6 AI2- 100 ohm
7 7 AI3+ By default, not in use. 0(4) ... 20 mA, Rin =
8 8 AI3- 100 ohm
rpm 9 9 AO1+ Motor speed 0(4)...20 mA = 0...motor nom.
10 10 AO1- speed, RL < 700 ohm
A 11 11 AO2+ Output current 0(4)...20 mA = 0...motor
12 12 AO2- nom. current, RL < 700 ohm
X22 X22
1 1 DI1 Start ( )
2 2 DI2 Stop ( )
* optional terminal block in ACS800-U2
3 3 DI3 Forward/Reverse 1)
and ACS800-U7
4 4 DI4 Acceleration & deceleration select 2)
1) Only effective if par. 10.03 is set to
5 5 DI5 Constant speed select 3)
REQUEST by the user. 6 6 DI6 Constant speed select 3)
7 7 +24VD +24 V DC max. 100 mA
2)
0 = open, 1 = closed
8 8 +24VD
DI4 Ramp times according to
9 9 DGND1 Digital ground
0 parameters 22.02 and 22.03
10 10 DGND2 Digital ground
1 parameters 22.04 and 22.05
11 11 DIIL Start interlock (0 = stop) 4)
3) X23 X23
See par. group 12 CONSTANT
SPEEDS. 1 1 +24V Auxiliary voltage output and input, non-
DI5 DI6 Operation 2 2 GND isolated, 24 V DC 250 mA 5)
0 0 Set speed through AI1 X25 X25
1 0 Constant speed 1 1 1 RO1 Relay output 1: ready
0 1 Constant speed 2 2 2 RO1
1 1 Constant speed 3 3 3 RO1
X26 X26
4) See parameter 21.09 START INTRL
1 1 RO2 Relay output 2: running
FUNC.
5) Total maximum current shared 2 2 RO2
between this output and optional 3 3 RO2
modules installed on the board. X27 X27
1 1 RO3 Relay output 3: fault (-1)
Fault 2 2 RO3
3 3 RO3
Motor control and I/O board (RMIO)
79
RMIO board specifications
Analogue inputs
With Standard Control Program two programmable differential current inputs (0 mA /
4 mA ... 20 mA, Rin = 100 ohm) and one programmable differential voltage input (-
10 V / 0 V / 2 V ... +10 V, Rin = 200 kohm).
The analogue inputs are galvanically isolated as a group.
Insulation test voltage 500 V AC, 1 min
Max. common mode voltage ±15 V DC
between the channels
Common mode rejection ratio > 60 dB at 50 Hz
Resolution 0.025% (12 bit) for the -10 V ... +10 V input. 0.5% (11 bit) for the 0 ... +10 V and 0 ...
20 mA inputs.
Inaccuracy ±0.5% (Full Scale Range) at 25 °C (77 °F). Temperature coefficient: ±100 ppm/°C
(±56 ppm/°F), max.
Constant voltage output
Voltage +10 V DC, 0, -10 V DC ± 0.5% (Full Scale Range) at 25 °C (77 °F). Temperature
coefficient: ±100 ppm/°C (±56 ppm/°F) max.
Maximum load 10 mA
Applicable potentiometer 1 kohm to 10 kohm
Auxiliary power output
Voltage 24 V DC ± 10%, short circuit proof
Maximum current 250 mA (shared between this output and optional modules installed on the RMIO)
Analogue outputs
Two programmable current outputs: 0 (4) to 20 mA, RL < 700 ohm
Resolution 0.1% (10 bit)
Inaccuracy ±1% (Full Scale Range) at 25 °C (77 °F). Temperature coefficient: ±200 ppm/°C
(±111 ppm/°F) max.
Digital inputs
With Standard Control Program six programmable digital inputs (common ground:
24 V DC, -15% to +20%) and a start interlock input. Group isolated, can be divided in
two isolated groups (see Isolation and grounding diagram below).
Thermistor input: 5 mA, < 1.5 kohm “1” (normal temperature), > 4 kohm “0”
(high temperature), open circuit “0” (high temperature).
Internal supply for digital inputs (+24 V DC): short-circuit proof. An external 24 V DC
supply can be used instead of the internal supply.
Insulation test voltage 500 V AC, 1 min
Logical thresholds < 8 V DC “0”, > 12 V DC “1”
Input current DI1 to DI 5: 10 mA, DI6: 5 mA
Filtering time constant 1 ms
Motor control and I/O board (RMIO)
80
Relay outputs
Three programmable relay outputs
Switching capacity 8 A at 24 V DC or 250 V AC, 0.4 A at 120 V DC
Minimum continuous current 5 mA rms at 24 V DC
Maximum continuous current 2 A rms
Insulation test voltage 4 kV AC, 1 minute
DDCS fibre optic link
With optional communication adapter module RDCO. Protocol: DDCS (ABB
Distributed Drives Communication System)
24 V DC power input
Voltage 24 V DC ± 10%
Typical current consumption 250 mA
(without optional modules)
Maximum current consumption 1200 mA (with optional modules inserted)
The terminals on the RMIO board as well as on the optional modules attachable to the board fulfil the Protective Extra
Low Voltage (PELV) requirements stated in EN 50178 provided that the external circuits connected to the terminals also
fulfil the requirements and the installation site is below 2000 m (6562 ft). Above 2000 m (6562 ft), see page 56.
Motor control and I/O board (RMIO)
81
Isolation and grounding diagram
(Test voltage: 500 V AC)
X20
1 VREF-
2 AGND
X21
1 VREF+
2 AGND
3 AI1+
4 AI1- Common mode
voltage between
5 AI2+
channels ±15 V
6 AI2-
7 AI3+
8 AI3-
9 AO1+
10 AO1-
11 AO2+
12 AO2-
X22
1 DI1
2 DI2
3 DI3
4 DI4
Jumper J1 settings:
9 DGND1
5 DI5 All digital inputs share a common
J1
6 DI6 ground. This is the default setting.
7 +24VD
8 +24VD Grounds of input groups
11 DIIL DI1…DI4 and DI5/DI6/DIIL
or
are separate (insulation
10 DGND2 voltage 50 V).
X23
1 +24 V
2 GND
X25
1 RO1
2 RO1
3 RO1
X26
1 RO2
2 RO2
3 RO2
X27
1 RO3
2 RO3
3 RO3
(Test voltage:
4 kV AC)
Ground
Motor control and I/O board (RMIO)
82
Motor control and I/O board (RMIO)
83
Installation checklist and start-up
Checklist
Check the mechanical and electrical installation of the drive before start-up. Go
through the checklist below together with another person. Read the Safety
instructions on the first pages of this manual before you work on the unit.
Check
MECHANICAL INSTALLATION
The ambient operating conditions are allowed. See Mechanical installation, Technical data: IEC data or NEMA
data, Ambient conditions.
The unit is fixed properly on floor and a vertical non-flammable wall. See Mechanical installation.
The cooling air will flow freely.
ELECTRICAL INSTALLATION See Planning the electrical installation, Electrical installation.
The motor and the driven equipment are ready for start. See Planning the electrical installation: Motor selection
and compatibility, Technical data: Motor connection.
The +E202 EMC filter capacitors are disconnected if the drive is connected to an IT (ungrounded) system.
The capacitors are reformed if stored over one year, refer to ACS 600/800 Capacitor Reforming Guide
[64059629 (English)].
The drive is grounded properly.
The mains (input power) voltage matches the drive nominal input voltage.
The mains (input power) connections at L1, L2 and L3 and their tightening torques are OK. See Technical data /
Cable entries.
Appropriate mains (input power) fuses and disconnector are installed.
The motor connections at U2, V2 and W2 and their tightening torques are OK. See Technical data / Cable entries.
The motor cable is routed away from other cables.
Voltage setting of the cooling fan transformer
Setting of the auxiliary voltage transformer T10 (if present). For location, see Maintenance / Cabinet layout.
Voltage setting of the IP 54 fan transformer T15 (if present). For location, see Maintenance / Cabinet layout.
Voltage setting of the brake resistor fan transformer (if present).
There are no power factor compensation capacitors in the motor cable.
The external control connections inside the drive are OK.
There are no tools, foreign objects or dust from drilling inside the drive.
Mains (input power) voltage cannot be applied to the output of the drive (with bypass connection).
Drive, motor connection box and other covers are in place.
Installation checklist and start-up
84
Start-up procedure
Action Additional information
Safety
Only qualified electricians are allowed to start-up the drive. The safety See chapter Safety instructions.
instructions must be followed during the start-up procedure.
Checks with no voltage connected
Check the tuning of the insulation monitoring device. Optional device. See delivery
specific circuit diagrams and
IRDH265 Operating Manual by
Bender (code: TGH1249).
Pt 100 settings (if present)
Starting the drive
Close the switch fuse (main disconnector).
Units with line contactor: Close the contactor by turning the start switch
on the cabinet door from OFF into START position for 2 seconds. Leave
the switch to ON position.
Control program set-up
Follow the instructions in the Firmware Manual to start up the drive and
to set the drive parameters.
On-load checks
Check that the Prevention of Unexpected Start function (if installed) Optional function. See delivery
works: specific circuit diagrams.
• Start and Stop the drive and wait until the motor has stopped.
• Open the Prevention of Unexpected Start switch (mounted on a control
desk). The indicating lamp should light.
• Give a Start command. The drive should not start.
• Reset the drive from the control panel.
Check that the cooling fans rotate freely in the right direction, and the air A paper sheet set on the intake
flows upwards. (door) gratings stays. The fans run
noiselessly.
Check the direction of rotation of the motor.
Check the correct operation of the emergency-stop circuits from each
operating location.
Installation checklist and start-up
85
Maintenance
What this chapter contains
This chapter contains preventive maintenance instructions.
Safety
WARNING! Read the Safety instructions on the first pages of this manual before
performing any maintenance on the equipment. Ignoring the safety instructions can
cause injury or death.
Maintenance intervals
If installed in an appropriate environment, the drive requires very little maintenance.
This table lists the routine maintenance intervals recommended by ABB.
Interval Maintenance For instruction, see section
Every year when Capacitor reforming Reforming
stored
Every year IP 54 air filter change Checking and replacing the air filters
IP 42 air filter check and change if necessary
IP 22 air filter check and change if necessary
Cleanliness check Heatsink
Every 6 years Cabinet cooling fan change (frame sizes R5 Replacing the cabinet fans (R5 and R6)
and R6)
Every 6 years Cabinet cooling fan change (frame size R8) Replacing the cabinet fans (frame size R8 only)
Every 6 years Change of additional cabinet cooling fan on Replacing the additional cabinet fan (frame sizes
the roof (frame sizes R7 and R8) R7 and R8 only with IP 22 and IP 42 when cabling:
bottom entry/exit)
Every 6 years Change of additional cabinet cooling fan at Replacing the additional cabinet fan (frame sizes
the bottom (frame sizes R7 and R8) R7 and R8 only with IP 22 and IP 42 when cabling:
top entry and bottom exit, bottom entry and top exit
or top entry/exit)
Every 6 years Change of optional brake resistor (1xSAFUR -
and 2xSAFUR) cabinet fan, optional du/dt
filter fan of types ACS800-07-0120-3 and -
0140-5
Every 6 years IP 54 and IP 54R fan change Replacing the IP 54 (UL type 12) fan in frame size
(frame sizes R6, R7 and R8) R6 or
Replacing the IP 54 (UL type 12) fan in frame sizes
R7 and R8
Maintenance
86
Every 6 years Drive module cooling fan change (frame Replacing the drive module fan (R5 and R6)
sizes R5 and R6)
Every 6 years Drive module cooling fan change (frame size Replacing the drive module fan (R7)
R7)
Every 6 years Drive module cooling fan change (frame size Replacing the drive module fan (R8)
R8)
Every 10 years Capacitor change Capacitors
Consult your local ABB Service representative for more details on the maintenance.
On the Internet, go to http://www.abb.com/drives and select Drive Services –
Maintenance and Field Services.
Required tools for maintenance
• 3 mm screw driver
• torque wrench with 500 mm (20 in.) or 2 x 250 mm (2 x 10 in.) extension bar
• 19 mm socket
for frame size R7: 13 mm magnetic end socket
for frame size R8: 17 mm magnetic end socket.
Screw Grade Tool Tightening torque
mm Nm lbf ft
M4 8.8 7 2 1.46
M5 8.8 8 4 3
M6 8.8 10 6...9 4...7
M8 8.8 13 15...22 11...16
M10 8.8 17 30...44 22...32
M12 8.8 19 50...75 37...55
Maintenance
87
Cabinet layout
Cabinet layout stickers are shown below. The symbols are described under
Designations.
Frame sizes R5 and R6
The options included are marked with x at the factory.
IP54 ROOF
OPTION 1
OPTION 2
OPTION 3
Maintenance
88
Frame sizes R7 and R8 without du/dt filter
The options included are marked with x at the factory.
IP22/42 BOTTOM ENTRY/EXIT
IP22/42 TOP ENTRY/EXIT
Maintenance
89
Frame sizes R7 and R8 with du/dt filter
The options included are marked with x at the factory.
IP22/42 BOTTOM
IP22/42 ENTRY/EXIT
BOTTOM ENTY/EXIT
IP22/42 TOP ENTRY/EXIT
Maintenance
90
Designations
Designation Component
A48,49 Control panel mounting platform, control panel
C1, C3 Fan capacitor
E1 Cabinet heater
F10.1-2 Auxiliary voltage transformer fuses
F11 Circuit breaker
F15.1-2 IP 22/42/54 fan fuses
F30.1-3 Motor auxiliary fan fuses
F51 Circuit breaker
G10 +24 VDC external power supply
K1 Line contactor
Q1, F1.1 -3 Switch fuse
S11 Start/Stop switch
S20 Emergency Stop switch
S21 Emergency Stop reset
S90 Earth fault reset
T10 Auxiliary voltage transformer
T15 IP 54 fan transformer
U1 drive module
X2 Additional terminal block for RMIO board
Y1.1 IP 54 fan
Y2 Additional cabinet fan
Y3.1 IP 22/42 fan
Z2 du/dt filter
Maintenance
91
Layout of the drive module
The layout stickers of the drive module are shown below. The stickers show all
possible components. Not all of them are present in each delivery. Components that
need to be changed regularly are listed below:
Designation Component
Y41 Cooling fan
C_ Capacitors
R7 R8
Code: 64572261 Code: 64601423
Maintenance
92
Checking and replacing the air filters
Check the air filters and replace if necessary (see Technical data for the correct filter
types). The inlet (door) filters can be accessed by removing the fastener(s) at the top
of the grating, then lifting the grating and pulling it away from the door. The outlet
(roof) filter in IP 54 units can be accessed by pulling the grating upwards.
Air filter mat
Heatsink
Check the cleanliness of the cabinet and the surroundings. When necessary, clean
the interior of the cabinet with a soft brush and a vacuum cleaner.
The module heatsink fins pick up dust from the cooling air. The drive runs into
overtemperature warnings and faults if the heatsink is not clean. When necessary,
contact ABB for cleaning of the heatsink (frame sizes R7 and R8).
In frame size R6, proceed as follows:
1. Remove the cooling fan (see section Fans).
2. Remove the drive module from the cabinet.
3. Blow dry clean compressed air from bottom to top and simultaneously use a
vacuum cleaner at the air outlet to trap the dust. Note: Prevent dust from entering
adjoining equipment.
4. Replace the cooling fan.
Fans
The lifespan of the cooling fan of the drive module is about 50 000 hours. The actual
lifespan depends on the running time of the fan, ambient temperature and dust
concentration. See the appropriate ACS800 firmware manual for the actual signal
which indicates the running time of the cooling fan.
Replacement fans are available from ABB. Do not use other than ABB specified
spare parts.
Maintenance
93
Replacing the drive module fan (R5 and R6)
To remove the fan, undo the fixing screws. Disconnect the cable. Install the fan in
reverse order.
Bottom view
Maintenance
94
Replacing the drive module fan (R7)
1. Remove the front cover.
2. Disconnect the discharging resistor wire(s).
3. Remove the DC capacitor pack by undoing the red fixing screws and pulling the
pack out.
4. Disconnect the fan supply wires (detachable connector).
5. Disconnect the fan capacitor wires.
6. Disconnect the AINP board wires from connectors X1 and X2.
7. Undo the red fixing screws of the fan cassette.
8. Press the snap-on holders to release the side cover.
9. Lift the handle and pull the fan cassette out.
10. Install the new fan and fan capacitor in reverse order to the above.
4
3 6
7
2
2 pcs in 8
690 V
units
9
5
8
3
3
3
DC+ DC-
Maintenance
95
Replacing the drive module fan (R8)
1. Remove the front cover.
2. Disconnect the fan capacitor and power supply wires.
3. Undo the red fastening screws of the plastic side cover of the fan. Shift the cover
to the right to free its right-hand edge and lift the cover off.
4. Undo the red fastening screws of the fan.
5. Lift the fan out of the cabinet.
6. Install the new fan and fan capacitor in reverse order to the above.
5
2
4
3
Maintenance
96
Replacing the cabinet fans (R5 and R6)
Replacing the fans at upper part of the cubicle
1. Remove the fan cassette from the cabinet as shown in Replacing the drive
module (R5 and R6).
2. Undo the fastening screws of the fans.
3. Install the new fans in reverse order to the above.
2 2 2 2
Fan cassette
(view from below)
2 2 2 2
Replacing the additional fan at the lower part of the cubicle (R6 with du/dt filter, +E205)
1. Remove the screws that mount the support frame of the fan to the cabinet frame.
2. Pull the fan support frame outwards and disconnect the fan supply wires
(detachable connector).
3. Remove the fan frame from the cabinet.
4. Remove the screws that mount the fan to the fan frame.
5. Install a new fan in reverse order.
Maintenance
97
Replacing the cabinet fans (frame size R8 only)
For location of the cabinet fans, see Cabinet layout.
1. Undo the fastening screws.
2. Disconnect the fan supply wires (detachable connector at the back edge of the
fan cassette).
3. Pull the fan cassette out.
4. Disconnect the fan wires from the terminal.
5. Undo the fastening screws of the fans.
6. Install the new fans in reverse order to the above.
1 1
5 5 5 5
5 5 5 5
Maintenance
98
Replacing the additional cabinet fan (frame sizes R7 and R8 only with IP 22 and
IP 42 when cabling: bottom entry/exit)
1. Remove the top plate of the cabinet roof by undoing the fastening screws.
2. Remove the fan cover by undoing the fastening screws.
3. Disconnect the fan supply wires (detachable connector) and undo the cable ties
on the fan cover.
4. Remove the fan capacitor by undoing the fastening screw of the clamp.
5. Pull the fan out.
6. Install the new fan and fan capacitor in reverse order to the above.
1 1 1 1
1 1
1 1
1 1
1 1 1 1
2 2
2 2
2 2
2 2
3 4
Cabinet front
Pro/E: 6469 4952 (cab-r7-8_roof_fan_bot-ee.asm), 6471 7154
Maintenance
99
Replacing the additional cabinet fan (frame sizes R7 and R8 only with IP 22 and
IP 42 when cabling: top entry and bottom exit, bottom entry and top exit or top
entry/exit)
1. Remove the shroud by undoing the fastening screws.
2. Disconnect the fan supply wires (detachable connector).
3. Remove the fan capacitor by undoing the fastening screw of the clamp.
4. Install the new fan and fan capacitor in reverse order to the above.
1 1
1
1 Pro/E: 6828 4759
Maintenance
100
Replacing the IP 54 (UL type 12) fan in frame size R6
1. Remove the front grating of the fan cubicle by lifting it upwards.
2. Remove the shroud by undoing the fastening screws.
3. Disconnect the fan supply wires (detachable terminal).
4. Undo the fastening screws of the fan.
5. Install the new fan in reverse order to the above.
2
2
4
4
2 4 4
3 2
Pro/E: 64784803A_ip54_roof-400,
Cabinet front
64784803I_ip54_roof-400_b-ee
Maintenance
101
Replacing the IP 54 (UL type 12) fan in frame sizes R7 and R8
1. Remove the front and back gratings of the fan cubicle by lifting them upwards.
2. Remove the shrouds by undoing the fastening screws.
3. Undo the fastening screws of the side/top cover of the fan.
4. Lift the side/top cover of the fan off.
5. Disconnect the fan supply wire connector from the cabinet roof (on top and
inside the cabinet).
6. Undo the fastening screws of the fan cassette at each corner.
7. Lift the fan cassette off.
8. Undo the cable ties on the top of the fan cassette.
9. Disconnect the cables (detachable terminals).
10. Remove the fan capacitor by undoing the fastening screw of the clamp.
11. Undo the fastening screws of the fan.
12. Pull the fan out.
13. Install the new fan and fan capacitor in reverse order to the above. Ensure that
the fan is centred and rotates freely.
2 2 4
1
3
2
2
3
7
6
5
5
Maintenance
102
10
9
8
8
9
8 8
12
11 11
Capacitors
The drive intermediate circuit employs several electrolytic capacitors. Their lifespan
is at least 90 000 hours depending on the operating time of the drive, loading and
ambient temperature. Capacitor life can be prolonged by lowering the ambient
temperature.
It is not possible to predict a capacitor failure. Capacitor failure is usually followed by
damage to the unit and an input cable fuse failure, or a fault trip. Contact ABB if
capacitor failure is suspected. Replacements are available from ABB. Do not use
other than ABB specified spare parts.
Reforming
Reform (re-age) spare part capacitors once a year according to ACS 600/800
Capacitor Reforming Guide [code: 64059629 (English)].
Replacing the capacitor pack (R7)
Replace the capacitor pack as described in section Replacing the drive module fan
(R7).
Maintenance
103
Replacing the capacitor pack (R8)
1. Remove the module from the cabinet as described in section Replacing the drive
module (R7 and R8).
2. Remove the front cover. Remove the profiled side plate.
3. Disconnect the discharging resistor wires.
4. Undo the red fastening screws.
5. Lift the capacitor pack out.
6. Install the new capacitor pack in reverse order to the above.
At the rear side (view from
4
below)
4
4 3
3
2 pcs in
690 V
units
4
4
2 pcs
M6x12 combi screw 4 M10 4 M6
Maintenance
104
Replacing the drive module (R5 and R6)
1. Open the swing-out frame. Undo screw (1) to open the swing-out frame wide.
2. Disconnect the control panel cable.
3. Disconnect the fan wires (detachable terminal).
4. Undo the fastening screws of the air baffle and fan cassette, and pull the air
baffle out.
5. Pull the fan cassette out.
6. Remove the shroud at the top of the module by undoing the fastening screws.
7. Remove the shrouds in the lower part of the cabinet.
8. Remove the additional fan (if any). See Replacing the additional fan at the lower
part of the cubicle (R6 with du/dt filter, +E205) on page 96.
9. Disconnect the control cables by detaching the RMIO board terminals.
10. Disconnect the power busbars and cables.
6 3 6
1 2
5 10 10 10 10 10 10 10 10
4 4
10 10
4 10 10 10
4
Maintenance
105
11. Fasten the slide rails at the bottom of the cabinet to the sides of the cabinet.
12. Undo the fastening screws of the module. Use a torque wrench with an extension
bar.
13. R5: Lift the module out. R6: Slide the module out onto a pallet truck.
14. Install the new module in reverse order to the above.
11
11
12 12
13
12 12
Maintenance
106
Replacing the drive module (R7 and R8)
1. Remove the shroud.
2. Undo the fastening screws.
3. Disconnect the input power busbars from the module.
4. Disconnect the power supply cable from the APOW board.
5. Disconnect the door wires.
6. Remove the air guide.
7. Remove the fastening bracket.
8. Remove the front cover of the module.
9. Disconnect the fibre optic cables from the AINT board and mark down the
terminals for reconnecting.
1 2
3 4
3
7
5
View when the
module cover is
removed
Photos of frame size R8
Maintenance
107
10. Disconnect the pedestal from the module by undoing the fastening (a) and
busbar connecting (b) screws.
Frame size R7
b
a a M6 combi screw
Tightening torque: 5 Nm (3.7 lbf ft)
b b b a
a
b a b M8x25 combi screw
b Tightening torque: 15...22 Nm
(11...16 lbf ft)
Frame size R8
a a
a a
b b b b b
a M6x16 combi screws b M10x25 combi screws
Tightening torque: 5 Nm (3.7 lbf ft) Tightening torque: 30...44 Nm (22...32 lbf ft)
Maintenance
108
11. Secure the module to a fork lift.
12. Pull the module from the cabinet onto the fork lift.
WARNING! Secure the module 11
properly. The module of frame size
R7 weighs 90 kg (198 lb). The
module of frame size R8 weighs
200 kg (441 lb). The centre of
gravity of the module is high.
12
13. Install the new module in reverse order to the above.
The module is slid in on the pedestal rails
(view from back, the back plate of the
cabinet removed)
WARNING! Fastening of screws (a) is important because the screws are required
for the grounding of the drive.
Maintenance
109
LEDs
This table describes LEDs of the drive.
Where LED When the LED is lit
RMIO board Red Drive in fault state
Green The power supply on the board is OK.
Control panel mounting platform Red Drive in fault state
Green The main + 24 V power supply for the control panel and the
RMIO board is OK.
AINT board V204 (green) +5 V voltage of the board is OK.
V309 (red) Prevention of unexpected start is ON.
V310 (green) IGBT control signal transmission to the gate driver control
boards is enabled.
Maintenance
110
Maintenance
111
Technical data
What this chapter contains
This chapter contains the technical specifications of the drive, e.g. the ratings, sizes
and technical requirements, provisions for fulfilling the requirements for CE and
other markings, and warranty policy.
IEC data
Ratings
The IEC ratings for the ACS800-07 with 50 Hz and 60 Hz supplies are given below.
The symbols are described below the table.
ACS800-07 size Nominal ratings No- Light-overload use Heavy-duty use Frame Air flow Heat
overload size dissipation
use
Icont.max Imax Pcont.max I2N PN I2hd Phd
A A kW A kW A kW m3/h W
Three-phase supply voltage 380 V, 400 V or 415 V
-0075-3 145 170 75 141 75 100 45 R5 405 1440
-0100-3 166 202 90 155 75 115 55 R6 405 1940
-0120-3 202 282 110 184 90 141 75 R6 405 2310
-0135-3 225 326 110 220 110 163 90 R6 405 2810
-0165-3 260 326 132 254 132 215 110 R6 405 3260
-0205-3 290 351 160 285 160 234 132 R6 405 4200
-0260-3 445 588 200 440 200 340 160 R8 1220 6600
-0320-3 521 588 250 516 250 370 200 R8 1220 7150
-0400-3 602 840 315 590 315 477 250 R8 1220 8100
-0440-3 693 1017 355 679 355 590 2) 315 R8 1220 8650
-0490-3 720 1017 400 704 400 635 3) 355 R8 1220 9100
Technical data
112
ACS800-07 size Nominal ratings No- Light-overload use Heavy-duty use Frame Air flow Heat
overload size dissipation
use
Icont.max Imax Pcont.max I2N PN I2hd Phd
A A kW A kW A kW m3/h W
Three-phase supply voltage 380 V, 400 V, 415 V, 440 V, 460 V, 480 V or 500 V
-0105-5 145 170 90 141 90 100 55 R5 405 2150
-0120-5 157 202 90 145 90 113 75 R6 405 2310
-0140-5 180 282 110 163 110 141 90 R6 405 2810
-0165-5 225 326 132 220 132 163 110 R6 405 3260
-0205-5 260 326 160 254 160 215 132 R6 405 3800
-0255-5 290 351 200 285 200 234 160 R6 405 4500
-0320-5 440 588 250 435 250 340 200 R8 1220 6850
-0400-5 515 588 315 510 315 370 250 R8 1220 7800
-0440-5 550 840 355 545 355 490 315 R8 1220 7600
2)
-0490-5 602 840 400 590 400 515 355 R8 1220 8100
-0550-5 684 1017 450 670 450 590 2) 400 R8 1220 9100
-0610-5 718 1017 500 704 500 632 3) 450 R8 1220 9700
Three-phase supply voltage 525 V, 550 V, 575 V, 600 V, 660 V or 690 V
-0070-7 79 104 75 73 55 54 45 R6 405 1220
-0100-7 93 124 90 86 75 62 55 R6 405 1650
-0120-7 113 172 110 108 90 86 75 R6 405 1960
-0145-7 134 190 132 125 110 95 90 R6 405 2660
-0175-7 166 245 160 155 132 131 110 R6 405 3470
-0205-7 190 245 160 180 160 147 132 R6 405 4180
-0260-7 175/230* 326 160/200* 175/212* 160/200* 163 160 R7 540 4800
-0320-7 315 433 315 290 250 216 200 R8 1220 6150
-0400-7 353 548 355 344 315 274 250 R8 1220 6650
-0440-7 396 656 400 387 355 328 315 R8 1220 7400
-0490-7 445 775 450 426 400 387 355 R8 1220 8450
-0550-7 488 853 500 482 450 426 400 R8 1220 8300
-0610-7 560 964 560 537 500 482 450 R8 1220 9750
TYPES BEING PHASED OUT **
Three-phase supply voltage 380 V, 400 V or 415 V
-0070-3 141 164 75 132 55 97 45 R6 405 1440
-0140-3 206 326 110 202 110 163 90 R7 540 3000
-0170-3 248 404 132 243 132 202 110 R7 540 3650
-0210-3 289 432 160 284 160 240 1) 132 R7 540 4300
Three-phase supply voltage 380 V, 400 V, 415 V, 440 V, 460 V, 480 V or 500 V
-0100-5 124 164 75 115 75 88 55 R6 405 1940
-0170-5 196 326 132 192 132 162 110 R7 540 3000
-0210-5 245 384 160 240 160 192 132 R7 540 3800
-0260-5 289 432 200 284 200 224 160 R7 540 4500
Three-phase supply voltage 525 V, 550 V, 575 V, 600 V, 660 V or 690 V
-0140-7 134 190 132 125 110 95 90 R7 540 2800
-0170-7 166 263 160 155 132 131 110 R7 540 3550
-0210-7 166/203* 294 160 165/195* 160 147 132 R7 540 4250
PDM code: 00096931-J
Technical data
113
1)
50% overload is available for one minute every 5 minutes if ambient temperature is less than 25 °C.
If ambient temperature is 40 °C, max. available overload is 37%.
2)
50% overload is available for one minute every 5 minutes if ambient temperature is less than 30 °C.
If ambient temperature is 40 °C, max. available overload is 40%.
3)
50% overload is available one minute every 5 minutes if ambient temperature is less than 20 °C. If
ambient temperature is 40 °C, max. available overload is 30%.
4)
Higher value is valid if ambient temperature is less than 35 °C.
*
higher value applicable if output frequency is above 41 Hz
**
MANUFACTURED ON SPECIAL ORDER ONLY
Symbols
Nominal ratings
Icont.max continuous rms output current. No overload capability at 40 °C.
Imax maximum output current. Available for 10 s at start, otherwise as long as allowed by drive
temperature.
Typical ratings:
No-overload use
Pcont.max typical motor power. The power ratings apply to most IEC 34 motors at the nominal voltage,
400 V, 500 V or 690 V.
Light-overload use (10% overload capability)
I2N continuous rms current. 10% overload is allowed for one minute every 5 minutes.
PN typical motor power. The power ratings apply to most IEC 34 motors at the nominal voltage,
400 V, 500 V or 690 V.
Heavy-duty use (50% overload capability)
I2hd continuous rms current. 50% overload is allowed for one minute every 5 minutes.
Phd typical motor power. The power ratings apply to most IEC 34 motors at the nominal voltage,
400 V, 500 V or 690 V.
Sizing
The current ratings are the same regardless of the supply voltage within one voltage range. To achieve
the rated motor power given in the table, the rated current of the drive must be higher than or equal to
the rated motor current.
Note 1: The maximum allowed motor shaft power is limited to 1.5 · Phd, 1.1 · PN or Pcont.max (whichever
value is greatest). If the limit is exceeded, motor torque and current are automatically restricted. The
function protects the input bridge of the drive against overload. If the condition exists for 5 minutes, the
limit is set to Pcont.max.
Note 2: The ratings apply at an ambient temperature of 40 °C (104 °F). At lower temperatures the
ratings are higher (except Imax).
Note 3: Use the DriveSize PC tool for a more accurate dimensioning if the ambient temperature is
below 40 °C (104 °F) or the drive is loaded cyclically.
Derating
The load capacity (current and power) decreases if the installation site altitude exceeds 1000 metres
(3281 ft), or if the ambient temperature exceeds 40 °C (104 °F).
Technical data
114
Temperature derating
In the temperature range +40 °C (+104 °F) to +50 °C (+122 °F), the rated output current is decreased
1 % for every additional 1 °C (1.8 °F). The output current is calculated by multiplying the current given
in the rating table by the derating factor.
Example If the ambient temperature is 50 °C (+122 °F), the derating factor is 100% - 1 % · 10 °C =
90% or 0.90. The output current is then 0.90 · I , 0.90 · I or 0.90 · I . °C
2N 2hd cont.max
Altitude derating
At altitudes from 1000 to 4000 m (3281 to 13123 ft) above sea level, the derating is 1% for every 100 m
(328 ft). For a more accurate derating, use the DriveSize PC tool. See Installation sites above 2000
metres (6562 feet) on page 56.
Fuses
The drive is equipped with aR fuses as standard. Standard aR fuses and optional gG
fuses for protection against short-circuit in the input power cable or drive are listed
below. Either fuse type may be used if it operates rapidly enough. Choose between
gG and aR fuses according to the table under Quick guide for selecting between gG
and aR fuses on page 120, or verify the operating time by checking that the short-
circuit current of the installation is at least the value given in the fuse table.
The short-circuit current can be calculated as follows:
U
Ik2-ph =
2· Rc2 + (Zk + Xc)2
where
Ik2-ph = short-circuit current in symmetrical two-phase short-circuit
U = network line-to-line voltage (V)
Rc = cable resistance (ohm)
Zk = zk · UN2/SN = transformer impedance (ohm)
zk = transformer impedance (%)
UN = transformer rated voltage (V)
SN = nominal apparent power of the transformer (kVA)
Xc = cable reactance (ohm).
Calculation example
Drive:
• ACS800-07-0260-3
• supply voltage U = 410 V
Transformer:
• rated power SN = 3000 kVA
• rated voltage (drive supply voltage) UN = 430 V
• transformer impedance zk = 7.2%.
Technical data
115
Supply cable:
• length = 170 m
• resistance/length = 0.112 ohm/km
• reactance/length = 0.0273 ohm/km.
UN2 (430 V)2
Zk = zk · = 0.072 · = 4.438 mohm
SN 3000 kVA
ohm
Rc = 170 m · 0.112 km = 19.04 mohm
ohm
Xc = 170 m · 0.0273 = 4.641 mohm
km
410 V
Ik2-ph = = 9.7 kA
2· (19.04 mohm)2 + (4.438 mohm + 4.641 mohm)2
The calculated short-circuit current 9.7 kA is higher than the minimum short-circuit current of the drive
gG fuse type OFAF3H500 (8280 A). -> The 500 V gG fuse (ABB Control OFAF3H500) can be used.
Notes concerning the fuse tables
Note 1: See also Planning the electrical installation: Thermal overload and short-circuit protection. For
UL recognized fuses, see NEMA data on page 124.
Note 2: In multicable installations, install only one fuse per phase (not one fuse per conductor).
Note 3: Larger fuses than the recommended ones must not be used.
Note 4: Fuses from other manufacturers can be used if they meet the ratings and the melting curve of
the fuse does not exceed the melting curve of the fuse mentioned in the table.
Technical data
116
Ultrarapid (aR) fuses
ACS800-07 Input Min. short- Fuse
size current circuit
current 1)
A A A A 2s V Manufacturer Type DIN 43620 Size
Three-phase supply voltage 380 V, 400 V or 415 V
-0075-3 142 1630 315 80 500 690 Bussmann 170M1572 DIN000
-0100-3 163 1280 315 46 500 690 Bussmann 170M3817 DIN1*
-0120-3 198 1810 400 105 000 690 Bussmann 170M3819 DIN1*
-0135-3 221 2210 500 145 000 690 Bussmann 170M5810 DIN2*
-0165-3 254 2620 550 190 000 690 Bussmann 170M5811 DIN2*
-0205-3 286 2620 550 190 000 690 Bussmann 170M5811 DIN2*
-0260-3 438 4000 800 465 000 690 Bussmann 170M6812 DIN3
-0320-3 501 5550 1000 945 000 690 Bussmann 170M6814 DIN3
-0400-3 581 7800 1250 1 950 000 690 Bussmann 170M8554 DIN3
-0440-3 674 8850 1400 3 900 000 690 Bussmann 170M8555 DIN3
-0490-3 705 8850 1400 3 900 000 690 Bussmann 170M8555 DIN3
Three-phase supply voltage 380 V, 400 V, 415 V, 440 V, 460 V, 480 V or 500 V
-0105-5 142 1630 315 80500 690 Bussmann 170M1572 DIN000
-0120-5 155 1280 315 46 500 690 Bussmann 170M3817 DIN1*
-0140-5 180 1810 400 105 000 690 Bussmann 170M3819 DIN1*
-0165-5 222 2210 500 145 000 690 Bussmann 170M5810 DIN2*
-0205-5 256 2620 550 190 000 690 Bussmann 170M5811 DIN2*
-0255-5 286 2620 550 190 000 690 Bussmann 170M5811 DIN2*
-0320-5 424 4000 800 465 000 690 Bussmann 170M6812 DIN3
-0400-5 498 5550 1000 945 000 690 Bussmann 170M6814 DIN3
-0440-5 543 7800 1250 1 950 000 690 Bussmann 170M8554 DIN3
-0490-5 590 7800 1250 1 950 000 690 Bussmann 170M8554 DIN3
-0550-5 669 8850 1400 3 900 000 690 Bussmann 170M8555 DIN3
-0610-5 702 8850 1400 3 900 000 690 Bussmann 170M8555 DIN3
Three-phase supply voltage 525 V, 550 V, 575 V, 600 V, 660 V or 690 V
-0070-7 79 520 125 8 500 690 Bussmann 170M1568 000
-0100-7 91 695 160 16 000 690 Bussmann 170M1569 000
-0120-7 112 750 200 15 000 690 Bussmann 170M3815 1*
-0145-7 131 1520 350 68 500 690 Bussmann 170M3818 DIN1*
-0175-7 162 1520 350 68 500 690 Bussmann 170M3818 DIN1*
-0205-7 186 1610 400 74 000 690 Bussmann 170M5808 DIN2*
-0260-7 217 1610 400 74 000 690 Bussmann 170M5808 DIN2*
-0320-7 298 3010 630 275 000 690 Bussmann 170M5812 DIN2*
-0400-7 333 2650 630 210 000 690 Bussmann 170M6810 DIN3
-0440-7 377 4000 800 465 000 690 Bussmann 170M6812 DIN3
-0490-7 423 4790 900 670 000 690 Bussmann 170M6813 DIN3
-0550-7 468 4790 900 670 000 690 Bussmann 170M6813 DIN3
-0610-7 533 5550 1000 945 000 690 Bussmann 170M6814 DIN3
Technical data
117
ACS800-07 Input Min. short- Fuse
size current circuit
current 1)
A A A A 2s V Manufacturer Type DIN 43620 Size
TYPES BEING PHASED OUT
Three-phase supply voltage 380 V, 400 V or 415 V
-0070-3 138 1630 315 80 500 690 Bussmann 170M1572 DIN000
-0140-3 196 1810 400 105 000 690 Bussmann 170M3819 DIN1*
-0170-3 237 2210 500 145 000 690 Bussmann 170M5810 DIN2*
-0210-3 286 2620 550 190 000 690 Bussmann 170M5811 DIN2*
Three-phase supply voltage 380 V, 400 V, 415 V, 440 V, 460 V, 480 V or 500 V
-0100-5 121 1630 315 80 500 690 Bussmann 170M1572 DIN000
-0170-5 191 1810 400 105 000 690 Bussmann 170M3819 DIN1*
-0210-5 243 2210 500 145 000 690 Bussmann 170M5810 DIN2*
-0260-5 291 2620 550 190 000 690 Bussmann 170M5811 DIN2*
Three-phase supply voltage 525 V, 550 V, 575 V, 600 V, 660 V or 690 V
-0140-7 126 1520 350 68 500 690 Bussmann 170M3818 DIN1*
-0170-7 156 1520 350 68 500 690 Bussmann 170M3818 DIN1*
-0210-7 191 1610 400 74 000 690 Bussmann 170M5808 DIN2*
PDM code: 00096931-H.22, 00556489
A2s value for -7 units at 660 V
1)
minimum short-circuit current of the installation
Technical data
118
Optional gG fuses
ACS800-07 Input current Min. short- Fuse
size circuit
current 1)
A A A A 2s V Manufacturer Type IEC size
Three-phase supply voltage 380 V, 400 V or 415 V
-0075-3 142 2400 160 200000 500 ABB Control OFAF00H160 00
-0100-3 163 2850 200 350 000 500 ABB Control OFAF1H200 1
-0120-3 198 3300 224 420 000 500 ABB Control OFAF1H224 1
-0135-3 221 3820 250 550 000 500 ABB Control OFAF1H250 1
-0165-3 254 4510 315 1100000 500 ABB Control OFAF2H315 2
-0205-3 286 4510 315 1100000 500 ABB Control OFAF2H315 2
-0260-3 438 8280 500 2 900 000 500 ABB Control OFAF3H500 3
-0320-3 501 10200 630 4 000 000 500 ABB Control OFAF3H630 3
-0400-3 581 10200 630 4 000 000 500 ABB Control OFAF3H630 3
-0440-3 674 13500 800 7 400 000 500 ABB Control OFAF3H800 3
-0490-3 705 13500 800 7 400 000 500 ABB Control OFAF3H800 3
Three-phase supply voltage 380 V, 400 V, 415 V, 440 V, 460 V, 480 V or 500 V
-0105-5 142 2400 160 200000 500 ABB Control OFAF00H160 00
-0120-5 155 2850 200 350 000 500 ABB Control OFAF1H200 1
-0140-5 180 2850 200 350 000 500 ABB Control OFAF1H200 1
-0165-5 222 3820 250 550 000 500 ABB Control OFAF1H250 1
-0205-5 256 4510 315 1100000 500 ABB Control OFAF2H315 2
-0255-5 286 4510 315 1100000 500 ABB Control OFAF2H315 2
-0320-5 424 8280 500 2 900 000 500 ABB Control OFAF3H500 3
-0400-5 498 10200 630 4 000 000 500 ABB Control OFAF3H630 3
-0440-5 543 10200 630 4 000 000 500 ABB Control OFAF3H630 3
-0490-5 590 10200 630 4 000 000 500 ABB Control OFAF3H630 3
-0550-5 669 13500 800 7 400 000 500 ABB Control OFAF3H800 3
-0610-5 702 13500 800 7 400 000 500 ABB Control OFAF3H800 3
Three-phase supply voltage 525 V, 550 V, 575 V, 600 V, 660 V or 690 V
-0070-7 79 1050 80 52200 690 ABB Control OFAA0GG80 0
-0100-7 91 1480 100 93000 690 ABB Control OFAA1GG100 1
-0120-7 112 1940 125 126000 690 ABB Control OFAA1GG125 1
-0145-7 131 2400 160 220000 690 ABB Control OFAA1GG160 1
-0175-7 162 2850 200 350000 690 ABB Control OFAA1GG200 1
-0205-7 186 3820 250 700000 690 ABB Control OFAA2GG250 2
-0260-7 217 3820 250 700 000 690 ABB Control OFAA2GG250 2
-0320-7 298 4510 315 820 000 690 ABB Control OFAA2GG315 2
-0400-7 333 6180 400 1 300 000 690 ABB Control OFAA3GG400 3
-0440-7 377 8280 500 3 800 000 690 ABB Control OFAA3H500 3
-0490-7 423 8280 500 3 800 000 690 ABB Control OFAA3H500 3
-0550-7 468 8280 500 3 800 000 690 ABB Control OFAA3H500 3
-0610-7 533 10800 630 10 000 000 690 Bussmann 630NH3G-690 * 3
Technical data
119
ACS800-07 Input current Min. short- Fuse
size circuit
current 1)
A A A A 2s V Manufacturer Type IEC size
TYPES BEING PHASED OUT
Three-phase supply voltage 380 V, 400 V or 415 V
-0070-3 138 2400 160 200 000 500 ABB Control OFAF00H160 00
-0140-3 196 3820 250 550 000 500 ABB Control OFAF1H250 1
-0170-3 237 4510 315 1 100 000 500 ABB Control OFAF2H315 2
-0210-3 286 4510 315 1 100 000 500 ABB Control OFAF2H315 2
Three-phase supply voltage 380 V, 400 V, 415 V, 440 V, 460 V, 480 V or 500 V
-0100-5 121 2400 160 200 000 500 ABB Control OFAF00H160 00
-0170-5 191 3820 250 550 000 500 ABB Control OFAF1H250 1
-0210-5 243 4510 315 1 100 000 500 ABB Control OFAF2H315 2
-0260-5 291 4510 315 1 100 000 500 ABB Control OFAF2H315 2
Three-phase supply voltage 525 V, 550 V, 575 V, 600 V, 660 V or 690 V
-0140-7 126 2400 160 220 000 690 ABB Control OFAA1GG160 1
-0170-7 156 2850 200 350 000 690 ABB Control OFAA1GG200 1
-0210-7 191 3820 250 700 000 690 ABB Control OFAA2GG250 2
PDM code: 00096931-H.22, 00556489
* rated breaking capacity only up to 50 kA
1)
minimum short-circuit current of the installation
Technical data
120
Quick guide for selecting between gG and aR fuses
The table below is a short cut in selecting between gG and aR fuses. The
combinations (cable size, cable length, transformer size and fuse type) in the table
fulfil the minimum requirements for the proper operation of the fuse.
ACS800-07 size Cable type Supply transformer minimum apparent power SN (kVA)
Copper Aluminium Maximum cable length with gG fuses Maximum cable length with aR fuses
10 m 50 m 100 m 10 m 100 m 200 m
Three-phase supply voltage 380 V, 400 V or 415 V
-0075-3 3×70 Cu 3×95 Al 130 140 160 99 99 140
-0100-3 3×95 Cu 3×120 Al 150 160 190 120 120 140
-0120-3 3×120 Cu 3×185 Al 170 190 210 140 140 140
-0130-3 3×150 Cu 3×240 Al 200 220 250 160 160 160
-0165-3 3×185 Cu 3×240 Al 240 260 310 180 180 200
-0205-3 3×240 Cu 2 × (3x120) Al 240 260 310 200 200 200
-0260-3 3 × (3×70) Cu 3 × (3×120) Al 430 460 560 310 310 310
-0320-3 3 × (3×95) Cu 2 × (3×240) Al 530 600 750 350 350 440
-0400-3 3 × (3×120) Cu 3 × (3×185) Al 530 600 750 410 470 660
-0440-3 3 × (3×150) Cu 3 × (3×240) Al 700 770 930 470 530 730
-0490-3 3 × (3×150) Cu 3 × (3×240) Al 700 770 930 490 530 730
Three-phase supply voltage 380 V, 400 V, 415 V, 440 V, 460 V, 480 V or 500 V
-0105-5 3×70 Cu 3×95 Al 160 170 190 130 130 150
-0120-5 3×95 Cu 3×120 Al 190 200 220 140 140 150
-0140-5 3×95 Cu 3×150 Al 190 200 220 160 160 160
-0150-5 3×120 Cu 3×185 Al 220 230 250 180 180 180
-0165-5 3x150 Cu 3x240 Al 250 260 290 200 200 200
-0205-5 3×185 Cu 3×240 Al 290 320 360 230 230 230
-0255-5 3×240 Cu 2 × (3×120) Al 290 320 360 250 250 250
-0320-5 2 × (3×120) Cu 3 × (3×95) Al 530 570 670 370 370 370
-0400-5 2 × (3×150) Cu 2 × (3×240) Al 660 720 840 440 440 480
-0440-5 3 × (3×95) Cu 3 × (3×150) Al 660 720 840 500 570 760
-0490-5 3 × (3×120) Cu 3 × (3×185) Al 660 720 840 520 570 760
-0550-5 2 × (3×240) Cu 3 × (3×240) Al 880 980 1200 580 670 880
-0610-5 3 × (3×150) Cu 3 × (3×240) Al 880 980 1200 610 670 880
Three-phase supply voltage 525 V, 550 V, 575 V, 600 V, 660 V or 690 V
-0070-7 3×25 Cu 3×50 Al 95 95 99 95 95 95
-0100-7 3×35 Cu 3×50 Al 130 140 150 110 110 110
-0120-7 3×50 Cu 3×70 Al 180 180 190 140 140 140
-0145-7 3×70 Cu 3×95 Al 220 220 240 160 160 160
-0175-7 3×95 Cu 3×120 Al 260 260 280 200 200 200
-0205-7 3×95 Cu 3×150 Al 340 360 390 230 230 230
-0260-7 3×150 Cu 3×185 Al 340 360 390 260 260 260
-0320-7 3×240 Cu 2 × (3×120) Al 400 410 430 360 360 360
-0400-7 3×240 Cu 3 × (3×70) Al 550 570 610 400 400 400
-0440-7 2 × (3×120) Cu 2 × (3×150) Al 730 780 860 460 460 460
-0490-7 2 × (3×120) Cu 3 × (3×95) Al 730 780 860 510 510 510
-0550-7 2 × (3×150) Cu 3 × (3×120) Al 730 780 860 560 560 560
-0610-7 3 × (3×95) Cu 3 × (3×150) Al 960 1000 1100 640 640 640
Technical data
121
ACS800-07 size Cable type Supply transformer minimum apparent power SN (kVA)
Copper Aluminium Maximum cable length with gG fuses Maximum cable length with aR fuses
10 m 50 m 100 m 10 m 100 m 200 m
TYPES BEING PHASED OUT
Three-phase supply voltage 380 V, 400 V or 415 V
-0070-3 3×70 Cu 3×95 Al 130 140 160 96 96 140
-0170-3 3×150 Cu 3×240 Al 240 260 310 170 170 170
-0210-3 3×240 Cu 2 × (3×120) Al 240 260 310 200 200 200
Three-phase supply voltage 380 V, 400 V, 415 V, 440 V, 460 V, 480 V or 500 V
-0100-5 3×70 Cu 3×95 Al 160 170 190 110 120 150
-0170-5 3×120 Cu 3×150 Al 250 270 310 200 200 200
-0210-5 3×150 Cu 3×240 Al 290 320 360 220 220 220
-0260-5 3×240 Cu 2 × (3×120) Al 290 320 360 260 260 260
Three-phase supply voltage 525 V, 550 V, 575 V, 600 V, 660 V or 690 V
-0140-7 3×70 Cu 3×95 Al 220 220 240 160 160 160
-0170-7 3×95 Cu 3×120 Al 260 260 280 190 190 190
-0210-7 3×120 Cu 3×150 Al 340 360 390 230 230 230
PDM code: 00556489 A
Note 1: The supply transformer minimum power in kVA is calculated with a zk value of 6% and
frequency 50 Hz.
Note 2: The table is not intended for transformer selection - that must be done separately.
The following parameters can effect on the correct operation of the protection:
• cable length, i.e. the longer the cable the weaker the fuse protection, as the long cable limits the
fault current
• cable size, i.e. the smaller the cable cross-section the weaker the fuse protection, as the small cable
size limits the fault current
• transformer size, i.e the smaller the transformer the weaker the fuse protection, as the small
transformer limits the fault current
• transformer impedance, i.e. the higher the zk the weaker the fuse protection as high impedance
limits the fault current.
The protection can be improved by installing a larger supply transformer and/or bigger cables, and in
most cases by selecting aR fuses instead of gG fuses. Selection of smaller fuses improves the
protection, but may also affect the fuse life time and lead to unnecessary operation of the fuses.
In case of any uncertainty regarding the drive protection, please contact your local ABB.
Technical data
122
Cable types
The table below gives copper and aluminium cable types for different load currents.
Cable sizing is based on max. 9 cables laid on a cable ladder side by side, three
ladder type trays one on top of the other, ambient temperature 30 °C, PVC
insulation, surface temperature 70 °C (EN 60204-1 and IEC 60364-5-52/2001). For
other conditions, size the cables according to local safety regulations, appropriate
input voltage and the load current of the drive.
Copper cables with concentric Aluminium cables with concentric
copper shield copper shield
Max. load Cable type Max. load Cable type
current current
A mm2 A mm2
56 3×16 69 3×35
71 3×25 83 3×50
88 3×35 107 3×70
107 3×50 130 3×95
137 3×70 151 3×120
167 3×95 174 3×150
193 3×120 199 3×185
223 3×150 235 3×240
255 3×185 214 2 × (3×70)
301 3×240 260 2 × (3×95)
274 2 × (3×70) 302 2 × (3×120)
334 2 × (3×95) 348 2 × (3×150)
386 2 × (3×120) 398 2 × (3×185)
446 2 × (3×150) 470 2 × (3×240)
510 2 × (3x185) 522 3 × (3×150)
602 2 × (3×240) 597 3 × (3×185)
579 3 × (3×120) 705 3 × (3×240)
669 3 × (3×150)
765 3 × (3×185)
903 3 × (3×240)
3BFA 01051905 C
Technical data
123
Cable entries
Mains, motor and brake resistor cable terminal sizes (per phase), maximum
accepted cable and tightening torques are given below.
Frame L1, L2, L3, U2, V2, W2, UDC+/R+, UDC-, R- Earthing PE
size Number of Hole Max. wire size Screw Tightening Screw Tightening
holes per diameter torque torque
phase
mm mm2 Nm Nm
1)
R5 1 60 185 M10 20...40 M10 30...44
R6 2) 1 60 185 M10 20...40 M10 30...44
R7 3 60 1×240 or M12 50...75 M10 30...44
2×185
R8 3 60 3×240 M12 50...75 M10 30...44
1)
external brake resistor (+D150) and DC connection terminals: wire size 6…70 mm2, screw M8,
tightening torque 15 Nm
2)
external brake resistor (+D150) and DC connection terminals: wire size 95…185 mm2, screw M10,
tightening torque 40 Nm
Dimensions, weights and noise
Frame size Height 1) Width 2) Depth 5) Weight Noise
IP 21/22/42 IP 54
mm mm mm mm kg dB
R5 2130 2315 430 689 300 63
R6 2130 2315 430 689 300 63
R7 2130 2315 830 3) 689 400 71
R8 2130 2315 830 4) 689 500 72
00184674 -J
1) in marine applications (+C121) extra height: 10 mm from the fastening bar at the bottom of the
cabinet
2) extra width for units with brake resistors (+D151): SAFURxxxFxxx 400 mm, 2xSAFURxxxFxxx
800 mm, 4xSAFURxxxFxxx 1600 mm
3) extra width for units with EMC filter (+E202): 200 mm
4) extra width for units with EMC filter (+E202): 400 mm
5) in marine applications (+C121) depth with fastening bars: 700 mm
Technical data
124
NEMA data
Ratings
The NEMA ratings for the ACS800-U7 and ACS800-07 with 60 Hz supplies are
given below. The symbols are described below the table. For sizing, derating and
50 Hz supplies, see IEC data.
ACS800-U7 size Imax Normal use Heavy-duty use Frame Air flow Heat
ACS800-07 size size dissipation
I2N PN I2hd Phd
A A HP A HP ft3/min BTU/Hr
Three-phase supply voltage 380 V, 400 V, 415 V, 440 V, 460 V, 480 V
-0100-5 164 124 100 96 75 R6 238 6610
-0120-5 202 157 125 124 100 R6 238 7890
-0140-5 282 180 150 156 125 R6 238 9600
-0165-5 326 220 150 165 125 R6 238 11140
-0205-5 326 245 200 215 150 R6 238 12980
-0270-5 ** 480 316 250 240 200 R8 718 15350
-0300-5 ** 568 361 300 302 250 R8 718 18050
-0320-5 588 435 350 340 250 R8 718 23250
-0400-5 588 510 400 370 300 R8 718 26650
-0440-5 840 545 450 490 400 R8 718 25950
-0490-5 840 590 500 515 3) 450 R8 718 27600
-0550-5 1017 670 550 590 3) 500 R8 718 31100
-0610-5 1017 718 4) 600 590 3) 500 R8 718 33000
Three-phase supply voltage 525 V, 575 V or 600 V
-0070-7 104 73 60 54 50 R6 238 4200
-0100-7 124 86 75 62 60 R6 238 5650
-0120-7 172 108 100 86 75 R6 238 6700
-0145-7 190 125 125 99 100 R6 238 9100
-0175-7 245 155 150 131 125 R6 238 11850
-0205-7 245 192 200 147 150 R6 238 14300
-0260-7 326 175/212* 150/200* 163 150 R7 318 16400
-0320-7 433 290 300 216 200 R8 718 21050
-0400-7 548 344 350 274 250 R8 718 22750
-0440-7 656 387 400 328 350 2) R8 718 25300
-0490-7 775 426 450 387 400 R8 718 28900
-0550-7 853 482 500 426 450 R8 718 28350
-0610-7 964 537 500 482 500 R8 718 33300
Technical data
125
ACS800-U7 size Imax Normal use Heavy-duty use Frame Air flow Heat
ACS800-07 size size dissipation
I2N PN I2hd Phd
A A HP A HP ft3/min BTU/Hr
TYPES BEING PHASED OUT
Three-phase supply voltage 380 V, 400 V, 415 V, 440 V, 460 V, 480 V
-0170-5 326 192 150 162 125 R7 318 10100
-0210-5 384 240 200 192 150 R7 318 12900
-0260-5 432 289 1) 250 2) 224 150 R7 318 15300
Three-phase supply voltage 525 V, 575 V or 600 V
-0140-7 190 125 125 95 100 2) R7 318 9600
-0170-7 263 155 150 131 125 R7 318 12150
-0210-7 294 165/195* 150/200* 147 150 R7 318 14550
PDM code: 00096931-G
1)
available if ambient temperature is less than 30 °C (86 °F). If ambient temperature is 40 °C (104 °F),
I2N is 286 A.
2)
special 4-pole high-efficiency NEMA motor
3)
50% overload is allowed for one minute every five minutes if ambient temperature is less than 30 °C
(86 °F). 40% overload is allowed if ambient temperature is 40 °C (104 °F).
4)
available if ambient temperature is less than 30 °C (86 °F). If ambient temperature is 40 °C
(104 °F), I2N is 704 A.
*
higher value available if output frequency is above 41 Hz
** ACS800-U7 types only
Symbols
Imax maximum output current. Available for 10 s at start, otherwise as long as allowed by drive
temperature.
Normal use (10% overload capability)
I2N continuous rms current. 10% overload is typically allowed for one minute every 5 minutes.
PN typical motor power. The power ratings apply to most 4-pole NEMA rated motors (460 V or
575 V).
Heavy-duty use (50% overload capability)
I2hd continuous rms current. 50% overload is typically allowed for one minute every 5 minutes.
Phd typical motor power. The power ratings apply to most 4-pole NEMA rated motors (460 V or
575 V).
Note: The ratings apply at an ambient temperature of 40 °C (104 °F). At lower temperatures the ratings
are higher.
Sizing
See page 113.
Derating
See page 113.
Technical data
126
Fuses
For branch circuit protection per NEC, the drive is equipped with UL class T or L
fuses listed below. Fast acting class T/L or faster fuses are recommended in the
USA.
Check from the fuse time-current curve that the operating time of the fuse is
below 0.1 seconds. The operating time depends on the supply network impedance
and the cross-sectional area and length of the supply cable. The short-circuit current
can be calculated as shown in section Fuses on page 114.
Note 1: See also Planning the electrical installation: Thermal overload and short-circuit protection.
Note 2: In multicable installations, install only one fuse per phase (not one fuse per conductor).
Note 3: Larger fuses than the recommended ones must not be used.
Note 4: Fuses from other manufacturers can be used if they meet the ratings and the melting curve of
the fuse does not exceed the melting curve of the fuse mentioned in the table.
Note 5: Circuit breakers must not be used without fuses.
Technical data
127
UL class T or L fuses
ACS800-U7 type Input Fuse
current
A A V Manufacturer Type UL class
Three-phase supply voltage 380 V, 400 V, 415 V, 440 V, 460 V or 480 V
-0100-5 121 150 600 Bussmann JJS-150 T
-0120-5 155 200 600 Bussmann JJS-200 T
-0140-5 179 225 600 Bussmann JJS-225 T
-0165-5 218 300 600 Bussmann JJS-300 T
-0205-5 243 350 600 Bussmann JJS-350 T
-0270-5 293 500 600 Bussmann JJS-500 T
-0300-5 331 500 600 Bussmann JJS-500 T
-0320-5 397 500 600 Bussmann JJS-500 T
-0400-5 467 600 600 Bussmann JJS-600 T
-0440-5 501 800 600 Ferraz A4BY800 L
-0490-5 542 800 600 Ferraz A4BY800 L
-0550-5 614 800 600 Ferraz A4BY800 L
-0610-5 661 800 600 Ferraz A4BY800 L
Three-phase supply voltage 525 V, 575 V or 600 V
-0070-7 70 100 600 Bussmann JJS-100 T
-0100-7 82 125 600 Bussmann JJS-125 T
-0120-7 103 150 600 Bussmann JJS-150 T
-0145-7 121 200 600 Bussmann JJS-200 T
-0175-7 150 200 600 Bussmann JJS-200 T
-0205-7 188 250 600 Bussmann JJS-250 T
-0260-7 199 300 600 Bussmann JJS-300 T
-0320-7 273 500 600 Bussmann JJS-500 T
-0400-7 325 500 600 Bussmann JJS-500 T
-0440-7 370 500 600 Bussmann JJS-500 T
-0490-7 407 600 600 Bussmann JJS-600 T
-0550-7 463 600 600 Bussmann JJS-600 T
-0610-7 513 700 600 Ferraz A4BY700 L
TYPES BEING PHASED OUT
Three-phase supply voltage 380 V, 400 V, 415 V, 440 V, 460 V or 480 V
-0170-5 175 250 600 Bussmann JJS-250 T
-0210-5 220 300 600 Bussmann JJS-300 T
-0260-5 267 400 600 Bussmann JJS-400 T
Three-phase supply voltage 525 V, 575 V or 600 V
-0140-7 117 200 600 Bussmann JJS-200 T
-0170-7 146 200 600 Bussmann JJS-200 T
-0210-7 184 250 600 Bussmann JJS-250 T
PDM code: 00096931-G
Technical data
128
Cable types
Cable sizing is based on NEC Table 310-16 for copper wires, 75 °C (167 °F) wire insulation at 40 °C
(104 °F) ambient temperature. Not more than three current-carrying conductors in raceway or cable or
earth (directly buried). For other conditions, dimension the cables according to local safety regulations,
appropriate input voltage and the load current of the drive.
Copper cables with concentric copper shield
Max. load Cable type
current
A AWG/kcmil
57 6
75 4
88 3
101 2
114 1
132 1/0
154 2/0
176 3/0
202 4/0
224 250 MCM or 2 × 1
251 300 MCM or 2 × 1/0
273 350 MCM or 2 × 2/0
295 400 MCM or 2 × 2/0
334 500 MCM or 2 × 3/0
370 600 MCM or 2 × 4/0 or 3 × 1/0
405 700 MCM or 2 × 4/0 or 3 × 2/0
449 2 × 250 MCM or 3 × 2/0
502 2 × 300 MCM or 3 × 3/0
546 2 × 350 MCM or 3 × 4/0
590 2 × 400 MCM or 3 × 4/0
669 2 × 500 MCM or 3 × 250 MCM
739 2 × 600 MCM or 3 × 300 MCM
810 2 × 700 MCM or 3 × 350 MCM
884 3 × 400 MCM or 4 × 250 MCM
1003 3 × 500 MCM or 4 × 300 MCM
1109 3 × 600 MCM or 4 × 400 MCM
1214 3 × 700 MCM or 4 × 500 MCM
Technical data
129
Cable entries
Input, motor and brake resistor cable terminal sizes (per phase) and tightening
torques are given below. Two-hole 1/2 inch diameter cable lugs can be used.
Frame L1, L2, L3, U2, V2, W2, UDC+/R+, UDC-, R- Earthing PE
size Max. cable Screw Tightening torque Screw Tightening torque
kcmil/AWG lbf ft lbf ft
R6 350 MCM 3/8 14.8...29.5 3/8 22...32
R7 2 × 250 MCM 1/2 37...55 3/8 22...32
R8 3 × 700 MCM 1/2 37...55 3/8 22...32
Dimensions, weights and noise
Frame size Height 1) Width 2) Depth 5) Weight Noise
UL type 1 UL type 12
in. in. in. in. lb dB
R6 84.22 91.08 16.93 27.28 700 63
R7 84.22 91.08 32.92 3) 27.28 900 71
R8 84.22 91.08 32.92 4) 27.28 1100 72
1) in marine applications (+C121) extra height: 0.39 in. from the fastening bar at the bottom of the
cabinet
2)
extra width for units with brake resistors (+D151): SAFURxxxFxxx 15.75 in., 2xSAFURxxxFxxx
19.68 in., 4xSAFURxxxFxxx 62.99 in.
3)
extra width for units with EMC filter (+E202): 7.87 in.
4)
extra width for units with EMC filter (+E202): 15.75 in.
5)
in marine applications (+C121) depth with fastening bars: 27.56 in.
Technical data
130
Free space around the unit
Frame Required free space around the unit for cooling
size Front Side Above*
mm in. mm in. mm in.
R5 150 5.91 - - 400 15.75
R6 150 5.91 - - 400 15.75
R7 150 5.91 - - 400 15.75
R8 150 5.91 - - 400 15.75
* measured from the base plate of the cabinet top
320 mm (12.28 in.) for fan replacement
in frame sizes R7 and R8
> 400 mm > 400 mm
(15.75 in.) IP 21/22/42 (15.75 in.) IP54
Space requirement for the door opening:
Frame sizes R5 and R6: 400 mm (15.75 in.)
Frame sizes R7 and R8: 800 mm (31.5 in.)
Technical data
131
Input power connection
Voltage (L1) 380/400/415 VAC 3-phase ± 10% for 400 VAC units
380/400/415/440/460/480/500 VAC 3-phase ± 10% for 500 VAC units
525/550/575/600/660/690 VAC 3-phase ± 10% for 690 VAC units
Rated short-time and peak
withstand current
IEC 60439-1 Icw / 1 sec. Ipk
50 kA 105 kA
UL 508A, US and Canada: The drive is suitable for use in a circuit capable of delivering not more
CSA C22.2 No. 14-05 than 100,000 symmetrical amperes (rms) at 600 V maximum.
Frequency 48 to 63 Hz, maximum rate of change 17%/s
Imbalance Max. ± 3% of nominal phase to phase input voltage
Fundamental power factor 0.98 (at nominal load)
(cos phi1)
Motor connection
Voltage (U2) 0 to L1, 3-phase symmetrical, Umax at the field weakening point
Frequency DTC mode: 0 to 3.2 · fFWP. Maximum frequency 300 Hz.
UNmains
fFWP = · fNmotor
UNmotor
fFWP: frequency at field weakening point; UNmains: mains (input power) voltage;
UNmotor: rated motor voltage; fNmotor: rated motor frequency
Frequency resolution 0.01 Hz
Current See section IEC data.
Power limit 1.5 · Phd, 1.1 · PN or Pcont.max (whichever value is greatest)
Field weakening point 8 to 300 Hz
Switching frequency 3 kHz (average). In 690 V units 2 kHz (average).
Maximum recommended Type code (EMC equipment) Max. motor cable length
motor cable length DTC control Scalar control
- 300 m (984 ft) 300 m (984 ft)
+E202 *, +E210 * 100 m (328 ft) 100 m (328 ft)
* Motor cable longer than 100 m (328 ft) is allowed but then the EMC Directive requirements may not
be fulfilled.
Efficiency
Approximately 98% at nominal power level
Technical data
132
Cooling
Method Internal fan, flow direction from front to top
Filter material Inlet (door) Outlet (roof)
IP22 / IP 42 units airTex G150 -
288 mm x 292 mm
688 mm x 521 mm
IP 54 units Luftfilter/airComp 300-50 Luftfilter/airTex G150
288 mm x 292 mm 2 pcs: 398 mm x 312 mm
688 mm x 521 mm
Free space around the unit See Free space around the unit.
Cooling air flow See IEC data.
Degrees of protection
IP 21 (UL type 1), IP 22 (UL type 1), IP 42 (UL type 2), IP 54 (UL type 12 for indoor use
only), IP 54R
Ambient conditions
Environmental limits for the drive are given below. The drive is to be used in a heated,
indoor, controlled environment.
Operation Storage Transportation
installed for stationary use in the protective package in the protective package
Installation site altitude 0 to 4000 m (13123 ft) above - -
sea level [above 1000 m
(3281 ft), see section
Derating]
Air temperature -15 to +50 °C (5 to 122 °F). -40 to +70 °C (-40 to -40 to +70 °C (-40 to
No frost allowed. See +158 °F) +158 °F)
section Derating.
Relative humidity 5 to 95% Max. 95% Max. 95%
No condensation allowed. Maximum allowed relative humidity is 60% in the presence of
corrosive gases.
Contamination levels No conductive dust allowed.
(IEC 60721-3-3, IEC 60721-3- Boards without coating: Boards without coating: Boards without coating:
2, IEC 60721-3-1) Chemical gases: Class 3C1 Chemical gases: Class 1C2 Chemical gases: Class 2C2
Solid particles: Class 3S2 Solid particles: Class 1S3 Solid particles: Class 2S2
Boards with coating: Boards with coating: Boards with coating:
Chemical gases: Class 3C2 Chemical gases: Class 1C2 Chemical gases: Class 2C2
Solid particles: Class 3S2 Solid particles: Class 1S3 Solid particles: Class 2S2
Atmospheric pressure 70 to 106 kPa 70 to 106 kPa 60 to 106 kPa
0.7 to 1.05 atmospheres 0.7 to 1.05 atmospheres 0.6 to 1.05 atmospheres
Vibration (IEC 60068-2) Max. 1 mm (0.04 in.) Max. 1 mm (0.04 in.) Max. 3.5 mm (0.14 in.)
(5 to 13.2 Hz), (5 to 13.2 Hz), (2 to 9 Hz),
max. 7 m/s2 (23 ft/s2) max. 7 m/s2 (23 ft/s2) max. 15 m/s2 (49 ft/s2)
(13.2 to 100 Hz) sinusoidal (13.2 to 100 Hz) sinusoidal (9 to 200 Hz) sinusoidal
Shock (IEC 60068-2-29) Not allowed Max. 100 m/s2 (330 ft./s2), Max. 100 m/s2 (330 ft./s2),
11 ms 11 ms
Free fall Not allowed 100 mm (4 in.) for weight 100 mm (4 in.) for weight
over 100 kg (220 lb) over 100 kg (220 lb)
Technical data
133
Materials
Cabinet Hot-dip zinc coated 1.5 mm thick steel sheet (thickness of coating approximately 20
micrometres). Polyester thermosetting powder coating (thickness approximately 80
micrometres) on visible surfaces. Colour RAL 7035 light beige semigloss.
Busbars Tin-plated copper
Fire safety of materials Insulating materials and non-metallic items mostly self-extinctive
(IEC 60332-1)
Package Wood. Plastic covering of the package: PE-LD, bands PP or steel.
Disposal The drive contains raw materials that should be recycled to preserve energy and natural
resources. The package materials are environmentally compatible and recyclable. All
metal parts can be recycled. The plastic parts can either be recycled or burned under
controlled circumstances, according to local regulations. Most recyclable parts are marked
with recycling marks.
If recycling is not feasible, all parts excluding electrolytic capacitors and printed circuit
boards can be landfilled. The DC capacitors (C1-1 to C1-x) contain electrolyte and the
printed circuit boards contain lead, both of which are classified as hazardous waste within
the EU. They must be removed and handled according to local regulations.
For further information on environmental aspects and more detailed recycling instructions,
please contact your local ABB distributor.
Applicable standards
The drive complies with the standards below. The compliance with the European Low
Voltage Directive is verified according to standards EN 61800-5-1 and EN 60204-1.
• EN 61800-5-1 (2003) Adjustable speed electrical power drive systems. Part 5-1: Safety requirements –
electrical, thermal and energy
• EN 60204-1 (2006) Safety of machinery. Electrical equipment of machines. Part 1: General requirements.
Provisions for compliance: The final assembler of the machine is responsible for installing
emergency-stop device.
• EN 60529: 1991 (IEC 529) Degrees of protection provided by enclosures (IP code)
• IEC 60664-1 (2007) Insulation coordination for equipment within low-voltage systems. Part 1: Principles,
requirements and tests.
• EN 61800-3 (2004) Adjustible speed electrical power drive systems. Part 3: EMC requirements and specific
test methods
• UL 508C (2002) UL Standard for Safety, Power Conversion Equipment, second edition
• UL 508A UL Standard for Industrial Control Panels, first edition
• NEMA 250 (2003) Enclosures for Electrical Equipment (1000 Volts Maximum)
• CSA C22.2 No. 14-05 Industrial control equipment
(2005)
Technical data
134
US patents
This product is protected by one or more of the following US patents:
4,920,306 5,301,085 5,463,302 5,521,483 5,532,568 5,589,754
5,612,604 5,654,624 5,799,805 5,940,286 5,942,874 5,952,613
6,094,364 6,147,887 6,175,256 6,184,740 6,195,274 6,229,356
6,252,436 6,265,724 6,305,464 6,313,599 6,316,896 6,335,607
6,370,049 6,396,236 6,448,735 6,498,452 6,552,510 6,597,148
6,600,290 6,741,059 6,774,758 6,844,794 6,856,502 6,859,374
6,922,883 6,940,253 6,934,169 6,956,352 6,958,923 6,967,453
6,972,976 6,977,449 6,984,958 6,985,371 6,992,908 6,999,329
7,023,160 7,034,510 7,036,223 7,045,987 7,057,908 7,059,390
7,067,997 7,082,374 7,084,604 7,098,623 7,102,325 7,109,780
7,164,562 7,176,779 7,190,599 7,215,099 7,221,152 7,227,325
7,245,197 7,250,739 7,262,577 7,271,505 7,274,573 7,279,802
7,280,938 7,330,095 7,349,814 7,352,220 7,365,622 7,372,696
7,388,765 D503,931 D510,319 D510,320 D511,137 D511,150
D512,026 D512,696 D521,466 D541,743S D541,744S D541,745S
D548,182S D548,183S
Technical data
135
CE marking
A CE mark is attached to the drive 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 2004/108EC).
Definitions
EMC stands for Electromagnetic Compatibility. It is the ability of electrical/electronic equipment to
operate without problems within an electromagnetic environment. Likewise, the equipment must not
disturb or interfere with any other product or system within its locality.
First environment includes establishments connected to a low-voltage network which supplies buildings
used for domestic purposes.
Second environment includes establishments connected to a network not supplying domestic premises.
Drive of category C2: drive of rated voltage less than 1000 V and intended to be installed and
commissioned only by a professional when used in the first environment. Note: A professional is a
person or organisation having necessary skills in installing and/or commissioning power drive systems,
including their EMC aspects.
Drive of category C3: drive of rated voltage less than 1000 V and intended for use in the second
environment and not intended for use in the first environment.
Drive of category C4: drive of rated voltage equal to or above 1000 V, or rated current equal to or above
400 A, or intended for use in complex systems in the second environment.
Compliance with the EMC Directive
The EMC Directive defines the requirements for immunity and emissions of electrical equipment used
within the European Union. The EMC product standard [EN 61800-3 (2004)] covers requirements
stated for drives.
Compliance with EN 61800-3 (2004)
First environment (drive of category C2)
The drive complies with the standard with the following provisions:
1. The drive is equipped with EMC filter E202.
2. The motor and control cables are selected as specified in the Hardware Manual.
3. The drive is installed according to the instructions given in the Hardware Manual.
4. Maximum cable length is 100 metres.
WARNING! The drive may cause radio interference if used in a residential or domestic environment.
The user is required to take measures to prevent interference, in addition to the requirements for CE
compliance listed above, if necessary.
Note: It is not allowed to install a drive equipped with EMC filter E202 on IT (unearthed) systems. The
supply network becomes connected to earth potential through the EMC filter capacitors which may
cause danger or damage the unit.
Technical data
136
Second environment (drive of category C3)
The drive complies with the standard with the following provisions:
1. The drive is equipped with EMC filter E200 [suitable for TN (earthed) systems] or E210 [suitable for
TN (earthed) and IT (unearthed) systems].
2. The motor and control cables are selected as specified in the Hardware Manual.
3. The drive is installed according to the instructions given in the Hardware Manual.
4. Maximum cable length is 100 metres.
WARNING! A drive of category C3 is not intended to be used on a low-voltage public network which
supplies domestic premises. Radio frequency interference is expected if the drive is used on such a
network.
Second environment (drive of category C4)
If the provisions under Second environment (drive of category C3) cannot be met, the requirements of
the standard can be met as follows:
1. It is ensured that no excessive emission is propagated to neighbouring low-voltage networks. In
some cases, the natural suppression in transformers and cables is sufficient. If in doubt, the supply
transformer with static screening between the primary and secondary windings can be used.
Medium voltage network
Supply transformer
Neighbouring network
Static screen
Point of measurement
Low voltage Low voltage
Equipment
Drive
(victim)
Equipment Equipment
2. An EMC plan for preventing disturbances is drawn up for the installation. A template is available
from the local ABB representative.
3. The motor and control cables are selected as specified in the Hardware Manual.
4. The drive is installed according to the instructions given in the Hardware Manual.
WARNING! A drive of category C4 is not intended to be used on a low-voltage public network which
supplies domestic premises. Radio frequency interference is expected if the drive is used on such a
network.
Machinery Directive
The drive complies with the European Union Machinery Directive (98/37/EC) requirements for an
equipment intended to be incorporated into machinery.
Technical data
137
“C-tick” marking
“C-tick” marking is required in Australia and New Zealand. A “C-tick” mark is attached to each drive in
order to verify compliance with the relevant standard (IEC 61800-3 (2004) – Adjustable speed electrical
power drive systems – Part 3: EMC product standard including specific test methods), mandated by the
Trans-Tasman Electromagnetic Compatibility Scheme.
Definitions
EMC stands for Electromagnetic Compatibility. It is the ability of electrical/electronic equipment to
operate without problems within an electromagnetic environment. Likewise, the equipment must not
disturb or interfere with any other product or system within its locality.
The Trans-Tasman Electromagnetic Compatibility Scheme (EMCS) was introduced by the Australian
Communication Authority (ACA) and the Radio Spectrum Management Group (RSM) of the New
Zealand Ministry of Economic Development (NZMED) in November 2001. The aim of the scheme is to
protect the radio frequency spectrum by introducing technical limits for emission from electrical/
electronic products.
First environment includes establishments connected to a low-voltage network which supplies buildings
used for domestic purposes.
Second environment includes establishments connected to a network not supplying domestic premises.
Drive of category C2: drive of rated voltage less than 1000 V and intended to be installed and
commissioned only by a professional when used in the first environment. Note: A professional is a
person or organisation having necessary skills in installing and/or commissioning power drive systems,
including their EMC aspects.
Drive of category C3: drive of rated voltage less than 1000 V and intended for use in the second
environment and not intended for use in the first environment.
Drive of category C4: drive of rated voltage equal to or above 1000 V, or rated current equal to or above
400 A, or intended for use in complex systems in the second environment.
Compliance with IEC 61800-3
First environment (drive of category C2)
The drive complies with the limits of IEC 61800-3 with the following provisions:
1. The drive is equipped with EMC filter E202.
2. The drive is installed according to the instructions given in the Hardware Manual.
3. The motor and control cables used are selected as specified in the Hardware Manual.
4. Maximum cable length is 100 metres.
WARNING! The drive may cause radio interference if used in a residential or domestic environment.
The user is required to take measures to prevent interference, in addition to the requirements for CE
compliance listed above, if necessary.
Note: The drive must not be equipped with the EMC filter E202 when installed to IT (unearthed)
systems. The mains becomes connected to earth potential through the EMC filter capacitors. In IT
systems this may cause danger or damage the unit.
Technical data
138
Second environment (drive of category C3)
The drive complies with the standard with the following provisions:
1. The drive is equipped with EMC filter E200 [suitable for TN (earthed) systems] or E210 [suitable for
TN (earthed) and IT (unearthed) systems].
2. The motor and control cables are selected as specified in the Hardware Manual.
3. The drive is installed according to the instructions given in the Hardware Manual.
4. Maximum cable length is 100 metres.
WARNING! A drive of category C3 is not intended to be used on a low-voltage public network which
supplies domestic premises. Radio frequency interference is expected if the drive is used on such a
network.
Second environment (drive of category C4)
If the provisions under Second environment (drive of category C3) cannot be met, the requirements of
the standard can be met as follows:
1. It is ensured that no excessive emission is propagated to neighbouring low-voltage networks. In
some cases, the natural suppression in transformers and cables is sufficient. If in doubt, the supply
transformer with static screening between the primary and secondary windings is strongly
recommended.
Medium voltage network
Supply transformer
Neighbouring network
Static screen
Point of measurement
Low voltage Low voltage
Equipment
Drive
(victim)
Equipment Equipment
2. An EMC plan for preventing disturbances is drawn up for the installation. A template is available
from the local ABB representative.
3. The drive is installed according to the instructions given in the Hardware Manual.
4. The motor and control cables used are selected as specified in the Hardware Manual.
WARNING! A drive of category C4 is not intended to be used on a low-voltage public network which
supplies domestic premises. Radio frequency interference is expected if the drive is used on such a
network.
Technical data
139
UL/CSA markings
The ACS800-U7 and the ACS800-07+C129 are C-UL US listed. The ACS800-07+C134 is CSA
marked. The approvals are valid with rated voltages (up to 600 V).
The drive is suitable for use on a circuit capable of delivering not more than 100,000 rms symmetrical
amperes at the drive nominal voltage (600 V maximum for 690 V units) when protected by fuses given
in the NEMA data fuse table. The ampere rating is based on tests done according to UL 508A.
The drive provides overload protection in accordance with the National Electrical Code (US) and
Canadian Electrical Code (Canada). See ACS800 Firmware Manual for setting. Default setting is off;
the setting must be activated at start-up.
The drives are to be used in a heated indoor controlled environment. See section Ambient conditions
for specific limits.
ABB brake choppers, when applied with appropriately sized brake resistors, will allow the drive to
dissipate regenerative energy (normally associated with quickly decelerating a motor). Proper
application of the brake chopper is defined in chapter Resistor braking. This can be applied to a single
drive or multiple drives with DC bus connected to allow a sharing of regenerative energy.
Equipment warranty and liability
The manufacturer warrants the equipment supplied against defects in design, materials and
workmanship for a period of twelve (12) months after installation or twenty-four (24) months from date
of manufacturing, whichever first occurs. The local ABB office or distributor may grant a warranty period
different to the above and refer to local terms of liability as defined in the supply contract.
The manufacturer is not responsible for
• any costs resulting from a failure if the installation, commissioning, repair, alternation, or ambient
conditions of the drive do not fulfil the requirements specified in the documentation delivered with
the unit and other relevant documentation.
• units subjected to misuse, negligence or accident
• units comprised of materials provided or designs stipulated by the purchaser.
In no event shall the manufacturer, its suppliers or subcontractors be liable for special, indirect,
incidental or consequential damages, losses or penalties.
If you have any questions concerning your ABB drive, please contact the local distributor or ABB office.
The technical data, information and specifications are valid at the time of printing. The manufacturer
reserves the right to modifications without prior notice.
Technical data
140
Technical data
141
Dimensional drawings
Example dimensional drawings with dimensions in milllimetres and [inches] are
shown below.
See ACS800-07/U7 Dimensional Drawings [3AFE 64775421 (English)] for
• location of cable connection terminals
• units with EMC filter, du/dt filter and brake resistors
• marine units
• US drawings.
Dimensional drawings
142
Frame sizes R5 and R6
64778340_1/5 K
Dimensional drawings
143
Frame sizes R7 and R8
68749930_1/7 C
Dimensional drawings
144
IP 54 and IP 54R units of frame sizes R7 and R8
68749930_6/6 C
Dimensional drawings
145
Resistor braking
What this chapter contains
This chapter describes how to select, protect and wire brake choppers and resistors.
The chapter also contains the technical data.
Availability of brake choppers and resistors
Brake choppers are optionally available as built-in units, indicated in the type code
by +D150.
Resistors are available as add-on kits or factory installed (+D151).
How to select the correct drive/chopper/resistor combination
1. Calculate the maximum power (Pmax) generated by the motor during braking.
2. Select a suitable drive / brake chopper / brake resistor combination for the
application according to the following tables (take account of other factors in the
drive selection also). The following condition must be met:
Pbr > Pmax
where
Pbr denotes Pbr5, Pbr10, Pbr30, Pbr60, or Pbrcont depending on the duty cycle.
3. Check the resistor selection. The energy generated by the motor during a 400-
second period must not exceed the resistor heat dissipation capacity ER.
If the ER value is not sufficient, it is possible to use a four-resistor assembly in which two standard
resistors are connected in parallel, two in series. The ER value of the four-resistor assembly is four
times the value specified for the standard resistor.
Note: A resistor other than the standard resistor can be used provided that:
• its resistance is not lower than the resistance of the standard resistor.
WARNING! Never use a brake resistor with a resistance below the value specified
for the particular drive / brake chopper / resistor combination. The drive and the
chopper are not able to handle the overcurrent caused by the low resistance.
Resistor braking
146
• the resistance does not restrict the braking capacity needed, i.e.,
2
UDC
Pmax <
R
where
Pmax maximum power generated by the motor during braking
UDC voltage over the resistor during braking, e.g.,
1.35 · 1.2 · 415 VDC (when supply voltage is 380 to 415 VAC),
1.35 · 1.2 · 500 VDC. (when supply voltage is 440 to 500 VAC) or
1.35 · 1.2 · 690 VDC (when supply voltage is 525 to 690 VAC).
R resistor resistance (ohm)
• the heat dissipation capacity (ER) is sufficient for the application (see step 3
above).
Optional brake chopper and resistor(s)
The nominal ratings for dimensioning the brake resistors for the ACS800-07/U7 are
given below at an ambient temperature of 40 °C (104 °F).
ACS800-07/U7 Frame Braking power of the chopper and Brake resistor(s)
type size the drive
5/60 s 10/60 s 30/60 s Type R ER PRcont
Pbr5 Pbr10 Pbr30 Pbrcont (ohm) (kJ) (kW)
(kW) (kW) (kW) (kW)
400 V units
-0075-3 R5 - - - 70 SAFUR80F500 6 2400 6
-0100-3 R6 - - - 83 SAFUR125F500 4 3600 9
-0120-3 R6 - - - 113 SAFUR125F500 4 3600 9
-0135-3 R6 - - - 132 SAFUR200F500 2.70 5400 13.5
-0165-3 R6 - - - 132 SAFUR200F500 2.70 5400 13.5
-0205-3 R6 - - - 160 SAFUR200F500 2.70 5400 13.5
-0260-3 R8 240 240 240 173 2XSAFUR210F575 1.70 8400 21
-0320-3 R8 300 300 300 143 2xSAFUR200F500 1.35 10800 27
-0400-3 R8 375 375 273 130 4xSAFUR125F500 1.00 14400 36
-0440-3 R8 473 355 237 120 4xSAFUR210F575 0.85 16800 42
-0490-3 R8 500 355 237 120 4xSAFUR210F575 0.85 16800 42
500 V units
-0105-5* R5 - - - 83 SAFUR80F500 6 2400 6
-0120-5 R6 - - - 113 SAFUR125F500 4 3600 9
-0140-5 R6 - - - 135 SAFUR125F500 4 3600 9
-0165-5 R6 - - - 160 SAFUR125F500 4 3600 9
-0205-5 R6 - - - 160 SAFUR125F500 4 3600 9
-0255-5* R6 - - - 200 SAFUR200F500 2.7 5400 13.5
-0270-5** R8 240 240 240 240 2xSAFUR125F500 2.00 7200 18
-0300-5** R8 280 280 280 280 2xSAFUR125F500 2.00 7200 18
-0320-5 R8 300 300 300 300 2xSAFUR125F500 2.00 7200 18
-0400-5 R8 375 375 375 234 2XSAFUR210F575 1.70 8400 21
-0440-5 R8 473 473 450 195 2xSAFUR200F500 1.35 10800 27
-0490-5 R8 480 480 470 210 2xSAFUR200F500 1.35 10800 27
-0550-5 R8 600 400 4) 300 170 4xSAFUR125F500 1.00 14400 36
-0610-5 R8 600 3) 400 4) 300 170 4xSAFUR125F500 1.00 14400 36
Resistor braking
147
ACS800-07/U7 Frame Braking power of the chopper and Brake resistor(s)
type size the drive
5/60 s 10/60 s 30/60 s Type R ER PRcont
Pbr5 Pbr10 Pbr30 Pbrcont (ohm) (kJ) (kW)
(kW) (kW) (kW) (kW)
690 V units
-0070-7 R6 - - - 45 SAFUR90F575 8.00 1800 4.5
-0100-7 R6 - - - 55 SAFUR80F500 6.00 2400 6
-0120-7 R6 - - - 75 SAFUR80F500 6.00 2400 6
-0145-7 R6 - - - 160 SAFUR80F500 6.00 2400 6
-0175-7 R6 - - - 160 SAFUR80F500 6.00 2400 6
-0205-7 R6 - - - 160 SAFUR80F500 6.00 2400 6
-0260-7 R7 135 5) 120 100 80 SAFUR80F500 6.00 2400 6
-0320-7 R8 300 300 300 260 SAFUR200F500 2.70 5400 13.5
-0400-7 R8 375 375 375 375 SAFUR200F500 2.70 5400 13.5
-0440-7 R8 430 430 430 385 SAFUR200F500 2.70 5400 13.5
-0490-7 R8 550 400 315 225 2xSAFUR125F500 2.00 7200 18
-0550-7 R8 550 400 315 225 2xSAFUR125F500 2.00 7200 18
-0610-7 R8 550 400 315 225 2xSAFUR125F500 2.00 7200 18
TYPES BEING PHASED OUT
400 V units
-0070-3 R6 - - - 68 SAFUR80F500 6 2400 6
-0140-3 R7 135 135 100 80 SAFUR200F500 2.70 5400 13.5
-0170-3 R7 165 150 100 80 SAFUR200F500 2.70 5400 13.5
-0210-3 R7 165 150 100 80 SAFUR200F500 2.70 5400 13.5
500 V units
-0100-5 R6 - - - 83 SAFUR125F500 4 3600 9
-0170-5* R7 165 132 2) 120 200 SAFUR200F500 2.7 5400 13.5
-0210-5 R7 198 132 2) 120 80 SAFUR200F500 2.70 5400 13.5
-0260-5 R7 198 1) 132 2) 120 80 SAFUR200F500 2.70 5400 13.5
690 V units
-0140-7 R7 125 5) 110 90 75 SAFUR80F500 6.00 2400 6
-0170-7 R7 125 6) 110 90 75 SAFUR80F500 6.00 2400 6
-0210-7 R7 125 6) 110 90 75 SAFUR80F500 6.00 2400 6
PDM code 00096931-J
Pbr5 Maximum braking power of the drive with the specified resistor(s). The drive and the chopper will withstand this
braking power for 5 seconds per minute.
Pbr10 The drive and the chopper will withstand this braking power for 10 seconds per minute.
Pbr30 The drive and the chopper will withstand this braking power for 30 seconds per minute.
Pbrcon The drive and the chopper will withstand this continuous braking power. The braking is considered continuous if the
t braking time exceeds 30 s.
Note: Check that the braking energy transmitted to the specified resistor(s) in 400 seconds does not exceed ER.
R Resistance value for the resistor assembly. Note: This is also the minimum allowed resistance for the brake
resistor.
ER Short energy pulse that the resistor assembly withstands every 400 seconds. This energy will heat the resistor
element from 40 °C (104 °F) to the maximum allowable temperature.
PRcont Continuous power (heat) dissipation of the resistor when placed correctly. Energy ER dissipates in 400 seconds.
* ACS800-0x types only
** ACS800-Ux types only
1) 240 kW possible if ambient temperature is below 33 °C (91 °F)
Resistor braking
148
2)
160 kW possible if ambient temperature is below 33 °C (91 °F)
3)
630 kW possible if ambient temperature is below 33 °C (91 °F)
4) 450 kW possible if ambient temperature is below 33 °C (91 °F)
5) 160 kW possible if ambient temperature is below 33 °C (91 °F)
Combined braking cycles for R7:
Examples
Pbr max 5 s or 10 s
Pbr5 or Pbr10
Pbr30
Pbrcont
No braking t
min. 30 s max 30 s min. 30 s max 30 s min. 30 s
• After Pbr5, Pbr10 or Pbr30 braking, the drive and the chopper will withstand Pbrcont continuously.
• Pbr5, Pbr10 or Pbr30 braking is allowed once every minute.
• After Pbrcont braking, there has to be a pause of at least 30 seconds without any braking if the subsequent braking power
is greater than Pbrcont.
• After Pbr5 or Pbr10 braking, the drive and the chopper will withstand Pbr30 within a total braking time of 30 seconds.
• Pbr10 braking is not acceptable after Pbr5 braking.
Combined braking cycles for R8:
Examples
Pbr max 5 s, 10 s or 30 s
Pbr5, Pbr10 or Pbr30
Pbrcont
No braking t
min. 60 s min. 60 s
• After Pbr5, Pbr10 or Pbr30 braking, the drive and the chopper will withstand Pbrcont continuously. (Pbrcont is the only
allowed braking power after Pbr5, Pbr10 or Pbr30.)
• Pbr5, Pbr10 or Pbr30 braking is allowed once every minute.
• After Pbrcont braking, there has to be a pause of at least 60 seconds without any braking if the subsequent braking power
is greater than Pbrcont.
All braking resistors must be installed outside the converter module. The resistors are built in an IP 00 metal frame. The
2xSAFUR and 4xSAFUR resistors are connected in parallel. Note: The SAFUR resistors are not UL listed.
Resistor braking
149
Resistor installation and wiring
All resistors must be installed outside the drive module in a place where they will
cool.
WARNING! The materials near the brake resistor must be non-flammable. The
surface temperature of the resistor is high. Air flowing from the resistor is of
hundreds of degrees Celsius. Protect the resistor against contact.
Use the cable type used for drive input cabling (refer to chapter Technical data) to
ensure the input fuses will also protect the resistor cable. Alternatively, two-
conductor shielded cable with the same cross-sectional area can be used. The
maximum length of the resistor cable(s) is 10 m (33 ft). For the connections, see the
power connection diagram of the drive.
If ordered, the resistors are factory installed in a cubicle(s) next to the drive cabinet.
Protection of frame size R5
It is highly recommended to equip the drive with a main contactor for safety reasons.
Wire the contactor so that it opens in case the resistor overheats. This is essential
for safety since the drive will not otherwise be able to interrupt the main supply if the
chopper remains conductive in a fault situation.
Below is a simple example wiring diagram.
L1 L2 L3
OFF
Fuses 2
1 3 5 13 3
ON
2 4 6 14 4
ACS800
U1 V1 W1
Θ Thermal switch
(standard in ABB re-
K1
sistors)
Resistor braking
150
Protection of frame sizes R6, R7 and R8
A main contactor is not required for protecting against resistor overheating when the
resistor is dimensioned according to the instructions and the internal brake chopper
is in use. The drive will disable power flow through the input bridge if the chopper
remains conductive in a fault situation. Note: If an external brake chopper (outside
the drive module) is used, a main contactor is always required.
A thermal switch (standard in ABB resistors) is required for safety reasons. The
cable must be shielded and not longer than the resistor cable.
With Standard Control Program, wire the thermal switch as shown below. By default,
the drive will stop by coasting when the switch opens.
RMIO:X22 or X2: X22
1 DI1
2 DI2
3 DI3
4 DI4
5 DI5
6 DI6
7 +24VD
Thermal switch 8 +24VD
(standard in ABB re- 9 DGND1
sistors) Θ
10 DGND2
11 DIIL
For other control programs, the thermal switch may be wired to a different digital
input. Programming of the input to trip the drive by “EXTERNAL FAULT” may be
needed. See the appropriate firmware manual.
Brake circuit commissioning
For Standard Control Program:
• Enable the brake chopper function (parameter 27.01).
• Switch off the overvoltage control of the drive (parameter 20.05).
• Check the resistance value setting (parameter 27.03).
• Frame sizes R6, R7 and R8: Check the setting of parameter 21.09. If stop by
coasting is required, select OFF2 STOP.
For the use of the brake resistor overload protection (parameters 27.02...27.05),
consult an ABB representative.
WARNING! If the drive is equipped with a brake chopper but the chopper is not
enabled by parameter setting, the brake resistor must be disconnected because the
protection against resistor overheating is then not in use.
For settings of other control programs, see the appropriate firmware manual.
Resistor braking
3AFE64702165 Rev G EN
EFFECTIVE: 19.1.2009
ABB Oy ABB Inc. ABB Beijing Drive Systems Co. Ltd.
AC Drives Automation Technologies No. 1, Block D, A-10 Jiuxianqiao Beilu
P.O. Box 184 Drives & Motors Chaoyang District
FI-00381 HELSINKI 16250 West Glendale Drive Beijing, P.R. China, 100015
FINLAND New Berlin, WI 53151 Telephone +86 10 5821 7788
Telephone +358 10 22 11 USA Fax +86 10 5821 7618
Fax +358 10 22 22681 Telephone 262 785-3200 Internet www.abb.com
Internet www.abb.com 800-HELP-365
Fax 262 780-5135
ACS800
Hardware Manual
ACS800-04 Drive Modules (0.55 to 200 kW)
ACS800-U4 Drive Modules (0.75 to 200 HP)
ACS800 Single Drive Manuals
HARDWARE MANUALS (appropriate manual is included in the
delivery)
ACS800-01/U1 Hardware Manual 0.55 to 200 kW (0.75 to 200 HP)
3AFE64382101 (English)
ACS800-01/U1/04 Marine Supplement 0.55 to 200 kW (0.75 to
200 HP) 3AFE64291275 (English)
ACS800-11/U11 Hardware Manual 5.5 to 110 kW (7.5 to 125 HP)
3AFE68367883 (English)
ACS800-31/U31 Hardware Manual 5.5 to110 kW (7.5 to 125 HP)
3AFE68599954 (English)
ACS800-02/U2 Hardware Manual 90 to 500 kW (125 to 600 HP)
3AFE64567373 (English)
ACS800-04/U4 Hardware Manual 0.55 to 200 kW (0.75 to 200 HP)
3AFE68372984 (English)
ACS800-04/04M/U4 Hardware Manual 45 to 560 kW (60 to
600 HP) 3AFE64671006 (English)
ACS800-04/04M/U4 Cabinet Installation 45 to 560 kW (60 to
600 HP) 3AFE68360323 (English)
ACS800-07/U7 Hardware Manual 45 to 560 kW (50 to 600 HP)
3AFE64702165 (English)
ACS800-07/U7 Dimensional Drawings 45 to 560 kW (50 to
600 HP) 3AFE64775421
ACS800-07 Hardware Manual 500 to 2800 kW
3AFE64731165 (English)
ACS800-17 Hardware Manual 55 to 2500 kW (75 to 2800 HP)
3AFE68397260 (English)
ACS800-37 Hardware Manual 55 to 2700 kW (75 to 3000 HP)
3AFE68557925 (English)
• Safety instructions
• Electrical installation planning
• Mechanical and electrical installation
• Motor control and I/O board (RMIO)
• Maintenance
• Technical data
• Dimensional drawings
• Resistor braking
FIRMWARE MANUALS, SUPPLEMENTS AND GUIDES
(appropriate documents are included in the delivery)
Standard Control Program Firmware Manual
3AFE64527592 (English)
System Control Program Firmware Manual
3AFE64670646 (English)
Control Program Template Firmware Manual
3AFE64616340 (English)
Master/Follower 3AFE64590430 (English)
Pump Control Program Firmware Manual
3AFE68478952 (English)
Extruder Control Program Supplement 3AFE64648543 (English)
Centrifuge Control Program Supplement 3AFE64667246 (English)
Traverse Control Program Supplement 3AFE64618334 (English)
Crane Control Program Firmware Manual 3BSE11179 (English)
Adaptive Programming Application Guide
3AFE64527274 (English)
OPTION MANUALS (delivered with optional equipment)
Fieldbus Adapters, I/O Extension Modules etc.
ACS800-04 Drive Modules
0.55 to 200 kW
ACS800-U4 Drive Modules
0.75 to 200 HP
Hardware Manual
3AFE68372984 Rev E EN
EFFECTIVE: 31.03.2008
© 2008 ABB Oy. All Rights Reserved.
5
Safety instructions
What this chapter contains
This chapter contains the safety instructions which you must follow when installing,
operating and servicing the drive. If ignored, physical injury or death may follow, or
damage may occur to the drive, the motor or driven equipment. Read the safety
instructions before you work on the unit.
Use of warnings and notes
There are two types of safety instructions throughout this manual: warnings and
notes. Warnings caution you about conditions which can result in serious injury or
death and/or damage to the equipment. They also tell you how to avoid the danger.
Notes draw attention to a particular condition or fact, or give information on a
subject. The warning symbols are used as follows:
Dangerous voltage warning warns of high voltage which can cause
physical injury and/or damage to the equipment.
General warning warns about conditions, other than those caused by
electricity, which can result in physical injury and/or damage to the
equipment.
Electrostatic discharge warning warns of electrostatic discharge which
can damage the equipment.
Hot surface warning warns of hot surfaces which can cause physical
injury.
Safety instructions
6
Installation and maintenance work
These warnings are intended for all who work on the drive, motor cable or motor.
WARNING! Ignoring the following 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, the motor cable or the motor when main power is
applied. After switching off the input power, always wait for 5 min to let the
intermediate circuit capacitors discharge before you start working on the drive,
the motor or the motor cable.
Always ensure by measuring with a multimeter (impedance at least 1 Mohm)
that:
1. voltage between drive input phases U1, V1 and W1 and the frame is close to
0V
2. voltage between terminals UDC+ and UDC- and the frame is close to 0 V.
• Do not work on the control cables when power is applied to the drive or to the
external control circuits. Externally supplied control circuits may cause
dangerous voltages inside the drive even when the main power on the drive is
switched off.
• Do not make any insulation or voltage withstand tests on the drive or drive
modules.
• When reconnecting the motor cable, always check that the phase order is
correct.
Note:
• The motor cable terminals on the drive are at a dangerously high voltage when
the input power is on, regardless of whether the motor is running or not.
• The brake control terminals (UDC+, UDC-, R+ and R- terminals) carry a
dangerous DC voltage (over 500 V).
• Depending on the external wiring, dangerous voltages (115 V, 220 V or 230 V)
may be present on the terminals of relay outputs RO1 to RO3 or on the optional
AGPS board (Prevention of Unexpected Start).
• The Prevention of Unexpected Start function does not remove the voltage from
the main and auxiliary circuits.
• At installation sites above 2000 m (6562 ft), the terminals of the RMIO board
and optional modules attached to the board do not fulfil the Protective Extra
Low Voltage (PELV) requirements stated in EN 50178.
Safety instructions
7
Grounding
These instructions are intended for all who are responsible for the grounding of the
drive.
WARNING! Ignoring the following instructions can cause physical injury, death,
increased electromagnetic interference and equipment malfunction:
• Ground the drive, motor and adjoining equipment to ensure personnel safety in
all circumstances, and to reduce electromagnetic emission and interference.
• Make sure that grounding conductors are adequately sized as required by
safety regulations.
• In a multiple-drive installation, connect each drive separately to protective
earth (PE).
• In first environment (EU EMC Directive): make a 360° high frequency
grounding of the motor cable entry at the cabinet lead-through.
• Do not install a drive with EMC filter option +E202 or +E200 on an ungrounded
power system or a high resistance-grounded (over 30 ohms) power system.
Note:
• Power cable shields are suitable for equipment grounding conductors only
when adequately sized to meet safety regulations.
• As the normal leakage current of the drive is higher than 3.5 mA AC or 10 mA
DC (stated by EN 50178, 5.2.11.1), a fixed protective earth connection is
required.
Safety instructions
8
Mechanical installation and maintenance
These instructions are intended for all who install and service the drive.
WARNING! Ignoring the following instructions can cause physical injury or death,
or damage to the equipment:
• Handle the unit carefully.
• The drive is heavy. Do not lift it alone. Place the unit only on its back.
• Beware of hot surfaces. Some parts, such as heatsinks of power
semiconductors, remain hot for a while after disconnection of the electrical
supply.
• Make sure that dust from borings and grindings does not enter the drive when
installing. Electrically conductive dust inside the unit may cause damage or
malfunctioning.
• Ensure sufficient cooling.
• Do not fasten the drive by riveting or welding.
Printed circuit boards
WARNING! Ignoring the following instructions can cause damage to the printed
circuit boards:
• The printed circuit boards contain components sensitive to electrostatic
discharge. Wear a grounding wrist band when handling the boards. Do not
touch the boards unnecessarily.
Fibre optic cables
WARNING! Ignoring the following instructions can cause equipment malfunction
and damage to the fibre optic cables:
• Handle the fibre optic cables with care. When unplugging optic cables, always
grab the connector, not the cable itself. Do not touch the ends of the fibres with
bare hands as the fibre is extremely sensitive to dirt. The minimum allowed
bend radius is 35 mm (1.4 in.).
Safety instructions
9
Operation
These warnings are intended for all who plan the operation of the drive or operate
the drive.
WARNING! Ignoring the following instructions can cause physical injury or death,
or damage to the equipment:
• Before adjusting the drive and putting it into service, make sure that the motor
and all driven equipment are suitable for operation throughout the speed range
provided by the drive. The drive can be adjusted to operate the motor at
speeds above and below the speed provided by connecting the motor directly
to the power line.
• Do not activate automatic fault reset functions of the Control Program if
dangerous situations can occur. When activated, these functions will reset the
drive and resume operation after a fault.
• Do not control the motor with the disconnecting device (means); instead, use
the control panel keys and , or commands via the I/O board of the drive.
The maximum allowed number of charging cycles of the DC capacitors (i.e.
power-ups by applying power) is five in ten minutes.
Note:
• If an external source for start command is selected and it is ON, the drive (with
Standard / Motion Control Program) will start immediately after fault reset
unless the drive is configured for 3-wire (a pulse) start/stop.
• When the control location is not set to Local (L not shown in the status row of
the display), the stop key on the control panel will not stop the drive. To stop
the drive using the control panel, press the LOC/REM key and then the stop
key .
Safety instructions
10
Permanent magnet motor
These are additional warnings concerning permanent magnet motor drives. Ignoring
the instructions can cause physical injury or death, or damage to the equipment.
Installation and maintenance work
WARNING! Do not work on the drive when the permanent magnet motor is rotating.
Also, when the supply power is switched off and the inverter is stopped, a rotating
permanent magnet motor feeds power to the intermediate circuit of the drive and the
supply connections become live.
Before installation and maintenance work on the drive:
• Stop the motor.
• Ensure that the motor cannot rotate during work. Prevent the start-up of any
drives in the same mechanical group by opening the “prevention of unexpected
start” switch and padlocking it. Make sure that no other system, like hydraulic
crawling drives, are able to rotate the motor directly or through any mechanical
connection like felt, nip, rope, etc.
• Ensure that there is no voltage on the drive power terminals:
Alternative 1) Disconnect the motor from the drive with a safety switch or by other
means. Measure that there is no voltage present on the drive input or output
terminals (U1, V1, W1, U2, V2, W2, UDC+, UDC-).
Alternative 2) Measure that there is no voltage present on the drive input or output
terminals (U1, V1, W1, U2, V2, W2, UDC+, UDC-). Ground the drive output
terminals temporarily by connecting them together as well as to the PE.
Alternative 3) If possible, both of the above.
Start-up and operation
WARNING! Do not run the motor over the rated speed. Motor overspeed leads to
overvoltage which may damage or explode the capacitors in the intermediate circuit
of the drive.
Controlling a permanent magnet motor is only allowed using the ACS800 Permanent
Magnet Synchronous Motor Drive Control Program, or other control programs in
scalar control mode.
Safety instructions
11
Table of contents
ACS800 Single Drive Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Safety instructions
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Use of warnings and notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Installation and maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Mechanical installation and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Printed circuit boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Fibre optic cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Permanent magnet motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Installation and maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Start-up and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Table of contents
About this manual
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Intended audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Categorization according to the frame size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Categorization according to the + code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Installation and commissioning flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Product and service inquiries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Product training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Providing feedback on ABB Drives manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Terms and abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
ACS800-04/U4
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Type code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Main circuit and control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Printed circuit boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Motor control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Planning the cabinet assembly
Table of contents
12
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Cabinet construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Disposition of the devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Grounding of mounting structures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Free space around the unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Cooling and degrees of protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Preventing the recirculation of hot air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Outside the cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Inside the cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Cabinet layout example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Cabinet heaters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Mounting the optional control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Installing the control panel directly on the cabinet door . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Control panel mounting platform kit (RPMP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
EMC requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Mechanical installation
Unpacking the unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Delivery check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
Before installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
Requirements for the installation site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
Floor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
Installation procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
Flange mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
Planning the electrical installation
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Motor selection and compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Protecting the motor insulation and bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
Requirements table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
Permanent magnet synchronous motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
Supply connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
Disconnecting device (means) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
EEA / Europe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
US . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
Main contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
Thermal overload and short-circuit protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
Thermal overload protection of the drive and the input and motor cables . . . . . . . . . . . . . . .47
Thermal overload protection of the motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
Protection against short-circuit in the motor cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
Protection against short-circuit inside the drive or in the supply cable . . . . . . . . . . . . . . . . . .48
Ground fault protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
Emergency stop devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
Prevention of Unexpected Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
Selecting the power cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
General rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
Alternative power cable types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
Table of contents
13
Motor cable shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Additional US requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Conduit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Armored cable / shielded power cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Power factor compensation capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Equipment connected to the motor cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Installation of safety switches, contactors, connection boxes, etc. . . . . . . . . . . . . . . . . . . . . 54
Bypass connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Before opening a contactor (DTC control mode selected) . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Protecting the relay output contacts and attenuating disturbances in case of inductive loads . . . . 55
Selecting the control cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Relay cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Control panel cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Connection of a motor temperature sensor to the drive I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Installation sites above 2000 metres (6562 feet) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Routing the cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Control cable ducts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Electrical installation
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Checking the insulation of the assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Input cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Motor and motor cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
IT (ungrounded) systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Power cable connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Connecting the power cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Grounding the motor cable shield at the motor end . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Frame sizes R2 to R4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Frame size R5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Frame size R6: Cable lug installation [16 to 70 mm2 (6 to 2/0 AWG) cables] . . . . . . . 64
Power cable protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Frame size R5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Frame size R6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Warning sticker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Connecting the control cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
360 degrees grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
When the outer surface of the shield is covered with non-conductive material . . . . . . 69
Connecting the shield wires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Cabling of I/O and fieldbus modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Pulse encoder module cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Installation of optional modules and PC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Fibre optic link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
External +24 V power supply for the RMIO board via terminal X34 . . . . . . . . . . . . . . . . . . . . . . . . 71
Parameter settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Connecting +24 V external power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Prevention of Unexpected Start, AGPS board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Table of contents
14
Motor control and I/O board (RMIO)
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77
Note on terminal labelling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77
Note on external power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77
Parameter settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77
External control connections (non-US) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78
External control connections (US) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79
RMIO board specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80
Analogue inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80
Constant voltage output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80
Auxiliary power output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80
Analogue outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80
Digital inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80
Relay outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81
DDCS fibre optic link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81
24 V DC power input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81
Installation checklist
Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83
Maintenance
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
Maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
Heatsink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86
Fan replacement (R2, R3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86
Fan replacement (R4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87
Fan replacement (R5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88
Fan replacement (R6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89
Additional fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89
Replacement (R2, R3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89
Replacement (R4, R5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90
Replacement (R6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90
Capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90
Reforming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90
LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90
Technical data
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91
IEC data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91
Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91
Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
Derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94
Temperature derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94
Table of contents
15
Altitude derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Cooling characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Cooling requirements for flange mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Frame sizes R2 to R4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Frame sizes R5 and R6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Calculation example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
gG fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Ultrarapid (aR) fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Quick guide for selecting between gG and aR fuses . . . . . . . . . . . . . . . . . . . . . . . . . 100
Cable types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Cable entries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Dimensions, weights and noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
NEMA data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Cable types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Cable entries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Dimensions, weights and noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Input power connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Motor connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Degrees of protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
AGPS-11C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Ambient conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Applicable standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
CE marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Compliance with the EMC Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Compliance with the EN 61800-3 (2004) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
First environment (drive of category C2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Second environment (drive of category C3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Second environment (drive of category C4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Machinery Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
“C-tick” marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Compliance with IEC 61800-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
First environment (drive of category C2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Second environment (drive of category C3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Second environment (drive of category C4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Marine type approvals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
UL/CSA markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
UL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Equipment warranty and liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Product protection in the US . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Table of contents
16
Dimensional drawings
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .117
Frame size R2 (with optional control panel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .118
Frame size R3 (with optional control panel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .119
Frame size R4 (with optional control panel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .120
Frame size R5 (with optional control panel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .121
Frame size R6 (with optional control panel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .122
Flange mounting kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .123
Flange mounting kit for frame size R2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .124
Flange mounting kit for frame size R3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .125
Flange mounting kit for frame size R4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .126
Flange mounting kit for frame size R5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .127
Flange mounting kit for frame size R6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .128
AGPS board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .129
Resistor braking
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .131
Availability of brake choppers and resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .131
How to select the correct drive/chopper/resistor combination . . . . . . . . . . . . . . . . . . . . . . . . . . . .131
Optional brake chopper and resistor(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .132
Resistor installation and wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .134
Protection of frame sizes R2 to R5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .135
Protection of frame size R6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .136
Brake circuit commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .136
Table of contents
17
About this manual
What this chapter contains
This chapter describes the intended audience and contents of this manual. It
contains a flowchart of steps in checking the delivery, installing and commissioning
the drive. The flowchart refers to chapters/sections in this manual and other
manuals.
Compatibility
The manual is compatible with ACS800-04/U4 (frame sizes R2...R6).
Intended audience
This manual is intended for people who plan the installation, install, commission, use
and service the drive. Read the manual before working on the drive. The reader is
expected to know the fundamentals of electricity, wiring, electrical components and
electrical schematic symbols.
This manual is written for readers worldwide. Both SI and imperial units are shown.
Special US instructions for installations within the United States that must be
installed per the National Electrical Code and local codes are marked with (US).
Categorization according to the frame size
Some instructions, technical data and dimensional drawings which concern only
certain frame sizes are marked with the symbol of the frame size R2, R3... or R6.
The frame size is not marked on the drive designation label. To identify the frame
size of your drive, see the rating tables in chapter Technical data.
Categorization according to the + code
The instructions, technical data and dimensional drawings which concern only
certain optional selections are marked with + codes, e.g. +E202. The options
included in the drive can be identified from the + codes visible on the type
designation label of the drive. The + code selections are listed in chapter ACS800-
04/U4 in section Type code.
About this manual
18
Contents
The chapters of this manual are briefly described below.
Safety instructions give safety instructions for the installation, commissioning,
operation and maintenance of the drive.
About this manual lists the steps in checking the delivery and installing and
commissioning the drive and refers to chapters/sections in this manual and other
manuals for particular tasks.
ACS800-04/U4 describes the drive.
Planning the cabinet assembly guides in planning the installation of a drive module
into a user-defined cabinet.
Mechanical installation instructs how to place and mount the drive.
Planning the electrical installation instructs on the motor and cable selection, the
protections and the cable routing.
Electrical installation shows how to wire the drive.
Motor control and I/O board (RMIO) shows the external control connections to the
I/O board.
Installation checklist contains a list for checking the mechanical and electrical
installation of the drive.
Maintenance contains preventive maintenance instructions.
Technical data contains the technical specifications of the drive, e.g. the ratings,
sizes and technical requirements, provisions for fulfilling the requirements for CE
and other markings and warranty policy.
Dimensional drawings contains the dimensional drawings of the drive.
Resistor braking describes how to select, protect and wire brake choppers and
resistors. The chapter also contains the technical data.
About this manual
19
Installation and commissioning flowchart
Task See
Identify the frame size of your drive: R2, R3, R4, R5 Technical data: IEC data or NEMA data
or R6.
Plan the installation. Technical data
Check the ambient conditions, ratings, required Planning the electrical installation
cooling air flow, input power connection, compatibility
Option manual (if optional equipment is
of the motor, motor connection, and other technical
included)
data.
Select the cables.
Unpack and check the units. Mechanical installation: Unpacking the unit
Check that all necessary optional modules and If the converter has been non-operational for
equipment are present and correct. more than one year, the converter DC link
Only intact units may be started up. capacitors need to be reformed. Ask ABB for
instructions.
Check the installation site. Mechanical installation: Before installation
Technical data
If the drive is about to be connected to an IT ACS800-04/U4: Type code
(ungrounded) system, check that the drive is not
For instructions on how to disconnect the EMC
equipped with EMC filtering.
filtering, contact ABB.
Install the drive in a cabinet. Mechanical installation
Route the cables. Planning the electrical installation: Routing the
cables
Check the insulation of the motor and the motor Electrical installation: Checking the insulation of
cable. the assembly
About this manual
20
Task See
Connect the power cables. Electrical installation, Motor control and I/O
Connect the control and the auxiliary control cables. board (RMIO), Resistor braking (optional) and
the optional module manual delivered with the
module.
Check the installation. Installation checklist
Commission the drive. Appropriate Firmware Manual
Commission the optional brake chopper (if present). Resistor braking
Operating of the drive: start, stop, speed control etc. Appropriate Firmware Manual
Product and service inquiries
Address any inquiries about the product to your local ABB representative, quoting
the type code and serial number of the unit in question. A listing of ABB sales,
support and service contacts can be found by navigating to www.abb.com/drives and
selecting Drives – Sales, Support and Service network on the right pane.
Product training
For information on ABB product training, navigate to www.abb.com/drives and select
Drives – Training courses on the right pane.
Providing feedback on ABB Drives manuals
Your comments on our manuals are welcome. Go to www.abb.com/drives, then
select successively Drives – Document Library – Manuals feedback form on the right
pane.
About this manual
21
Terms and abbreviations
Term/Abbreviation Explanation
CDP312R Drive control panel
DDCS Distributed Drives Communication System; a protocol used in optical fibre
communication inside and between ABB drives.
EMC Electromagnetic Compatibility
Frame (size) Size of the frame into which the drive module is assembled. Several
supply modules with different nominal powers may have the same frame
size. The term refers to modules that have a similar mechanical
construction.
To determine the frame size of a drive module, refer to the rating tables in
chapter Technical data.
IGBT Insulated Gate Bipolar Transistor; a voltage-controlled semiconductor type
widely used in inverters due to their easy controllability and high switching
frequency.
I/O Input/Output
AGPS Gate driver Power Supply board. An optional board used to implement the
Prevention of Unexpected Start function.
RDCO DDCS communication option module
RDIO Digital I/O Extension Module
RFI Radio-frequency interference
RINT Main circuit board
RMIO Motor control and I/O board. The external I/O control signals are
connected to RMIO.
RPMP Control panel mounting platform kit
About this manual
22
About this manual
23
ACS800-04/U4
What this chapter contains
This chapter describes the operating principle and construction of the drive in short.
Layout
The ACS800-04/U4 (frame sizes R2 to R6) is an IP20 drive module for controlling
AC motors. It is to be installed into a cabinet by the customer with wall fastening.
Control panel CDP312R Frame size R2
(optional)
Option slots
Power cable
terminal
Heatsink
PE
Location of the components vary depending on the frame size.
ACS800-04/U4
24
Type code
The type code contains information on the specifications and configuration of the
drive. The first digits from left express the basic configuration (e.g. ACS800-04-
0016-3). The optional selections are given thereafter, separated by + signs (e.g.
+E202). The main selections are described below. Not all selections are available for
all types. For more information, refer to ACS800 Ordering Information
[3AFE64556568 (English)], available on request.
Selection Alternatives
Product series ACS800 product series
Type 04 Drive module. When no options are selected: IP20, no control panel, no
EMC filter, Standard Control Program, brake chopper in frame sizes R2,
R3, and R4 (only 690 V), boards without coating, one set of manuals.
U4 Drive module (USA). When no options are selected: UL open type, no
control panel, no EMC filter, Standard Control Program, brake chopper in
frame sizes R2, R3, and R4 (only 690 V), boards without coating, one set
of manuals.
Size See Technical data: IEC data or NEMA data.
Voltage range 2 208/220/230/240 V AC
(nominal rating in bold) 3 380/400/415 V AC
5 380/400/415/440/460/480/500 V AC
7 525/575/600/690 V AC
+ options
Control panel J400 Control panel CDP312R assembled on the drive module
J414 Control panel holder for frame sizes R2, R3 and R4 (not to be used with
option J400)
Construction C132 Marine drive (coated boards included)
C135 Flange mounting. Flange mounting plate assembled. IP55 for heat sink
side and IP20 for drive front side.
Filter E200 EMC/RFI filter for second environment TN (grounded) system, drive
category C3
E202 EMC/RFI filter for first environment TN (grounded) system, drive category
C2. (Not available for 690 V units.)
E210 EMC/RFI filter for second environment TN/IT (grounded/ungrounded)
system, drive category C3 (frame size R6 only)
Resistor braking D150 Brake chopper. Included as standard in frame sizes R2, R3 and R4 (only
690 V).
Safety Q950 Prevention of Unexpected Start: AGPS board and 3 m connection wire.
Fieldbus K... Refer to ACS800 Ordering Information [3AFE64556568 (English)].
I/O L...
Control program N...
Manual language R...
Specialities P901 Coated boards
P904 Extended warranty
ACS800-04/U4
25
Main circuit and control
Diagram
This diagram shows the control interfaces and the main circuit of the drive. Location
of terminals vary depending on the drive frame size.
Drive
Optional module 1: RMBA, RAIO, RDIO,
Motor Slot1 RDNA, RLON, RIBA, RPBA, RCAN, RCNA,
control and RMBP, RETA, RRIA or RTAC
I/O board
(RMIO)
Slot2
Optional module 2: RTAC, RAIO, RRIA or
RDIO
External control via
analogue/digital X33 DDCS communication option module 3:
inputs and outputs RDCO-01, RDCO-02 or RDCO-03
The fibre optic channels provided by the
X41
RDCO module can be used for fieldbus
connection (Nxxx fieldbus adapter modules),
Prevention of Unexpected
PC connection (DriveWare® PC tools) or
Start (AGPS board)
Advant Fieldbus 100 connection (e.g.
AC 800M, AC80)
= ~
Input power
~ = Output power
Brake chopper in frame sizes R2, R3 and
690 V frame R4 (optional in other frame
sizes).
R- UDC+ UDC-
R+
ACS800-04/U4
26
Operation
This table describes the operation of the main circuit in short.
Component Description
Six-pulse rectifier Converts the three-phase AC voltage to DC voltage.
Capacitor bank Energy storage which stabilizes the intermediate circuit DC voltage.
IGBT inverter Converts the DC voltage to AC voltage and vice versa. The motor
operation is controlled by switching the IGBTs.
Printed circuit boards
The drive contains the following printed circuit boards as standard:
• main circuit board (RINT)
• motor control and I/O board (RMIO)
• EMC filter board (RRFC) when EMC equipment is selected or varistor board
(RVAR) otherwise.
Motor control
The motor control is based on the Direct Torque Control (DTC) method. Two phase
currents and DC link voltage are measured and used for the control. The third phase
current is measured for earth fault protection.
ACS800-04/U4
27
Planning the cabinet assembly
What this chapter contains
This chapter guides in planning the installation of a drive module into a user-defined
cabinet. The issues discussed are essential for safe and trouble-free use of the drive
system.
Note: The installation examples in this manual are provided only to help the installer
in designing the installation. The installation must always be designed and made
according to applicable local laws and regulations. ABB does not assume any
liability whatsoever for any installation which breaches the local laws and/or other
regulations.
Cabinet construction
The cabinet frame must be sturdy enough to carry the weight of the drive
components, control circuitry and other equipment installed in it.
The cabinet must protect the drive module against contact and meet the
requirements for dust and humidity (see chapter Technical data).
Disposition of the devices
For easy installation and maintenance, a spacious layout is recommended. Sufficient
cooling air flow, obligatory clearances, cables and cable support structures all
require space.
For layout examples, see section Cabinet layout example.
Grounding of mounting structures
Make sure all cross-members or shelves on which components are mounted are
properly grounded and the connecting surfaces left unpainted.
Note: Ensure that the modules are properly grounded through their fastening points
to the installation base.
Planning the cabinet assembly
28
Free space around the unit
The modules can be installed side by side. Recommended free space above and
below the drive to enable cooling air flow, service and maintenance is shown below
in millimetres and [inches].
The temperature of the cooling air entering the unit must not exceed the maximum
allowed ambient temperature. See section Ambient conditions in chapter Technical
data.
200 [7.9]
300 [12]
IP20 (UL open type)
Planning the cabinet assembly
29
Cooling and degrees of protection
The cabinet must have enough free space for the components to ensure sufficient
cooling. Observe the minimum clearances given for each component.
The air inlets and outlets must be equipped with gratings that
• guide the air flow
• protect against contact
• prevent water splashes from entering the cabinet.
The drawing below shows two typical cabinet cooling solutions. The air inlet is at the
bottom of the cabinet, while the outlet is at the top, either on the upper part of the
door or on the roof.
Air outlet
Air inlet
Arrange the cooling air flow through the modules so that the requirements given in
chapter Technical data are met:
• cooling air flow
Note: The values in Technical data apply to continuous nominal load. If the load is cyclic or less
than nominal, less cooling air is required.
• allowed ambient temperature
• the air inlet and outlet sizes required for the module cooling and recommended
filter material (if used).
In addition to the above, the heat dissipated by cables and other additional
equipment must also be ventilated.
The internal cooling fans of the modules are usually sufficient to keep the component
temperatures low enough in IP22 (UL type 1) cabinets.
Planning the cabinet assembly
30
In IP54 (UL type 12) cabinets, thick filter mats are used to prevent water splashes
from entering the cabinet. This entails the installation of additional cooling
equipment, such as a hot air exhaust fan.
The installation site must be sufficiently ventilated.
Preventing the recirculation of hot air
Normal vertical mounting Flange mounting
Main
Cabinet (side view) air Cabinet (side view)
flow
out
HOT
AREA Air flow out
Main air flow out HOT AREA
Air baffle
Air baffle plate
plates
COOL AREA COOL AREA
Main air flow in Air flow in
Main
air
flow
in
Outside the cabinet
Prevent hot air circulation outside the cabinet by leading the outcoming hot air away
from the area where the inlet air to the cabinet is taken. Possible solutions are listed
below:
• gratings that guide air flow at the air inlet and outlet
• air inlet and outlet at different sides of the cabinet
• cool air inlet in the lower part of the front door and an extra exhaust fan on the
roof of the cabinet.
Planning the cabinet assembly
31
Inside the cabinet
Prevent hot air circulation inside the cabinet with leak-proof air baffle plates. No
gaskets are usually required.
When several modules are installed vertically in one cabinet, the hot air from one
module must not be allowed to enter another module. In a cabinet with multiple
modules, a practical way of achieving this is to install a mounting plate to separate
the cool area (at the front part of the cabinet) from the hot area (back part). The
mounting plate can be fastened to two vertical pillars on both left and right. Since the
air outlet at the top of the modules points directly upwards, the air must be guided to
the hot area. See cabinet layout examples below.
Cabinet layout example
Vertical mounting
AC switch fuse
AC fuse bases
AC fuses
Airflow guides
du/dt filter Hot area
Cool area
Mounting
plates
Modules
Motor cable entries
Front view of three R2 Side view of three R3
modules in cabinet modules in cabinet
Planning the cabinet assembly
32
Cabinet heaters
Use a cabinet heater if there is a risk of condensation in the cabinet. Although the
primary function of the heater is to keep the air dry, it may also be required for
heating at low temperatures. When placing the heater, follow the instructions
provided by its manufacturer.
Mounting the optional control panel
The optional control panel CDP312R is factory assembled on the drive module.The
panel can also be fastened directly to the cabinet door or to a mounting platform.
Installing the control panel directly on the cabinet door
Fasten the control panel from the back side with two screws of one of the following
types:
• standard screw with nominal diameter of 4 mm (0.16 in.)
• tapping screw with nominal diameter of 4.2 mm (0.17 in.) DIN 7981 C, DIN 7982
C, DIN 7983 C or DIN 7976 C
• PT screw for thermoplastics with nominal diameter of 4 mm (0.16 in.).
View from outside the cabinet door
Control panel
Cabinet door
4...8 mm
(0.16...0.31 in.)
Control panel footprint
Tightening torque:
1 Nm (0.74 lbf ft) 10 mm (0.39 in.)
Planning the cabinet assembly
33
Control panel mounting platform kit (RPMP)
For installation of the mounting platform, see Control Panel Mounting Platform Kit
(RPMP) Installation Guide [3AFE64677560 (English)].
EMC requirements
Generally, the fewer and smaller the holes in the cabinet, the better the interference
attenuation. The maximum recommended diameter of a hole in galvanic metal
contact in the covering cabinet structure is 100 mm. Special attention must be paid
to the cooling air inlet and outlet gratings.
The best galvanic connection between the steel panels is achieved by welding them
together as no holes are necessary. If welding is not possible, the seams between
the panels are recommended to be left unpainted and equipped with special
conductive EMC strips to provide adequate galvanic connection. Usually, reliable
strips are made of flexible silicon mass covered with a metal mesh. The non-
tightened touch-contact of the metal surfaces is not sufficient, so a conductive
gasket between the surfaces is required. The maximum recommended distance
between assembly screws is 100 mm.
Sufficient high-frequency grounding network must be constructed in the cabinet to
avoid voltage differences and forming of high-impedance radiator structures. A good
high-frequency grounding is made with short flat copper braids for low inductance.
One-point high-frequency grounding cannot be used due to the long distances inside
the cabinet.
First environment EMC compliance *) of the drive requires 360° high frequency
grounding of the motor cable shields at their entries. The grounding can be
implemented by a knitted wire mesh screening as shown below.
Bare cable shield
Cable ties
Knitted wire mesh
Lead-through plate
Cable
Cabinet bottom plate
*) First environment EMC compliance is defined in section CE marking in chapter Technical data.
Planning the cabinet assembly
34
360° high frequency grounding of the control cable shields is recommended at their
entries. The shields can be grounded by means of conductive shielding cushions
pressed against the cable shield from both directions:
Bare cable shield Shielding cushion
(conductive)
Cabinet bottom plate
Cable
Cable grommet
Planning the cabinet assembly
35
Mechanical installation
Unpacking the unit
The drive is delivered in a box that also contains:
• plastic bag containing: screws (M3), clamps and cable lugs (2 mm2, M3) for
grounding the control cable screens
• residual voltage warning stickers
• hardware, firmware and other module manuals
• delivery documents.
Unpack the unit of frame sizes R2 to R5 as follows.
Tear
Mechanical installation
36
Delivery check
Check that there are no signs of damage. Before attempting installation and
operation, check the information on the type designation label of the drive to verify
that the unit is of the correct type. The label includes IEC rating, C-UL US, CSA,
C-tick and CE markings, a type code and a serial number, which allow individual
recognition of each unit. The first digit of the serial number refers to the
manufacturing plant. The next four digits refer to the unit’s manufacturing year and
week, respectively. The remaining digits complete the serial number so that there
are no two units with the same serial number.
The type designation label is attached to the heat sink and the serial number label to
the upper part of the back plate of the unit.
Type designation label
Serial number label
Before installation
Check the installation site according to the requirements below. See Dimensional
drawings for frame details.
Requirements for the installation site
See Technical data for the allowed operation conditions of the drive.
Floor
The floor/material below the cabinet should be non-flammable.
Mechanical installation
37
Installation procedure
1. Mark the locations for the four holes. The mounting points are shown in
Dimensional drawings. With frame sizes R2...R5, use the mounting template cut
from the package.
2. Fix the screws or bolts to the marked locations.
3. Position the drive onto the screws on the cabinet wall. Note: Lift the drive by its
chassis (R6: by its lifting holes).
4. Tighten the screws in the cabinet wall securely.
Mechanical installation
38
Flange mounting
The flange mounting plate is factory assembled on the drive. With flange mounting,
the degree of protection is IP55 for the heat sink side and IP20 for the drive front
side. The drive front side must always be housed in a cabinet.
R6 with flange mounting plate
Connect a drive with flange mounting plate as follows:
1. Make the appropriate mounting and screw holes for the drive into the mounting
plate. The sizes and locations of the holes vary according to the frame size. See
chapter Dimensional drawings. Screw holes can be replaced with rivet nuts.
Recommended type is closed M6 rivet nut, L = 23 mm, code 23351060030 /
Rivkle provided by Böllhoff (www.boellhoff.de).
2. Lift the drive by its lifting lugs and place it into the mounting hole.
3. Fix the washers and screws (M6) delivered with the drive (MRP code 68390419).
The tightening torque is 2 Nm.
Note: The flange mounting kit does not ground the drive. The drive needs to be
grounded according to instructions given in chapter Electrical installation.
Note: Maximum allowed vibration for the drive has not been tested with flange
mounting. If the drive is exposed to vibration, it is recommended to fix the drive also
from the normal mounting holes located on the heat sink. See section Installation
procedure.
Mechanical installation
39
R6 flange mounting
1
2 Lifting lug
Mounting plate
3
Washer
Screw
Mechanical installation
40
Mechanical installation
41
Planning the electrical installation
What this chapter contains
This chapter contains the instructions that you must follow when selecting the motor,
cables, protections, cable routing and way of operation for the drive system.
Note: The installation must always be designed and made according to applicable
local laws and regulations. ABB does not assume any liability whatsoever for any
installation which breaches the local laws and/or other regulations. Furthermore, if
the recommendations given by ABB are not followed, the drive may experience
problems that the warranty does not cover.
Motor selection and compatibility
1. Select the motor according to the rating tables in chapter Technical data. Use the
DriveSize PC tool if the default load cycles are not applicable.
2. Check that the motor ratings lie within the allowed ranges of the drive control
program:
• motor nominal voltage is 1/2 ... 2 · UN of the drive
• motor nominal current is 1/6 ... 2 · I2hd of the drive in DTC control and
0 ... 2 · I2hd in scalar control. The control mode is selected by a drive parameter.
3. Check that the motor voltage rating meets the application requirements:
• If no resistor braking is in use, the motor voltage rating is UN.
UN = rated input voltage of the drive
• If frequent or long term brake cycles will be used, the motor voltage rating is
UACeq.
UACeq = UDC/1.35
where
UACeq is the equivalent AC power source voltage of the drive in V AC.
UDC is the maximum DC link voltage of the drive in V DC.
For resistor braking: UDC = 1.2 × 1.35 × UN.
See note 6 below the Requirements table.
4. Consult the motor manufacturer before using a motor in a drive system where the
motor nominal voltage differs from the AC power source voltage.
Planning the electrical installation
42
5. Ensure that the motor insulation system withstands the maximum peak voltage in
the motor terminals. See the Requirements table below for the required motor
insulation system and drive filtering.
Example: When the supply voltage is 440 V and the drive is operating in motor
mode only, the maximum peak voltage in the motor terminals can be
approximated as follows: 440 V · 1.35 · 2 = 1190 V. Check that the motor
insulation system withstands this voltage.
Protecting the motor insulation and bearings
The output of the drive comprises – regardless of output frequency – pulses of
approximately 1.35 times the equivalent mains network voltage with a very short rise
time. This is the case with all drives employing modern IGBT inverter technology.
The voltage of the pulses can be almost double at the motor terminals, depending on
the attenuation and reflection properties of the motor cable and the terminals. This in
turn can cause additional stress on the motor and motor cable insulation.
Modern variable speed drives with their fast rising voltage pulses and high switching
frequencies can generate current pulses that flow through the motor bearings, which
can gradually erode the bearing races and rolling elements.
The stress on motor insulation can be avoided by using optional ABB du/dt filters.
du/dt filters also reduce bearing currents.
To avoid damage to motor bearings, the cables must be selected and installed
according to the instructions given in the hardware manual. In addition, insulated N-
end (non-driven end) bearings and output filters from ABB must be used according
to the following table. Two types of filters are used individually or in combinations:
• optional du/dt filter (protects motor insulation system and reduces bearing
currents).
• common mode filter (mainly reduces bearing currents).
Planning the electrical installation
43
Requirements table
The following table shows how to select the motor insulation system and when an optional ABB du/dt
filter, insulated N-end (non-driven end) motor bearings and ABB common mode filters are required. The
motor manufacturer should be consulted regarding the construction of the motor insulation and
additional requirements for explosion-safe (Ex) motors. Failure of the motor to fulfil the following
requirements or improper installation may shorten motor life or damage the motor bearings and voids
the warranty.
Motor type Nominal mains Requirement for
voltage (AC line Motor ABB du/dt filter, insulated N-end bearing and ABB common
voltage) insulation mode filter
Manufacturer
system PN < 100 kW 100 kW < PN < PN > 350 kW
and 350 kW or or
frame size < IEC frame size > IEC frame size > IEC
315 315 400
PN < 134 HP 134 HP < PN < PN > 469 HP
and frame size < 469 HP or frame size >
NEMA 500 or frame size > NEMA 580
NEMA 500
A Random- UN < 500 V Standard - +N + N + CMF
B wound M2_ 500 V < UN < 600 V Standard + du/dt + du/dt + N + du/dt + N + CMF
B and M3_
or
Reinforced - +N + N + CMF
600 V < UN < 690 V Reinforced + du/dt + du/dt + N + du/dt + N + CMF
Form-wound 380 V < UN < 690 V Standard n.a. + N + CMF PN < 500 kW: + N
HX_ and + CMF
AM_ PN > 500 kW: + N
+ CMF + du/dt
Old* form- 380 V < UN < 690 V Check with the + du/dt with voltages over 500 V + N + CMF
wound HX_ motor
and modular manufacturer.
Random- 0 V < UN < 500 V Enamelled wire + N + CMF
wound HX_ 500 V < UN < 690 V with fibre glass + du/dt + N + CMF
and AM_ ** taping
Planning the electrical installation
44
Motor type Nominal mains Requirement for
voltage (AC line Motor ABB du/dt filter, insulated N-end bearing and ABB common
voltage) insulation mode filter
Manufacturer
system PN < 100 kW 100 kW < PN < PN > 350 kW
and 350 kW or or
frame size < IEC frame size > IEC frame size > IEC
315 315 400
PN < 134 HP 134 HP < PN < PN > 469 HP
and frame size < 469 HP or frame size >
NEMA 500 or frame size > NEMA 580
NEMA 500
N Random- UN < 420 V Standard: ÛLL = - + N or CMF + N + CMF
O wound and 1300 V
N form-wound 420 V < UN < 500 V Standard: ÛLL = + du/dt + du/dt + N + du/dt + N + CMF
- 1300 V or
A + du/dt + CMF
B
or
B
Reinforced: - + N or CMF + N + CMF
ÛLL = 1600 V,
0.2
microsecond
rise time
500 V < UN < 600 V Reinforced: ÛLL + du/dt + du/dt + N + du/dt + N + CMF
= 1600 V or
+ du/dt + CMF
or
Reinforced: - + N or CMF + N + CMF
ÛLL = 1800 V
600 V < UN < 690 V Reinforced: + du/dt + du/dt + N + du/dt + N + CMF
ÛLL = 1800 V
Reinforced: - N + CMF N + CMF
ÛLL = 2000 V,
0.3
microsecond
rise time ***
* manufactured before 1.1.1998
** For motors manufactured before 1.1.1998, check for additional instructions with the motor
manufacturer.
*** If the intermediate DC circuit voltage of the drive will be increased from the nominal level by resistor
braking or by the IGBT Supply Control Program (parameter selectable function), check with the
motor manufacturer if additional output filters are needed in the applied drive operation range.
Planning the electrical installation
45
Note 1: The abbreviations used in the table are defined below.
Abbreviation Definition
UN nominal voltage of the supply network
ÛLL peak line-to-line voltage at motor terminals which the motor insulation must withstand
PN motor nominal power
du/dt du/dt filter at the output of the drive +E205
CMF common mode filter +E208
N N-end bearing: insulated motor non-driven end bearing
n.a. Motors of this power range are not available as standard units. Consult the motor manufacturer.
Note 2: Explosion-safe (Ex) motors
The motor manufacturer should be consulted regarding the construction of the motor insulation and
additional requirements for explosion-safe (Ex) motors.
Note 3: High-output motors and IP23 motors
For motors with higher rated output than what is stated for the particular frame size in EN 50347 (2001)
and for IP23 motors, the requirements of ABB random-wound motor series M3AA, M3AP, M3BP are
given below. For other motor types, see the Requirements table above. Apply the requirements of
range 100 kW < PN < 350 kW to motors with PN < 100 kW. Apply the requirements of range
PN > 350 kW to motors within the range 100 kW < PN < 350 kW. In other cases, consult the motor
manufacturer.
Motor type Nominal mains Requirement for
Manufacturer
voltage (AC line Motor ABB du/dt filter, insulated N-end bearing and ABB common
voltage) insulation mode filter
system PN < 55 kW 55 kW < PN < PN > 200 kW
200 kW
PN < 74 HP 74 HP < PN < PN > 268 HP
268 HP
A Random- UN < 500 V Standard - +N + N + CMF
B wound M3AA, 500 V < U < 600 V Standard + du/dt + du/dt + N + du/dt + N + CMF
N
B M3AP, M3BP
or
Reinforced - +N + N + CMF
600 V < UN < 690 V Reinforced + du/dt + du/dt + N + du/dt + N + CMF
Note 4: HXR and AMA motors
All AMA machines (manufactured in Helsinki) for drive systems have form-wound windings. All HXR
machines manufactured in Helsinki starting 1.1.1998 have form-wound windings.
Note 5: ABB motors of types other than M2_, M3_, HX_ and AM_
Use the selection criteria given for non-ABB motors.
Note 6: Resistor braking of the drive
When the drive is in braking mode for a large part of its operation time, the intermediate circuit DC
voltage of the drive increases, the effect being similar to increasing the supply voltage by up to 20
percent. The voltage increase should be taken into consideration when determining the motor insulation
requirement.
Example: Motor insulation requirement for a 400 V application must be selected as if the drive were
supplied with 480 V.
Planning the electrical installation
46
Note 7: Calculating the rise time and the peak line-to-line voltage
The peak line-to-line voltage at the motor terminals generated by the drive as well as the voltage rise
time depend on the cable length. The requirements for the motor insulation system given in the table
are “worst case” requirements covering installations with 30 metre and longer cables. The rise time can
be calculated as follows: t = 0.8 · ÛLL/(du/dt). Read ÛLL and du/dt from the diagrams below. Multiply
the values of the graph by the supply voltage (UN).With resistor braking, the ÛLL and du/dt values are
approximately 20 % higher.
3.0 5.5
ÛLL/UN 5.0
2.5 du/dt
------------- (1/μs)
4.5 UN
2.0 4.0
3.5
1.5
3.0
ÛLL/UN
1.0 2.5
du/dt
------------- (1/μs)
UN 2.0
0.5
1.5
0.0 1.0
100 200 300 100 200 300
Cable length (m) Cable length (m)
With du/dt filter Without du/dt filter
Note 8: Sine filters protect the motor insulation system. Therefore, du/dt filter can be replaced with
a sine filter. The peak phase-to-phase voltage with the sine filter is approximately 1.5 × UN.
Note 9: Common mode filter is available as a separate kit (one box including three rings for one cable).
Permanent magnet synchronous motor
Only one permanent magnet motor can be connected to the inverter output.
It is recommended to install a safety switch between the permanent magnet
synchronous motor and the drive output. The switch is needed to isolate the motor
during any maintenance work on the drive.
Supply connection
Disconnecting device (means)
Install a hand-operated input 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 position for installation and maintenance work.
Planning the electrical installation
47
EEA / Europe
If the drive is used in an application which must meet the European Union Machinery
Directive according to standard EN 60204-1 Safety of Machinery, the disconnecting
device must be one of the following types:
• a switch-disconnector of utilization category AC-23B (EN 60947-3)
• a disconnector that has an auxiliary contact that in all cases causes switching
devices to break the load circuit before the opening of the main contacts of the
disconnector (EN 60947-3)
• a circuit breaker suitable for isolation in accordance with EN 60947-2.
US
The disconnecting means must conform to the applicable safety regulations.
Main contactor
If used, dimension the contactor according to the nominal voltage and current of the
drive. The utilization category (IEC 947-4) is AC-1.
Fuses
See section Thermal overload and short-circuit protection.
Thermal overload and short-circuit protection
Thermal overload protection of the drive and the input and motor cables
The drive protects itself and the input and motor cables against thermal overload
when the cables are dimensioned according to the nominal current of the drive. No
additional thermal protection devices are needed.
WARNING! If the drive is connected to multiple motors, a separate thermal overload
switch or a circuit breaker must be used for protecting each cable and motor. These
devices may require a separate fuse to cut off the short-circuit current.
Planning the electrical installation
48
Thermal overload protection of the motor
According to regulations, the motor must be protected against thermal overload and
the current must be switched off when overload is detected. The drive includes a
motor thermal protection function that protects the motor and switches off the current
when necessary. Depending on a drive parameter value, the function either monitors
a calculated temperature value (based on a motor thermal model) or an actual
temperature indication given by motor temperature sensors. The user can tune the
thermal model further by feeding in additional motor and load data.
The most common temperature sensors are:
• motor sizes IEC180.225: thermal switch (e.g. Klixon)
• motor sizes IEC200.250 and larger: PTC or Pt100.
See the firmware manual for more information on the motor thermal protection, and
the connection and use of the temperature sensors.
Protection against short-circuit in the motor cable
The drive protects the motor cable and motor in a short-circuit situation when the
motor cable is dimensioned according to the nominal current of the drive. No
additional protection devices are needed.
Protection against short-circuit inside the drive or in the supply cable
Arrange the protection according to the following guide lines.
Circuit diagram Short-circuit
protection
Protect the drive and
Distribution Drive or drive input cable with fuses
board Input cable module or a circuit breaker.
See footnotes 1) and
1) 2).
~ M
~ 3~
2)
~ M
I>
~ 3~
1) Size the fuses according to instructions given in chapter Technical data. The fuses will protect the input
cable in short-circuit situations, restrict drive damage and prevent damage to adjoining equipment in
case of a short-circuit inside the drive.
Planning the electrical installation
49
2) Circuit breakers which have been tested by ABB with the ACS800 can be used. Fuses must be used
with other circuit breakers. Contact your local ABB representative for 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 inherent operating principle and construction of circuit breakers,
independent of the manufacturer, hot ionized gases may escape from the breaker
enclosure in case of a short-circuit. To ensure safe use, special attention must be paid to
the installation and placement of the breakers. Follow the manufacturer’s instructions.
Note: Circuit breakers must not be used without fuses in the USA.
Ground fault protection
The drive is equipped with an internal ground fault protective function to protect the
unit against ground faults in the motor and the motor cable. This is not a personal
safety or a fire protection feature. The ground fault protective function can be
disabled with a parameter, refer to the appropriate ACS800 Firmware Manual.
The EMC filter of the drive includes capacitors connected between the main circuit
and the frame. These capacitors and long motor cables increase the ground leakage
current and may cause fault current circuit breakers to function.
Emergency stop devices
For safety reasons, install the emergency stop devices at each operator control
station and at other operating stations where emergency stop may be needed.
Note: Pressing the stop key ( ) on the control panel of the drive does not generate
an emergency stop of the motor or separate the drive from dangerous potential.
Planning the electrical installation
50
Prevention of Unexpected Start
The drive can be equipped with an optional Prevention of Unexpected Start function
according to standards IEC/EN 60204-1: 1997; ISO/DIS 14118: 2000 and EN 1037:
1996.
The Prevention of Unexpected Start function disables the control voltage of the
power semiconductors, thus preventing the inverter from generating the AC voltage
required to rotate the motor. By using this function, short-time operations (like
cleaning) and/or maintenance work on non-electrical parts of the machinery can be
performed without switching off the AC power supply to the drive.
The operator activates the Prevention of Unexpected Start function by opening a
switch on a control desk. An indicating lamp on the control desk will light, signalling
that the prevention is active. The switch can be locked out.
A Gate Driver Power Supply board (AGPS) and a 3 m connection wire are delivered
with the Prevention of Unexpected Start option kit. The Prevention of Unexpected
Start function complies with EN954-1 categories 1 and 3 when the following
installations are made:
The user must install on a control desk near the machinery:
• switching/disconnecting device for the circuitry. “Means shall be provided to
prevent inadvertent, and/or mistaken closure of the disconnecting device.”
EN 60204-1: 1997.
• indicating lamp; on = starting the drive is prevented, off = drive is operative.
• safety relay (type BD5935 has been approved by ABB)
(Switching/disconnecting device, indicating lamp and safety relay are not included in
the delivery.)
For connections to the drive, see section Prevention of Unexpected Start, AGPS
board in chapter Electrical installation.
WARNING! The Prevention of Unexpected Start function does not disconnect the
voltage of the main and auxiliary circuits from the drive. Therefore maintenance work
on electrical parts of the drive or the motor can only be carried out after isolating the
drive system from the main supply.
Note: The Prevention of Unexpected Start function is not intended for stopping the
drive. If a running drive is stopped by using the Prevention of Unexpected Start
function, the drive will cut off the motor supply voltage and the motor will coast to
stop.
Planning the electrical installation
51
Selecting the power cables
General rules
Dimension the mains (input power) and motor cables according to local
regulations:
• The cable must be able to carry the drive load current. See chapter Technical
data for the rated currents.
• The cable must be rated for at least 70 °C maximum permissible temperature of
conductor in continuous use. For US, see section Additional US requirements.
• The inductance and impedance of the PE conductor/cable (grounding wire) must
be rated according to permissible touch voltage appearing under fault conditions
(so that the fault point voltage will not rise excessively when a ground fault
occurs).
• 600 V AC cable is accepted for up to 500 V AC. 750 V AC cable is accepted for
up to 600 V AC. For 690 V AC rated equipment, the rated voltage between the
conductors of the cable should be minimum 1 kV.
For drive frame size R5 and larger, or motors larger than 30 kW (40 HP),
symmetrical shielded motor cable must be used (figure below). A four-conductor
system can be used up to frame size R4 with up to 30 kW (40 HP) motors, but
shielded symmetrical motor cable is always recommended. The shield(s) of motor
cable(s) must have 360° bonding at both ends.
Note: When continuous metal conduit is employed, shielded cable is not required.
The conduit must have bonding at both ends as with cable shield.
A four-conductor system is allowed for input cabling, but shielded symmetrical cable
is recommended. To operate as a protective conductor, the shield conductivity must
be as follows when the protective conductor is made of the same metal as the phase
conductors:
Cross-sectional area of the phase Minimum cross-sectional area of the corresponding
conductors protective conductor
S (mm2) Sp (mm2)
S < 16 S
16 < S < 35 16
35 < S S/2
Compared to a four-conductor system, the use of symmetrical shielded cable
reduces electromagnetic emission of the whole drive system as well as the stress on
motor insulation, bearing currents and wear.
The motor cable and its PE pigtail (twisted shield) should be kept as short as
possible in order to reduce high frequency electromagnetic emission, as well as
stray currents outside the cable and capacitive current (relevant in power range
below 20 kW).
Planning the electrical installation
52
Alternative power cable types
Power cable types that can be used with the drive are represented below.
Recommended
Symmetrical shielded cable: three phase conductors A separate PE conductor is required if the conductivity
and a concentric or otherwise symmetrically of the cable shield is < 50% of the conductivity of the
constructed PE conductor, and a shield phase conductor.
PE conductor Shield
and shield Shield
PE
PE
PE Shield
A four-conductor system:
three phase conductors
and a protective
conductor.
Not allowed for motor cables Not allowed for motor cables with phase
conductor cross section larger than 10 mm2
[motors > 30 kW (40 HP)].
Motor cable shield
To effectively suppress radiated and conducted radio-frequency emissions, the
shield conductivity must be at least 1/10 of the phase conductor conductivity. The
requirements are easily met with a copper or aluminium shield. The minimum
requirement of the motor cable shield of the drive is shown below. It consists of a
concentric layer of copper wires with an open helix of copper tape or copper wire.
The better and tighter the shield, the lower the emission level and the bearing
currents.
Copper wire screen Helix of copper tape Inner insulation
Insulation jacket
or copper wire
Cable core
Planning the electrical installation
53
Additional US requirements
Type MC continuous corrugated aluminium armor cable with symmetrical grounds or
shielded power cable must be used for the motor cables if metallic conduit is not
used. For the North American market, 600 V AC cable is accepted for up to
500 V AC. 1000 V AC cable is required above 500 V AC (below 600 V AC). For
drives rated over 100 amperes, the power cables must be rated for 75 °C (167 °F).
Conduit
Separate parts of a conduit must be coupled together, bridge the joints with a ground
conductor bonded to the conduit on each side of the joint. Bond the conduits also to
the drive enclosure and motor frame. Use separate conduits for input power, motor,
brake resistor, and control wiring. When conduit is employed, type MC continuous
corrugated aluminium armor cable or shielded cable is not required. A dedicated
ground cable is always required.
Note: Do not run motor wiring from more than one drive in the same conduit.
Armored cable / shielded power cable
Six conductor (3 phases and 3 ground) type MC continuous corrugated aluminium
armor cable with symmetrical grounds is available from the following suppliers (trade
names in parentheses):
• Anixter Wire & Cable (Philsheath)
• BICC General Corp (Philsheath)
• Rockbestos Co. (Gardex)
• Oaknite (CLX).
Shielded power cables are available from Belden, LAPPKABEL (ÖLFLEX) and
Pirelli.
Planning the electrical installation
54
Power factor compensation capacitors
Power factor compensation is not needed with AC drives. However, if a drive is to be
connected in a system with compensation capacitors installed, note the following
restrictions.
WARNING! Do not connect power factor compensation capacitors or harmonic
filters to the motor cables (between the drive and the motor). They are not meant to
be used with AC drives and can cause permanent damage to the drive or
themselves.
If there are power factor compensation capacitors in parallel with the three phase
input of the drive:
1. Do not connect a high-power capacitor to the power line while the drive is
connected. The connection will cause voltage transients that may trip or even
damage the drive.
2. If capacitor load is increased/decreased step by step when the AC drive is
connected to the power line: Ensure that the connection steps are low enough not
to cause voltage transients that would trip the drive.
3. Check that the power factor compensation unit is suitable for use in systems with
AC drives i.e. harmonic generating loads. In such systems, the compensation unit
should typically be equipped with a blocking reactor or harmonic filter.
Equipment connected to the motor cable
Installation of safety switches, contactors, connection boxes, etc.
To minimize the emission level when safety switches, contactors, connection boxes
or similar equipment are installed in the motor cable between the drive and the
motor:
• EU: Install the equipment in a metal enclosure with 360 degrees grounding for the
screens of both the incoming and outgoing cable, or connect the screens of the
cables otherwise together.
• US: Install the equipment in a metal enclosure in a way that the conduit or motor
cable shielding runs consistently without breaks from the drive to the motor.
Bypass connection
WARNING! Never connect the supply power to the drive output terminals U2, V2
and W2. If frequent bypassing is required, employ mechanically connected switches
or contactors. Mains (line) voltage applied to the output can result in permanent
damage to the unit.
Planning the electrical installation
55
Before opening a contactor (DTC control mode selected)
Stop the drive and wait for the motor to stop before opening a contactor between the
output of the drive and the motor when the DTC control mode is selected. See the
appropriate ACS800 Control Program Firmware Manual for the required parameter
settings. Otherwise, the contactor will be damaged. In scalar control, the contactor
can be opened with the drive running.
Protecting the relay output contacts and attenuating disturbances in case
of inductive loads
Inductive loads (relays, contactors, motors) cause voltage transients when switched
off.
The relay contacts on the RMIO board are protected with varistors (250 V) against
overvoltage peaks. In spite of this, it is highly recommended to equip inductive loads
with noise attenuating circuits [varistors, RC filters (AC) or diodes (DC)] in order 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 RMIO board terminal block.
RMIO
Relay outputs
Varistor X25
1 RO1
230 V AC 2 RO1
3 RO1
RC filter X26
1 RO2
230 V AC 2 RO2
3 RO2
Diode X27
1 RO3
24 VD C 2 RO3
3 RO3
Planning the electrical installation
56
Selecting the control cables
All control cables must be shielded.
Use a double-shielded twisted pair cable (Figure a, e.g. JAMAK by Draka NK
Cables, Finland) for analogue signals. This type of cable is recommended for the
pulse encoder signals also. Employ one individually shielded pair for each signal. Do
not use common return for different analogue signals.
A double-shielded cable is the best alternative for low-voltage digital signals but
single-shielded twisted multipair cable (Figure b) is also usable.
a b
A double-shielded twisted A single-shielded twisted
pair cable multipair cable
Run analogue and digital signals in separate, shielded 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-controlled
signals be run as twisted pairs.
Never mix 24 V DC and 115/230 V AC signals in the same cable.
Relay cable
The cable type with braided metallic screen (e.g. ÖLFLEX by LAPPKABEL,
Germany) has been tested and approved by ABB.
Control panel cable
In remote use, the cable connecting the control panel to the drive must not exceed
3 metres (10 ft). The cable type tested and approved by ABB is used in control panel
option kits.
Planning the electrical installation
57
Connection of a motor temperature sensor to the drive I/O
WARNING! IEC 60664 requires double or reinforced insulation between live parts
and the surface of accessible parts of electrical equipment which are either non-
conductive or conductive but not connected to the protective earth.
To fulfil this requirement, the connection of a thermistor (and other similar
components) to the digital inputs of the drive can be implemented in three alternate
ways:
1. There is double or reinforced insulation between the thermistor and live parts of
the motor.
2. Circuits connected to all digital and analogue inputs of the drive are protected
against contact and insulated with basic insulation (the same voltage level as the
drive main circuit) from other low voltage circuits.
3. An external thermistor relay is used. The insulation of the relay must be rated for
the same voltage level as the main circuit of the drive. For connection, see
ACS800 Firmware Manual.
Installation sites above 2000 metres (6562 feet)
WARNING! Protect against direct contact when installing, operating and servicing
the RMIO board wiring and optional modules attached to the board. The Protective
Extra Low Voltage (PELV) requirements stated in EN 50178 are not fulfilled at
altitudes above 2000 m (6562 ft).
Routing the cables
Route the motor cable away from other cable routes. Motor cables of several drives
can be run in parallel installed next to each other. It is recommended that the motor
cable, input power cable and control cables be installed on separate trays. Avoid
long parallel runs of motor cables with other cables in order to decrease
electromagnetic interference caused by the rapid changes in the drive output
voltage.
Where control cables must cross power cables make sure they are arranged at an
angle as near to 90 degrees as possible. Do not run extra cables through the drive.
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.
Planning the electrical installation
58
A diagram of the cable routing is below.
Motor cable
Drive
min 300 mm (12 in.)
Power cable
Input power cable Motor cable
min 200 mm (8 in.) 90°
min 500 mm (20 in.)
Control cables
Control cable ducts
230 V 230 V
24 V (120 V) 24 V (120 V)
Not allowed unless the 24 V cable is Lead 24 V and 230 V (120 V) control
insulated for 230 V (120 V) or insulated cables in separate ducts inside the
with an insulation sleeving for cabinet.
230 V (120 V).
Planning the electrical installation
59
Electrical installation
What this chapter contains
This chapter describes the electrical installation procedure of the drive.
WARNING! The work described in this chapter may only be carried out by a qualified
electrician. Follow the Safety instructions on the first pages of this manual. Ignoring
the safety instructions can cause injury or death.
Make sure that the drive is disconnected from the mains (input power) during
installation. If the drive is already connected to the mains, wait for 5 min after
disconnecting mains power.
Checking the insulation of the assembly
Drive
Do not make any voltage tolerance or insulation resistance tests (e.g. hi-pot or
megger) on any part of the drive as testing can damage the drive. Every drive has
been tested for insulation between the main circuit and the chassis (2500 V rms
50 Hz for 1 second) at the factory. Also, there are voltage-limiting circuits inside the
drive which cut down the testing voltage automatically.
Input cable
Check the insulation of the input cable according to local regulations before
connecting it to the drive.
Motor and motor cable
Check the insulation of the motor and motor cable as follows:
1. Check that the motor cable is disconnected from the drive output terminals U2,
V2 and W2.
M 2. Measure the insulation resistances of the motor cable and the motor between
ohm each phase and the Protective Earth by using a measuring voltage of 1 kV DC.
PE
The insulation resistance must be higher than 1 Mohm.
Electrical installation
60
IT (ungrounded) systems
Ensure that the drive is not equipped with optional EMC filter, i.e. type code does not
include selections +E200 or +E202.
However if EMC filters exist, disconnect the EMC filter capacitors of selections
+E202 and +E200 before connecting the drive to an ungrounded system. For
detailed instructions on how to do this, please contact your local ABB distributor.
WARNING! If a drive with EMC filter selection +E202 or +E200 is installed on an IT
system [an ungrounded power system or a high resistance-grounded (over 30 ohms)
power system], the system will be connected to earth potential through the EMC
filter capacitors of the drive. This may cause danger or damage the unit.
Electrical installation
61
Power cable connection
Power cable connection
Drive with brake chopper included
INPUT UDC+ UDC- OUTPUT
PE U1 V1 W1 R- R+ U2 V2 W2
1) 2)
(PE) PE (PE)
3)
V1 W1
U1
External brake
For alternatives, see
Planning the electrical
resistor (360
degrees grounding
3 ~
installation: Motor
required)
Disconnecting device
(means). L1 L2 L3
Connecting the power cables
• Connect the twisted shield of the cable to the drive grounding terminal. Note:
cable lugs are needed in frame sizes R2 and R3.
• Supply cable grounding: If shielded cable is used, and the conductivity of the
shield is < 50% of the conductivity of the phase conductor, use a separate PE
cable (1) or a cable with a grounding conductor (2). With shielded cable 360°
grounding of the supply cables is recommended.
Motor cable grounding: Use a separate grounding cable (3) if the conductivity of
the cable shield is < 50% of the conductivity of the phase conductor and there is
no symmetrically constructed grounding conductor in the cable (see Planning the
electrical installation: Selecting the power cables).
360 degrees grounding is required at the cabinet entry in first environment
installations. First environment EMC compliance is defined in chapter Technical
data.
Note: 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.
Note: Do not use an asymmetrically constructed motor cable. Connecting its
fourth conductor at the motor end increases bearing currents and causes extra
wear.
Electrical installation
62
• Connect the phase conductors of the mains cable to the U1, V1 and W1 terminals
and the phase conductors of the motor cable to the U2, V2 and W2 terminals.
Strip the conductor ends as follows to fit them inside the power cable connection
terminals.
Note: Lead the unstripped cable as close to the terminals as possible. All
unstripped parts must be protected against contact.
Frame size Stripping length
mm in.
R2, R3 10 0.39
R4, R5 16 0.63
R6 28 1.10
• Secure the cables outside the unit mechanically.
• Ground the other end of the input cable shield or PE conductor at the distribution
board.
Grounding the motor cable shield at the motor end
For minimum radio frequency interference ground the cable shield 360 degrees at
the lead-through of the motor terminal box
360 degrees grounding
Conductive gaskets
or ground the cable by twisting the shield as follows: flattened width > 1/5 · length.
b > 1/5 · a
b
a
Electrical installation
63
Frame sizes R2 to R4
U1 V1 W1 UDC+
R- R+ UDC- U2 V2 W2
PE
PE
Input power cable Motor cable
Frame size R5
UDC+
PE U1 V1 W1 R- R+ UDC- U2 V2 W2 PE
Input power cable Motor cable
Electrical installation
64
Frame size R6: Cable lug installation [16 to 70 mm2 (6 to 2/0 AWG) cables]
U1 UDC+
U1
U1 V1 W1 R- R+ UDC- U2 V2 W2 Remove the screw terminals.
Fasten the cable lugs to the
remaining bolts with M10
nuts.
Isolate the ends of the cable
lugs with insulating tape or
shrink tube
PE
Input power cable Motor cable
Electrical installation
65
Frame size R6: Cable terminal installation [95 to 185 mm2 (3/0 to 2×4/0 AWG)
cables]
U1 UDC+
U1
U1 V1 W1 R- R+ UDC- U2 V2 W2
PE a. Connect the cable to the terminal.
b. Connect the terminal to the drive.
WARNING! If the wire size is less than
95 mm2 (3/0 AWG), a cable lug must
be used. A cable of wire size less than
95 mm2 (3/0 AWG) connected to this
terminal will loosen and may damage
the drive.
Input power cable Motor cable
Power cable protection
Frame size R5
Cover the power cable terminals as follows:
1. Cut holes for the installed cables into the clear plastic shroud.
2. Press the shroud onto the terminals.
1 2
Electrical installation
66
Removal of the shroud with a screw driver:
Frame size R6
Cover the power cable terminals as follows:
1. Cut holes for the installed cables into the clear plastic shroud in cable lug
installations.
2. Press the shroud onto the terminals.
View of cable terminal
2 installation
Removal of the shroud by lifting up with a screw driver from the corner:
Warning sticker
There are warning stickers in different languages inside the packing box of the drive.
Attach a warning sticker in the language of your choice onto the plastic skeleton
above the power cable terminals.
Electrical installation
67
Connecting the control cables
Connect the control cables as described below. Connect the conductors to the
appropriate detachable terminals of the RMIO board [see chapter Motor control and
I/O board (RMIO)]. Tighten the screws to secure the connection.
Terminals
Location of terminals vary depending on the drive frame size.
Frame sizes R2 to R4
The control cable connection terminals are
exposed when the control panel mounting platform
is turned aside by pulling this knob. Be careful, do Detachable connection terminals (pull up)
not use excess force when pulling.
X39 for control panel cable
(control panel is an option)
Terminal for optional Optional module 1
Prevention of Unexpected
Start
X41 Optional module 2
I/O cables: Ground the
control cable shields in the DDCS communication
holes with screws. See option module 3:
section 360 degrees RDCO
grounding.
Place the warning
sticker here
4
Relay outputs
3
2
1
Electrical installation
68
Frame sizes R5 and R6
View of frame size R6
Control panel X41 for Prevention of
(optional) Unexpected Start (AGPS
board)
Optional module 1 Optional module 2
DDCS communication option module 3: RDCO
Control cable
grounding: see
section 360 Place the warning sticker here
degrees
grounding X41 Detachable connection terminals (pull up)
Terminal for optional
Prevention of Unexpected
Start
Electrical installation
69
360 degrees grounding
Insulation
4
3
2
1
Double-shielded cable Single-shielded cable
When the outer surface of the shield is covered with non-conductive material
• Strip the cable carefully (do not cut the grounding wire and the shield)
• Turn the shield inside out to expose the conductive surface.
• Wrap the grounding wire around the conductive surface.
• Slide a conductive clamp onto the conductive part.
• Fasten the clamp to the grounding plate with a screw as close as possible to the
terminals where the wires are about to be connected.
Connecting the shield wires
Single shielded cables: Twist the grounding wires of the outer shield and connect
them through the shortest possible route to the nearest grounding hole with a cable
lug and a screw. Double shielded cables: Connect each pair cable shield (twisted
grounding wires) with other pair cable shields of the same cable to the nearest
grounding hole with a cable lug and a screw.
Do not connect shields of different cables to the same cable lug and grounding
screw.
Leave the other end of the shield unconnected or ground it indirectly via a few
nanofarads high-frequency capacitor (e.g. 3.3 nF / 630 V). The shield can also be
grounded directly at both ends if they are in the same ground line with no significant
voltage drop between the end points.
Keep the signal wire pairs twisted as close to the terminals as possible. Twisting the
wire with its return wire reduces disturbances caused by inductive coupling.
Electrical installation
70
Cabling of I/O and fieldbus modules
Module
As short as possible
Shield
4
3
2
1
Note: The RDIO module does not
include a terminal for cable shield
grounding. Ground the pair cable
shields here.
Pulse encoder module cabling
As short as
possible
Note1: If the encoder is of
1
2 unisolated type, ground the encoder
3
4 cable at the drive end only. If the
encoder is galvanically isolated
from the motor shaft and the stator
frame, ground the encoder cable
Shield
shield at the drive and the encoder
RTAC end.
Note 2: Twist the pair cable wires.
Wrap copper tape around the
stripped part of the cable under the
clamp. Be careful. Do not cut the
grounding wire. Clamp as close to
the terminals as possible.
Electrical installation
71
Installation of optional modules and PC
The optional module (such as fieldbus adapter, I/O extension module and the pulse
encoder interface) is inserted in the optional module slot of the RMIO board (see
section Connecting the control cables) and fixed with two screws. See the
appropriate optional module manual for cable connections.
Fibre optic link
A DDCS fibre optic link is provided via the RDCO optional module for PC tools,
master/follower link, NDIO, NTAC, NAIO and fieldbus adapter modules of type Nxxx.
See RDCO User’s Manual for connections. Observe colouring codes when installing
fibre optic cables. Blue connectors go to blue terminals, and grey connectors to grey
terminals.
When installing multiple modules on the same channel connect them in a ring.
External +24 V power supply for the RMIO board via terminal X34
This section describes how to connect an external +24 V power supply for the RMIO
board via terminal X34. For the current consumption of the RMIO board, see chapter
Motor control and I/O board (RMIO).
Note: External power is easier to supply to the RMIO board via terminal X23, see
chapter Motor control and I/O board (RMIO).
Parameter settings
In Standard Control Program, set parameter 16.09 CTRL BOARD SUPPLY to
EXTERNAL 24V if the RMIO board is powered from an external supply.
Connecting +24 V external power supply
1. Break off the tab covering the +24 V DC power input connector with pliers.
2. Lift the connector upwards.
3. Disconnect the wires from the connector (keep the connector for later use).
4. Isolate the ends of the wires individually with insulating tape.
5. Cover the isolated ends of the wires with insulating tape.
6. Push the wires inside the skeleton.
7. Connect the wires of the +24 V external power supply to the disconnected
connector:
if a two-way connector, + wire to terminal 1 and - wire to terminal 2
if a three-way connector, + wire to terminal 2 and - wire to terminal 3.
8. Plug the connector in.
Electrical installation
72
Frame sizes R2 to R4 Frame sizes R5 and R6
X34
4
4
Electrical installation
73
5 6 7
RMIO board RMIO board
1 2 3 1 2 3
X34 X34
+ - + -
1 2 1 2 3
8
Connection of a two-way Connection of a three-way
connector connector
Electrical installation
74
Prevention of Unexpected Start, AGPS board
WARNING! Dangerous voltages can be present on the AGPS board even when the
115...230 V supply is switched off. Follow the Safety instructions on the first pages of
this manual and the instruction in this section when working on the AGPS board.
Make sure that the drive is disconnected from the mains (input power) and the
115...230 V source for the AGPS board is switched off during installation and
maintenance. If the drive is already connected to the mains, wait for 5 min after
disconnecting mains power.
Connect the optional AGPS board as follows:
• Remove the enclosure cover by undoing the fixing screws (1).
• Ground the unit via the bottom plate of the enclosure or via terminal X1:1 of the
AGPS board.
• Connect the cable delivered with the kit between terminal block X2 of the AGPS
board (2) and drive terminal block X41.
• Connect a cable between connector X1 of the AGPS board (3) and the
115...230 V source.
• Fasten the enclosure cover back with screws.
X2
X1
115...230 V
3
Electrical installation
75
Note: Location of the X41 terminal block varies according to the drive frame size,
see page 67.
Note: Maximum cable length between AGPS terminal block X2 and drive terminal
block is restricted to 10 m.
For technical data see section AGPS-11C in chapter Technical data.
Electrical installation
76
The following figure presents the circuit diagram of the Prevention of Unexpected
Start.
/U4
3AFE00374994
Electrical installation
77
Motor control and I/O board (RMIO)
What this chapter contains
This chapter shows
• external control connections to the RMIO board for the ACS800 Standard Control
Program (Factory Macro)
• specifications of the inputs and outputs of the board.
This chapter applies to ACS800 units which employ RMIO-01 board from revision J
onwards and RMIO-02 board from revision H onwards.
Note on terminal labelling
Optional modules (Rxxx) may have identical terminal designations with the RMIO
board.
Note on external power supply
External +24 V power supply for the RMIO board is recommended if
• the application requires a fast start after connecting the input power supply
• fieldbus communication is required when the input power supply is disconnected.
The RMIO board can be supplied from an external power source via terminal X23 or
X34 or via both X23 and X34. The internal power supply to terminal X34 can be left
connected when using terminal X23.
WARNING! If the RMIO board is supplied from an external power source via
terminal X34, the loose end of the cable removed from the RMIO board terminal
must be secured mechanically to a location where it cannot come into contact with
electrical parts. If the screw terminal plug of the cable is removed, the wire ends
must be individually insulated.
Parameter settings
In Standard Control Program, set parameter 16.09 CTRL BOARD SUPPLY to
EXTERNAL 24V if the RMIO board is powered from an external supply.
Motor control and I/O board (RMIO)
78
External control connections (non-US)
External control cable connections to the RMIO board for the ACS800 Standard
Control Program (Factory Macro) are shown below. For external control connections
of other control macros and programs, see the appropriate Firmware Manual.
X20
Terminal block size: 1 VREF- Reference voltage -10 V DC, 1 kohm < RL
cables 0.3 to 3.3 mm2 (22 to 12 AWG) 2 AGND < 10 kohm
Tightening torque: X21
0.2 to 0.4 Nm (0.2 to 0.3 lbf ft) 1 VREF+ Reference voltage 10 V DC, 1 kohm < RL <
2 AGND 10 kohm
3 AI1+ Speed reference 0(2) ... 10 V, Rin >
4 AI1- 200 kohm
5 AI2+ By default, not in use. 0(4) ... 20 mA, Rin =
6 AI2- 100 ohm
7 AI3+ By default, not in use. 0(4) ... 20 mA, Rin =
8 AI3- 100 ohm
rpm 9 AO1+ Motor speed 0(4)...20 mA = 0...motor nom.
10 AO1- speed, RL < 700 ohm
A 11 AO2+ Output current 0(4)...20 mA = 0...motor
12 AO2- nom. current, RL < 700 ohm
X22
1 DI1 Stop/Start
1) Only
effective if par. 10.03 is set to 2 DI2 Forward/Reverse 1)
REQUEST by the user. 3 DI3 Not in use
4 DI4 Acceleration & deceleration select 2)
2)
0 = open, 1 = closed 5 DI5 Constant speed select 3)
DI4 Ramp times according to 6 DI6 Constant speed select 3)
0 parameters 22.02 and 22.03 7 +24VD +24 V DC max. 100 mA
1 parameters 22.04 and 22.05 8 +24VD
9 DGND1 Digital ground
3)
See par. group 12 CONSTANT SPEEDS. 10 DGND2 Digital ground
DI5 DI6 Operation 11 DIIL Start interlock (0 = stop) 4)
0 0 Set speed through AI1 X23
1 0 Constant speed 1 1 +24V Auxiliary voltage output and input, non-
0 1 Constant speed 2 2 GND isolated, 24 V DC 250 mA 5)
1 1 Constant speed 3 X25
1 RO1 Relay output 1: ready
4) 2 RO1
See parameter 21.09 START INTRL
FUNC. 3 RO1
5)
Total maximum current shared X26
between this output and optional 1 RO2 Relay output 2: running
modules installed on the board.
2 RO2
3 RO2
X27
1 RO3 Relay output 3: fault (-1)
Fault 2 RO3
3 RO3
Motor control and I/O board (RMIO)
79
External control connections (US)
External control cable connections to the RMIO board for the ACS800 Standard
Control Program (Factory Macro US version) are shown below. For external control
connections of other control macros and programs, see the appropriate Firmware
Manual.
X20
Terminal block size: 1 VREF- Reference voltage -10 V DC, 1 kohm < RL
2
cables 0.3 to 3.3 mm (22 to 12 AWG) 2 AGND < 10 kohm
Tightening torque: X21
0.2 to 0.4 Nm (0.2 to 0.3 lbf ft) 1 VREF+ Reference voltage 10 V DC, 1 kohm < RL <
2 AGND 10 kohm
3 AI1+ Speed reference 0(2) ... 10 V, Rin >
4 AI1- 200 kohm
5 AI2+ By default, not in use. 0(4) ... 20 mA, Rin =
6 AI2- 100 ohm
7 AI3+ By default, not in use. 0(4) ... 20 mA, Rin =
8 AI3- 100 ohm
rpm 9 AO1+ Motor speed 0(4)...20 mA = 0...motor nom.
10 AO1- speed, RL < 700 ohm
A 11 AO2+ Output current 0(4)...20 mA = 0...motor
12 AO2- nom. current, RL < 700 ohm
X22
1 DI1 Start ( )
1)
Only effective if par. 10.03 is set to 2 DI2 Stop ( )
REQUEST by the user. 3 DI3 Forward/Reverse 1)
4 DI4 Acceleration & deceleration select 2)
2)
0 = open, 1 = closed 5 DI5 Constant speed select 3)
DI4 Ramp times according to 6 DI6 Constant speed select 3)
0 parameters 22.02 and 22.03 7 +24VD +24 V DC max. 100 mA
1 parameters 22.04 and 22.05 8 +24VD
9 DGND1 Digital ground
3) See par. group 12 CONSTANT 10 DGND2 Digital ground
SPEEDS. 11 DIIL Start interlock (0 = stop) 4)
DI5 DI6 Operation X23
0 0 Set speed through AI1 1 +24V Auxiliary voltage output and input, non-
1 0 Constant speed 1
2 GND isolated, 24 V DC 250 mA 5)
0 1 Constant speed 2
X25
1 1 Constant speed 3
1 RO1 Relay output 1: ready
4) 2 RO1
See parameter 21.09 START INTRL
3 RO1
FUNC.
5) Total maximum current shared X26
between this output and optional 1 RO2 Relay output 2: running
modules installed on the board. 2 RO2
3 RO2
X27
1 RO3 Relay output 3: fault (-1)
Fault 2 RO3
3 RO3
Motor control and I/O board (RMIO)
80
RMIO board specifications
Analogue inputs
With Standard Control Program two programmable differential current inputs (0 mA /
4 mA ... 20 mA, Rin = 100 ohm) and one programmable differential voltage input (-
10 V / 0 V / 2 V ... +10 V, Rin > 200 kohm).
The analogue inputs are galvanically isolated as a group.
Insulation test voltage 500 V AC, 1 min
Max. common mode voltage ±15 V DC
between the channels
Common mode rejection ratio > 60 dB at 50 Hz
Resolution 0.025% (12 bit) for the -10 V ... +10 V input. 0.5% (11 bit) for the 0 ... +10 V and
0 ... 20 mA inputs.
Inaccuracy ±0.5% (Full Scale Range) at 25 °C (77 °F). Temperature coefficient: ±100 ppm/°C
(±56 ppm/°F), max.
Constant voltage output
Voltage +10 V DC, 0, -10 V DC ± 0.5% (Full Scale Range) at 25 °C (77 °F). Temperature
coefficient: ±100 ppm/°C (±56 ppm/°F) max.
Maximum load 10 mA
Applicable potentiometer 1 kohm to 10 kohm
Auxiliary power output
Voltage 24 V DC ± 10%, short-circuit proof
Maximum current 250 mA (without any optional modules inserted onto slots 1 and 2)
Analogue outputs
Two programmable current outputs: 0 (4) to 20 mA, RL < 700 ohm
Resolution 0.1% (10 bit)
Inaccuracy ±1% (Full Scale Range) at 25 °C (77 °F). Temperature coefficient: ±200 ppm/°C
(±111 ppm/°F) max.
Digital inputs
With Standard Control Program six programmable digital inputs (common ground:
24 V DC, -15% to +20%) and a start interlock input. Group isolated, can be divided in
two isolated groups (see Isolation and grounding diagram below).
Thermistor input: 5 mA, < 1.5 kohm “1” (normal temperature), > 4 kohm “0”
(high temperature), open circuit “0” (high temperature).
Internal supply for digital inputs (+24 V DC): short-circuit proof. An external 24 V DC
supply can be used instead of the internal supply.
Insulation test voltage 500 V AC, 1 min
Logical thresholds < 8 V DC “0”, > 12 V DC “1”
Input current DI1 to DI 5: 10 mA, DI6: 5 mA
Filtering time constant 1 ms
Motor control and I/O board (RMIO)
81
Relay outputs
Three programmable relay outputs
Switching capacity 8 A at 24 V DC or 250 V AC, 0.4 A at 120 V DC
Minimum continuous current 5 mA rms at 24 V DC
Maximum continuous current 2 A rms
Contact material Silver Cadmium Oxide (AgCdO)
Insulation test voltage 4 kV AC, 1 minute
DDCS fibre optic link
With optional communication adapter module RDCO. Protocol: DDCS (ABB
Distributed Drives Communication System)
24 V DC power input
Voltage 24 V DC ±10%
Typical current consumption 250 mA
(without optional modules)
Maximum current consumption 1200 mA (with optional modules inserted)
The terminals on the RMIO board as well as on the optional modules attachable to the board fulfil the Protective Extra
Low Voltage (PELV) requirements stated in EN 50178 provided that the external circuits connected to the terminals also
fulfil the requirements and the installation site is below 2000 m (6562 ft). Above 2000 m (6562 ft), see page 57.
Motor control and I/O board (RMIO)
82
Isolation and grounding diagram
(Test voltage: 500 V AC)
X20
1 VREF-
2 AGND
X21
1 VREF+
2 AGND
3 AI1+
4 AI1- Common mode
5 AI2+ voltage between
6 AI2- channels ±15 V
7 AI3+
8 AI3-
9 AO1+
10 AO1-
11 AO2+
12 AO2-
X22
1 DI1
2 DI2
3 DI3
4 DI4 Jumper J1 settings:
9 DGND1
5 DI5 All digital inputs share a
J1
6 DI6 common ground. This is the
7 +24VD default setting.
8 +24VD
11 DIIL
10 DGND2
X23 Grounds of input
1 +24 V or groups DI1…DI4 and
2 GND DI5/DI6/DIIL are
X25 separate (insulation
voltage 50 V).
1 RO1
2 RO1
3 RO1
X26
1 RO2
2 RO2
3 RO2
X27
1 RO3
2 RO3
3 RO3
(Test voltage:
4 kV AC)
Ground
Motor control and I/O board (RMIO)
83
Installation checklist
Checklist
Check the mechanical and electrical installation of the drive before start-up. Go
through the checklist below together with another person. Read the Safety
instructions on the first pages of this manual before you work on the unit.
Check
MECHANICAL INSTALLATION
The ambient operating conditions are allowed. (See Mechanical installation, Technical data:
IEC data or NEMA data, Ambient conditions.)
The unit is fixed properly into the cabinet. (See Planning the cabinet assembly and
Mechanical installation.)
The cooling air will flow freely.
The motor and the driven equipment are ready for start. (See Planning the electrical
installation: Motor selection and compatibility, Technical data: Motor connection.)
ELECTRICAL INSTALLATION (See Planning the electrical installation, Electrical installation.)
Drive does not include the EMC filter option (+E202, +E200) or the +E202 and +E200 EMC
filter capacitors are disconnected if the drive is connected to an IT (ungrounded) system.
The capacitors are reformed if stored over one year (refer to ACS600/800 Capacitor
Reforming Guide [3AFE64059629 (English)].
The drive is grounded properly.
The mains (input power) voltage matches the drive nominal input voltage.
The mains (input power) connections at U1, V1 and W1 and their tightening torques are OK.
Appropriate mains (input power) fuses and disconnector are installed.
The motor connections at U2, V2 and W2 and their tightening torques are OK.
The motor cable is routed away from other cables.
There are no power factor compensation capacitors in the motor cable.
The external control connections inside the drive are OK.
There are no tools, foreign objects or dust from drilling inside the drive.
Mains (input power) voltage cannot be applied to the output of the drive (with bypass
connection).
Motor connection box and other covers are in place.
Installation checklist
84
Check
Modules with prevention of unexpected start option only (AGPS board): The prevention of
unexpected start circuit is completed.
Installation checklist
85
Maintenance
What this chapter contains
This chapter contains preventive maintenance instructions.
Safety
WARNING! Read the Safety instructions on the first pages of this manual before
performing any maintenance on the equipment. Ignoring the safety instructions can
cause injury or death.
Maintenance intervals
If installed in an appropriate environment, the drive requires very little maintenance.
This table lists the routine maintenance intervals recommended by ABB.
Maintenance Interval Instruction
Capacitor reforming Every year when stored See Reforming.
Heatsink temperature check Depends on the dustiness of See Heatsink.
and cleaning the environment (every 6 to 12
months)
Change of additional cooling Every three years See Additional fan.
fan.
Cooling fan change Every six years See Fan.
Frame size R4 and up: Every ten years See Capacitors.
capacitor change
Heatsink
The heatsink fins pick up dust from the cooling air. The drive runs into
overtemperature warnings and faults if the heatsink is not clean. In a “normal”
environment (not dusty, not clean) the heatsink should be checked annually, in a
dusty environment more often.
Clean the heatsink as follows (when necessary):
1. Remove the cooling fan (see section Fan).
2. Blow clean compressed air (not humid) from bottom to top and simultaneously
use a vacuum cleaner at the air outlet to trap the dust. Note: If there is a risk of
the dust entering adjoining equipment, perform the cleaning in another room.
3. Replace the cooling fan.
Maintenance
86
Fan
The cooling fan lifespan of the drive is about 50 000 operating hours. The actual
lifespan depends on the drive usage and ambient temperature. See the appropriate
ACS800 Firmware Manual for an actual signal which indicates the hours of usage of
the fan. For resetting the running time signal after a fan replacement, please contact
ABB.
Fan failure can be predicted by the increasing noise from fan bearings and the
gradual rise in the heatsink temperature in spite of heatsink cleaning. If the drive is
operated in a critical part of a process, fan replacement is recommended once these
symptoms start appearing. Replacement fans are available from ABB. Do not use
other than ABB specified spare parts.
Fan replacement (R2, R3)
To remove the fan, release the retaining clips. Disconnect the cable. Install the new
fan in reverse order.
Bottom view
Maintenance
87
Fan replacement (R4)
1. Loosen the screws that fasten the fan mounting plate to the frame.
2. Push the fan mounting plate to the left and pull it out.
3. Disconnect the fan power cable.
4. Undo the screws that fasten the fan to the fan mounting plate.
5. Install the new fan in reverse order.
1 1 Bottom view
2
3
View from above fan
plate pulled out
4 4
4 4
Maintenance
88
Fan replacement (R5)
1. Undo the fastening screws of the swing-out frame.
2. Open the swing-out frame.
3. Disconnect the cable.
4. Undo the fastening screws of the fan.
5. Install the new fan in reverse order.
Bottom view
4 4 2
Maintenance
89
Fan replacement (R6)
To remove the fan, undo the fixing screws. Disconnect the cable. Install the new fan
in reverse order.
Bottom view
Additional fan
In ACS800-04/U4 (R2...R6) units there is an additional fan in all types except in
-0001-2, -0002-2, -0003-2, -0003-3, -0004-3, -0005-3, -0004-5, -0005-5 and
-0006-5.
Replacement (R2, R3)
To remove the fan, release the retaining clip (1). Disconnect the cable (2, detachable
terminal). Install the new fan in reverse order.
Air flow upwards
1
2
Rotation direction
View from above
Maintenance
90
Replacement (R4, R5)
The fan is located on the lower right-hand side of the unit (R4) or on the right-hand
side of the control panel (R5). Lift the fan out and disconnect the cable. Install the fan
in reverse order.
Replacement (R6)
To remove the fan, release the retaining clips by pulling the back edge (1) of the fan
upwards. Disconnect the cable (2, detachable terminal). Install the new fan in
reverse order.
Air flow upwards
Rotation direction
2 View from above
1
Capacitors
The drive intermediate circuit employs several electrolytic capacitors. Their lifespan
is from 45 000 to 90 000 hours depending on drive loading and ambient
temperature. Capacitor life can be prolonged by lowering the ambient temperature.
It is not possible to predict a capacitor failure. Capacitor failure is usually followed by
a mains fuse failure or a fault trip. Contact ABB if capacitor failure is suspected.
Replacements for frame size R4 and up are available from ABB. Do not use other
than ABB specified spare parts.
Reforming
Reform (re-age) spare part capacitors once a year according to ACS600/800
Capacitor Reforming Guide [3AFE64059629 (English)].
LEDs
This table describes LEDs of the drive.
Where LED When the LED is lit
RMIO board Red Drive in fault state
Green The power supply on the board is OK.
Maintenance
91
Technical data
What this chapter contains
This chapter contains the technical specifications of the drive, e.g. the ratings, sizes
and technical requirements, provisions for fulfilling the requirements for CE and
other markings and warranty policy.
IEC data
Ratings
The IEC ratings for the ACS800-04 with 50 Hz and 60 Hz supplies are given below.
The symbols are described below the table.
ACS800-04 size Nominal No-overload Light-overload Heavy-duty use Frame Air Heat
ratings use use size flow dissipation
Icont.max Imax Pcont.max I2N PN I2hd Phd
A kW
A A kW A kW m3/h W
Three-phase supply voltage 208 V, 220 V, 230 V or 240 V
-0001-2 5.1 6.5 1.1 4.7 0.75 3.4 0.55 R2 35 100
-0002-2 6.5 8.2 1.5 6.0 1.1 4.3 0.75 R2 35 100
-0003-2 8.5 10.8 1.5 7.7 1.5 5.7 1.1 R2 35 100
-0004-2 10.9 13.8 2.2 10.2 2.2 7.5 1.5 R2 35 120
-0005-2 13.9 17.6 3 12.7 3 9.3 2.2 R2 35 140
-0006-2 19 24 4 18 4 14 3 R3 69 160
-0009-2 25 32 5.5 24 5,5 19 4 R3 69 200
-0011-2 34 46 7.5 31 7.5 23 5.5 R3 69 250
-0016-2 44 62 11 42 11 32 7.5 R4 103 340
-0020-2 55 72 15 50 11 37 7.5 R4 103 440
-0025-2 72 86 18.5 69 18.5 49 11 R5 250 530
-0030-2 86 112 22 80 22 60 15 R5 250 610
-0040-2 103 138 30 94 22 69 18.5 R5 250 810
-0050-2 141 164 37 132 37 97 30 R6 405 1190
-0060-2 166 202 45 155 45 115 30 R6 405 1190
-0070-2 202 282 55 184 55 141 37 R6 405 1440
Technical data
92
ACS800-04 size Nominal No-overload Light-overload Heavy-duty use Frame Air Heat
ratings use use size flow dissipation
Icont.max Imax Pcont.max I2N PN I2hd Phd
A kW
A A kW A kW m3/h W
Three-phase supply voltage 380 V, 400 V or 415 V
-0003-3 5.1 6.5 1.5 4.7 1.5 3.4 1.1 R2 35 100
-0004-3 6.5 8.2 2.2 5.9 2.2 4.3 1.5 R2 35 120
-0005-3 8.5 10.8 3 7.7 3 5.7 2.2 R2 35 140
-0006-3 10.9 13.8 4 10.2 4 7.5 3 R2 35 160
-0009-3 13.9 17.6 5.5 12.7 5.5 9.3 4 R2 35 200
-0011-3 19 24 7.5 18 7.5 14 5.5 R3 69 250
-0016-3 25 32 11 24 11 19 7.5 R3 69 340
-0020-3 34 46 15 31 15 23 11 R3 69 440
-0023-3 40 46 22 39 18.5 28 15 R3 69 520
-0025-3 44 62 22 41 18.5 32 15 R4 103 530
-0030-3 55 72 30 50 22 37 18.5 R4 103 610
-0035-3 59 72 30 57 30 41 22 R4 103 660
-0040-3 72 86 37 69 30 49 22 R5 168 810
-0050-3 86 112 45 80 37 60 30 R5 168 990
-0060-3 103 138 55 100 55 69 37 R5 168 1190
-0075-3 145 170 75 141 75 100 45 R5 405 1440
-0070-3 141 164 75 132 55 97 45 R6 405 1440
-0100-3 166 202 90 155 75 115 55 R6 405 1940
-0120-3 202 282 110 184 90 141 75 R6 405 2310
-0135-3 225 326 110 220 110 163 90 R6 405 2810
-0165-3 260 326 132 254 132 215 110 R6 405 3260
-0205-3 290 351 160 285 160 234 132 R6 405 4200
Three-phase supply voltage 380 V, 400 V, 415 V, 440 V, 460 V, 480 V or 500 V
-0004-5 4.9 6.5 2.2 4.5 2.2 3.4 1.5 R2 35 120
-0005-5 6.2 8.2 3 5.6 3 4.2 2.2 R2 35 140
-0006-5 8.1 10.8 4 7.7 4 5.6 3 R2 35 160
-0009-5 10.5 13.8 5.5 10 5.5 7.5 4 R2 35 200
-0011-5 13.2 17.6 7.5 12 7.5 9.2 5.5 R2 35 250
-0016-5 19 24 11 18 11 13 7.5 R3 69 340
-0020-5 25 32 15 23 15 18 11 R3 69 440
-0025-5 34 46 18.5 31 18.5 23 15 R3 69 530
-0028-5 38 46 22 37 22 27 18.5 R3 69 590
-0030-5 42 62 22 39 22 32 18.5 R4 103 610
-0040-5 48 72 30 44 30 36 22 R4 103 810
-0045-5 56 72 37 54 37 39 22 R4 103 950
-0050-5 65 86 37 61 37 50 30 R5 168 990
-0060-5 79 112 45 75 45 60 37 R5 168 1190
-0070-5 96 138 55 88 55 69 45 R5 168 1440
-0105-5 145 170 90 141 90 100 55 R5 405 2150
-0100-5 124 164 75 115 75 88 55 R6 405 1940
-0120-5 157 202 90 145 90 113 75 R6 405 2310
-0140-5 180 282 110 163 110 141 90 R6 405 2810
-0165-5 225 326 132 220 132 163 110 R6 405 3260
-0205-5 260 326 160 254 160 215 132 R6 405 3800
-0255-5 290 351 200 285 200 234 160 R6 405 4500
Technical data
93
ACS800-04 size Nominal No-overload Light-overload Heavy-duty use Frame Air Heat
ratings use use size flow dissipation
Icont.max Imax Pcont.max I2N PN I2hd Phd
A kW
A A kW A kW m3/h W
Three-phase supply voltage 525 V, 550 V, 575 V, 600 V, 660 V or 690 V
-0011-7 13 14 11 11.5 7.5 8.5 5.5 R4 103 300
-0016-7 17 19 15 15 11 11 7.5 R4 103 340
-0020-7 22 28 18.5 20 15 15 11 R4 103 440
-0025-7 25 38 22 23 18.5 19 15 R4 103 530
-0030-7 33 44 30 30 22 22 18.5 R4 103 610
-0040-7 36 54 30 34 30 27 22 R4 103 690
-0050-7 51 68 45 46 37 34 30 R5 250 840
-0060-7 57 84 55 52 45 42 37 R5 250 1010
-0070-7 79 104 75 73 55 54 45 R6 405 1220
-0100-7 93 124 90 86 75 62 55 R6 405 1650
-0120-7 113 172 110 108 90 86 75 R6 405 1960
-0145-7 134 190 132 125 110 95 90 R6 405 2660
-0175-7 166 245 160 155 132 131 110 R6 405 3470
-0205-7 190 245 160 180 160 147 132 R6 405 4180
PDM code: 00096931-J
Symbols
Nominal ratings
Icont.max continuous rms output current. No overload capability at 40 °C.
Imax maximum output current. Available for 10 s at start, otherwise as long as allowed by drive
temperature.
Typical ratings:
No-overload use
Pcont.max typical motor power. The power ratings apply to most IEC 34 motors at the nominal voltage,
230 V, 400 V, 500 V or 690 V.
Light-overload use (10% overload capability)
I2N continuous rms current. 10% overload is allowed for one minute every 5 minutes.
PN typical motor power. The power ratings apply to most IEC 34 motors at the nominal voltage,
230 V, 400 V, 500 V or 690 V.
Heavy-duty use (50% overload capability)
I2hd continuous rms current. 50% overload is allowed for one minute every 5 minutes.
Phd typical motor power. The power ratings apply to most IEC 34 motors at the nominal voltage,
230 V, 400 V, 500 V or 690 V.
Sizing
The current ratings are the same regardless of the supply voltage within one voltage range. To achieve
the rated motor power given in the table, the rated current of the drive must be higher than or equal to
the rated motor current.
Note 1: The maximum allowed motor shaft power is limited to 1.5 · Phd, 1.1 · PN or Pcont.max (whichever
value is greatest). If the limit is exceeded, motor torque and current are automatically restricted. The
function protects the input bridge of the drive against overload. If the condition exists for 5 minutes, the
limit is set to Pcont.max.
Note 2: The ratings apply in ambient temperature of 40°C (104°F). In lower temperatures the ratings
are higher (except Imax).
Note 3: Use the DriveSize PC tool for a more accurate dimensioning if the ambient temperature is
below 40°C (104°F) or the drive is loaded cyclically.
Technical data
94
Derating
The load capacity (current and power) decreases if the installation site altitude exceeds 1000 metres
(3300 ft), or if the ambient temperature exceeds 40 °C (104 °F).
Temperature derating
In the temperature range +40 °C (+104 °F) to +50 °C (+122 °F) the rated output current is decreased by
1% for every additional 1 °C (1.8 °F). The output current is calculated by multiplying the current given in
the rating table by the derating factor.
Example If the ambient temperature is 50°C (+122 °F), the derating factor is 100% - 1 % · 10 °C =
90% or 0.90. The output current is then 0.90 · I or 0.90 · I . °C
2N 2hd
Altitude derating
In altitudes from 1000 to 4000 m (3300 to 13123 ft) above sea level, the derating is 1% for every 100 m
(328 ft). For a more accurate derating, use the DriveSize PC tool. See Installation sites above 2000
metres (6562 feet) on page 57.
Cooling characteristics
ACS800-04 Minimum effective area of air inlet Minimum effective area of air outlet
frame size cm2 cm2
IP22 cabinet IP54 cabinet IP22 cabinet IP54 cabinet
R2 125 250 200 400
R3 250 500 400 800
R4 375 750 600 1200
R5 500 1000 800 1600
R6 1000 2000 1600 3200
Cooling requirements for flange mounting
ACS800-04 Air flow: drive front side Air flow: heat sink side
frame size m3/h m3/h
R2 18 35
R3 30 69
R4 30 103
R5 30 168
R6 30 405
Technical data
95
Fuses
gG and aR fuses for protection against short-circuit in the input power cable or drive
are listed below. Either fuse type may be used if it operates rapidly enough.
Frame sizes R2 to R4
Check from the fuse time-current curve that the operating time of the fuse is
below 0.5 seconds. The operating time depends on the supply network impedance
and the cross-sectional area and length of the supply cable. The short-circuit current
can be calculated as shown below in section Frame sizes R5 and R6.
Note 1: See also Planning the electrical installation: Thermal overload and short-circuit protection. For
UL recognized fuses, see NEMA data on page 103.
Note 2: In multicable installations, install only one fuse per phase (not one fuse per conductor).
Note 3: Larger fuses than the recommended ones must not be used.
Note 4: Fuses from other manufacturers can be used if they meet the ratings and the melting curve of
the fuse does not exceed the melting curve of the fuse mentioned in the table.
ACS800-04 Input Fuse
size current A A2s V Manufacturer Type IEC size
Three-phase supply voltage 208 V, 220 V, 230 V or 240 V
-0001-2 4.4 10 483 500 ABB Control OFAF000H10 000
-0002-2 5.2 10 483 500 ABB Control OFAF000H10 000
-0003-2 6.7 10 483 500 ABB Control OFAF000H10 000
-0004-2 9.3 16 993 500 ABB Control OFAF000H16 000
-0005-2 12 16 993 500 ABB Control OFAF000H16 000
-0006-2 16 20 1620 500 ABB Control OFAF000H20 000
-0009-2 23 25 3100 500 ABB Control OFAF000H25 000
-0011-2 31 40 9140 500 ABB Control OFAF000H40 000
-0016-2 40 50 15400 500 ABB Control OFAF000H50 000
-0020-2 51 63 21300 500 ABB Control OFAF000H63 000
Three-phase supply voltage 380 V, 400 V or 415 V
-0003-3 4.7 10 483 500 ABB Control OFAF000H10 000
-0004-3 6.0 10 483 500 ABB Control OFAF000H10 000
-0005-3 7.9 10 483 500 ABB Control OFAF000H10 000
-0006-3 10 16 993 500 ABB Control OFAF000H16 000
-0009-3 13 16 993 500 ABB Control OFAF000H16 000
-0011-3 17 20 1620 500 ABB Control OFAF000H20 000
-0016-3 23 25 3100 500 ABB Control OFAF000H25 000
-0020-3 32 40 9140 500 ABB Control OFAF000H40 000
-0023-3 38 50 15400 500 ABB Control OFAF000H50 000
-0025-3 42 50 15400 500 ABB Control OFAF000H50 000
-0030-3 53 63 21300 500 ABB Control OFAF000H63 000
-0035-3 56 63 21300 500 ABB Control OFAF000H63 000
Technical data
96
ACS800-04 Input Fuse
size current A A2s V Manufacturer Type IEC size
Three-phase supply voltage 380 V, 400 V, 415 V, 440 V, 460 V, 480 V or 500 V
-0004-5 4.7 10 483 500 ABB Control OFAF000H10 000
-0005-5 5.9 10 483 500 ABB Control OFAF000H10 000
-0006-5 7.7 10 483 500 ABB Control OFAF000H10 000
-0009-5 10.0 16 993 500 ABB Control OFAF000H16 000
-0011-5 12.5 16 993 500 ABB Control OFAF000H16 000
-0016-5 17 20 1620 500 ABB Control OFAF000H20 000
-0020-5 23 25 3100 500 ABB Control OFAF000H25 000
-0025-5 31 40 9140 500 ABB Control OFAF000H40 000
-0028-5 36 50 15400 500 ABB Control OFAF000H50 000
-0030-5 41 50 15400 500 ABB Control OFAF000H50 000
-0040-5 47 63 21300 500 ABB Control OFAF000H63 000
-0045-5 54 63 21300 500 ABB Control OFAF000H63 000
Three-phase supply voltage 525 V, 550 V, 575 V, 600 V, 660 V or 690 V
-0011-7 12 16 1100 690 ABB Control OFAA000GG16 000
-0016-7 15 20 2430 690 ABB Control OFAA000GG20 000
-0020-7 21 25 4000 690 ABB Control OFAA000GG25 000
-0025-7 24 32 7000 690 ABB Control OFAA000GG32 000
-0030-7 33 35 11400 690 ABB Control OFAA000GG35 000
-0040-7 35 50 22800 690 ABB Control OFAA000GG50 000
PDM code:00096931-J
Frame sizes R5 and R6
Choose between gG and aR fuses according to the table under Quick guide for
selecting between gG and aR fuses on page 100, or verify the operating time by
checking that the short-circuit current of the installation is at least the value
given in the fuse table. The short-circuit current can be calculated as follows:
U
Ik2-ph =
2· Rc2 + (Zk + Xc)2
where
Ik2-ph = short-circuit current in symmetrical two-phase short-circuit (A)
U = network line-to-line voltage (V)
Rc = cable resistance (ohm)
Zk = = zk · UN2/SN = transformer impedance (ohm)
zk = transformer impedance (%)
UN = transformer rated voltage (V)
SN = nominal apparent power of the transformer (kVA)
Xc = cable reactance (ohm).
Technical data
97
Calculation example
Drive:
• ACS800-04-0075-3
• supply voltage U = 410 V
Transformer:
• rated power SN = 600 kVA
• rated voltage UN = 430 V
• transformer impedance zk = 7.2%.
Supply cable:
• length = 170 m
• resistance/length = 0.398 ohm/km
• reactance/length = 0.082 ohm/km.
UN2 (430 V)2
Zk = zk · = 0.072 · = 22.19 mohm
SN 600 kVA
ohm
Rc = 170 m · 0.398 km = 67.66 mohm
ohm
Xc = 170 m · 0.082 = 13.94 mohm
km
410 V
Ik2-ph = = 2.7 kA
2· (67.66 mohm)2 + (22.19 mohm + 13.94 mohm)2
The calculated short-circuit current 2.7 kA is higher than the minimum short-circuit current of the drive
gG fuse type OFAF00H160 (2400 A). -> The 500 V gG fuse (ABB Control OFAF00H160) can be used.
Technical data
98
gG fuses
ACS800-04 size Input Min. short- Fuse
current circuit
current 1)
A A A2s * V Manufacturer Type IEC size
Three-phase supply voltage 208 V, 220 V, 230 V or 240 V
-0025-2 67 1050 80 34500 500 ABB Control OFAF000H80 000
-0030-2 81 1480 100 63600 500 ABB Control OFAF000H100 000
-0040-2 101 1940 125 103000 500 ABB Control OFAF00H125 00
-0050-2 138 2400 160 200000 500 ABB Control OFAF00H160 00
-0060-2 163 2850 200 350000 500 ABB Control OFAF1H200 1
-0070-2 202 3300 224 420000 500 ABB Control OFAF1H224 1
Three-phase supply voltage 380 V, 400 V or 415 V
-0040-3 69 1050 80 34500 500 ABB Control OFAF000H80 000
-0050-3 83 1480 100 63600 500 ABB Control OFAF000H100 000
-0060-3 100 1940 125 103000 500 ABB Control OFAF00H125 00
-0075-3 142 2400 160 200000 500 ABB Control OFAF00H160 00
-0070-3 138 2400 160 200000 500 ABB Control OFAF00H160 00
-0100-3 163 2850 200 350000 500 ABB Control OFAF1H200 1
-0120-3 198 3300 224 420000 500 ABB Control OFAF1H224 1
-0135-3 221 3820 250 550000 500 ABB Control OFAF1H250 1
-0165-3 254 4510 315 1100000 500 ABB Control OFAF2H315 2
-0205-3 286 4510 315 1100000 500 ABB Control OFAF2H315 2
Three-phase supply voltage 380 V, 400 V, 415 V, 440 V, 460 V, 480 V or 500 V
-0050-5 64 1050 80 34500 500 ABB Control OFAF000H80 000
-0060-5 78 1480 100 63600 500 ABB Control OFAF000H100 000
-0070-5 95 1940 125 103000 500 ABB Control OFAF00H125 00
-0105-5 142 2400 160 200000 500 ABB Control OFAF00H160 00
-0100-5 121 2400 160 200000 500 ABB Control OFAF00H160 00
-0120-5 155 2850 200 350000 500 ABB Control OFAF1H200 1
-0140-5 180 2850 200 350000 500 ABB Control OFAF1H200 1
-0165-5 222 3820 250 550000 500 ABB Control OFAF1H250 1
-0205-5 256 4510 315 1100000 500 ABB Control OFAF2H315 2
-0255-5 286 4510 315 1100000 500 ABB Control OFAF2H315 2
Three-phase supply voltage 525 V, 550 V, 575 V, 600 V, 660 V or 690 V
-0050-7 52 740 63 28600 690 ABB Control OFAA0GG63 0
-0060-7 58 740 63 28600 690 ABB Control OFAA0GG63 0
-0070-7 79 1050 80 52200 690 ABB Control OFAA0GG80 0
-0100-7 91 1480 100 93000 690 ABB Control OFAA1GG100 1
-0120-7 112 1940 125 126000 690 ABB Control OFAA1GG125 1
-0145-7 131 2400 160 220000 690 ABB Control OFAA1GG160 1
-0175-7 162 2850 200 350000 690 ABB Control OFAA1GG200 1
-0205-7 186 3820 250 700000 690 ABB Control OFAA2GG250 2
PDM code:00096931-J, 00556489
* maximum total I2t value for 550 V or 690 V
1)
minimum short-circuit current of the installation
Note 1: See also Planning the electrical installation: Thermal overload and short-circuit protection. For
UL recognized fuses, see NEMA data on page 103.
Note 2: In multicable installations, install only one fuse per phase (not one fuse per conductor).
Note 3: Larger fuses than the recommended ones must not be used.
Note 4: Fuses from other manufacturers can be used if they meet the ratings and the melting curve of
the fuse does not exceed the melting curve of the fuse mentioned in the table.
Technical data
99
Ultrarapid (aR) fuses
ACS800-04 size Input Min. Fuse
current short-
circuit
current 1)
A A A2s V Manufacturer Type IEC size
Three-phase supply voltage 208 V, 220 V, 230 V or 240 V
-0025-2 67 400 100 4650 690 Bussmann 170M1567 DIN000
-0030-2 81 520 125 8500 690 Bussmann 170M1568 DIN000
-0040-2 101 695 160 8500 690 Bussmann 170M1569 DIN000
-0050-2 138 1630 315 80500 690 Bussmann 170M1572 DIN000
-0060-2 163 1280 315 46500 690 Bussmann 170M3817 DIN1*
-0070-2 202 1810 400 105000 690 Bussmann 170M3819 DIN1*
Three-phase supply voltage 380 V, 400 V or 415 V
-0040-3 69 400 100 4650 690 Bussmann 170M1567 DIN000
-0050-3 83 520 125 8500 690 Bussmann 170M1568 DIN000
-0060-3 100 695 160 8500 690 Bussmann 170M1569 DIN000
-0075-3 142 1630 315 80500 690 Bussmann 170M1572 DIN000
-0070-3 138 1630 315 80500 690 Bussmann 170M1572 DIN000
-0100-3 163 1280 315 46500 690 Bussmann 170M3817 DIN1*
-0120-3 198 1810 400 105000 690 Bussmann 170M3819 DIN1*
-0135-3 221 2210 500 145000 690 Bussmann 170M5810 DIN2*
-0165-3 254 2620 550 190000 690 Bussmann 170M5811 DIN2*
-0205-3 286 2620 550 190000 690 Bussmann 170M5811 DIN2*
Three-phase supply voltage 380 V, 400 V, 415 V, 440 V, 460 V, 480 V or 500 V
-0050-5 64 400 100 4650 690 Bussmann 170M1567 DIN000
-0060-5 78 520 125 8500 690 Bussmann 170M1568 DIN000
-0070-5 95 520 125 8500 690 Bussmann 170M1568 DIN000
-0105-5 142 1630 315 80500 690 Bussmann 170M1572 DIN000
-0100-5 121 1630 315 80500 690 Bussmann 170M1572 DIN000
-0120-5 155 1280 315 46500 690 Bussmann 170M3817 DIN1*
-0140-5 180 1810 400 105000 690 Bussmann 170M3819 DIN1*
-0165-5 222 2210 500 145000 690 Bussmann 170M5810 DIN2*
-0205-5 256 2620 550 190000 690 Bussmann 170M5811 DIN2*
-0255-5 286 2620 550 190000 690 Bussmann 170M5811 DIN2*
Three-phase supply voltage 525 V, 550 V, 575 V, 600 V, 660 V or 690 V
-0050-7 52 400 100 4650 690 Bussmann 170M1567 000
-0060-7 58 400 100 4650 690 Bussmann 170M1567 000
-0070-7 79 520 125 8500 690 Bussmann 170M1568 000
-0100-7 91 695 160 16000 690 Bussmann 170M1569 000
-0120-7 112 750 200 15000 690 Bussmann 170M3815 1*
-0145-7 131 1520 350 68500 690 Bussmann 170M3818 DIN1*
-0175-7 162 1520 350 68500 690 Bussmann 170M3818 DIN1*
-0205-7 186 1610 400 74000 690 Bussmann 170M5808 DIN2*
PDM code: 00096931-J, 00556489
1)
minimum short-circuit current of the installation
Note 1: See also Planning the electrical installation: Thermal overload and short-circuit protection. For
UL recognized fuses, see NEMA data on page 103.
Note 2: In multicable installations, install only one fuse per phase (not one fuse per conductor).
Note 3: Larger fuses than the recommended ones must not be used.
Note 4: Fuses from other manufacturers can be used if they meet the ratings and the melting curve of
the fuse does not exceed the melting curve of the fuse mentioned in the table.
Technical data
100
Quick guide for selecting between gG and aR fuses
The table below is a short cut in selecting between gG and aR fuses. The
combinations (cable size, cable length, transformer size and fuse type) in the table
fulfil the minimum requirements for the proper operation of the fuse.
ACS800-01 size Cable type Supply transformer minimum apparent power SN (kVA)
Copper Aluminium Maximum cable length with gG fuses Maximum cable length with aR fuses
10 m 50 m 100 m 10 m 100 m 200 m
Three-phase supply voltage 208 V, 220 V, 230 V or 240 V
-0025-2 3×25 Cu 3×35 Al 33 39 28 28
-0030-2 3×35 Cu 3×50 Al 46 56 34 34
-0040-2 3×50 Cu 3×70 Al 60 73 42 42
-0050-2 3×70 Cu 3×95 Al 75 89 58 71
-0060-2 3×95 Cu 3×120 Al 89 110 68 71
-0070-2 3×120 Cu 3×185 Al 110 120 84 84
Three-phase supply voltage 380 V, 400 V or 415 V
-0040-3 3×25 Cu 3×35 Al 56 59 72 50 50 50
-0050-3 3×35 Cu 3×50 Al 79 85 110 60 60 60
-0060-3 3×50 Cu 3×70 Al 110 120 140 72 72 72
-0075-3 3×70 Cu 3×95 Al 130 140 160 99 99 140
-0070-3 3×70 Cu 3×95 Al 130 140 170 100 100 140
-0100-3 3×95 Cu 3×120 Al 160 170 200 120 120 140
-0120-3 3×120 Cu 3×185 Al 180 190 220 150 150 150
-0135-3 3×150 Cu 3×240 Al 210 220 260 160 160 160
-0165-3 3×185 Cu 3×240 Al 250 270 320 190 190 200
-0205-3 3×240 Cu 2×(3×95) Al 232 257 310 134 153 196
Three-phase supply voltage 380 V, 400 V, 415 V, 440 V, 460 V, 480 V or 500 V
-0050-5 3×25 Cu 3×35 Al 67 70 79 56 56 56
-0060-5 3×25 Cu 3×50 Al 95 110 130 68 68 68
-0070-5 3×35 Cu 3×70 Al 130 140 160 83 83 83
-0105-5 3×70 Cu 3×95 Al 160 170 190 130 130 150
-0100-5 3×70 Cu 3×95 Al 160 170 190 110 120 150
-0120-5 3×95 Cu 3×120 Al 190 200 220 140 140 150
-0140-5 3×95 Cu 3×150 Al 190 200 220 160 160 160
-0165-5 3×150 Cu 3×240 Al 250 260 290 200 200 200
-0205-5 3×185 Cu 3×240 Al 290 320 360 230 230 230
-0255-5 3×240 Cu 2×(3×95) Al 289 312 355 167 185 218
Three-phase supply voltage 525 V, 550 V, 575 V, 600 V, 660 V or 690 V
-0050-7 3×16 Cu 3×25 Al 65 67 70 63 63 63
-0060-7 3×16 Cu 3×25 Al 70 70 70 70 70 70
-0070-7 3×25 Cu 3×50 Al 95 95 99 95 95 95
-0100-7 3×35 Cu 3×50 Al 130 140 150 110 110 110
-0120-7 3×50 Cu 3×70 Al 180 180 190 140 140 140
-0145-7 3×70 Cu 3×95 Al 220 220 240 160 160 160
-0175-7 3×95 Cu 3×120 Al 260 260 280 200 200 200
-0205-7 3×95 Cu 3×150 Al 340 360 390 230 230 230
PDM code: 00556489 A
Note 1: The supply transformer minimum power in kVA is calculated with a zk value of 6% and
frequency 50 Hz.
Note 2: The table is not intended for transformer selection - that must be done separately.
Technical data
101
The following parameters can effect on the correct operation of the protection:
• cable length, i.e. the longer the cable the weaker the fuse protection, as the long cable limits the
fault current
• cable size, i.e. the smaller the cable the weaker the fuse protection, as the small cable size limits the
fault current
• transformer size, i.e the smaller the transformer the weaker the fuse protection, as the small
transformer limits the fault current
• transformer impedance, i.e. the higher the zk the weaker the fuse protection as high impedance
limits the fault current.
The protection can be improved by installing a bigger supply transformer and/or bigger cables, and in
most cases by selecting aR fuses instead of gG fuses. Selection of smaller fuses improves the
protection, but may also affect the fuse life time and lead to unnecessary operation of the fuses.
In case of any uncertainty regarding the drive protection, please contact your local ABB.
Cable types
The table below gives copper and aluminium cable types for different load currents.
Cable sizing is based on max. 9 cables laid on a cable ladder side by side, ambient
temperature 30 °C, PVC insulation, surface temperature 70 °C (EN 60204-1 and
IEC 60364-5-52/2001). For other conditions, size the cables according to local
safety regulations, appropriate input voltage and the load current of the drive.
Copper cables with concentric Aluminium cables with concentric
copper shield copper shield
Max. load current Cable type Max. load current Cable type
A mm2 A mm2
13 3×1.5 61 3×25
18 3×2.5 69 3×35
24 3×4 83 3×50
30 3×6 107 3×70
42 3×10 130 3×95
56 3×16 151 3×120
71 3×25 174 3×150
88 3×35 199 3×185
107 3×50 235 3×240
137 3×70 274 3 × (3×50)
167 3×95 260 2 × (3×95)
193 3×120
223 3×150
255 3×185
3BFA 01051905 C
Technical data
102
Cable entries
Brake resistor, mains and motor cable terminal sizes (per phase) and tightening
torques are given below.
Frame U1, V1, W1, U2, V2, W2, R+, R- Earthing PE
size Maximum wire size Tightening torque Maximum wire size Tightening torque
mm2 Nm mm2 Nm
R2 up to 16 * 1.2...1.5 up to 10 1.5
R3 up to 16 * 1.2...1.5 up to 10 1.5
R4 up to 25 2…4 up to 16 3.0
R5 6...70 15 6...70 15
R6 95...185 ** 20...40 95 8
* 16 mm2 rigid solid cable, 10 mm2 flexible stranded cable
** with cable lugs 16...70 mm2, tightening torque 20...40 Nm. Cable lugs are not included in the delivery.
See page 64.
Dimensions, weights and noise
Frame size Height Width Depth* Weight Noise
mm mm mm kg dB
R2 370 165 193...226 8 62
R3 420 173 231.5...265 13 62
R4 490 240 252.2...271.5 24 62
R5 602 265 275.5 32 65
R6 700 300 399 64 65
* Depth depends on the options included in the drive.
Technical data
103
NEMA data
Ratings
The NEMA ratings for the ACS800-U4 with 60 Hz supplies are given below. The
symbols are described below the table. For sizing, derating and 50 Hz supplies, see
section IEC data.
ACS800-U4 size Imax Normal use Heavy-duty use Frame Air flow Heat
size dissipation
I2N PN I2hd Phd
A A HP A HP ft3/min BTU/Hr
Three-phase supply voltage 208 V, 220 V, 230 V or 240 V
-0002-2 8.2 6.6 1.5 4.6 1 R2 21 350
-0003-2 10.8 8.1 2 6.6 1.5 R2 21 350
-0004-2 13.8 11 3 7.5 2 R2 21 410
-0006-2 24 21 5 13 3 R3 41 550
-0009-2 32 27 7.5 17 5 R3 41 680
-0011-2 46 34 10 25 7.5 R3 41 850
-0016-2 62 42 15 31 10 R4 61 1150
-0020-2 72 54 20 * 42 15 ** R4 61 1490
-0025-2 86 69 25 54 20 ** R5 147 1790
-0030-2 112 80 30 68 25 ** R5 147 2090
-0040-2 138 104 40 * 80 30 ** R5 147 2770
-0050-2 164 132 50 104 40 R6 238 3370
-0060-2 202 157 60 130 50 ** R6 238 4050
-0070-2 282 192 75 154 60 ** R6 238 4910
Three-phase supply voltage 380 V, 400 V, 415 V, 440 V, 460 V or 480 V
-0004-5 6.5 4.9 3 3.4 2 R2 21 410
-0005-5 8.2 6.2 3 4.2 2 R2 21 480
-0006-5 10.8 8.1 5 5.6 3 R2 21 550
-0009-5 13.8 11 7.5 8.1 5 R2 21 690
-0011-5 17.6 14 10 11 7.5 R2 21 860
-0016-5 24 21 15 15 10 R3 41 1150
-0020-5 32 27 20 21 15 R3 41 1490
-0025-5 46 34 25 27 20 R3 41 1790
-0030-5 62 42 30 34 25 R4 61 2090
-0045-5 72 54 40 39 30 R4 61 2770
-0050-5 86 65 50 52 40 R5 147 3370
-0060-5 112 79 60 65 50 R5 147 4050
-0070-5 138 96 75 77 60 R5 147 4910
-0105-5 170 141 100 100 75 R5 238 7340
-0100-5 164 124 100 96 75 R6 238 6610
-0120-5 202 157 125 124 100 R6 238 7890
-0140-5 282 180 150 156 125 R6 238 9600
-0205-5 326 254 200 215 150 R6 238 12980
Technical data
104
ACS800-U4 size Imax Normal use Heavy-duty use Frame Air flow Heat
size dissipation
I2N PN I2hd Phd
A A HP A HP ft3/min BTU/Hr
Three-phase supply voltage 525 V, 575 V or 600 V
-0011-7 14 11.5 10 8.5 7.5 R4 61 1050
-0016-7 19 15 10 11 10 R4 61 1200
-0020-7 28 20 15/20*** 15 15** R4 61 1550
-0025-7 38 23 20 20 20** R4 61 1850
-0030-7 44 30 25/30*** 25 25** R4 61 2100
-0040-7 54 34 30 30 30** R4 61 2400
-0050-7 68 46 40 40 40** R5 147 2900
-0060-7 84 52 50 42 40 R5 147 3450
-0070-7 104 73 60 54 50 R6 238 4200
-0100-7 124 86 75 62 60 R6 238 5650
-0120-7 172 108 100 86 75 R6 238 6700
-0145-7 190 125 125 99 100 R6 238 9100
-0175-7 245 155 150 131 125 R6 238 11900
-0205-7 245 192 200 147 150 R6 238 14300
PDM code: 00096931-J
*
Overload may be limited to 5% at high speeds (> 90% speed) by the internal power limit of the drive.
The limitation also depends on motor characteristics and network voltage.
**
Overload may be limited to 40% at high speeds (> 90% speed) by the internal power limit of the
drive. The limitation also depends on motor characteristics and network voltage.
*** Higher rating is available with special 4-pole high-efficiency NEMA motor.
Symbols
Nominal ratings
Imax maximum output current. Available for 10 s at start, otherwise as long as allowed by drive
temperature.
Normal use (10% overload capability)
I2N continuous rms current. 10% overload is typically allowed for one minute every 5 minutes.
PN typical motor power. The power ratings apply to most 4-pole NEMA rated motors (230 V,
460 V or 575 V).
Heavy-duty use (50% overload capability)
I2hd continuous rms current. 50% overload is typically allowed for one minute every 5 minutes.
Phd typical motor power. The power ratings apply to most 4-pole NEMA rated motors (230 V,
460 V or 575 V).
Note 1: The ratings apply in ambient temperature of 40°C (104°F). In lower temperatures the ratings
are higher (except Imax).
Sizing
See page 93.
Derating
See page 94.
Technical data
105
Fuses
UL class T fuses for branch circuit protection are listed below. Fast acting class T or
faster fuses are recommended in the USA.
Check from the fuse time-current curve that the operating time of the fuse is
below 0.5 seconds for units of frame sizes R2 to R4 and 0.1 seconds for units
of frame sizes R5 and R6. The operating time depends on the supply network
impedance and the cross-sectional area and length of the supply cable. The short-
circuit current can be calculated as shown in section Frame sizes R5 and R6 on
page 96.
Note 1: See also Planning the electrical installation: Thermal overload and short-circuit protection.
Note 2: In multicable installations, install only one fuse per phase (not one fuse per conductor).
Note 3: Larger fuses than the recommended ones must not be used.
Note 4: Fuses from other manufacturers can be used if they meet the ratings and the melting curve of
the fuse does not exceed the melting curve of the fuse mentioned in the table.
ACS800-U4 Frame size Input Fuse
type current
A A V Manufacturer Type UL class
Three-phase supply voltage 208 V, 220 V, 230 V or 240 V
-0002-2 R2 5.2 10 600 Bussmann JJS-10 T
-0003-2 R2 6.5 10 600 Bussmann JJS-10 T
-0004-2 R2 9.2 15 600 Bussmann JJS-15 T
-0006-2 R3 18 25 600 Bussmann JJS-25 T
-0009-2 R3 24 30 600 Bussmann JJS-30 T
-0011-2 R3 31 40 600 Bussmann JJS-40 T
-0016-2 R4 38 50 600 Bussmann JJS-50 T
-0020-2 R4 49 70 600 Bussmann JJS-70 T
-0025-2 R5 64 90 600 Bussmann JJS-90 T
-0030-2 R5 75 100 600 Bussmann JJS-100 T
-0040-2 R5 102 125 600 Bussmann JJS-125 T
-0050-2 R6 126 175 600 Bussmann JJS-175 T
-0060-2 R6 153 200 600 Bussmann JJS-200 T
-0070-2 R6 190 250 600 Bussmann JJS-250 T
Three-phase supply voltage 380 V, 400 V, 415 V, 440 V, 460 V or 480 V
-0004-5 R2 4.1 10 600 Bussmann JJS-10 T
-0005-5 R2 5.4 10 600 Bussmann JJS-10 T
-0006-5 R2 6.9 10 600 Bussmann JJS-10 T
-0009-5 R2 9.8 15 600 Bussmann JJS-15 T
-0011-5 R2 13 20 600 Bussmann JJS-20 T
-0016-5 R3 18 25 600 Bussmann JJS-25 T
-0020-5 R3 24 35 600 Bussmann JJS-35 T
-0025-5 R3 31 40 600 Bussmann JJS-40 T
-0030-5 R4 40 50 600 Bussmann JJS-50 T
-0045-5 R4 54 70 600 Bussmann JJS-70 T
-0050-5 R5 63 80 600 Bussmann JJS-80 T
-0060-5 R5 77 100 600 Bussmann JJS-100 T
-0070-5 R5 94 125 600 Bussmann JJS-125 T
-0105-5 R5 138 150 600 Bussmann JJS-150 T
-0100-5 R6 121 150 600 Bussmann JJS-150 T
-0120-5 R6 155 200 600 Bussmann JJS-200 T
-0140-5 R6 179 225 600 Bussmann JJS-225 T
-0205-5 R6 243 350 600 Bussmann JJS-350 T
Technical data
106
ACS800-U4 Frame size Input Fuse
type current
A A V Manufacturer Type UL class
Three-phase supply voltage 525 V, 575 V, 600 V
-0011-7 R4 10 20 600 Bussmann JJS-20 T
-0016-7 R4 13 20 600 Bussmann JJS-20 T
-0020-7 R4 19 30 600 Bussmann JJS-30 T
-0025-7 R4 21 30 600 Bussmann JJS-30 T
-0030-7 R4 29 45 600 Bussmann JJS-45 T
-0040-7 R4 32 45 600 Bussmann JJS-45 T
-0050-7 R5 45 70 600 Bussmann JJS-70 T
-0060-7 R5 51 80 600 Bussmann JJS-80 T
-0070-7 R6 70 100 600 Bussmann JJS-100 T
-0100-7 R6 82 125 600 Bussmann JJS-125 T
-0120-7 R6 103 150 600 Bussmann JJS-150 T
-0145-7 R6 121 200 600 Bussmann JJS-200 T
-0175-7 R6 150 200 600 Bussmann JJS-200 T
-0205-7 R6 188 250 600 Bussmann JJS-250 T
PDM code: 00096931-J
Cable types
Cable sizing is based on NEC Table 310-16 for copper wires, 75 °C (167 °F) wire insulation at 40 °C
(104 °F) ambient temperature. Not more than three current-carrying conductors in raceway or cable or
earth (directly buried). For other conditions, dimension the cables according to local safety regulations,
appropriate input voltage and the load current of the drive.
Copper cables with concentric copper shield
Max. load current Cable type
A
AWG/kcmil
18 14
22 12
31 10
44 8
57 6
75 4
88 3
101 2
114 1
132 1/0
154 2/0
176 3/0
202 4/0
224 250 MCM or 2 x 1
251 300 MCM or 2 x 1/0
PDM code: 00096931
Technical data
107
Cable entries
Brake resistor, input and motor cable (per phase) terminal sizes and tightening
torques are given below.
Frame U1, V1, W1, U2, V2, W2, R+, R- Earthing PE
size Maximum wire size Tightening torque Maximum wire size Tightening torque
AWG lbf ft AWG lbf ft
R2 up to 6 * 0.9…1.1 up to 8 1.1
R3 up to 6 * 0.9...1.1 up to 8 1.1
R4 up to 4 1.5…3.0 up to 5 2.2
R5 10...2/0 11.1 10...2/0 11.1
R6 3/0...2×4/0 ** 14.8...29.5 4/0 5.9
* 6 AWG rigid solid cable, 8 AWG flexible stranded cable
** with cable lugs 6...2/0 AWG, tightening torque 14.8...29.5 lbf ft. Cable lugs are not included in the
delivery. See page 64.
Dimensions, weights and noise
Frame size Height Width Depth* Weight Noise
in. in. in. lb dB
R2 14.57 6.5 7.6...8.9 18 62
R3 16.54 6.81 9.11...10.43 29 62
R4 19.29 9.45 9.93...10.69 53 62
R5 23.70 10.43 10.85...11.11 71 65
R6 27.56 11.81 15.71 141 65
* Depth depends on the options included in the drive.
Input power connection
Voltage (U1) 208/220/230/240 V AC 3-phase ±10% for 230 V AC units
380/400/415 V AC 3-phase ±10% for 400 V AC units
380/400/415/440/460/480/500 V AC 3-phase ±10% for 500 V AC units
525/550/575/600/660/690 V AC 3-phase ±10% for 690 V AC units
Rated conditional short- 65 kA when protected by fuses given in the IEC data fuse tables.
circuit current (IEC 60439-1)
Short-circuit current US and Canada: The drive is suitable for use on a circuit capable of delivering not more
protection (UL 508 C than 100 kA rms symmetrical amperes at the drive nominal voltage when protected by
CSA C22.2 No. 14-05) fuses given in the NEMA data fuse table.
Frequency 48 to 63 Hz, maximum rate of change 17%/s
Imbalance Max. ±3% of nominal phase to phase input voltage
Fundamental power factor 0.98 (at nominal load)
(cos phi1)
Technical data
108
Motor connection
Voltage (U2) 0 to U1, 3-phase symmetrical, Umax at the field weakening point
Frequency DTC mode: 0 to 3.2 · fFWP. Maximum frequency 300 Hz.
UNmains
fFWP = · fNmotor
UNmotor
fFWP: frequency at field weakening point; UNmains: mains (input power) voltage;
UNmotor: rated motor voltage; fNmotor: rated motor frequency
Frequency resolution 0.01 Hz
Current See section IEC data.
Power limit 1.5 · Phd, 1.1 · PN or Pcont.max (whichever value is greatest)
Field weakening point 8 to 300 Hz
Switching frequency 3 kHz (average). In 690 V units 2 kHz (average).
Maximum recommended Sizing method Max. motor cable length
motor cable length DTC control Scalar control
according to I2N and I2hd R2 to R3: 100 m (328 ft) R2: 150 m (492 ft)
according to Icont.max at R4 to R6: 300 m (984 ft) R3 to R6: 300 m (984 ft)
ambient temperatures below
30°C (86°F)
according to Icont.max at R2: 50 m (164 ft) Note: This applies to units with EMC filter
ambient temperatures above also.
30°C (86°F) R3 and R4: 100 m (328 ft)
R5 and R6: 150 m (492 ft)
Note: With cables longer than 100 m (328 ft), the EMC Directive requirements may not be
fulfilled. See section CE marking.
Efficiency
Approximately 98% at nominal power level
Cooling
Method Internal fan, flow direction from bottom to top.
Free space around the unit See chapter Mechanical installation.
Degrees of protection
IP20 (UL open type). See chapter Planning the cabinet assembly.
Technical data
109
AGPS-11C
Nominal input voltage 115...230 V AC ±10%
Nominal input current 0.1 A (230 V) / 0.2 A (115 V)
Nominal frequency 50/60 Hz
Max. external fuse 16 A
X1 terminal sizes 3 x 2.5 mm2
Output voltage 15 V DC ±0.5 V
Nominal output current 0.4 A
X2 terminal block type JST B4P-VH
Ambient temperature 0...50 °C
Relative humidity Max. 90%, no condensation allowed
Dimensions (with enclosure) 167 x 128 x 52 mm (Height x Width x Depth)
Weight (with enclosure) 0.75 kg
Approvals C-UL, US listed
Ambient conditions
Environmental limits for the drive are given below. The drive is to be used in a heated,
indoor, controlled environment.
Operation Storage Transportation
installed for stationary use in the protective package in the protective package
Installation site altitude 0 to 4000 m (13123 ft) above - -
sea level [above 1000 m
(3281 ft), see section
Derating]
Air temperature -15 to +50 °C (5 to 122 °F). -40 to +70 °C (-40 to -40 to +70 °C (-40 to
No frost allowed. See section +158 °F) +158 °F)
Derating.
Relative humidity 5 to 95% Max. 95% Max. 95%
No condensation allowed. Maximum allowed relative humidity is 60% in the presence of
corrosive gases.
Contamination levels No conductive dust allowed.
(IEC 60721-3-3, IEC 60721-3- Boards without coating: Boards without coating: Boards without coating:
2, IEC 60721-3-1) Chemical gases: Class 3C1 Chemical gases: Class 1C2 Chemical gases: Class 2C2
Solid particles: Class 3S2 Solid particles: Class 1S3 Solid particles: Class 2S2
Boards with coating: Boards with coating: Boards with coating:
Chemical gases: Class 3C2 Chemical gases: Class 1C2 Chemical gases: Class 2C2
Solid particles: Class 3S2 Solid particles: Class 1S3 Solid particles: Class 2S2
Atmospheric pressure 70 to 106 kPa 70 to 106 kPa 60 to 106 kPa
0.7 to 1.05 atmospheres 0.7 to 1.05 atmospheres 0.6 to 1.05 atmospheres
Vibration (IEC 60068-2)* Max. 1 mm (0.04 in.) Max. 1 mm (0.04 in.) Max. 3.5 mm (0.14 in.)
(5 to 13.2 Hz), (5 to 13.2 Hz), (2 to 9 Hz),
max. 7 m/s2 (23 ft/s2) max. 7 m/s2 (23 ft/s2) max. 15 m/s2 (49 ft/s2)
(13.2 to 100 Hz) sinusoidal (13.2 to 100 Hz) sinusoidal (9 to 200 Hz) sinusoidal
Shock (IEC 60068-2-29) Not allowed Max. 100 m/s2 (330 ft./s2), Max. 100 m/s2 (330 ft./s2),
11 ms 11 ms
Free fall Not allowed 250 mm (10 in.) for weight 250 mm (10 in.) for weight
under 100 kg (220 lb) under 100 kg (220 lb)
100 mm (4 in.) for weight 100 mm (4 in.) for weight
over 100 kg (220 lb) over 100 kg (220 lb)
*Note: For frame sizes R2 to R4 with panel option maximum allowed vibration is 3 m/s2. For higher vibration use the
RPMP kit. See Control Panel Mounting Platform Kit (RPMP) Installation Guide [3AFE64677560 (English)].
Technical data
110
Materials
Drive enclosure • PC/ABS 2.5 mm, colour NCS 1502-Y (RAL 90021 / PMS 420 C)
• hot-dip zinc coated steel sheet 1.5 to 2 mm, thickness of coating 100 micrometres
• cast aluminium AlSi (R2 and R3)
• extruded aluminium AlSi (R4 to R6)
Package Corrugated cardboard (frames R2 to R5 and option modules), plywood and wood (frame
size R6), expanded polystyrene. Plastic covering of the package: PE-LD, bands PP or
steel.
Disposal The drive contains raw materials that should be recycled to preserve energy and natural
resources. The package materials are environmentally compatible and recyclable. All
metal parts can be recycled. The plastic parts can either be recycled or burned under
controlled circumstances, according to local regulations. Most recyclable parts are marked
with recycling marks.
If recycling is not feasible, all parts excluding electrolytic capacitors and printed circuit
boards can be landfilled. The DC capacitors (C1-1 to C1-x) contain electrolyte and the
printed circuit boards contain lead, both of which are classified as hazardous waste within
the EU. They must be removed and handled according to local regulations.
For further information on environmental aspects and more detailed recycling instructions,
please contact your local ABB distributor.
Applicable standards
The drive complies with the following standards. The compliance with the European Low
Voltage Directive is verified according to standards EN 61800-5-1 and EN 60204-1.
• EN 60204-1 (2006) Safety of machinery. Electrical equipment of machines. Part 1: General requirements.
Provisions for compliance: The final assembler of the machine is responsible for installing
- an emergency-stop device
- a supply disconnecting device
- the ACS800-04/U4 into a cabinet.
• EN 60529: 1991 Degrees of protection provided by enclosures (IP code)
(IEC 60529)
• IEC 60664-1 (2007) Insulation coordination for equipment within low-voltage systems. Part 1: Principles,
requirements and tests.
• EN 61800-3 (2004) Adjustable speed electrical power drive systems. Part 3: EMC requirements and specific
test methods
• EN 61800-5-1 (2003) Adjustable speed electrical power drive systems. Part 5-1: Safety requirements –
electrical, thermal and energy
• UL 508C (2002) UL Standard for Safety, Power Conversion Equipment, second edition
• NEMA 250 (2003) Enclosures for Electrical Equipment (1000 Volts Maximum)
• CSA C22.2 No. 14-05 Industrial control equipment
(2005)
Technical data
111
CE marking
A CE mark is attached to the drive 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 2004/108EC).
Definitions
EMC stands for Electromagnetic Compatibility. It is the ability of electrical/electronic equipment to
operate without problems within an electromagnetic environment. Likewise, the equipment must not
disturb or interfere with any other product or system within its locality.
First environment includes establishments connected to a low-voltage network which supplies buildings
used for domestic purposes.
Second environment includes establishments connected to a network not supplying domestic premises.
Drive of category C2: drive of rated voltage less than 1000 V and intended to be installed and
commissioned only by a professional when used in the first environment. Note: A professional is
a person or organisation having necessary skills in installing and/or commissioning power drive
systems, including their EMC aspects.
Drive of category C3: drive of rated voltage less than 1000 V and intended for use in the second
environment and not intended for use in the first environment.
Drive of category C4: drive of rated voltage equal to or above 1000 V, or rated current equal to or above
400 A, or intended for use in complex systems in the second environment.
Compliance with the EMC Directive
The EMC Directive defines the requirements for immunity and emissions of electrical equipment used
within the European Union. The EMC product standard [EN 61800-3 (2004)] covers requirements
stated for drives.
Compliance with the EN 61800-3 (2004)
First environment (drive of category C2)
The drive complies with the standard with the following provisions:
1. The drive is equipped with EMC filter +E202.
2. The motor and control cables are selected as specified in the Hardware Manual.
3. The drive is installed according to the instructions given in the Hardware Manual.
4. Maximum cable length is 100 metres.
WARNING! The drive may cause radio interference if used in a residential or domestic environment.
The user is required to take measures to prevent interference, in addition to the requirements for CE
compliance listed above, if necessary.
Note: It is not allowed to install a drive equipped with EMC filter +E202 on IT (unearthed) systems. The
supply network becomes connected to earth potential through the EMC filter capacitors which may
cause danger or damage the unit.
Technical data
112
Second environment (drive of category C3)
The drive complies with the standard with the following provisions:
1. Frame sizes R2…R5: The drive is equipped with EMC filter +E200. The filter is suitable for TN
(earthed) systems only.
Frame size R6: The drive is equipped with EMC filter +E210. The filter is suitable for TN (earthed)
and IT (unearthed) systems.
2. The motor and control cables are selected as specified in the Hardware Manual.
3. The drive is installed according to the instructions given in the Hardware Manual.
4. Maximum cable length is 100 metres.
WARNING! A drive of category C3 is not intended to be used on a low-voltage public network which
supplies domestic premises. Radio frequency interference is expected if the drive is used on such
a network.
Second environment (drive of category C4)
If the provisions under Second environment (drive of category C3) cannot be met, e.g. the drive cannot
be equipped with EMC filter +E200 when installed to an IT (unearthed) network, the requirements of the
standard can be met as follows:
1. It is ensured that no excessive emission is propagated to neighbouring low-voltage networks. In
some cases, the inherent suppression in transformers and cables is sufficient. If in doubt, a supply
transformer with static screening between the primary and secondary windings can be used.
Medium voltage network
Supply transformer
Neighbouring network
Static screen
Point of measurement
Low voltage Low voltage
Equipment
Drive
(victim)
Equipment Equipment
2. An EMC plan for preventing disturbances is drawn up for the installation. A template is available
from the local ABB representative.
3. The motor and control cables are selected as specified in the Hardware Manual.
4. The drive is installed according to the instructions given in the Hardware Manual.
WARNING! A drive of category C4 is not intended to be used on a low-voltage public network which
supplies domestic premises. Radio frequency interference is expected if the drive is used on such
a network.
Machinery Directive
The drive complies with the European Union Machinery Directive (98/37/EC) requirements for an
equipment intended to be incorporated into machinery.
Technical data
113
“C-tick” marking
“C-tick” marking is required in Australia and New Zealand. A “C-tick” mark is attached to each drive in
order to verify compliance with the relevant standard (IEC 61800-3 (2004) – Adjustable speed electrical
power drive systems. Part 3: EMC requirements and specific test methods), mandated by the
Trans-Tasman Electromagnetic Compatibility Scheme.
Definitions
EMC stands for Electromagnetic Compatibility. It is the ability of electrical/electronic equipment to
operate without problems within an electromagnetic environment. Likewise, the equipment must not
disturb or interfere with any other product or system within its locality.
The Trans-Tasman Electromagnetic Compatibility Scheme (EMCS) was introduced by the Australian
Communication Authority (ACA) and the Radio Spectrum Management Group (RSM) of the New
Zealand Ministry of Economic Development (NZMED) in November 2001. The aim of the scheme is to
protect the radiofrequency spectrum by introducing technical limits for emission from electrical/
electronic products.
First environment includes establishments connected to a low-voltage network which supplies buildings
used for domestic purposes.
Second environment includes establishments connected to a network not supplying domestic premises.
Drive of category C2: drive of rated voltage less than 1000 V and intended to be installed and
commissioned only by a professional when used in the first environment. Note: A professional is
a person or organisation having necessary skills in installing and/or commissioning power drive
systems, including their EMC aspects.
Drive of category C3: drive of rated voltage less than 1000 V and intended for use in the second
environment and not intended for use in the first environment.
Drive of category C4: drive of rated voltage equal to or above 1000 V, or rated current equal to or above
400 A, or intended for use in complex systems in the second environment.
Compliance with IEC 61800-3
First environment (drive of category C2)
The drive complies with the limits of IEC 61800-3 with the following provisions:
1. The drive is equipped with EMC filter +E202.
2. The drive is installed according to the instructions given in the Hardware Manual.
3. The motor and control cables used are selected as specified in the Hardware Manual.
4. Maximum cable length is 100 metres.
WARNING! The drive may cause radio interference if used in a residential or domestic environment.
The user is required to take measures to prevent interference, in addition to the requirements for CE
compliance listed above, if necessary.
Note: The drive must not be equipped with EMC filter +E202 when installed to IT (unearthed) systems.
The mains becomes connected to earth potential through the EMC filter capacitors. In IT systems this
may cause danger or damage the unit.
Technical data
114
Second environment (drive of category C3)
The drive complies with the standard with the following provisions:
1. Frame sizes R2…R5: The drive is equipped with EMC filter +E200. The filter is suitable for TN
(earthed) systems only.
Frame size R6: The drive is equipped with EMC filter +E210. The filter is suitable for TN (earthed)
and IT (unearthed) systems.
2. The motor and control cables are selected as specified in the Hardware Manual.
3. The drive is installed according to the instructions given in the Hardware Manual.
4. Maximum cable length is 100 metres.
WARNING! A drive of category C3 is not intended to be used on a low-voltage public network which
supplies domestic premises. Radio frequency interference is expected if the drive is used on such
a network.
Second environment (drive of category C4)
If the provisions under Second environment (drive of category C3) cannot be met, e.g. the drive cannot
be equipped with EMC filter +E200 when installed to an IT (unearthed) network, the requirements of the
standard can be met as follows for restricted distribution:
1. It is ensured that no excessive emission is propagated to neighbouring low-voltage networks. In
some cases, the inherent suppression in transformers and cables is sufficient. If in doubt, a supply
transformer with static screening between the primary and secondary windings can be used.
Medium voltage network
Supply transformer
Neighbouring network
Static screen
Point of measurement
Low voltage Low voltage
Equipment
Drive
(victim)
Equipment Equipment
2. An EMC plan for preventing disturbances is drawn up for the installation. A template is available
from the local ABB representative.
3. The motor and control cables are selected as specified in the Hardware Manual.
4. The drive is installed according to the instructions given in the Hardware Manual.
WARNING! A drive of category C4 is not intended to be used on a low-voltage public network which
supplies domestic premises. Radio frequency interference is expected if the drive is used on such
a network.
Marine type approvals
See ACS800-01/U1/04/U4 Marine Supplement [3AFE68291275 (English)].
Technical data
115
UL/CSA markings
The ACS800-04 and ACS800-U4 are C-UL US listed and CSA marked.
UL
The drive is suitable for use on a circuit capable of delivering not more than 100 kA rms symmetrical
amperes at the drive nominal voltage (600 V maximum for 690 V units) when protected by fuses given
in the NEMA data fuse table. The ampere rating is based on tests done according to UL 508C.
The drive provides overload protection in accordance with the National Electrical Code (US). See
ACS800 Firmware Manual for setting. Default setting is off, must be activated at start-up.
The drives are to be used in a heated indoor controlled environment. See section Ambient conditions
for specific limits.
Brake chopper - ABB has brake choppers that, when applied with appropriately sized brake resistors,
will allow the drive to dissipate regenerative energy (normally associated with quickly decelerating
a motor). Proper application of the brake chopper is defined in chapter Resistor braking.
Equipment warranty and liability
The manufacturer warrants the equipment supplied against defects in design, materials and
workmanship for a period of twelve (12) months after installation or twenty-four (24) months from date
of manufacturing, whichever first occurs. The local ABB office or distributor may grant a warranty period
different to the above and refer to local terms of liability as defined in the supply contract.
The manufacturer is not responsible for
• any costs resulting from a failure if the installation, commissioning, repair, alternation, or ambient
conditions of the drive do not fulfil the requirements specified in the documentation delivered with
the unit and other relevant documentation.
• units subjected to misuse, negligence or accident
• units comprised of materials provided or designs stipulated by the purchaser.
In no event shall the manufacturer, its suppliers or subcontractors be liable for special, indirect,
incidental or consequential damages, losses or penalties.
This is the sole and exclusive warranty given by the manufacturer with respect to the equipment and is
in lieu of and excludes all other warranties, express or implied, arising by operation of law or otherwise,
including, but not limited to, any implied warranties of merchantability or fitness for a particular purpose.
If you have any questions concerning your ABB drive, please contact the local distributor or ABB office.
The technical data, information and specifications are valid at the time of printing. The manufacturer
reserves the right to modifications without prior notice.
Technical data
116
Product protection in the US
This product is protected by one or more of the following US patents:
4,920,306 5,301,085 5,463,302 5,521,483 5,532,568 5,589,754
5,612,604 5,654,624 5,799,805 5,940,286 5,942,874 5,952,613
6,094,364 6,147,887 6,175,256 6,184,740 6,195,274 6,229,356
6,252,436 6,265,724 6,305,464 6,313,599 6,316,896 6,335,607
6,370,049 6,396,236 6,448,735 6,498,452 6,552,510 6,597,148
6,600,290 6,741,059 6,774,758 6,844,794 6,856,502 6,859,374
6,922,883 6,940,253 6,934,169 6,956,352 6,958,923 6,967,453
6,972,976 6,977,449 6,984,958 6,985,371 6,992,908 6,999,329
7,023,160 7,034,510 7,036,223 7,045,987 7,057,908 7,059,390
7,067,997 7,082,374 7,084,604 7,098,623 7,102,325 7,109,780
7,164,562 7,176,779 7,190,599 7,215,099 7,221,152 7,227,325
7,245,197 7,262,577 D503,931 D510,319 D510,320 D511,137
D511,150 D512,026 D512,696 D521,466 D541,743S D541,744S
D541,745S D548,182 D548,183
Other patents are pending.
Technical data
117
Dimensional drawings
What this chapter contains
Dimensional drawings of the ACS800-04/U4, flange mounting kits and AGPS board
are shown below. The dimensions are given in millimetres and [inches].
Dimensional drawings
118
Frame size R2 (with optional control panel)
3AFE68347432
Dimensional drawings
119
Frame size R3 (with optional control panel)
3AFE68360544
Dimensional drawings
120
Frame size R4 (with optional control panel)
3AFE68364655
Dimensional drawings
121
Frame size R5 (with optional control panel)
3AFE68365741
Dimensional drawings
122
Frame size R6 (with optional control panel)
3AFE68365945
Dimensional drawings
123
Flange mounting kits
Flange mounting kit dimensions:
Lifting lug
7 [0.276]
H
D
Frame size H W D
mm [in.] mm [in.] mm [in.]
R2 476.5 [18.76] 235.5 [9.27] 25 [0.984]
R3 530.5 [20.89] 245.5 [9.67] 25 [0.984]
R4 595.95 [23.46] 373.6 [14.71] 25 [0.984]
R5 700 [27.56] 398.8 [15.70] 25 [0.984]
R6 786 [30.94] 433.4 [17.06] 25 [0.984]
Dimensional drawings
124
Flange mounting kit for frame size R2
[5.51]
[0.276]
[15.16]
22
[0.866] [7.54]
[5.51]
[2.17]
98.25
[3.87]
[0
.7
87
]
3AFE68361001
[6.69]
Dimensional drawings
125
Flange mounting kit for frame size R3
[7.09]
[0.394]
[6.30]
[17.32]
[0.276]
[6.30]
22
105.25
[2.36]
[4.14]
[0.866] [7.93]
3AFE68370418
Dimensional drawings
126
Flange mounting kit for frame size R4
86.8
[3.42]
142.95
[5.63]
[12.40]
21
[4.96]
[0.827]
[0.276]
[11.81]
[20.08]
[6.53]
[1.30]
[5.23]
[3.94]
[6.02]
]
153
87
3AFE68375371
.7
[0
Dimensional drawings
127
Flange mounting kit for frame size R5
[4.33] [13.39]
[14.33]
[8.66]
[0.276]
[24.57]
[8.66]
[0.866]
[4.33]
[3.15]
[5.12]
130
3AFE68371619
]
87
.7
119.4
[0
[4.70]
Dimensional drawings
128
Flange mounting kit for frame size R6
[8.66]
[0
.7
87
]
[0.709]
18
[4.84]
16.7
[15.75] [0.657]
[6.61]
[0.276]
[6.61]
[28.35]
[6.61]
[3.94]
[0.787]
[4.84]
3AFE68367280
]
100
87
116.7
.7
[4.59] [3.94]
[0
Dimensional drawings
129
AGPS board
$)(
Dimensional drawings
130
Dimensional drawings
131
Resistor braking
What this chapter contains
This chapter describes how to select, protect and wire brake choppers and resistors.
The chapter also contains the technical data.
Availability of brake choppers and resistors
Frame R2 and R3 drives and 690 V units of frame size R4 have a built-in brake
chopper as standard equipment. For other units, brake choppers are optionally
available as built-in units, indicated in the type code by +D150.
Resistors are available as add-on kits.
How to select the correct drive/chopper/resistor combination
1. Calculate the maximum power (Pmax) generated by the motor during braking.
2. Select a suitable drive / brake chopper / brake resistor combination for the
application according to the following tables (take account of other factors in the
drive selection also). The following condition must be met:
Pbr > Pmax
3. Check the resistor selection. The energy generated by the motor during a 400
second period must not exceed the resistor heat dissipation capacity ER.
If the ER value is not sufficient, it is possible to use a four-resistor assembly in which two standard
resistors are connected in parallel, two in series. The ER value of the four-resistor assembly is four
times the value specified for the standard resistor.
Resistor braking
132
Note: A resistor other than the standard resistor can be used provided that:
• its resistance is not lower than the resistance of the standard resistor.
• the resistance does not restrict the braking capacity needed, i.e.
2
UDC
Pmax <
R
where
Pmax maximum power generated by the motor during braking
UDC voltage over the resistor during braking, e.g.
1.35 · 1.2 · 415 V DC (when supply voltage is 380 to 415 V AC),
1.35 · 1.2 · 500 V DC. (when supply voltage is 440 to 500 V AC) or
1.35 · 1.2 · 690 V DC (when supply voltage is 525 to 690 V AC).
R resistor resistance (ohm)
• the heat dissipation capacity (ER) is sufficient for the application (see step 3
above).
WARNING! Never use a brake resistor with a resistance below the value specified
for the particular drive / brake chopper / resistor combination. The drive and the
chopper are not able to handle the overcurrent caused by the low resistance.
Optional brake chopper and resistor(s)
The nominal ratings for dimensioning the brake resistors are given below at an
ambient temperature of 40°C (104°F).
ACS800-04 type Braking power of the chopper and Brake resistor(s)
ACS800-U4 type the drive
Pbrcont Type R ER PRcont
(kW) (ohm) (kJ) (kW)
230 V units
-0001-2 0.55 SACE08RE44 44 210 1
-0002-2 0.8 SACE08RE44 44 210 1
-0003-2 1.1 SACE08RE44 44 210 1
-0004-2 1.5 SACE08RE44 44 210 1
-0005-2 2.2 SACE15RE22 22 420 2
-0006-2 3.0 SACE15RE22 22 420 2
-0009-2 4.0 SACE15RE22 22 420 2
-0011-2 5.5 SACE15RE13 13 435 2
-0016-2 11 SAFUR90F575 8 1800 4.5
-0020-2 17 SAFUR90F575 8 1800 4.5
-0025-2 23 SAFUR80F500 6 2400 6
-0030-2 28 SAFUR125F500 4 3600 9
-0040-2 33 SAFUR125F500 4 3600 9
-0050-2 45 2xSAFUR125F500 2 7200 18
-0060-2 56 2xSAFUR125F500 2 7200 18
-0070-2 68 2xSAFUR125F500 2 7200 18
Resistor braking
133
ACS800-04 type Braking power of the chopper and Brake resistor(s)
ACS800-U4 type the drive
Pbrcont Type R ER PRcont
(kW) (ohm) (kJ) (kW)
400 V units
-0003-3 1.1 SACE08RE44 44 210 1
-0004-3 1.5 SACE08RE44 44 210 1
-0005-3 2.2 SACE08RE44 44 210 1
-0006-3 3.0 SACE08RE44 44 210 1
-0009-3 4.0 SACE08RE44 44 210 1
-0011-3 5.5 SACE15RE22 22 420 2
-0016-3 7.5 SACE15RE22 22 420 2
-0020-3 11 SACE15RE22 22 420 2
-0023-3 11 SACE15RE22 22 420 2
-0025-3 23 SACE15RE13 13 435 2
-0030-3 28 SACE15RE13 13 435 2
-0035-3 28 SACE15RE13 13 435 2
-0040-3 33 SAFUR90F575 8 1800 4.5
-0050-3 45 SAFUR90F575 8 1800 4.5
-0060-3 56 SAFUR90F575 8 1800 4.5
-0075-3 70 SAFUR80F500 6 2400 6
-0070-3 68 SAFUR80F500 6 2400 6
-0100-3 83 SAFUR125F500 4 3600 9
-0120-3 113 SAFUR125F500 4 3600 9
-0135-3 132 SAFUR200F500 2.7 5400 13.5
-0165-3 132 SAFUR200F500 2.7 5400 13.5
500 V units
-0004-5 1.5 SACE08RE44 44 210 1
-0005-5 2.2 SACE08RE44 44 210 1
-0006-5 3.0 SACE08RE44 44 210 1
-0009-5 4.0 SACE08RE44 44 210 1
-0011-5 5.5 SACE08RE44 44 210 1
-0016-5 7.5 SACE15RE22 22 420 2
-0020-5 11 SACE15RE22 22 420 2
-0025-5 15 SACE15RE22 22 420 2
-0028-5 15 SACE15RE22 22 420 2
-0030-5 28 SACE15RE13 13 435 2
-0040-5 33 SACE15RE13 13 435 2
-0045-5 33 SACE15RE13 13 435 2
-0050-5 45 SAFUR90F575 8 1800 4.5
-0060-5 56 SAFUR90F575 8 1800 4.5
-0070-5 68 SAFUR90F575 8 1800 4.5
-0105-5 83 SAFUR80F500 6 2400 6
-0100-5 83 SAFUR125F500 4 3600 9
-0120-5 113 SAFUR125F500 4 3600 9
-0140-5 135 SAFUR125F500 4 3600 9
-0165-5 160 SAFUR125F500 4 3600 9
-0205-5 160 SAFUR125F500 4 3600 9
Resistor braking
134
ACS800-04 type Braking power of the chopper and Brake resistor(s)
ACS800-U4 type the drive
Pbrcont Type R ER PRcont
(kW) (ohm) (kJ) (kW)
690 V units
-0011-7 8.0 SACE08RE44 44 210 1
-0016-7 11 SACE08RE44 44 210 1
-0020-7 16 SACE08RE44 44 210 1
-0025-7 20 SACE08RE44 44 210 1
-0030-7 28 SACE15RE22 22 420 2
-0040-7 22 / 33 1) SACE15RE22 22 420 2
-0050-7 45 SACE15RE13 13 435 2
-0060-7 56 SACE15RE13 13 435 2
-0070-7 68 SAFUR90F575 8 1800 4.5
-0100-7 83 SAFUR90F575 8 1800 4.5
-0120-7 113 SAFUR80F500 6 2400 6
-0145-7 160 SAFUR80F500 6 2400 6
-0175-7 160 SAFUR80F500 6 2400 6
-0205-7 160 SAFUR80F500 6 2400 6
PDM code 00096931-J
PbrcontThe drive and the chopper will withstand this continuous braking power. The braking is considered continuous if the
braking time exceeds 30 s.
Note: The braking energy transmitted to the specified resistor(s) in 400 seconds may not exceed ER.
R Resistance value for the listed resistor assembly. Note: This is also the minimum allowed resistance for the braking
resistor.
ER Short energy pulse that the resistor assembly withstands every 400 seconds. This energy will heat the resistor
element from 40°C (104°F) to the maximum allowable temperature.
PRcont Continuous power (heat) dissipation of the resistor when placed correctly. Energy ER dissipates in 400 seconds.
1)
22 kW with standard 22 ohm resistor and 33 kW with 32…37 ohm resistor
All braking resistors must be installed outside the converter module. The SACE braking resistors are built in an IP21 metal
housing. The SAFUR braking resistors are built in an IP00 metal frame. Note: The SACE and SAFUR resistors are not UL
listed.
Resistor installation and wiring
All resistors must be installed outside the drive module in a place where they will
cool.
WARNING! The materials near the brake resistor must be non-flammable. The
surface temperature of the resistor is high. Air flowing from the resistor is of
hundreds of degrees Celsius. Protect the resistor against contact.
Use the cable type used for drive input cabling (see to chapter Technical data) to
ensure the input fuses will also protect the resistor cable. Alternatively, two-
conductor shielded cable with the same cross-sectional area can be used. The
maximum length of the resistor cable(s) is 10 m (33 ft). For the connections, see the
power connection diagram of the drive.
Resistor braking
135
Protection of frame sizes R2 to R5
It is highly recommended to equip the drive with a main contactor for safety reasons.
Wire the contactor so that it opens in case the resistor overheats. This is essential
for safety since the drive will not otherwise be able to interrupt the main supply if the
chopper remains conductive in a fault situation.
Below is a simple example wiring diagram.
L1 L2 L3
1
OFF
Fuses 2
1 3 5 13 3
ON
2 4 6 14 4
ACS800
U1 V1 W1
Θ Thermal switch (stand-
ard in ABB resistors)
K1
Resistor braking
136
Protection of frame size R6
A main contactor is not required for protecting against resistor overheating when the
resistor is dimensioned according to the instructions and the internal brake chopper
is used. The drive will disable power flow through the input bridge if the chopper
remains conductive in a fault situation. Note: If an external brake chopper (outside
the drive module) is used, a main contactor is always required.
A thermal switch (standard in ABB resistors) is required for safety reasons. The
cable must be shielded and not longer than the resistor cable.
With Standard Control Program, wire the thermal switch as shown below. By default,
the drive will stop by coasting when the switch opens.
RMIO:X22 or X2: X22
1 DI1
2 DI2
3 DI3
4 DI4
5 DI5
6 DI6
7 +24V
Resistor thermal
8 +24V
switch (standard in
ABB resistors) 9 DGND
Θ
10 DGND
11 DIIL
For other control programs, the thermal switch may be wired to a different digital
input. Programming of the input to trip the drive by “EXTERNAL FAULT” may be
needed. See the appropriate Firmware Manual.
Brake circuit commissioning
For Standard Control Program:
• Enable the brake chopper function (parameter 27.01).
• Switch off the overvoltage control of the drive (parameter 20.05).
• Check the resistance value setting (parameter 27.03).
• Frame sizes R6: Check the setting of parameter 21.09. If stop by coasting is
required, select OFF2 STOP.
For the use of the brake resistor overload protection (parameters 27.02...27.05),
consult an ABB representative.
WARNING! If the drive is equipped with a brake chopper but the chopper is not
enabled by parameter setting, the brake resistor must be disconnected because the
protection against resistor overheating is then not in use.
For settings of other control programs, see the appropriate Firmware Manual.
Resistor braking
3AFE68372984 Rev E EN
EFFECTIVE: 31.03.2008
ABB Oy ABB Inc. ABB Beijing Drive Systems Co. Ltd.
AC Drives Automation Technologies No. 1, Block D, A-10 Jiuxianqiao Beilu
P.O. Box 184 Drives & Motors Chaoyang District
FI-00381 HELSINKi 16250 West Glendale Drive Beijing, P.R. China, 100015
FINLAND New Berlin, WI 53151 Telephone +86 10 5821 7788
Telephone +358 10 22 211 USA Fax +86 10 5821 7618
Telefax +358 10 22 22681 Telephone 262 785-3200 Internet www.abb.com
Internet www.abb.com 800-HELP-365
Fax 262 780-5135
ACS800
Hardware Manual
ACS800-07 Drives (500 to 2800 kW)
ACS800 Single Drive Manuals
HARDWARE MANUALS (appropriate manual is included in the
delivery)
ACS800-01/U1 Hardware Manual 0.55 to 160 kW (0.75 to 200 HP)
3AFE64382101 (English)
ACS800-01/U1/04 Marine Supplement 0.55 to 160 kW (0.75 to
200 HP) 3AFE64291275 (English)
ACS800-11/U11 Hardware Manual 5.5 to 110 kW (7.5 to 125 HP)
3AFE68367883 (English)
ACS800-31/U31 Hardware Manual 5.5 to110 kW (7.5 to 125 HP)
3AFE68599954 (English)
ACS800-02/U2 Hardware Manual 90 to 500 kW (125 to 600 HP)
3AFE64567373 (English)
ACS800-04/U4 Hardware Manual 0.55 to 160 kW (0.75 to 200 HP)
3AFE68372984 (English)
ACS800-04/04M/U4 Hardware Manual 45 to 560 kW (60 to
600 HP) 3AFE64671006 (English)
ACS800-04/04M/U4 Cabinet Installation 45 to 560 kW (60 to
600 HP) 3AFE68360323 (English)
ACS800-07/U7 Hardware Manual 45 to 560 kW (50 to 600 HP)
3AFE64702165 (English)
ACS800-07/U7 Dimensional Drawings 45 to 560 kW (50 to
600 HP) 3AFE64775421
ACS800-07 Hardware Manual 500 to 2800 kW
3AFE64731165 (English)
ACS800-17 Hardware Manual 55 to 2500 kW (75 to 2800 HP)
3AFE68397260 (English)
ACS800-37 Hardware Manual 55 to 2700 kW (75 to 3000 HP)
3AFE68557925 (English)
• Safety instructions
• Electrical installation planning
• Mechanical and electrical installation
• Motor control and I/O board (RMIO)
• Maintenance
• Technical data
• Dimensional drawings
• Resistor braking
FIRMWARE MANUALS, SUPPLEMENTS AND GUIDES
(appropriate documents are included in the delivery)
Standard Control Program Firmware Manual
3AFE64527592 (English)
System Application Program Firmware Manual
3AFE64670646 (English)
Application Program Template Firmware Manual
3AFE64616340 (English)
Master/Follower 3AFE64590430 (English)
Pump Control Application Program Firmware Manual
3AFE68478952 (English)
Extruder Control Program Supplement 3AFE64648543 (English)
Centrifuge Control Program Supplement 3AFE64667246 (English)
Traverse Control Program Supplement 3AFE64618334 (English)
Crane Control Program Firmware Manual 3BSE11179 (English)
Adaptive Programming Application Guide
3AFE64527274 (English)
OPTION MANUALS (delivered with optional equipment)
Fieldbus Adapters, I/O Extension Modules etc.
ACS800-07 Drives
500 to 2800 kW
Hardware Manual
3AFE64731165 REV E EN
EFFECTIVE: 15.2.2008
© 2008 ABB Oy. All Rights Reserved.
5
Safety instructions
What this chapter contains
This chapter contains safety instructions you must follow when installing, operating
and servicing the drive. If ignored, physical injury or death may follow, or damage
may occur to the drive, the motor or driven equipment. Read the safety instructions
before you work on the unit.
Usage of warnings and notes
There are two types of safety instructions throughout this manual: warnings and
notes. Warnings caution you about conditions which can result in serious injury or
death and/or damage to the equipment, and advise on how to avoid the danger.
Notes draw attention to a particular condition or fact, or give information on a
subject. The warning symbols are used as follows:
Dangerous voltage warning warns of high voltages which can cause
physical injury and/or damage to the equipment.
General warning warns about conditions, other than those caused by
electricity, which can result in physical injury and/or damage to the
equipment.
Electrostatic discharge warning warns of electrostatic discharge which
can damage the equipment.
Safety instructions
6
Installation and maintenance work
These warnings are intended for all who work on the drive, motor cable or motor.
Ignoring the instructions can cause physical injury or death, or damage the
equipment.
WARNING!
• Only qualified electricians are allowed to install and maintain the drive.
• The main switch on the cabinet door does not remove the voltage from the input
busbars of the drive. Before working on the drive, isolate the whole drive from
the supply.
• Never work on the drive, the motor cable or the motor when main power is
applied. After switching off the input power, always wait for 5 min to let the
intermediate circuit capacitors discharge before you start working on the drive,
the motor or the motor cable. Measure the voltage between terminals UDC+
and UDC- (L+ and L–) with a multimeter (impedance at least 1 Mohm) to
ensure that the drive is discharged before beginning work.
• Apply temporary grounding before working on the unit.
• Do not work on the control cables when power is applied to the drive or to the
external control circuits. Externally supplied control circuits may cause
dangerous voltages to exist inside the drive even when the main power of the
drive is switched off.
• Do not make any insulation or voltage withstand tests on the drive or drive
modules.
• When reconnecting the motor cable, always check that the phase order is
correct.
• When joining shipping splits (if any), check the cable connections at the joints
before switching on the supply voltage.
• Live parts on the inside of the doors are protected against direct contact.
Special attention shall be paid when handling metallic shrouds.
Note:
• The motor cable terminals on the drive are at a dangerously high voltage when
the input power is on, regardless of whether the motor is running or not.
• The brake control terminals (UDC+, UDC-, R+ and R- terminals) carry a
dangerous DC voltage (over 500 V).
• Depending on the external wiring, dangerous voltages (115 V, 220 V or 230 V)
may be present on the relay outputs of the drive system.
• The Prevention of Unexpected Start function does not remove the voltage from
the main and auxiliary circuits.
Safety instructions
7
WARNING!
• During the installation procedure, the inverter modules may have to be
temporarily extracted from the cabinet. The modules have a high centre of
gravity. In order to minimise the danger of toppling over, keep the support legs
of the modules extended whenever manoeuvring the modules outside the
cabinet.
• Electrically conductive dust inside the unit may cause damage or lead to
malfunction. Make sure that dust from drilling does not enter the drive when
installing.
• Fastening the cabinet by riveting or welding is not recommended. However, if
welding is necessary, ensure the return wire is properly connected in order not
to damage the electronic equipment in the cabinet. Also ensure that welding
fumes are not inhaled.
• Ensure sufficient cooling of the unit.
• Cooling fans may continue to rotate for a while after the disconnection of the
electrical supply.
• Some parts inside the drive cabinet, such as heatsinks of power
semiconductors, remain hot for a while after the disconnection of the electrical
supply.
WARNING!
• The printed circuit boards contain components sensitive to electrostatic
discharge. Wear a grounding wrist band when handling the boards. Do not
touch the boards unnecessarily.
Safety instructions
8
Grounding
These instructions are intended for all who are responsible for the grounding of the
drive. Incorrect grounding can cause physical injury, death or equipment malfunction
and increase electromagnetic interference.
WARNING!
• Ground the drive, the motor and adjoining equipment to ensure personnel
safety in all circumstances, and to reduce electromagnetic emission and pick-
up.
• Make sure that grounding conductors are adequately sized as required by
safety regulations.
• In a multiple-drive installation, connect each drive separately to protective
earth (PE).
• Do not install a drive equipped with an EMC (line) filter to an ungrounded
power system or a high resistance-grounded (over 30 ohms) power system.
Note:
• Power cable shields are suitable for equipment grounding conductors only
when adequately sized to meet safety regulations.
• As the normal leakage current of the drive is higher than 3.5 mA AC or 10 mA
DC (stated by EN 50178, 5.2.11.1), a fixed protective earth connection is
required.
Fibre optic cables
WARNING!
• Handle the fibre optic cables with care. When unplugging optic cables, always
grab the connector, not the cable itself. Do not touch the ends of the fibres with
bare hands as the fibre is extremely sensitive to dirt. The minimum allowed
bend radius is 35 mm (1.4”).
Safety instructions
9
Operation
These warnings are intended for all who plan the operation of the drive or operate
the drive. Ignoring the instructions can cause physical injury or death or damage the
equipment.
WARNING!
• If the drive is equipped with an optional brake unit, make sure there are
inverters connected to the intermediate circuit before start. As a rule of thumb,
the sum capacitance of the inverters connected must be at least 30% of the
sum capacitance of all inverters.
• Close the switch fuses of all parallel-connected inverters before start.
• Do not open the DC switch fuse of an inverter when the inverter is running.
WARNING!
• Before adjusting the drive and putting it into service, make sure that the motor
and all driven equipment are suitable for operation throughout the speed range
provided by the drive. The drive can be adjusted to operate the motor at
speeds above and below the speed provided by connecting the motor directly
to the power line.
• Do not activate automatic fault reset functions of the Standard Application
Program if dangerous situations can occur. When activated, these functions
will reset the drive and resume operation after a fault.
• Do not control the motor with the disconnecting device (means); instead, use
the control panel keys and , or commands via the I/O board of the drive.
The maximum allowed number of charging cycles of the DC capacitors (i.e.
power-ups by applying power) is five in ten minutes.
Note:
• If an external source for start command is selected and it is ON, the drive (with
Standard Application Program) will start immediately after fault reset unless the
drive is configured for 3-wire (a pulse) start/stop.
• When the control location is not set to Local (L not shown in the status row of
the display), the stop key on the control panel will not stop the drive. To stop
the drive using the control panel, press the LOC/REM key and then the stop
key .
Safety instructions
10
Permanent magnet motor drives
These are additional warnings concerning permanent magnet motor drives.
WARNING! Do not work on the drive when the permanent magnet motor is rotating.
Also when the supply power is switched off, a rotating permanent magnet motor
feeds power to the intermediate circuit of the drive and also the supply connections
become live (even when the inverter is stopped!).
Installation and maintenance work
• Disconnect the motor from the drive with a safety switch
and additionally, if possible,
• lock the motor shaft and ground the motor connection terminals temporarily by
connecting them together as well as to the PE.
Operation
Do not run the motor above the rated speed. Motor overspeed leads to overvoltage
which may result in explosion of the capacitors in the intermediate circuit of the drive.
Application program
Controlling a permanent magnet motor is only allowed using the ACS800 Permanent
Magnet Synchronous Motor Drive Application Program, or using other application
programs in scalar control mode only.
Safety instructions
11
Table of contents
ACS800 Single Drive Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Safety instructions
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Usage of warnings and notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Installation and maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Fibre optic cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Permanent magnet motor drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Installation and maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Application program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Table of contents
About this manual
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Target audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Common chapters for multiple products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Categorization according to the frame size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Installation and commissioning flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Product and service inquiries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Product training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Providing feedback on ABB Drives manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Terms and abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Hardware description
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
The ACS800-07 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Cabinet line-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Swing-out frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Cabling direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Single-line circuit diagram of the drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Door switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Load switch-disconnector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Auxiliary voltage switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Earthing/Grounding switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Other door controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Supply unit control electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Table of contents
12
Reading and setting of values (page 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Reading and setting of values (page 2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Terminal blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Digital input and relay output terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Emergency stop input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Earth (ground) current function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Power loss ride-through function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
Inverter unit control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
Motor control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Reduced run capability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Type code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
Mechanical installation
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Required tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Moving the unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
…by crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
…by fork-lift or pallet truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
…on rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Laying the unit on its back . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Final placement of the unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
Before installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
Delivery check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
Installation procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
Fastening the cabinet to the floor (Non-marine units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
Clamping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
Holes inside the cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
Fastening the unit to the floor and wall (Marine units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
Joining the shipping splits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
Connecting the DC busbars and the PE busbar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
DC busbars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
PE busbar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
Cable duct in the floor below the cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
Cooling air intake through bottom of cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
Electric welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
Planning the electrical installation
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
Motor selection and compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
Protecting the motor insulation and bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
Requirements table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
Permanent magnet synchronous motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
Thermal overload and short-circuit protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
Thermal overload protection of the drive and the input and motor cables . . . . . . . . . . . . . . .59
Table of contents
13
Thermal overload protection of the motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Protection against short-circuit in the motor cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Protection against short-circuit inside the drive or in the supply cable . . . . . . . . . . . . . . . . . 60
Earth fault (Ground fault) protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Emergency stop devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Restarting after an emergency stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Prevention of unexpected start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Selecting the power cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
General rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Alternative power cable types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Motor cable shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Additional US requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Conduit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Armored cable / shielded power cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Power factor compensation capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Equipment connected to the motor cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Installation of safety switches, contactors, connection boxes, etc. . . . . . . . . . . . . . . . . . . . . 65
Bypass connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Before opening an output contactor (in DTC motor control mode) . . . . . . . . . . . . . . . . . . . . 65
Relay output contacts and inductive loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Selecting the control cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Relay cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Control panel cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Coaxial cable (for use with Advant Controllers AC 80/AC 800) . . . . . . . . . . . . . . . . . . . . . . . 67
Connection of a motor temperature sensor to the drive I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Installation sites above 2000 metres (6562 feet) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Routing the cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Control cable ducts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Electrical installation
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Before installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Checking the insulation of the assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Motor and motor cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
IT (ungrounded) systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Setting the earth fault (ground fault) trip level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Grounded systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
IT (ungrounded) systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Input power connection – Units without load switch-disconnector or air circuit breaker . . . . . . . . . 73
Connection diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
6-pulse connection, two supply modules in parallel . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
12-pulse connection, two supply modules in parallel . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Connection procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Use of the dual-cable screw lug connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Removal of the dual-cable screw lug connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Input power connection – Units with load switch-disconnector or air circuit breaker . . . . . . . . . . . 77
Connection diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
6-pulse connection, two supply modules in parallel . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
12-pulse connection, two supply modules in parallel . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Table of contents
14
Connection procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79
Motor connection – Units without common motor terminal cubicle . . . . . . . . . . . . . . . . . . . . . . . . .80
Output busbars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80
Connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80
Connection procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82
Motor connection – Units with common motor terminal cubicle . . . . . . . . . . . . . . . . . . . . . . . . . . . .84
Connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84
Connection procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84
Control connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
Drive control connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
Supply unit control connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
Connection procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86
Installation of optional modules and PC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88
Cabling of I/O and fieldbus modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88
Cabling of pulse encoder interface module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88
Fibre optic link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88
Connections and tap settings of the auxiliary voltage transformer . . . . . . . . . . . . . . . . . . . . . . . . .89
Installation of brake resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89
Motor control and I/O board (RMIO)
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91
To which products this chapter applies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91
Note on cabinet-installed ACS800 drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91
Note on terminal labelling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91
Note on external power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92
Parameter settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92
External control connections (non-US) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
External control connections (US) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94
RMIO board specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95
Analogue inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95
Constant voltage output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95
Auxiliary power output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95
Analogue outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95
Digital inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95
Relay outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96
DDCS fibre optic link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96
24 VDC power input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96
Installation checklist and start-up
Installation checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99
Start-up procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100
Basic checks with no voltage connected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100
Connecting voltage to input terminals and auxiliary circuit . . . . . . . . . . . . . . . . . . . . . . . . . .100
Starting the supply unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101
Checks with the supply unit running . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101
Application program set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101
On-load checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101
Table of contents
15
Maintenance
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Replacing the PPCS branching unit (APBU-xx) memory backup battery . . . . . . . . . . . . . . . . . . . 105
Checking and replacing the air filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Power connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Cooling fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Power module cooling fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Supply module fan replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Inverter module fan replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Control and I/O cubicle cooling fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Air circuit breaker cubicle fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
IP54 (UL type 12) fan replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Heatsinks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Reforming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Capacitor replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Other maintenance actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Power module replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Fault tracing
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Supply unit status, fault and warning LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Other LEDs of the drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Technical data
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Temperature derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Altitude derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
ACS800-07 frame sizes and power module types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Internal AC fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
DC fuses at inverter module input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Fuses for main circuit voltage measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
DC fuses for the DSU module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Input power connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Motor connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Degrees of protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Ambient conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Tightening torques for power connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Applicable standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Table of contents
16
CE marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .128
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .128
Compliance with the EMC Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .128
Compliance with the EN 61800-3 + Amendment A11 (2000) . . . . . . . . . . . . . . . . . . . . . . . .128
First environment (restricted distribution) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .128
Second environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .129
Machinery Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .129
“C-tick” marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .130
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .130
Compliance with IEC 61800-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .130
First environment (restricted distribution) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .130
Second environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .131
Dimensions
Cabinet line-ups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .133
Frame size 1×D4 + 2×R8i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .138
Frame size 1×D4 + 2×R8i (with load switch-disconnector) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .141
Frame size 1×D4 + 2×R8i (with top entry/exit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .147
Frame size 2×D4 + 2×R8i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .150
Frame size 2×D4 + 2×R8i (with load switch-disconnector) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .153
Frame size 2×D4 + 3×R8i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .156
Frame size 2×D4 + 3×R8i (with load switch-disconnector) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .159
Frame size 2×D4 + 3×R8i (with air circuit breaker) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .163
Frame size 3×D4 + 4×R8i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .167
Frame size 3×D4 + 4×R8i (with load switch-disconnector) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .170
Frame size 3×D4 + 4×R8i (with air circuit breaker) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .174
Common motor terminal cubicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .178
300 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .178
400 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .179
600 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .180
Resistor braking
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .181
Resistor braking options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .181
Chopper/Resistor combinations – Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .182
Brake resistors – Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .182
Verifying the capacity of the braking equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .183
Custom resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .183
Calculating the maximum braking power (Pbr) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .184
Example 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .184
Example 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .184
Example 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .185
Custom resistor installation and wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .186
Brake circuit commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .187
Table of contents
17
About this manual
What this chapter contains
This chapter describes the intended audience and contents of the manual. It
contains a flowchart of steps in checking the delivery, installing and commissioning
the drive. The flowchart refers to chapters/sections in this manual and other
manuals.
Target audience
This manual is intended for people who plan the installation, install, commission, use
and service the drive. Read the manual before working on the drive. The reader is
expected to know the fundamentals of electricity, wiring, electrical components and
electrical schematic symbols.
The manual is written for readers worldwide. Both SI and imperial units are shown.
Special US instructions for installations within the United States that must be
installed per the National Electrical Code and local codes are marked with (US).
Common chapters for multiple products
Some chapters in this manual apply to several products including the ACS800-07.
Other product types may be mentioned in these chapters.
Categorization according to the frame size
Some instructions, technical data and dimensional drawings which concern only
certain drive frame sizes are marked with the symbol of the frame size (such as
“1×D4 + 2×R8i”, etc.). The frame size is not marked on the drive designation label.
To identify the frame size of your drive, see the rating tables in chapter Technical
data.
Contents
The chapters of this manual are briefly described below.
Safety instructions gives safety instructions for the installation, commissioning,
operation and maintenance of the drive.
About this manual introduces this manual.
Hardware description describes the drive.
Mechanical installation instructs how to move, place and mount the drive.
Planning the electrical installation provides advice on motor and cable selection, the
protective functions of the drive, and cable routing.
Electrical installation describes the cabling and wiring of the drive.
About this manual
18
Motor control and I/O board (RMIO) shows external control connections to the motor
control and I/O board and its specifications.
Installation checklist and start-up helps in checking the mechanical and electrical
installation of the drive.
Maintenance contains preventive maintenance instructions.
Fault tracing contains troubleshooting instructions.
Technical data contains the technical specifications of the drive, e.g. ratings, frame
sizes and technical requirements, provisions for fulfilling the requirements for CE
and other markings and warranty policy.
Dimensions contains information on the dimensions of the drive.
Resistor braking describes how to select, protect and wire optional brake choppers
and resistors.
Installation and commissioning flowchart
Task See
Plan the installation. Technical data
Check the ambient conditions, ratings, required Planning the electrical installation
cooling air flow, input power connection, compatibility Option manuals (if optional equipment is
of the motor, motor connection, and other technical included)
data.
Select the cables.
Unpack and check the units. Mechanical installation
Check the type code indicated by the type Hardware description
designation label with the original order. If the drive is For instructions on how to disconnect the EMC/
about to be connected to an IT (ungrounded) system, RFI filtering, contact your local ABB
check that the drive is not equipped with EMC/RFI representative.
filtering +E202. Check that all necessary optional
If the converter has been non-operational for
modules and equipment are present and correct.
more than one year, the converter DC link
capacitors need to be reformed. Contact your
local ABB representative for more information.
Only intact units may be started up.
Check the installation site. Mechanical installation, Technical data
Route the cables. Planning the electrical installation: Routing the
cables
Mount the cabinet line-up. Mechanical installation
Check the insulation of the motor and the motor Electrical installation: Checking the insulation of
cable. the assembly
About this manual
19
Task See
Connect the power cables. Connect the control and Mechanical installation, Planning the electrical
the auxiliary control cables. installation, Electrical installation, Resistor
braking (optional)
Check the installation. Installation checklist and start-up
Commission the drive. Installation checklist and start-up and
appropriate firmware manual
Commission the optional brake chopper (if present). Resistor braking
Product and service inquiries
Address any inquiries about the product to your local ABB representative, quoting
the type code and serial number of the unit in question. A listing of ABB sales,
support and service contacts can be found by navigating to www.abb.com/drives and
selecting Drives – Sales, Support and Service network.
Product training
For information on ABB product training, navigate to www.abb.com/drives and select
Drives – 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).
About this manual
20
Terms and abbreviations
Term/Abbreviation Explanation
APBU Type of optical branching unit used for connecting parallel-
connected converter modules to the RDCU.
DSSB Diode Supply System Board
DSU Diode Supply Unit
Frame (size) Relates to the construction type of the component in question. For
example, several drive types with different power ratings may have
the same basic construction, and this term is used in reference to all
those drive types.
With the ACS800-07 (> 500 kW), the frame size of the drive
indicates the quantity and frame size of the supply modules, plus the
quantity and frame size of the inverter modules, e.g. “2×D4 + 4×R8i”.
To determine the frame size of a drive type, see the rating tables in
the chapter Technical data.
RDCU Drive control unit.
THD Total Harmonic Distortion
About this manual
21
Hardware description
What this chapter contains
This chapter describes the construction of the drive in short.
The ACS800-07
The ACS800-07 is a cabinet-mounted drive for controlling AC motors.
Cabinet line-up
The drive consists of several cubicles that contain the supply and motor terminals,
1 to 4 diode supply module(s), 2 to 6 inverter modules, and optional equipment. The
actual arrangement of the cubicles vary from type to type and the selected options.
See the chapter Dimensions for the different line-up variations.
The picture below shows the main components of a frame 1×D4 + 2×R8i drive.
No. Description
1 Supply (input) cable lead-throughs. Top entry optional.
2 Supply module.
14
3 Input terminals (behind module). Input cables connect here
7
6 if a load switch-disconnector cubicle is not present.
4 Chassis socket for quick supply module connection (behind
module).
5 Supply module switch-disconnector. Not present if the drive
is equipped with an optional load switch-disconnector
cubicle.
5
6 Supply unit control board (DSSB; mounted sideways).
Contains an actual value display and status LEDs.
8 7 Inverter DC fuses.
4 8 Inverter modules.
12 9 Chassis socket for inverter module output connection
3 (behind each module).
10 Output terminals (behind each module). Motor cables
9 9
connect here if a common motor terminal cubicle is not
present.
2
10 10
11 Motor (output) cable lead-throughs. Not used if optional
common motor terminal cubicle is present.
12 Swing-out frame. Contains the drive control unit with I/O
terminals, and provides space for standard and optional
electrical equipment.
13 13 Auxiliary voltage transformer (accessible by opening the
swing-out frame).
11 11 14 Auxiliary voltage switch with fuses.
1
Hardware description
22
The following drawing represents a 2×D4 + 2×R8i drive with optional load switch-
disconnector.
17
5
9 10
8 8
4
11
7 7
15
3
12 12
6
13 13
16
14 14
1
No. Description No. Description
1 Supply (input) cable lead-throughs. Top entry optional. 10 Inverter DC fuses.
2 Input busbars. 11 Inverter modules.
3 Load switch-disconnector. 12 Chassis socket for inverter module output connection
(behind each module).
4 Earthing/Grounding switch (optional). 13 Output terminals (behind each module). Motor cables
connect here if a common motor terminal cubicle is not
present.
5 AC fuses. Only present if the drive is equipped with a 14 Motor (output) cable lead-throughs. Not used if optional
load switch-disconnector or air circuit breaker. common motor terminal cubicle is present.
6 Supply modules. 15 Swing-out frame. Contains the drive control unit with I/O
terminals, and provides space for standard and optional
electrical equipment.
7 Chassis socket for quick supply module connection 16 Auxiliary voltage transformer (accessible by opening the
(behind each module). swing-out frame).
8 Supply module switch-disconnectors (coupled to an 17 Auxiliary voltage switch.
operating handle on the cabinet door). Not present if the
drive is equipped with a load switch-disconnector or air
circuit breaker.
9 Supply unit control board (DSSB; mounted sideways).
Contains an actual value display and status LEDs.
Hardware description
23
Swing-out frame
The swing-out frame inside the control and I/O cubicle provides space for the control
electronics of the drive, I/O terminal blocks, and optional electrical equipment. The
lead-throughs for I/O cables, the auxiliary voltage transformer, and further space for
additional equipment are available behind the frame. The frame can be opened by
removing the two locking screws (arrowed in the picture below) and moving the
swing-out frame aside. (Depending on selected options, actual equipment of the
drive may differ from what is depicted below.)
Remove screws (arrowed) to
release swing-out frame
Drive control unit
(RDCU) with I/O
terminal blocks
Space for optional
terminal block X2
Terminal block X1
I/O cable entry (into
swing-out frame)
Mounting rails for
additional equipment
Auxiliary voltage
transformer
I/O cable entry (into
cabinet)
Hardware description
24
Cabling direction
The drawing below shows the available power cabling directions of the drive. Note
that the desired cabling direction must be specified on ordering.
4 3 3 Description
6 6 8 1 Main supply – Bottom entry at each supply module (without load
switch-disconnector or air breaker)
2 Main supply – Bottom entry with load switch-disconnector or air
circuit breaker
3 Main supply – Top entry at each supply module (without load
switch-disconnector or air circuit breaker) (not for IP54)
A B C D
4 Main supply – Top entry with load switch-disconnector or air
circuit breaker
5 Motor output – Bottom exit at each inverter module (without
common motor terminal cubicle)
6 Motor output – Top exit at each inverter module (without common
motor terminal cubicle). Added depth: 130 mm
7 Motor output – Bottom exit with common motor terminal cubicle
5 5 7
8 Motor output – Top exit with common motor terminal cubicle
2 1 1
A Load switch-disconnector or air circuit breaker cubicle (optional)
B Control, I/O and supply cubicle
C Inverter unit cubicle
D Common motor terminal cubicle (optional)
Hardware description
DC bus
M M
M M
400 VAC 400 VAC
M M
Single-line circuit diagram of the drive
230/115
VAC
M Notes:
Main 3~ – The diagram represents a frame 2×D4 + 2×R8i drive
Supply with 2 brake chopper/resistor units (optional), and without
load switch-disconnector, air circuit breaker or common
motor output cubicles.
– The supply modules are not equipped with internal
contactors if an air circuit breaker is ordered.
+24 VDC – The supply modules are not equipped with internal
switch-disconnectors if a load switch-disconnector or air
400 VAC circuit breaker is ordered.
230/115 VAC
Ground fault supervision
Voltage display of DSSB
Motor fan supply
25
Hardware description
26
Controls
Door switches
Load switch-disconnector
The drive has a load switch-disconnector handle. In units without an optional load
switch-disconnector (+F253), the handle operates the internal switch-disconnector
contained within each supply module.
WARNING! The load switch-disconnector does not switch off the auxiliary voltages
inside the cabinet. In units without option +F253, the switch-disconnector does not
switch off the voltage at the input terminals of the supply module(s).
Note: On units without the line contactor option (+F250) and the load switch-
disconnector option (+F253), the supply unit will start rectifying as soon as the
switch-disconnector(s) within the supply module(s) is closed.
Auxiliary voltage switch
The auxiliary voltage switch controls the voltage supply to the auxiliary voltage
transformer.
Earthing/Grounding switch
An earthing/grounding switch for temporary grounding is optionally available.
Other door controls
The following switches are mounted on the door of the control and I/O cubicle:
Operating switch (units with
Supply unit fault reset main contactors only)
button “START” position closes the
main contactors and the supply
unit starts rectifying. In the
“OFF” position, the main
contactors are open.
Emergency stop button
(optional)
Auxiliary voltage switch-disconnector (not shown)
Controls the power supply to the auxiliary voltage
transformers, ground fault supervision, motor fan
supply, and the voltage display of the DSSB board.
Hardware description
27
Supply unit control electronics
The supply module(s) is controlled by the DSSB (Diode supply system board),
located inside the control and I/O cubicle. The DSSB is connected to – and powered
from – the supply module(s) via the quick connectors at the back of the modules.
The DSSB contains the following LEDs:
Unit display
Actual value display
Displayed actual value
- Three phase voltages Display selection keys
- Six phase currents
- DC link voltage
- DC link current
- DC link power (default)
Status LEDs
See chapter Fault tracing.
“READY” LED
DSU_DISPLAY.TIF
Hardware description
28
Reading and setting of values (page 1 of 2)
Setting power loss ride- Switching fault trip on/off for Activating earth current func-
through time 1) earth current function 2) tion and setting wake-up
level 2)
Continued
Display
Mode
+
on next
page …
Enter
Settings and autoexit (20 s.)
Diagn.
Mode
Set time in sec. (up and Select ON or OFF (down Select: NONE, 1, 2, …
autoexit (20 s.) down keys) key) [A] (up and down keys)
Display
Mode
+ +
autoexit (2 s.)
autoexit (2s.)
+
Press up key
Display
Mode
Press down key
+ Press up and down keys simultaneously
autoexit (2s.)
Direction of display change
Display
Mode
Setting accepted
1) For more information, see section Power loss ride-through
function on page 34.
2) For more information, see section Earth (ground) current
function on page 33.
Hardware description
29
Reading and setting of values (page 2 of 2)
Setting number of parallel Displaying diagnostics Setting overload
modules 3) codes supervision
… continued
from previous Display
Mode
page
exit
Set no. of parallel mod- EFC module Select ON or OFF (down
ules peak 4) count 5) key)
VAC phase balance
0-100% 6)
autoexit (2s.)
+
Display
Mode
Display autoexit (2s.)
Mode
Display
Mode
LED on
LED off
3) No. of modules (1...5). DSSB needs the value for scaling the current output
signal connected to current meters on cabinet door (optional equipment).
4) Displays earth current peak value
5) Displays module count set in AOS
6) Displays VAC phase balance
Hardware description
30
Terminal blocks
X500 Ribbon cable to DSCB board via module quick connector
X2 Measurement for actual value display (factory-wired)
1 DC+ Intermediate circuit voltage (+ and - busbars)
2 DC-
X3 Measurement for actual value display (factory-wired)
1 U Phase voltage
2 V Phase voltage
3 W Phase voltage
X4 24 V (or 48 V) output, short-circuit protected, live when AC power input of DSU is live
1 -24V Power supply output: +24 VDC / max. 3 A and -24 VDC / max. 0.5 A (or
2 +24V 48 VDC / max 0.5 A)
Note: Terminals can also be used to supply DSU control boards externally
3 Ground
during input power break. Use two 24 V / 1 A floating power supplies.
Connect between +24V & Ground and Ground & -24V.
X5 Remote digital inputs
See Digital input and relay output terminals on page 31.
X6, X7 Relay outputs
See Digital input and relay output terminals on page 31.
X8 Emergency stop input
See Emergency stop input on page 32.
X9 Phase current output for an external display device (e.g. a meter on the cabinet door).
For scaling, see Reading and setting of values (page 2 of 2) on page 29. Use single phase
meters. Connect the meter between the current output terminal and ground (cabinet frame).
Type tested and used by ABB: BQ307 by Iskra (www.iskra-mis.si).
1 U1.1 Phase current value as a 0…1 mA signal (= 0…nominal DSU current)
2 V1.1 Phase current value as a 0…1 mA signal (= 0…nominal DSU current)
3 W1.1 Phase current value as a 0…1 mA signal (= 0…nominal DSU current)
4 U1.2 Phase current value as a 0…1 mA signal (= 0…nominal DSU current)
5 V1.2 Phase current value as a 0…1 mA signal (= 0…nominal DSU current)
6 W1.2 Phase current value as a 0…1 mA signal (= 0…nominal DSU current)
X10 Local digital inputs
See Digital input and relay output terminals on page 31.
Hardware description
31
Digital input and relay output terminals
The DSU can be controlled through two control interfaces: local and remote. The
operation switches placed on the cabinet door are connected to the local control
interface. The remote control interface can be used in parallel when control by other
external devices is needed.
S11 S11
1 DSSB board terminals
1 3 ST
0 X10 Local digital inputs
1 START 0 -> 1: DSU closes main contactors and starts rectifying.
2 4
Note: Local ON input must be switched on.
1
0
1 2 ON 1: DSU is rectifying.1) 0: DSU stops rectifying and opens
START
contactors.
3
3 +24 V +24 VDC
S21 S21 4 RESET 0 -> 1: Reset
X1 13
13
14
5 RESET LED Ground for reset button LED
X2 14
X1
X2
0
1
6 +24 V +24 VDC
Digital input data X5 Remote digital inputs 2)
Input voltage: “1” = 15…48 VDC or 1-2 ON 1: DSU is rectifying.1) 0: DSU stops rectifying and opens
15…230 VAC. All inputs must be of the contactors. Note: If start command was given through local
same type (AC or DC). START input, DSU stops only after local ON input is
Internal connection: switched off.
3-4 START 0 -> 1: DSU closes main contactors and starts rectifying.
Note: Local and remote ON inputs must be switched on.
DI 5-6 RESET 0 -> 1: Reset
7-8 EXT.FAULT 1: External fault. DSU trips. 0: No external fault.
X6 Relay outputs 2)
1-2 RO1 Off: Fault
Relay output data 3 -
Contact rating: 4-5 RO2 On: Running
230 VAC / 1 A continuous X7 Relay outputs 2)
Internal connection: 1-2 RO3 Overtemperature warning
3 -
4-5 RO4 Off: Earth (ground) fault detected
RO
6 -
7-8 RO5 Off: Emergency stop acknowledgement to inverter
1) After the power switch-on, the DSU first charges the contactor control
capacitors (~ 3 s at first start) and checks the fault status. DSU starts rectifying
only after the contactors are closed by the START input.
2) These DSSB board terminals are wired to a separate terminal block to which
the user connections are to be made. See the circuit diagrams delivered with the
unit.
Hardware description
32
Emergency stop input
The DSSB board has a built-in logic that fulfils the emergency stop requirements
according to IEC/EN60204-1 / Category 0 (Immediate removal of power) provided
that:
• the Diode Supply Unit (DSU) is equipped with optional main contactors, and
• an emergency stop button is wired to the emergency stop input of the DSU. See
the figure below for connection to the DSSB board.
When the emergency stop is activated, the DSU stops and opens the main
contactors. Normal operation resumes after the emergency stop is deactivated and
the DSU is reset.
Note: Emergency stop according to category 0 and category 1 (controlled
emergency stop) are available as factory-installed options. The category 1 option
requires additional wirings that are not visible in the figure below. See the circuit
diagrams delivered with the unit for more information.
Emergency stop button wired to DSSB board
DSSB board terminals
X4
1 -24V -24 VDC
2 +24V +24 VDC
3 Ground Ground
X8 Emergency stop input
1 EM +24V 0: Emergency stop
2 EM -24V 0: Emergency stop
Note: The DSSB board terminals are wired to a separate terminal block to
which the user connections are made. See circuit diagrams delivered with the
unit.
Additional emergency stop buttons can be connected in series.
Hardware description
33
Earth (ground) current function
The control board (DSSB) measures the input currents of the diode supply unit. The
earth current function constantly monitors the sum of the phase currents. The chart
below describes the operation.
START
Is earth current
function active? 1) No
Yes
Is earth current
No above wake up level? 2)
Yes
Is fault trip
selection ON for the No
earth current function?
3)
Yes
DSU trips to a fault, illuminates DSU continues operation and DSU does not monitor earth
earth fault LED and energizes energizes relay output (earth current.
relay output (earth current current warning).
fault).
1) Function is inactive when the wake up level is set to NONE (default setting). See page 28.
2) See page 28 for setting/checking the wake up level of the earth current function.
3) See page 28 for the fault trip selection (ON = fault trip, OFF = warning).
For information on the LEDs, see the chapter Fault tracing.
Hardware description
34
Power loss ride-through function
The power loss ride-through function keeps the supply unit operative over an
unexpected input power break. The user can activate the function by setting the
power loss ride-through delay with the buttons on the DSSB board.
Note: Units with an air circuit breaker require an external UPS for the function to be
available.
The table below describes the operation of the function.
Duration of the What happens during the break What happens after the
break break
Shorter than If the DC voltage drops less than 30%, The supply unit resumes
power loss ride- • the diode bridge stays in normal operating rectifying automatically.
through time. mode, and
• the supply unit keeps the internal contactors
energised.
If the DC voltage drops more than 30%, The supply unit “wakes up”
• the diode bridge switches into charging automatically and
mode and further into stand-by (only the • closes the internal
DSSB board is kept live by a backup contactors,
capacitor), • charges the DC bus,
• relay output RO2 (Running) de-energises, • starts rectifying, and
and
• energises relay output RO2.
• the internal contactors open.
Longer than The supply unit stops and opens the main Operation continues only after
power loss ride- contactors. manual reset and restart.
through time.
The delay setting range is 0 to 40 seconds. For instructions on the setting, see page
28.
Inverter unit control
The inverter unit is controlled by an RDCU drive control unit located in the swing-out
frame. The RDCU is connected to the inverter modules by a fibre optic link,
distributed through an optical branching unit. In the inverter modules, the optic link
connects to the AINT board, the terminals of which are accessible through a hole on
the front panel of the module.
A control panel (type CDP-312R) is installed on the door of the drive. The CDP-312R
is the user interface of the inverters of the drive, providing the essential controls such
as Start/Stop/Direction/Reset/Reference, and the parameter settings for the drive
application program. See the Firmware Manual for further information.
Hardware description
35
This diagram shows the control interfaces of the inverter unit.
Drive control unit
(RDCU)
Control panel Optional module 1: I/O extension (RAIO,
Motor control
and I/O board RDIO), pulse encoder interface (RTAC), or
(RMIO) fieldbus adapter (e.g. RMBA, RDNA, RPBA)
Optional module 2: I/O extension (RAIO,
External control via RDIO) or pulse encoder interface (RTAC)
analogue/digital inputs Optional module 3: DDCS communication
and outputs option (RDCO-01, RDCO-02 or RDCO-03)
Input power To motor
Supply Inverter
module(s) module(s)
Brake choppers and
resistors (optional)
Motor control
The motor control is based on the Direct Torque Control (DTC) method. Two phase
currents and DC link voltage are measured and used for the control. The third phase
current is measured for earth fault protection.
Reduced run capability
If one of parallel-connected supply or inverter modules must be taken out of the
cabinet for service, it is possible to continue operation using the remaining modules,
albeit at reduced power. For directions, contact your local ABB representative.
Hardware description
36
Type code
The type code of the drive is indicated on the type designation label, attached on the
supply cubicle door. The type code contains information on the specifications and
configuration of the drive. The first digits from left express the basic configuration
(e.g. ACS800-07-0610-3). The optional selections are given thereafter, separated by
+ signs (e.g. +E202). The main selections are described below.
Note: The information below is for quick reference only and does not contain all
conditions and details. For more information, refer to ACS800 Ordering Information
(code: 64556568), available through ABB representatives.
Selection Alternatives
Product series ACS800 product series
Type 07 = cabinet-mounted
When no options are selected: IP21 (UL Type 1), main switch/
disconnector(s), 230 V auxiliary voltage, du/dt filtering (+E205), common
mode filtering (CMF) (+E208), EMC/RFI filtering for second environment
(+E210), Standard Application Program, bottom entry/exit of cables,
coated circuit boards, set of English manuals.
Size Refer to Technical data: Ratings.
Voltage range 3 = 380/400/415 VAC
(nominal rating in bold) 5 = 380/400/415/440/460/480/500 VAC
7 = 525/575/600/690 VAC
+ options
I/O options Refer to ACS800 Ordering Information (3AFY64556568 [English]).
Fieldbus adapter
Application program
Degree of protection B053 = IP22 (UL Type 1)
B054 = IP42 (UL Type 1)
B055 = IP54 (UL Type 12) (Not available with +C134)
B059 = IP54R (with connection to air outlet duct)
Construction C121 = Marine construction (reinforced mechanical parts and fastening,
marking of conductors [A1], door handles, self-extinctive materials)
C129 = UL Listed (115 V AC auxiliary voltage, cable conduit entries, all
components UL listed/recognized, max. supply voltage 600 V; +F253,
+F260 and top entry of cables are standard)
C134 = CSA Approved (as +C129, with CSA approved components)
Filters E202 = EMC/RFI filtering for first environment TN (grounded) system,
restricted (A-limits). Only for 6-pulse ACS800-07-0610-3 and -0760-5.
Requires +F253 and +F260.
E206 = Sine output filters (Not available with +C121, +C129 or +C134)
Note: du/dt filtering (+E205), common mode filtering (CMF) (+E208), and
EMC/RFI filtering for second environment (+E210) are standard
equipment.
Resistor braking D150 = brake choppers
D151 = brake resistors (not available in IP54 or IP54R)
Hardware description
37
Selection Alternatives
Line options F250+Q951 = line contactor + emergency stop (Category 0)
F250+Q952 = line contactor + emergency stop (Category 1)
F253+F260 = aR AC fuses + load switch-disconnector (6-pulse) (Load
switch-disconnectors in DSU modules removed)
A004+F253+F260 = aR AC fuses + load switch-disconnector (12-pulse)
(Load switch-disconnectors in supply modules removed) (with +C129
and +C134, second cubicle for load switch-disconnector added)
F255+F260+Q951 = air circuit breaker + emergency stop (Category 0)
(6-pulse only) (Not available with frame 1×D4 + n×R8i) (Load switch-
disconnectors and main contactors in supply modules removed)
F255+F260+Q952 = air circuit breaker + emergency stop (Category 1)
(6-pulse only) (Not available with frame 1×D4 + n×R8i) (Load switch-
disconnectors and main contactors in supply modules removed)
F259 = earthing switch (only with +F253 or +F255) (Not available with
+C129 or +C134)
Cabling H351 = top entry (IP54 and IP54R require +F253 or +F255)
H353 = top exit
H358 = US/UK gland/conduit plate (standard with +C129 and +C134)
H359 = common motor terminal cubicle
Auxiliary voltage G304 = 115 VAC auxiliary voltage (standard with +C129 and +C134)
Cabinet options G300 = cabinet heaters (external supply) (Not available with +C129 or
+C134)
G313 = motor heater output (external supply)
G307 = terminals for external control voltage (UPS)
G317 = busbar supply conductors (6-pulse only) (Requires +F253 or
+F255)
G330 = halogen-free wiring and materials (Not available with +C129 or
+C134)
Language of manuals Rxxx
Refer to ACS800 Ordering Information (3AFY64556568 [English]).
Starter of auxiliary motor M602 = 2.5 … 4 A (1, 2 or 4 pcs)
fan M603 = 4 … 6.3 A (1, 2 or 4 pcs)
M604 = 6.3 … 10 A (1, 2 or 4 pcs)
M605 = 10 … 16 A (1 or 2 pcs)
M606 = 16 … 25 A (1 pc)
Safety features Q950 = prevention of unexpected start (Category 3)
Q954 = earth fault monitoring (IT [ungrounded] system)
Q959 = red-coloured trip pushbutton for external breaker
Special P902 = customised (described in Technical appendix on ordering)
P904 = extended warranty
P913 = special colour
Hardware description
38
Hardware description
39
Mechanical installation
What this chapter contains
This chapter describes the mechanical installation procedure of the drive.
General
See chapter Technical data for allowable operating conditions and requirements for
free space around the unit.
The unit should be installed in an upright vertical position.
The floor that the unit is installed on should be of non-flammable material, as
smooth as possible, and strong enough to support the weight of the unit. The floor
flatness must be checked with a spirit level before the installation of the cabinets into
their final position. The maximum allowed deviation from the surface level is 5 mm in
every 3 metres. The installation site should be levelled, if necessary, as the cabinet
is not equipped with adjustable feet.
The wall behind the unit should be of non-flammable material.
Provide the drive with the amount of fresh cooling air given in Technical data.
Note: Very wide cabinet line-ups are delivered as “shipping splits”.
Required tools
The tools required for moving the unit to its final position, fastening it to the floor and
tightening the connections are listed below.
• crane, fork-lift or pallet truck (check load capacity!); iron bar, jack and rollers
• Pozidrive and Torx (2.5–6 mm) screwdrivers for the tightening of the frame
screws
• torque wrench
• set of wrenches or sockets for joining shipping splits.
Mechanical installation
40
Moving the unit
…by crane
Use the steel lifting lugs attached to the top of
the cabinet. Insert the lifting ropes or slings into
the holes of the lifting lugs.
The lifting lugs can be removed (not mandatory)
once the cabinet is in its final position. If the
lifting lugs are removed, the bolts must be
refastened to retain the degree of protection
of the cabinet.
IP54 units
Allowed minimum height of lifting ropes or slings
for IP54 units is 2 metres.
Mechanical installation
41
…by fork-lift or pallet truck
The centre of gravity may be quite high. Be therefore careful
when transporting the unit. Tilting the cabinets must be
avoided.
The units are to be moved only in the upright position.
If using a pallet truck, check its load capacity before
attempting to move the unit.
…on rollers
(Not allowed with Marine versions)
Remove the wooden bottom frame which is part of
the shipment.
Lay the unit on the rollers and move it carefully until
close to its final location.
Remove the rollers by lifting the unit with a crane,
fork-lift, pallet truck or jack as described above.
Laying the unit on its back
If the cabinet needs to be laid on its back, it
must be supported from below beside the
Cabinet back panel Support cubicle seams as shown.
Notes:
• Transportation of a unit on its back is only
allowed if the unit is equipped for such
transportation at the factory.
• Never lay or transport a unit with sine filters
(i.e. with option code +E206) on its back.
Mechanical installation
42
Final placement of the unit
The cabinet can be moved into its final position with an
iron bar and a wooden piece at the bottom edge of the
cabinet. Care is to be taken to properly place the
wooden piece so as not to damage the cabinet frame.
Mechanical installation
43
Before installation
Delivery check
The drive delivery contains:
• drive cabinet line-up
• optional modules (if ordered) installed into the control rack at the factory
• ramp for extracting supply and inverter modules from the cabinet
• hardware manual
• appropriate firmware manuals and guides
• optional module manuals
• delivery documents.
Check that there are no signs of damage. Before attempting installation and
operation, check the information on the type designation label of the drive to verify
that the unit is of the correct type. The label includes an IEC and NEMA rating, C-UL
US, and CSA markings, a type code and a serial number, which allow individual
recognition of each unit. The first digit of the serial number refers to the
manufacturing plant. The next four digits refer to the unit’s manufacturing year and
week respectively. The remaining digits complete the serial number so that there are
no two units with the same serial number.
The type designation label is located on the supply unit door.
Each power module (i.e. supply and inverter module) is also individually labelled.
Mechanical installation
44
Installation procedure
1 See detailed instructions in the following few
pages.
(1) The cabinet can be installed with its back
against a wall, or back-to-back with another unit.
Fasten the unit (or first shipping split) to the floor
A with fastening clamps or through the holes inside
A
the cabinet. See section Fastening the cabinet to
the floor (Non-marine units).
With marine versions, fasten the unit (or first
shipping split) to the floor and wall/roof as
described in section Fastening the unit to the floor
and wall (Marine units).
Note: A clearance of 400 mm minimum above the
basic roof level of the cabinet (see inset on left) is
Top clearances required for cooling.
> 320 mm (12.3”)
for fan replace- Note: Leave some space at the left-hand and
ment
> 400 mm > 400 mm
right-hand sides of the line-up (A) to allow the
(15.75”) (15.75”) doors to open sufficiently.
IP22/42 IP54
Note: Any height adjustment must be done before
fastening the units or shipping splits together.
Height adjustment can be done by using metal
shims between the bottom frame and floor.
2
(2) Remove the lifting bars (if present). In marine
units, also replace the lifting lugs with L-profiles
(see below). Use the original bolts to block any
unused holes.
(3) If the line-up consists of shipping splits, fasten
the first split to the second. Each shipping split
includes a joining cubicle where the busbars
connect to the next split.
(4) Fasten the second shipping split to the floor.
(5) Join the DC busbars and the PE busbars.
(6) Repeat steps (2) to (5) for the remaining
3 shipping splits.
Mechanical installation
45
Fastening the cabinet to the floor (Non-marine units)
The cabinet is to be fastened to the floor by using clamps along the edge of the
cabinet bottom, or by bolting the cabinet to the floor through the holes inside.
Clamping
Insert the clamps into the twin slots along the front and rear edges of the cabinet
frame body and fasten them to the floor with a bolt. The recommended maximum
distance between the clamps is 800 mm (31.5”).
If there is not enough working space behind the cabinet for mounting, replace the
lifting lugs at the top with L-brackets (not included) and fasten the top of the cabinet
to the wall.
Slot detail, front view
(dimensions in millimetres)
Clamp dimensions (in millimetres) Distances between slots
Cubicle Distance in millimetres and (inches)
Width
(mm)
Cabinet frame
300 150 (5.9”)
400 250 (9.85”)
Cabinet frame 600 450 (17.7”)
700 550 (21.65”)
800 650 (25.6”)
L-bracket
M16 screw
Cabinet top
Fastening the cabinet at the top with
L-brackets (side view)
Mechanical installation
46
Holes inside the cabinet
The cabinet can be fastened to the floor using the fastening holes inside the cabinet,
if they are accessible. The recommended maximum distance between the fastening
points is 800 mm (31.5”).
If there is not enough working space behind the cabinet for mounting, replace the
lifting lugs at the top with L-brackets (not included) and fasten the top of the cabinet
to the wall.
Fastening holes inside the
cabinet (arrowed)
L-bracket
M16 screw
25 mm (0.985”)
Cabinet top
Fastening the cabinet at the top with
L-brackets (side view)
Distances between fastening holes Added width:
Bolt size: M10 to M12 (3/8” to 1/2”). Side panels of the cabinet: 15 mm (0.6”)
Back panel of the cabinet: 10 mm (0.4”)
Cubicle Distance between holes Gap between cubicles (mm):
Width Outer
Ø31 mm (1.22”) IP 20...42 IP 54
300 150 mm (5.9”)
400 250 (9.85”) ≈ 0.5 ≈1
(0.02”) (0.04”)
600 450 (17.7”)
700 550 (21.65”)
800 650 (25.6”)
Mechanical installation
47
Fastening the unit to the floor and wall (Marine units)
The unit must be fastened to the floor and roof (wall) as follows:
Bolt the unit to the floor through the holes in
1
each flat bar at the base of the cabinet using
M10 or M12 screws.
If there is not enough room behind the cabinet
2
for installation, clamp the rear ends of the flat
bars as shown in figure (2).
Fasten the top of the cabinet to the rear wall
3
and/or roof using brackets.
Use M10 or M12 screws; welding is not
recommended (see section Electric
welding below).
2 3
L-bracket
Back panel of M16 bolt
Clamps cabinet
Flat bars at base of cabinet Cabinet
Fastening the cabinet at the top with
Clamping the cabinet to the brackets (side view)
floor at the back
Mechanical installation
48
Joining the shipping splits
The busbar systems and wiring harnesses of two shipping splits are joined in the
common motor terminal cubicle (if present) or a busbar joining cubicle. Special M6
screws for fastening the shipping splits together are enclosed in a plastic bag inside
the rightmost cubicle of the first shipping split. The threaded bushings are already
mounted on the post.
Threaded bushing
Procedure
Maximum tightening torque:
5 Nm (3 ft.-lbs)
7 7
• Fasten the front post of the joining section with 7 screws to the front frame post of
the next cubicle.
Mechanical installation
49
• Remove any intermediate or partitioning plates covering the rear posts of the
joining cubicle.
Partitioning
plate
Busbar joining Intermediate plate Back posts accessible
cubicle
• Fasten the rear post of the joining section with seven screws (below the busbar
joining part) to the rear post of the next cubicle.
• Replace all partitioning plates in the upper part of it after connecting the DC
busbars (see section Connecting the DC busbars and the PE busbar).
Connecting the DC busbars and the PE busbar
Horizontal main DC busbars and the PE busbar are connected from the front of the
joining cubicle. All necessary materials are located in the joining cubicle.
• Remove the front metal partitioning plate located in the busbar joining cubicle.
• Unscrew the bolts of the joint pieces.
• Connect the busbars with the joint pieces (see figure below). For aluminium
busbars, suitable anti-oxidant joint compound must be used to avoid corrosion
and to ensure good electrical connection. The oxide layer must be scrubbed off
from the joints before applying the compound.
• Refit all shrouds for safety of personnel.
Mechanical installation
50
DC busbars
The DC busbar connection is shown below.
1 1 Joint pieces
1
1
Tighten the bolts to
55–70 Nm (40–50 ft.-lbs.)
Side view of single busbar connection
PE busbar
The PE busbar runs continuously through the line-up near the floor at the back. The
connection is shown below. No separate nuts are needed.
Top view PE busbar
Tighten the screws to
55–70 Nm (40–50 ft.-lbs.)
Shipping split A Shipping split B
Mechanical installation
51
Miscellaneous
Cable duct in the floor below the cabinet
A cable duct can be constructed below the 400 mm wide middle part of the cabinet.
The cabinet weight lies on the two 100 mm wide transverse sections which the floor
must carry.
Viewed from above Side view
With heavy
cabinets support
the structural C-
sections from
below.
This area can be used for a
cable duct
Prevent the cooling air flow
from the cable duct to the
cabinet by bottom plates.
To ensure the degree of
protection for the cabinet
use the original bottom Cables
plates delivered with the
unit. With user-defined
cable entries, take care of
the degree of protection, fire
protection and EMC
compliance.
Mechanical installation
52
Cooling air intake through bottom of cabinet
Units with air intake through the bottom of the cabinet (optional feature) are intended
for installation on an air duct in the floor. The required air inlets in the floor are as
listed below. Refer also to the dimensional drawings delivered with the unit.
• for DSU supply cubicles: w × 505 mm, where w equals cubicle width – 50 mm
• for ISU supply cubicles, inverter unit cubicles, control cubicles, switch/breaker
cubicles: w × 400 mm, where w equals cubicle width – 50 mm
• w × 130 mm at the back of the cabinet line-up, where w equals the total width of
adjacent cubicles with air inlets. This area may or may not be consistent through
the width of the whole line-up.
Example
Diode supply cubicle Load switch-discon- Inverter cubicle Common motor
Cubicle width: 700 mm nector cubicle Cubicle width: 600 mm terminal cubicle
Air inlet size: Cubicle width: 400 mm Air inlet size: (No air inlet required)
650 × 505 mm Air inlet size: 550 × 400 mm
350 × 400 mm
Notes:
• The plinth of the cabinet must be supported all round.
• The air duct must be able to supply a sufficient volume of cooling air. The
minimum air flow values are given in the Technical data section of the Hardware
Manual.
• The cubicles of diode supply units require a larger air inlet area than other
cubicles.
• Some cubicles (mainly those without active, heat-generating components) require
no air inlet.
Mechanical installation
53
Electric welding
It is not recommended to fasten the cabinet by welding.
Cabinets without flat bars at the base
• Connect the return conductor of the welding equipment to the cabinet frame at
the bottom within 0.5 metres of the welding point.
Cabinets with flat bars at the base
• Weld only the flat bar under the cabinet, never the cabinet frame itself.
• Clamp the welding electrode onto the flat bar about to be welded or onto the floor
within 0.5 metres of the welding point.
WARNING! If the welding return wire is connected improperly, the welding circuit
may damage electronic circuits in the cabinet. The thickness of the zinc coating of
the cabinet frame is 100 to 200 micrometres; on the flat bars the coating is
approximately 20 micrometres. Ensure that the welding fumes are not inhaled.
Mechanical installation
54
Mechanical installation
55
Planning the electrical installation
What this chapter contains
This chapter contains the instructions that you must follow when selecting the motor,
cables, protections, cable routing and way of operation for the drive system.
Note: The installation must always be designed and made according to applicable
local laws and regulations. ABB does not assume any liability whatsoever for any
installation which breaches the local laws and/or other regulations. Furthermore, if
the recommendations given by ABB are not followed, the drive may experience
problems that the warranty does not cover.
Motor selection and compatibility
1. Select the motor according to the rating tables in chapter Technical Data. Use the
DriveSize PC tool if the default load cycles are not applicable.
2. Check that the motor ratings lie within the allowed ranges of the drive control
program:
• motor nominal voltage is 1/2 ... 2 · UN of the drive
• motor nominal current is 1/6 ... 2 · I2hd of the drive in DTC control and
0 ... 2 · I2hd in scalar control. The control mode is selected by a drive parameter.
3. Check that the motor voltage rating meets the application requirements:
• The motor voltage is selected according to the AC voltage feeding the drive
when the drive is equipped with a diode input bridge (a non-regenerative drive)
and will operate in motor mode (i.e. no braking).
• The motor nominal voltage is selected according to “the equivalent AC power
source voltage of the drive” if the intermediate DC circuit voltage of the drive is
increased from the nominal level by resistor braking or by the control program
of a regenerative IGBT line side converter (parameter selectable function).
The equivalent AC power source voltage for the drive is calculated as follows:
UACeq = UDCmax/1.35
where
UACeq = equivalent AC power source voltage of the drive
UDCmax = maximum intermediate DC circuit voltage of the drive
See notes 6 and 7 below the Requirements table.
Planning the electrical installation
56
4. Consult the motor manufacturer before using a motor in a drive system where the
motor nominal voltage differs from the AC power source voltage.
5. Ensure that the motor insulation system withstands the maximum peak voltage in
the motor terminals. See the Requirements table below for the required motor
insulation system and drive filtering.
Example: When the supply voltage is 440 V and the drive is operating in motor
mode only, the maximum peak voltage in the motor terminals can be
approximated as follows: 440 V · 1.35 · 2 = 1190 V. Check that the motor
insulation system withstands this voltage.
Protecting the motor insulation and bearings
The output of the drive comprises – regardless of output frequency – pulses of
approximately 1.35 times the equivalent mains network voltage with a very short rise
time. This is the case with all drives employing modern IGBT inverter technology.
The voltage of the pulses can be almost double at the motor terminals, depending on
the attenuation and reflection properties of the motor cable and the terminals. This in
turn can cause additional stress on the motor and motor cable insulation.
Modern variable speed drives with their fast rising voltage pulses and high switching
frequencies can cause current pulses that flow through the motor bearings, which
can gradually erode the bearing races and rolling elements.
The stress on motor insulation can be avoided by using optional ABB du/dt filters.
du/dt filters also reduce bearing currents.
To avoid damage to motor bearings, the cables must be selected and installed
according to the instructions given in this manual. In addition, insulated N-end (non-
driven end) bearings and output filters from ABB must be used according to the
following table. Two types of filters are used individually or in combinations:
• du/dt filtering (protects motor insulation system and reduces bearing currents).
• common mode filtering (CMF) (mainly reduces bearing currents).
Planning the electrical installation
57
Requirements table
The following table shows how to select the motor insulation system and when an
optional ABB du/dt filter, insulated N-end (non-driven end) motor bearings and ABB
common mode filters are required. The motor manufacturer should be consulted
regarding the construction of the motor insulation and additional requirements for
explosion-safe (EX) motors. Failure of the motor to fulfil the following requirements
or improper installation may shorten motor life or damage the motor bearings.
Motor type Nominal mains Requirement for
voltage (AC line
Motor insulation ABB du/dt filter, insulated N-end bearing and ABB common mode
voltage)
system filter
Manufacturer
PN < 100 kW 100 kW < PN < 350 kW PN > 350 kW
and or or
frame size < IEC 315 frame size > IEC 315 frame size > IEC 400
PN < 134 HP 134 HP < PN < 469 HP PN > 469 HP
and frame size or frame size or frame size
< NEMA 500 > NEMA 500 > NEMA 580
A Random- UN < 500 V Standard - +N + N + CMF
B wound M2_
500 V < UN < 600 V Standard + du/dt + du/dt + N + du/dt + N + CMF
and M3_
B or
Reinforced - +N + N + CMF
600 V < UN < 690 V Reinforced + du/dt + du/dt + N + du/dt + N + CMF
Form-wound 380 V < UN < 690 V Standard n.a. + N + CMF PN < 500 kW:
HX_ and AM_ + N + CMF
PN > 500 kW:
+ N + CMF + du/dt
Old* form- 380 V < UN < 690 V Check with the + du/dt with voltages over 500 V + N + CMF
wound HX_ motor
and modular manufacturer.
Random- 0 V < UN < 500 V Enamelled wire + N + CMF
wound HX_ with fibre glass
500 V < UN < 690 V + du/dt + N + CMF
and AM_ ** taping
N Random- UN < 420 V Standard: ÛLL = - + N or CMF + N + CMF
O wound and 1300 V
form-wound
N 420 V < UN < 500 V Standard: ÛLL = + du/dt + du/dt + N + du/dt + N + CMF
- 1300 V
or
A + du/dt + CMF
B
or
B
Reinforced: ÛLL = - + N or CMF + N + CMF
1600 V, 0.2 µs
rise time
500 V < UN < 600 V Reinforced: ÛLL = + du/dt + du/dt + N + du/dt + N + CMF
1600 V
or
+ du/dt + CMF
or
Reinforced: ÛLL = - + N or CMF + N + CMF
1800 V
600 V < UN < 690 V Reinforced: ÛLL = + du/dt + du/dt + N + du/dt + N + CMF
1800 V
Reinforced: ÛLL = - N + CMF N + CMF
2000 V, 0.3 µs
rise time ***
Planning the electrical installation
58
* manufactured before 1.1.1998
** For motors manufactured before 1.1.1998, check for additional instructions with the motor manufacturer.
*** If the intermediate DC circuit voltage of the drive will be increased from the nominal level by resistor braking or
by the IGBT supply unit control program (parameter selectable function), check with the motor manufacturer if
additional output filters are needed in the applied drive operation range.
Note 1: The abbreviations used in the table are defined below.
Abbreviation Definition
UN nominal voltage of the supply network
ÛLL peak line-to-line voltage at motor terminals which the motor insulation must withstand
PN motor nominal power
du/dt du/dt filtering at the output of the drive (+E205)
CMF common mode filtering (+E208)
N N-end bearing: insulated motor non-driven end bearing
n.a. Motors of this power range are not available as standard units. Consult the motor manufacturer.
Note 2: Explosion-safe (EX) motors
The motor manufacturer should be consulted regarding the construction of the motor insulation and
additional requirements for explosion-safe (EX) motors.
Note 3: High-output motors and IP 23 motors
For motors with higher rated output than what is stated for the particular frame size in EN 50347 (2001)
and for IP 23 motors, the requirements of ABB random-wound motor series M3AA, M3AP, M3BP are
given below. For other motor types, see the Requirements table above. Apply the requirements of
range “100 kW < PN < 350 kW” to motors with PN < 100 kW. Apply the requirements of range PN >
350 kW to motors within the range “100 kW < PN < 350 kW”. In other cases, consult the motor
manufacturer.
Manufacturer
Motor type Nominal mains Requirement for
voltage (AC line
Motor insulation ABB du/dt filter, insulated N-end bearing and ABB common mode
voltage) system filter
PN < 55 kW 55 kW < PN < 200 kW PN > 200 kW
PN < 74 HP 74 HP < PN < 268 HP PN > 268 HP
A Random- UN < 500 V Standard - +N + N + CMF
B wound M3AA,
500 V < UN < 600 V Standard + du/dt + du/dt + N + du/dt + N + CMF
B M3AP, M3BP
or
Reinforced - +N + N + CMF
600 V < UN < 690 V Reinforced + du/dt + du/dt + N + du/dt + N + CMF
Note 4: HXR and AMA motors
All AMA machines (manufactured in Helsinki) for drive systems have form-wound windings. All HXR
machines manufactured in Helsinki starting 1.1.1998 have form-wound windings.
Note 5: ABB motors of types other than M2_, M3_, HX_ and AM_
Use the selection criteria given for non-ABB motors.
Note 6: Resistor braking of the drive
When the drive is in braking mode for a large part of its operation time, the intermediate circuit DC
voltage of the drive increases, the effect being similar to increasing the supply voltage by up to 20
percent. The voltage increase should be taken into consideration when determining the motor insulation
requirement.
Example: Motor insulation requirement for a 400 V application must be selected as if the drive were
supplied with 480 V.
Note 7: Drives with an IGBT supply unit
Planning the electrical installation
59
If voltage is raised by the drive (this is a parameter selectable function for special applications only),
select the motor insulation system according to the increased intermediate circuit DC voltage level,
especially in the 500 V supply voltage range.
Note 8: Calculating the rise time and the peak line-to-line voltage
The peak line-to-line voltage at the motor terminals generated by the drive as well as the voltage rise
time depend on the cable length. The requirements for the motor insulation system given in the table
are “worst case” requirements covering installations with 30-metre and longer cables. The rise time can
be calculated as follows: t = 0.8 · ÛLL/(du/dt). Read ÛLL and du/dt from the diagrams below. Multiply
the values of the graph by the supply voltage (UN). In case of drives with an IGBT supply unit or resistor
braking, the ÛLL and du/dt values are approximately 20% higher.
3.0 5.5
ÛLL/UN 5.0
2.5 du/dt
------------- (1/μs)
4.5 UN
2.0 4.0
3.5
1.5
3.0
ÛLL/UN
1.0 2.5
du/dt
------------- (1/μs)
UN 2.0
0.5
1.5
0.0 1.0
100 200 300 100 200 300
Cable length (m) Cable length (m)
With du/dt Filter Without du/dt Filter
Note 9: Sine filters
Sine filters protect the motor insulation system. Therefore, a du/dt filter can be replaced with a sine
filter. The peak phase-to-phase voltage with a sine filter is approximately 1.5 × UN.
Permanent magnet synchronous motor
Only one permanent magnet motor can be connected to the inverter output.
It is recommended to install a safety switch between a permanent magnet
synchronous motor and the motor cable. The switch is needed to isolate the motor
during any maintenance work on the drive.
Thermal overload and short-circuit protection
Thermal overload protection of the drive and the input and motor cables
The drive protects itself and the input and motor cables against thermal overload
when the cables are dimensioned according to the nominal current of the drive. No
additional thermal protection devices are needed.
WARNING! If the drive is connected to multiple motors, a separate thermal overload
Planning the electrical installation
60
switch or a circuit breaker must be used for protecting each cable and motor. These
devices may require a separate fuse to cut off the short-circuit current.
Thermal overload protection of the motor
According to regulations, the motor must be protected against thermal overload and
the current must be switched off when overload is detected. The drive includes a
motor thermal protection function that protects the motor and switches off the current
when necessary. Depending on a drive parameter value, the function either monitors
a calculated temperature value (based on a motor thermal model) or an actual
temperature indication given by motor temperature sensors. The user can tune the
thermal model further by feeding in additional motor and load data.
See the firmware manual for more information on the motor thermal protection, and
the connection and use of the temperature sensors.
Protection against short-circuit in the motor cable
The drive protects the motor cable and the motor in a short-circuit situation when the
motor cable is dimensioned according to the nominal current of the drive. No
additional protection devices are needed.
Protection against short-circuit inside the drive or in the supply cable
• If the drive is equipped with internal AC fuses (option code +F260), install external
protection (such as fuses) at the supply to protect the input cable.
• If the drive is not equipped with AC input fuses, install external fuses at the supply
to protect the input cable and the drive. Use the AC fuse types listed in the
chapter Technical data on page 120, or equivalent fuses. Six fuses are needed for
each DSU module.
WARNING! Circuit breakers are not capable of providing sufficient protection
because they are inherently slower than fuses. Always use fuses with circuit
breakers.
Earth fault (Ground fault) protection
Both the supply unit and the inverter unit are equipped with an internal earth fault
protective function to protect the drive against earth faults in the drive, motor and
motor cable (This is not a personal safety or a fire protection feature). The function is
not active in the supply unit by default. Both earth fault protective functions can be
disabled; refer to User’s Manual of the supply unit and the Firmware Manual of the
drive application program respectively.
See the ACS800 Ordering Information (3AFY64556568 [English], available on
request) for other available earth fault protection options.
The EMC filter (if present) includes capacitors connected between the main circuit
and the frame. These capacitors and long motor cables increase the earth leakage
current and may cause fault current circuit breakers to function.
Planning the electrical installation
61
Emergency stop devices
For safety reasons, install the emergency stop devices at each operator control
station and at other operating stations where emergency stop may be needed.
Pressing the stop key ( ) on the control panel of the drive, or turning the operating
switch of the drive from position “1” to “0” does not generate an emergency stop of
the motor or separate the drive from dangerous potential.
An emergency stop function is optionally available for stopping and switching off the
whole drive. Two modes are available: immediate removal of power (Category 0)
and controlled emergency stop (Category 1).
Restarting after an emergency stop
After an emergency stop, the emergency stop button must be released and a reset
performed before the main contactor (or air circuit breaker) can be closed and the
drive started.
Prevention of unexpected start
The drive can be equipped with an optional prevention of unexpected start function
according to standards IEC/EN 60204-1: 1997; ISO/DIS 14118: 2000 and EN 1037:
1996. The circuit conforms to EN954-1, Category 3.
The function is achieved by disconnecting the control voltage to the power
semiconductors of the inverters of the drive. Thus it is not possible for the power
semiconductors to switch and generate the AC voltage needed to rotate the motor.
In case of faulty main circuit components, the DC voltage from the busbars can be
conducted to the motor but an AC motor cannot rotate without the field generated by
an AC voltage.
The operator activates the prevention of unexpected start function using a switch
mounted on a control desk. When the function is activated, the switch is opened, and
an indicator lamp will light.
WARNING! The prevention of unexpected start function does not disconnect the
voltage of the main and auxiliary circuits from the drive. Therefore maintenance work
on electrical parts of the drive can only be carried out after isolating the drive system
from the main supply.
Note: If a running drive is stopped by using the prevention of unexpected start
function, the drive will cut off the motor supply voltage and the motor will coast to
stop.
Selecting the power cables
General rules
Dimension the supply (input power) and motor cables according to local
regulations:
Planning the electrical installation
62
• The cable must be able to carry the drive load current. See chapter Technical
data for the rated currents.
• The cable must be rated for at least 70 °C maximum permissible temperature of
conductor in continuous use. For US, see Additional US requirements.
• The inductance and impedance of the PE conductor/cable (grounding wire) must
be rated according to permissible touch voltage appearing under fault conditions
(so that the fault point voltage will not rise excessively when an ground fault
occurs).
• 600 VAC cable is accepted for up to 500 VAC. For 690 VAC rated equipment, the
rated voltage between the conductors of the cable should be minimum 1 kV.
For drive frame size R5 and larger, or motors larger than 30 kW, symmetrical
shielded motor cable must be used (figure below). A four-conductor system can be
used up to frame size R4 with up to 30 kW motors, but shielded symmetrical motor
cable is recommended.
Note: When continuous conduit is employed, shielded cable is not required.
A four-conductor system is allowed for input cabling, but shielded symmetrical cable
is recommended. To operate as a protective conductor, the shield conductivity must
be as follows when the protective conductor is made of the same metal as the phase
conductors:
Cross-sectional area of the phase Minimum cross-sectional area of the
conductors corresponding protective conductor
S (mm2) Sp (mm2)
S < 16 S
16 < S < 35 16
35 < S S/2
Compared to a four-conductor system, the use of symmetrical shielded cable
reduces electromagnetic emission of the whole drive system as well as motor
bearing currents and wear.
Note: The cabinet configuration of the drive may require multiple supply and/or
motor cabling. Refer to the connection diagrams in Electrical installation.
The motor cable and its PE pigtail (twisted screen) should be kept as short as
possible in order to reduce electromagnetic emission as well as capacitive current.
Planning the electrical installation
63
Alternative power cable types
Power cable types that can be used with the drive are represented below.
Recommended
Symmetrical shielded cable: three phase conductors A separate PE conductor is required if the conductivity
and a concentric or otherwise symmetrically of the cable shield is < 50 % of the conductivity of the
constructed PE conductor, and a shield phase conductor.
PE conductor Shield
and shield Shield
PE
PE
PE Shield
A four-conductor system:
three phase conductors
and a protective
conductor.
Not allowed for motor cables Not allowed for motor cables with phase
conductor cross section larger than 10 mm2
(motors > 30 kW).
Motor cable shield
To effectively suppress radiated and conducted radio-frequency emissions, the
shield conductivity must be at least 1/10 of the phase conductor conductivity. The
requirements are easily met with a copper or aluminium shield. The minimum
requirement of the motor cable shield of the drive is shown below. It consists of a
concentric layer of copper wires with an open helix of copper tape. The better and
tighter the shield, the lower the emission level and the bearing currents.
Copper wire screen Helix of copper tape Inner insulation
Insulation jacket
Cable core
Additional US requirements
Type MC continuous corrugated aluminum armor cable with symmetrical grounds or
shielded power cable must be used for the motor cables if metallic conduit is not
used. For the North American market, 600 VAC cable is accepted for up to 500 VAC.
1000 VAC cable is required above 500 VAC (below 600 VAC). For drives rated over
100 amperes, the power cables must be rated for 75 °C (167 °F).
Planning the electrical installation
64
Conduit
Where conduits must be coupled together, bridge the joint with a ground conductor
bonded to the conduit on each side of the joint. Bond the conduits also to the drive
enclosure. Use separate conduits for input power, motor, brake resistors, and control
wiring. When conduit is employed, type MC continuous corrugated aluminum armor
cable or shielded cable is not required. A dedicated ground cable is always required.
Do not run motor wiring from more than one drive in the same conduit.
Armored cable / shielded power cable
The motor cables can be run in the same cable tray as other 460 V or 600 V power
wiring. Control and signal cables must not be run in the same tray as power cables.
Six conductor (3 phases and 3 ground) type MC continuous corrugated aluminum
armor cable with symmetrical grounds is available from the following suppliers (trade
names in parentheses):
• Anixter Wire & Cable (Philsheath)
• BICC General Corp (Philsheath)
• Rockbestos Co. (Gardex)
• Oaknite (CLX).
Shielded power cables are available from Belden, LAPPKABEL (ÖLFLEX) and
Pirelli, among others.
Planning the electrical installation
65
Power factor compensation capacitors
Power factor compensation is not needed with AC drives. However, if a drive is to be
connected to a system with compensation capacitors already installed, note the
following restrictions.
WARNING! Do not connect power factor compensation capacitors to the motor
cables (between the drive and the motor). They are not meant to be used with AC
drives and can cause permanent damage to the drive or themselves.
If there are power factor compensation capacitors in parallel with the three-phase
input of the drive:
• Do not connect a high-power capacitor to the power line while the drive is
connected. The connection will cause voltage transients that may trip or even
damage the drive.
• If capacitor load is increased/decreased step by step when the AC drive is
connected to the power line, ensure that the connection steps are low enough not
to cause voltage transients that would trip the drive.
• Check that the power factor compensation unit is suitable for use in systems with
AC drives, i.e. harmonic-generating loads. In such systems, the compensation
unit should typically be equipped with a blocking reactor or harmonic filter.
Equipment connected to the motor cable
Installation of safety switches, contactors, connection boxes, etc.
To minimize the emission level when safety switches, contactors, connection boxes
or similar equipment are installed in the motor cable between the drive and the
motor:
• EU: Install the equipment in a metal enclosure with 360 degrees grounding for the
shields of both the incoming and outgoing cables, or in another way connect the
shields of the cables together.
• US: Install the equipment in a metal enclosure in a way that the conduit or motor
cable shielding runs consistently without breaks from the drive to the motor.
Bypass connection
WARNING! Never connect the supply power to the drive output terminals U2, V2
and W2. If frequent bypassing is required, employ mechanically connected switches
or contactors. Mains (line) voltage applied to the output can result in permanent
damage to the unit.
Before opening an output contactor (in DTC motor control mode)
Stop the drive and wait for the motor to stop before opening a contactor between the
output of the drive and the motor when the DTC control mode is selected. (See the
Planning the electrical installation
66
Firmware Manual of the drive for the required parameter settings.) Otherwise, the
contactor will be damaged.
In scalar control, the contactor can be opened with the drive running.
Relay output contacts and inductive loads
Inductive loads (such as relays, contactors, motors) cause voltage transients when
switched off.
The relay contacts of the RMIO board are protected with varistors (250 V) against
overvoltage peaks. In spite of this, it is highly recommended to equip inductive loads
with noise attenuating circuits (varistors, RC filters [AC] or diodes [DC]) in order 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 the protective components at the terminal block.
Relay outputs
Varistor
RO (NC)
RO (C)
230 VAC
RO (NO)
RC filter
RO (NC)
230 VAC RO (C)
RO (NO)
Diode
RO (NC)
24 VDC RO (C)
RO (NO)
Planning the electrical installation
67
Selecting the control cables
All control cables must be shielded.
Use a double-shielded twisted pair cable (see figure a) for analogue signals. This
type of cable is recommended for the pulse encoder signals also. Employ one
individually shielded pair for each signal. Do not use common return for different
analogue signals.
A double-shielded cable is the best alternative for low-voltage digital signals but
single-shielded twisted multipair cable (figure b) is also usable.
a b
Double-shielded twisted Single-shielded twisted
pair cable pair cable
Run analogue and digital signals in separate, shielded 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-controlled
signals be run as twisted pairs.
Never mix 24 VDC and 115 / 230 VAC signals in the same cable.
Relay cable
The cable type with braided metallic screen (e.g. ÖLFLEX LAPPKABEL, Germany)
has been tested and approved by ABB.
Control panel cable
In remote use, the cable connecting the control panel to the drive must not exceed 3
metres (10 ft). The cable type tested and approved by ABB is used in control panel
option kits.
Coaxial cable (for use with Advant Controllers AC 80/AC 800)
• 75 ohm
• RG59, diameter 7 mm or RG11, diameter 11 mm
• Maximum cable length: 300 m (1000 ft)
Planning the electrical installation
68
Connection of a motor temperature sensor to the drive I/O
WARNING! IEC 60664 requires double or reinforced insulation between live parts
and the surface of accessible parts of electrical equipment which are either non-
conductive or conductive but not connected to the protective earth.
To fulfil this requirement, the connection of a thermistor (and other similar
components) to the digital inputs of the drive can be implemented in three alternate
ways:
1. There is double or reinforced insulation between the thermistor and live parts of
the motor.
2. Circuits connected to all digital and analogue inputs of the drive are protected
against contact and insulated with basic insulation (the same voltage level as the
drive main circuit) from other low voltage circuits.
3. An external thermistor relay is used. The insulation of the relay must be rated for
the same voltage level as the main circuit of the drive. For connection, see the
Firmware Manual.
Installation sites above 2000 metres (6562 feet)
WARNING! Protect against direct contact when installing, operating and servicing
the RMIO board wiring and optional modules attached to the board. The Protective
Extra Low Voltage (PELV) requirements stated in EN 50178 are not fulfilled at
altitudes above 2000 m (6562 ft).
Routing the cables
Route the motor cable away from other cable routes. Motor cables of several drives
can be run in parallel installed next to each other. It is recommended that the motor
cable, input power cable and control cables be installed on separate trays. Avoid
long parallel runs of motor cables with other cables in order to decrease
electromagnetic interference caused by the rapid changes in the drive output
voltage.
Where control cables must cross power cables make sure they are arranged at an
angle as near to 90 degrees as possible. Do not run extra cables through the drive.
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.
Planning the electrical installation
69
A diagram of the cable routing is below.
Motor cable
Drive
min 300 mm (12 in.)
Power cable
Input power cable Motor cable
min 200 mm (8 in.) 90 ° min 500 mm (20 in.)
Control cables
Control cable ducts
24 V 230/120 V 24 V 230/120 V
Not allowed unless the 24 V Lead 24 V and 230/120 V control
cable is insulated for 230/120 V cables in separate ducts inside
or insulated with insulation the cabinet.
sleeving for 230/120 V.
Planning the electrical installation
70
Planning the electrical installation
71
Electrical installation
What this chapter contains
This chapter describes the electrical installation procedure of the drive.
WARNING! Only qualified electricians are allowed to carry out the work described in
this chapter. Follow the Safety instructions on the first pages of this manual. Ignoring
the safety instructions can cause injury or death.
WARNING! During the installation procedure, the supply and inverter modules may
have to be temporarily extracted from the cabinet. The modules are heavy, and have
a high centre of gravity. In order to minimise the danger of toppling over, keep the
sheet metal support supplied with the drive attached to the modules whenever
manoeuvring them outside the cabinet.
Before installation
Checking the insulation of the assembly
Every drive has been tested for insulation between the main circuit and the chassis
(2500 V rms 50 Hz for 1 second) at the factory. Therefore, do not make any voltage
tolerance or insulation resistance tests (e.g. hi-pot or megger) on any part of the
drive. When checking the insulation of the assembly, proceed in the following
manner:
WARNING! Check the insulation before connecting the drive to the supply. Make
sure that the drive is disconnected from the supply (input power).
Motor and motor cable
Check the insulation of the motor and motor cable as follows:
1. Check that the motor cable is connected to the motor, and disconnected from the
drive output terminals U2, V2 and W2.
2. Measure the insulation resistance of the motor cable and motor between each
phase and the Protective Earth using a measuring voltage of 500 VDC. The
insulation resistance of an ABB motor must exceed 10 Mohm (reference value at
25 °C). For the insulation resistance of other motors, please consult the
manufacturer's instructions.
Electrical installation
72
• Note: Moisture inside the motor casing will reduce the insulation resistance. If this
is suspected, dry the motor and repeat the measuring.
U1
M
V1
3~
ohm W1
PE
IT (ungrounded) systems
EMC filter +E202 is not suitable for use in an IT (ungrounded) system. If the drive is
equipped with EMC filter +E202, disconnect the filter before connecting the drive to
the supply network. For detailed instructions on how to do this, please contact your
local ABB representative.
WARNING! If a drive with EMC filter +E202 is installed on an IT system [an
ungrounded power system or a high resistance-grounded (over 30 ohms) power
system], the system will be connected to earth potential through the EMC filter
capacitors of the drive. This may cause danger or damage the unit.
Setting the earth fault (ground fault) trip level
Grounded systems
See page 28.
IT (ungrounded) systems
On ungrounded systems, an external monitoring unit (Bender IRDH265 or IRDH275,
option +Q954) is used. Refer to its documentation for set-up instructions.
Note: On ungrounded systems, the internal earth current monitoring must be
deactivated. See page 28.
Electrical installation
73
Input power connection – Units without load switch-disconnector or air
circuit breaker
Connection diagrams
6-pulse connection, two supply modules in parallel
PE PE
L11
L21
L31
L12
*)
L22
L32
L1
L2
L3
L11
L21
L31
L12
*)
L22
L32
Notes:
• No parallel cabling is shown here.
• Each input terminal of the supply modules must be fed through a dedicated fuse. The fuses are
specified in Technical data.
*) Contactors are optional
Electrical installation
74
12-pulse connection, two supply modules in parallel
PE PE
L11
L21
L31
*)
L12
L1 L22
L2 L32
L3
L1
L2
L3
L11
L21
L31
*)
L12
L22
L32
Notes:
• No parallel cabling (for each module) is shown here.
It is also possible to connect all input power terminals of module 1 to the transformer Y-output and
module 2 to the transformer D-output. Note, however, that then the two bridges inside a single
module do not form a 12-pulse connection any more. This means that the benefits of the 12-pulse
connection are not available during a temporary operation with one module out of use (e.g. for
maintenance).
• Each input terminal of the supply modules must be fed through a dedicated fuse. The fuses are
specified in Technical data.
• The secondaries of the transformer must not be grounded.
*) Contactors are optional
Electrical installation
75
Connection procedure
WARNING! The supply modules are heavy and have a high centre of gravity. Be careful when
manoeuvring the modules.
Removal of module:
(1) Turn the supply (rectifier) module switch-disconnector handle to open
position.
(2) Release the door handle and open the supply unit door.
(3) Remove the fastening screws at the top of the module.
(3b) Units with marine construction (+C121) only: Remove fan (see page
107 for instructions) and the two fastening screws at the rear bottom of the
3
module frame.
(4) Loosen the connector locking screw (hexagonal socket head).
(5) Place the module pull-out ramp against the cabinet base. Make sure 4
the ramp is secured to the cabinet frame.
(6) Pull the module carefully out of the cabinet along the ramp. 6
3b
Remove the plastic insulators covering the input power terminals.
Lead the cables into the inside of the cabinet. Make the 360° earthing
arrangement at the cable entries as shown below.
Grommet (in
IP54 units only)
Connect the cables as follows:
• Twist the cable shields to bundles and connect to cabinet PE (ground)
busbar. Connect the separate ground conductors/cables to cabinet PE
(ground) busbar.
• Connect the phase conductors to the input power terminals (U1.1 …).
Depending on the cable size, use cable lugs or dual-cable screw lug
connectors. For details on the terminals and tightening torques, see
Technical data – Input power connection on page 122, and section Use of
the dual-cable screw lug connector below.
Refit the plastic insulators onto the input power terminals.
Push the module back in – mind your fingers – and tighten the fastening screws. Tighten the connector
locking screw to 4 Nm (3 lbf.ft). Please note that the module can only mate with the quick connector when
the switch-disconnector is in open position.
Remove the module pull-out ramp and close the cubicle doors.
Electrical installation
76
Use of the dual-cable screw lug connector
1
2
3
Removal of the dual-cable screw lug connector
Electrical installation
77
Input power connection – Units with load switch-disconnector or air
circuit breaker
Connection diagrams
6-pulse connection, two supply modules in parallel
PE PE
*) 1L1
L1 Switching,
1L2
L2 breaking,
1L3 disconnecting
L3
and grounding
**) devices ***)
Incoming cubicle
***)
Supply module cubicle
Notes:
*)
Fuses are not required if the input power line is constructed of busbars that withstand the transformer short
circuit current.
**)
The cable lead-through details (number and size of holes), and cable connection details (number and
dimensions of busbars, tightening torque) are given in chapter Technical data, section Input power
connection.
***)
There are no contactors inside the supply module(s) when the drive is equipped with an air circuit breaker.
Electrical installation
78
12-pulse connection, two supply modules in parallel
PE PE
*) 1L1 Switching, breaking,
disconnecting and
1L2
grounding devices
1L3
2L1
***)
Switching, breaking,
2L2 disconnecting and
2L3 grounding devices
**)
Incoming cubicle
***)
Supply module cubicle
Notes:
*)
Fuses are not required if the input power line is constructed of busbars that withstand the transformer
short circuit current.
**)
No bridging (connecting 1L1 to 2L1, 1L2 to 2L2, and 1L3 to 2L3) is allowed!
There are two separate incoming cubicles – one for terminals 1L1, 1L2 and 1L3, the other for 2L1, 2L2
and 2L3 – if a) the unit is equipped with air circuit breakers, b) the drive is UL listed, or c) the incoming
cubicle is designed for a busbar connection.
The cable lead-through details (number and size of holes), and cable connection details (number and
dimensions of busbars, tightening torque) are given in chapter Technical data, section Input power
connection.
***)
There are no contactors inside the modules when the drive is equipped with air circuit breakers.
Electrical installation
79
Connection procedure
Open the door of the incoming (load switch-disconnector or air circuit breaker) cubicle.
Remove any shrouds covering the input terminals and cable entries.
Lead the cables into the cubicle. Make the 360° earthing arrangement at the cable entries as shown below.
Grommet (in IP54
units only)
Cut the cables to suitable length.
Strip the cables and conductors.
Twist the cable screens into bundles and connect to cabinet PE (ground) busbar.
Connect the separate ground conductors/cables to cabinet PE (ground) busbar.
Connect the phase conductors to the input terminals using the torques given in chapter Technical data,
section Input power connection.
Refit the shrouds removed earlier.
Close the door.
Electrical installation
80
Motor connection – Units without common motor terminal cubicle
Output busbars
The motor cables are to be connected to the output busbars behind each inverter
module. The location and dimensions of the busbars are visible in the dimensional
drawings delivered with the drive, as well as the example drawings presented in this
manual.
Connection diagram
The diagram below shows a drive with a single inverter module. 360° earthing is to
be used at cable entries.
PE
U2
V2
U1
V1
M
W2
W1 3~
PE
Inverter unit cubicle
The recommended cable types are given in chapter Planning the electrical installation.
Whenever the inverter unit consists of parallel-connected inverter modules, all the
modules (two are shown below) are to be cabled separately to the motor.
PE
U2
V2
W2
U1
V1
M
W1 3~
U2 PE
V2
W2
Inverter unit cubicle
The recommended cable types are given in chapter Planning the electrical installation.
Electrical installation
81
WARNING! The cabling from all inverter modules to the motor must be physically
identical considering cable type, cross-sectional area, and length.
PE
U2
V2
W2
U1
V1
M
W1 3~
U2 PE
V2
W2
Inverter unit cubicle
Electrical installation
82
Connection procedure
WARNING! The inverter modules are heavy and have a high centre of gravity. Be careful when
manoeuvring the modules. In order to minimise the danger of toppling over, keep the support legs
of the modules extended whenever manoeuvring the modules outside the cabinet.
Extract each inverter module from the cubicle as follows:
(1) Open the door of the inverter cubicle.
(2) Remove the shroud covering the upper part of the cubicle.
(3) Open the transparent cover on the front of the inverter module and disconnect the fibre optic cables.
Move the cables aside.
(4) Remove the L-shaped DC busbars on top of the module.
(5) Disconnect the terminal block (X50) next to the DC busbars.
(6) Remove the two module fastening screws (6a) at the top. At the base of the module, loosen the two
fastening screws (6b) but leave them in place; lift the bracket (6c) into the up position.
(7) Insert the module pull-out ramp under the two screws at the base of the module and tighten.
(8) Pull the module carefully out of the cubicle along the ramp. Make sure the wires do not catch.
(9) Extend the support legs of the module. Keep the legs extended until the module is about to be inserted
back into the cubicle.
6a
4
3
8
9a 9b
6c
6b
Electrical installation
83
Lead the cables into the cabinet below each inverter module. Make the 360° earthing arrangement at the
cable entry as shown.
Grommet (in IP54
units only)
Cut the cables to suitable length.
Strip the cables and conductors.
Twist the cable screens into bundles and connect to cabinet PE (ground) busbar.
Connect any separate ground conductors/cables to cabinet PE (ground) busbar.
Connect the phase conductors to the output terminals.
Use the tightening torques specified in Technical data – Motor connection on page 124.
Insert each inverter module into the cubicle as follows:
(1) Move the inverter module close to the ramp, then retract the support legs of the module.
(2) Push the module back into the cubicle – mind your fingers.
(3) Refasten the module fixing screws at the top, reconnect the DC busbars.
(4) Reconnect the cables (X50, fibre optic cables).
(5) Loosen the module fastening screws at the base of the module and remove the pull-out ramp. Flip the
module fastening bracket into the down position and tighten the screws.
Close the doors.
At the motor, connect the cables according to instructions from the motor manufacturer. Pay special
attention to the phase order.
For minimum radio frequency interference:
• ground the cable shield 360 degrees at the lead-through of the motor terminal box
360 degrees grounding
Conductive gaskets
• or ground the cable by twisting the shield as follows: flattened width > 1/5 × length.
b > 1/5 × a
b
a
Electrical installation
84
Motor connection – Units with common motor terminal cubicle
Connection diagram
PE
U2
V2
U1
V1
M
W2
W1 3~
PE
Inverter unit cubicle Common motor terminal
cubicle
The recommended cable types are given in chapter Planning the electrical installation.
Connection procedure
See the connection procedure on page 83.
Electrical installation
85
Control connections
Drive control connections
The control connections are made on the terminal blocks provided in the swing-out
frame of the drive. Refer to the circuit diagrams delivered with the drive, and to the
chapter Motor control and I/O board (RMIO).
Supply unit control connections
The supply unit is controlled using the local control devices mounted on the cabinet
door, or the buttons on the DSSB board. No external control connections by the user
are needed. However, the user can connect certain external devices to the supply
module. It is possible to:
• control the supply unit through the remote control inputs (On, Start, Reset,
External fault)
• halt the supply unit by an external emergency stop button (if the unit is equipped
with a local emergency stop button)
• read supply unit’s status information through the relay outputs (Fault, Running,
External 48 VDC supply on, Earth fault, emergency stop)
• feed the supply unit’s control boards from an external +48 VDC supply.
Refer to the circuit diagrams delivered with the drive for the connection terminals for
the external control devices. For additional information on the control connections
see the ACA631/633 Cabinet-installed Diode Supply Unit (DSU) User’s Manual
(Code: 64735501 [English]), available through ABB representatives.
Electrical installation
86
Connection procedure
Turn the supply (rectifier) unit switch-disconnector into open position.
Release the door handle and open the door of the control and I/O cubicle.
Remove the two locking screws at the edge of the swing-out frame and open the frame.
Run the cables into the inside of the cabinet through the grommets provided.
Top entry units only: If several cables need to be run through one grommet, use Loctite 5221 (cat. no.
25551) under the grommet to seal the cable entry.
Run the cables between the EMI conductive cushions as shown below. Strip the cable at this location to
enable proper connection of the bare shield and the cushions. Tighten the cushions firmly onto the cable
shields.
Side view
Strain relief EMI conductive
cushions
Grommet Lead-through plate
If the outer surface of a cable shield is non-conductive, turn the shield inside out as shown below and
apply copper foil to keep the shielding continuous. Do not cut the grounding wire (if present).
Stripped cable Conductive surface of Stripped part covered
the shield exposed with copper foil
Copper foil
Cable shield Shielded twisted pair
Grounding wire
On top entry units, sort the cables so that the thinnest and thickest cables are at opposite ends of the
opening.
Top view
Thickest cable Thinnest cable
Electrical installation
87
Run the cables to the swing-out frame as shown below. Wherever possible, use the existing cable trunking
(1) in the cabinet. Use sleeving wherever the cables are laid against sharp edges. Leave some slack in the
cable at the hinge (2) to allow the frame to open fully. Tie the cables to the braces (3) to provide strain
relief.
Swing-out frame open Cable routing example
3
1
Cut the cables to suitable length. Strip the cables and conductors.
Twist the cable shields into bundles and connect them to the ground terminal nearest to the terminal block.
Keep the unshielded portion of the cables as short as possible.
Connect the conductors to appropriate terminals (see the chapter Motor control and I/O board (RMIO) and
the circuit diagrams delivered with the unit).
Close the swing-out frame, refasten, and close the doors.
Electrical installation
88
Installation of optional modules and PC
The optional module (such as fieldbus adapter, I/O extension module and the pulse
encoder interface) is inserted into the optional module slot of the RDCU drive control
unit) and fixed with two screws. See the appropriate optional module manual for
further instructions.
Cabling of I/O and fieldbus modules
Module
Keep unshielded portion as
short as possible
Shield
1
2
3
4
To nearest PE terminal
Cabling of pulse encoder interface module
CHASSIS
Note 1: If the encoder is of unisolated
RTAC-01
PULSE ENCODER INTERFACE
GND
12345678 123456
SHLD
F01
type, ground the encoder cable at the
AB E
23 6
SHLD
CD
45
789
CHA
drive end only. If the encoder is
CHA+
CHB
CHA-
X2
Keep unshielded portion as
WD/
galvanically isolated from the motor
CHB+
INIT
CHB-
NODE ID
short as possible CHZ+
CHZ- shaft and the stator frame, ground the
0V
0V
encoder cable shield at the drive and
the encoder end.
1
2
3
4
V OUT
+15V
X1
V IN
+24V
Note 2: Twist the pair cable wires.
Fibre optic link
A DDCS fibre optic link is provided via the RDCO optional module for PC tools,
master/follower link, NDIO, NTAC, NAIO, AIMA I/O module adapter and fieldbus
adapter modules of type Nxxx. See RDCO User’s Manual [3AFE 64492209
(English)] for the connections. Observe colour coding when installing fibre optic
cables. Blue connectors go to blue terminals, and grey connectors to grey terminals.
When installing multiple modules on the same channel, connect them in a ring.
Electrical installation
89
Connections and tap settings of the auxiliary voltage transformer
3~ Input
Primary
Secondary
Output
3~ input 1~ output 3~ output
Supply Tap settings Supply 230 V 115 V 400 V (50 Hz) 320 V (60 Hz)
Terminals
voltage A1 to... B1 to… C1 to… voltage Terminals Tap setting Terminals Tap setting Terminals Terminals
690 V A1, B1, C1 C2 A2 B2 690 V a3, n1 230– a4, n1 115– a1, b1, c1 a2, b2, c2
660 V A1, B1, C1 C2 A2 B2 660 V a3, n1 230+ a4, n1 115+ a1, b1, c1 a2, b2, c2
600 V A1, B1, C1 C3 A3 B3 600 V a3, n1 230– a4, n1 115– a1, b1, c1 a2, b2, c2
575 V A1, B1, C1 C3 A3 B3 575 V a3, n1 230+ a4, n1 115+ a1, b1, c1 a2, b2, c2
525 V A1, B1, C1 C4 A4 B4 525 V a3, n1 230– a4, n1 115– a1, b1, c1 a2, b2, c2
500 V A1, B1, C1 C4 A4 B4 500 V a3, n1 230+ a4, n1 115+ a1, b1, c1 a2, b2, c2
480 V A1, B1, C1 C5 A5 B5 480 V a3, n1 230– a4, n1 115– a1, b1, c1 a2, b2, c2
460 V A1, B1, C1 C5 A5 B5 460 V a3, n1 230+ a4, n1 115+ a1, b1, c1 a2, b2, c2
440 V A1, B1, C1 C6 A6 B6 440 V a3, n1 230– a4, n1 115– a1, b1, c1 a2, b2, c2
415 V A1, B1, C1 C6 A6 B6 415 V a3, n1 230+ a4, n1 115+ a1, b1, c1 a2, b2, c2
400 V A1, B1, C1 C7 A7 B7 400 V a3, n1 230– a4, n1 115– a1, b1, c1 a2, b2, c2
380 V A1, B1, C1 C7 A7 B7 380 V a3, n1 230+ a4, n1 115+ a1, b1, c1 a2, b2, c2
Installation of brake resistors
See the chapter Resistor braking.
Electrical installation
90
Electrical installation
91
Motor control and I/O board (RMIO)
What this chapter contains
This chapter shows
• external control connections to the RMIO board for the the ACS800 Standard
Application Program (Factory Macro)
• specifications of the inputs and outputs of the board.
To which products this chapter applies
This chapter applies to ACS800 units which employ the RMIO board.
Note on cabinet-installed ACS800 drives
The terminals of the RMIO board are optionally wired to terminal block X2. The
connections shown below apply also to terminal block X2 (the markings are identical
to the ones on the RMIO board).
Terminals of X2 accept cables from 0.5 to 4.0 mm2 (22 to 12 AWG). The tightening
torque for screw terminals is 0.4 to 0.8 Nm (0.3 to 0.6 lbf.ft). For disconnecting wires
from spring terminals, use a screwdriver with a blade thickness of 0.6 mm (0.024”)
and width of 3.5 mm (0.138”), e.g. Phoenix Contact SZF 1-0,6X3,5.
Note on terminal labelling
Optional modules (type Rxxx) may have terminal designations that coincide with
those of the RMIO board.
Motor control and I/O board (RMIO)
92
Note on external power supply
External +24 V power supply for the RMIO board is recommended if
• the application requires a fast start after the connection of the input power
• fieldbus communication is required when input power is disconnected.
The RMIO board can be supplied from an external power source via terminal X23 or
X34 or via both X23 and X34. The internal power supply to terminal X34 can be left
connected when using terminal X23.
WARNING! If the RMIO board is supplied from an external power source via
terminal X34, the loose end of the cable removed from the RMIO board terminal
must be secured mechanically to a location where it cannot come into contact with
electrical parts. If the screw terminal plug of the cable is removed, the wire ends
must be individually insulated.
WARNING! If the RMIO board is powered from two power supplies (connected to
X23 and X34), and the external power supply connected to X23 is also used to
power external equipment, equip the RMIO branch of the circuit with a diode as
shown below. The diode ensures that the RMIO board will not be damaged by
overcurrent in case the external power supply fails.
X34
RMIO 2 + External or
internal power
3 - supply
X23
+ 1 +24V Auxiliary voltage output
+24 V DC and input, non-isolated,
- 2 GND 24 V DC 250 mA
Other
equipment
Parameter settings
In the Standard Application Program, set parameter 16.09 CTRL BOARD SUPPLY
to EXTERNAL 24V if the RMIO board is powered from an external supply.
Motor control and I/O board (RMIO)
93
External control connections (non-US)
External control cable connections to the RMIO board for the ACS800 Standard
Application Program (Factory Macro) are shown below. For external control
connections of other application macros and programs, see the appropriate
Firmware Manual.
X20
Terminal block size: 1 VREF- Reference voltage -10 VDC, 1 kohm < RL <
cables 0.3 to 3.3 mm2 (22 to 12 AWG) 2 AGND 10 kohm
Tightening torque: X21
0.2 to 0.4 Nm (0.2 to 0.3 lbf ft) 1 VREF+ Reference voltage 10 VDC, 1 kohm < RL <
2 AGND 10 kohm
3 AI1+ Speed reference 0(2) ... 10 V, Rin >
4 AI1- 200 kohm
5 AI2+ By default, not in use. 0(4) ... 20 mA, Rin =
6 AI2- 100 ohm
7 AI3+ By default, not in use. 0(4) ... 20 mA, Rin =
8 AI3- 100 ohm
rpm 9 AO1+ Motor speed 0(4)...20 mA = 0...motor nom.
10 AO1- speed, RL < 700 ohm
A 11 AO2+ Output current 0(4)...20 mA = 0...motor
12 AO2- nom. current, RL < 700 ohm
X22
1 DI1 Stop/Start
1) Only effective if par. 10.03 is set to 2 DI2 Forward/Reverse 1)
REQUEST by the user. 3 DI3 Not in use
4 DI4 Acceleration & deceleration select 2)
2) 0 = open, 1 = closed 5 DI5 Constant speed select 3)
DI4 Ramp times according to 6 DI6 Constant speed select 3)
0 parameters 22.02 and 22.03 7 +24VD +24 VDC max. 100 mA
1 parameters 22.04 and 22.05 8 +24VD
9 DGND1 Digital ground
3)
See par. group 12 CONSTANT
10 DGND2 Digital ground
SPEEDS.
11 DIIL Start interlock (0 = stop) 4)
DI5 DI6 Operation
0 0 Set speed through AI1
X23
1 0 Constant speed 1 1 +24V Auxiliary voltage output and input, non-
0 1 Constant speed 2 2 GND isolated, 24 VDC 250 mA 5)
1 1 Constant speed 3 X25
1 RO1 Relay output 1: ready
4) See parameter 21.09 START INTRL 2 RO1
FUNC. 3 RO1
5) Total maximum current shared
X26
between this output and optional
modules installed on the board. 1 RO2 Relay output 2: running
2 RO2
3 RO2
X27
1 RO3 Relay output 3: fault (-1)
Fault 2 RO3
3 RO3
Motor control and I/O board (RMIO)
94
External control connections (US)
External control cable connections to the RMIO board for the ACS800 Standard
Application Program (Factory Macro US version) are shown below. For external
control connections of other application macros and programs, see the appropriate
Firmware Manual.
X20
Terminal block size: 1 VREF- Reference voltage -10 VDC, 1 kohm < RL <
cables 0.3 to 3.3 mm2 (22 to 12 AWG) 2 AGND 10 kohm
Tightening torque: X21
0.2 to 0.4 Nm (0.2 to 0.3 lbf ft) 1 VREF+ Reference voltage 10 VDC, 1 kohm < RL <
2 AGND 10 kohm
3 AI1+ Speed reference 0(2) ... 10 V, Rin >
4 AI1- 200 kohm
5 AI2+ By default, not in use. 0(4) ... 20 mA, Rin =
6 AI2- 100 ohm
7 AI3+ By default, not in use. 0(4) ... 20 mA, Rin =
8 AI3- 100 ohm
rpm 9 AO1+ Motor speed 0(4)...20 mA = 0...motor nom.
10 AO1- speed, RL < 700 ohm
A 11 AO2+ Output current 0(4)...20 mA = 0...motor
12 AO2- nom. current, RL < 700 ohm
X22
1 DI1 Start ( )
1) Only effective if par. 10.03 is set to 2 DI2 Stop ( )
REQUEST by the user. 3 DI3 Forward/Reverse 1)
4 DI4 Acceleration & deceleration select 2)
2) 0 = open, 1 = closed 5 DI5 Constant speed select 3)
DI4 Ramp times according to 6 DI6 Constant speed select 3)
0 parameters 22.02 and 22.03 7 +24VD +24 VDC max. 100 mA
1 parameters 22.04 and 22.05 8 +24VD
9 DGND1 Digital ground
3)
See par. group 12 CONSTANT
10 DGND2 Digital ground
SPEEDS.
11 DIIL Start interlock (0 = stop) 4)
DI5 DI6 Operation
0 0 Set speed through AI1
X23
1 0 Constant speed 1 1 +24V Auxiliary voltage output and input, non-
0 1 Constant speed 2 2 GND isolated, 24 VDC 250 mA 5)
1 1 Constant speed 3 X25
1 RO1 Relay output 1: ready
4) See parameter 21.09 START INTRL 2 RO1
FUNC. 3 RO1
5) Total maximum current shared
X26
between this output and optional
modules installed on the board. 1 RO2 Relay output 2: running
2 RO2
3 RO2
X27
1 RO3 Relay output 3: fault (-1)
Fault 2 RO3
3 RO3
Motor control and I/O board (RMIO)
95
RMIO board specifications
Analogue inputs
With Standard Application Program two programmable differential current inputs
(0 mA / 4 mA ... 20 mA, Rin = 100 ohm) and one programmable differential voltage
input (-10 V / 0 V / 2 V ... +10 V, Rin > 200 kohm).
The analogue inputs are galvanically isolated as a group.
Isolation test voltage 500 VAC, 1 min
Max. common mode voltage ±15 VDC
between the channels
Common mode rejection ratio > 60 dB at 50 Hz
Resolution 0.025 % (12 bit) for the -10 V ... +10 V input. 0.5 % (11 bit) for the 0 ... +10 V and 0 ...
20 mA inputs.
Inaccuracy ± 0.5 % (Full Scale Range) at 25 °C (77 °F). Temperature coefficient: ± 100 ppm/°C
(± 56 ppm/°F), max.
Constant voltage output
Voltage +10 VDC, 0, -10 VDC ± 0.5 % (Full Scale Range) at 25 °C (77 °F). Temperature
coefficient: ± 100 ppm/°C (± 56 ppm/°F) max.
Maximum load 10 mA
Applicable potentiometer 1 kohm to 10 kohm
Auxiliary power output
Voltage 24 VDC ± 10 %, short circuit proof
Maximum current 250 mA (shared between this output and optional modules installed on the RMIO)
Analogue outputs
Two programmable current outputs: 0 (4) to 20 mA, RL < 700 ohm
Resolution 0.1 % (10 bit)
Inaccuracy ± 1 % (Full Scale Range) at 25 °C (77 °F). Temperature coefficient: ± 200 ppm/°C
(± 111 ppm/°F) max.
Digital inputs
With Standard Application Program six programmable digital inputs (common ground:
24 VDC, -15 % to +20 %) and a start interlock input. Group isolated, can be divided in
two isolated groups (see Isolation and grounding diagram below).
Thermistor input: 5 mA, < 1.5 kohm “1” (normal temperature), > 4 kohm “0”
(high temperature), open circuit “0” (high temperature).
Internal supply for digital inputs (+24 VDC): short circuit proof. An external 24 VDC
supply can be used instead of the internal supply.
Isolation test voltage 500 VAC, 1 min
Logical thresholds < 8 VDC “0”, > 12 VDC “1”
Input current DI1 to DI 5: 10 mA, DI6: 5 mA
Filtering time constant 1 ms
Motor control and I/O board (RMIO)
96
Relay outputs
Three programmable relay outputs
Switching capacity 8 A at 24 VDC or 250 VAC, 0.4 A at 120 VDC
Minimum continuous current 5 mA rms at 24 VDC
Maximum continuous current 2 A rms
Isolation test voltage 4 kVAC, 1 minute
DDCS fibre optic link
With optional communication adapter module RDCO. Protocol: DDCS (ABB
Distributed Drives Communication System)
24 VDC power input
Voltage 24 VDC ± 10%
Typical current consumption 250 mA
(without optional modules)
Maximum current consumption 1200 mA (with optional modules inserted)
The terminals on the RMIO board as well as on the optional modules attachable to the board fulfil the Protective Extra
Low Voltage (PELV) requirements stated in EN 50178 provided that the external circuits connected to the terminals also
fulfil the requirements and the installation site is below 2000 m (6562 ft). Above 2000 m (6562 ft), see page 68.
Motor control and I/O board (RMIO)
97
Isolation and grounding diagram
(Test voltage: 500 V AC)
X20
1 VREF-
2 AGND
X21
1 VREF+
2 AGND
3 AI1+
4 AI1- Common mode
voltage between
5 AI2+
channels ±15 V
6 AI2-
7 AI3+
8 AI3-
9 AO1+
10 AO1-
11 AO2+
12 AO2-
X22
1 DI1
2 DI2
3 DI3
4 DI4
Jumper J1 settings:
9 DGND1
5 DI5 All digital inputs share a common
J1
6 DI6 ground. This is the default setting.
7 +24VD
8 +24VD Grounds of input groups
11 DIIL DI1…DI4 and DI5/DI6/DIIL
or
are separate (isolation
10 DGND2 voltage 50 V).
X23
1 +24 V
2 GND
X25
1 RO1
2 RO1
3 RO1
X26
1 RO2
2 RO2
3 RO2
X27
1 RO3
2 RO3
3 RO3
(Test voltage:
4 kV AC)
Ground
Motor control and I/O board (RMIO)
98
Motor control and I/O board (RMIO)
99
Installation checklist and start-up
Installation checklist
Check the mechanical and electrical installation of the drive before start-up. Go
through the checklist below together with another person. Read the Safety
instructions on the first pages of this manual before you work on the unit.
Check…
MECHANICAL INSTALLATION
The ambient operating conditions are allowed. See Electrical installation, Technical data: Ratings or Ambient
conditions.
The unit is fixed properly to floor. See Mechanical installation.
The cooling air will flow freely.
ELECTRICAL INSTALLATION See Planning the electrical installation, Electrical installation.
The motor and the driven equipment are ready for start.
The EMC filter (option +E202) is disconnected if the drive is connected to an IT (ungrounded) system.
The drive is grounded properly.
The supply (input power) voltage matches the nominal input voltage of the drive.
The supply (input power) connection to the input terminals are OK and the phase order is correct.
Appropriate supply (input power) fuses and disconnector are installed.
The motor connections at the output terminals are OK.
The motor cable is routed away from other cables.
Settings of the auxiliary voltage transformer.
There are no power factor compensation capacitors in the motor cable.
The external control connections inside the drive are OK.
There are no tools, foreign objects or dust from drilling inside the drive.
Supply (input power) voltage cannot be applied to the output of the drive (with a bypass connection).
For drives with Category 1 Emergency stop function: The time relay has been set to a suitable value (e.g.
somewhat longer than the stop ramp of the inverter units).
All shrouds are in place.
Installation checklist and start-up
100
Start-up procedure
Action Additional information
WARNING! Ensure that the disconnector of the supply transformer is
locked to open position, i.e. no voltage is, or cannot be connected to
drive inadvertently. Check also by measuring that there is no voltage
connected.
Basic checks with no voltage connected
If the unit is equipped with an air circuit breaker, check the current trip Optional device. See the delivery
limits of the breaker (preset at the factory). specific circuit diagrams.
General rule
Ensure the selectivity condition is fulfilled i.e. the breaker trips at a lower
current than the protection device of the supplying network, and that the
limit is high enough not to cause unnecessary trips during the
intermediate DC circuit load peak at start.
Long-term current limit
As a rule of thumb, this should be set to the rated AC current of the
module.
Peak current limit
As a rule of thumb, this should be set to a value 3-4 times the rated AC
current of the module.
Check the settings of the relays and breakers/switches of the auxiliary Optional devices. See delivery
circuits. specific circuit diagrams.
Disconnect any unfinished or unchecked 230/115 VAC cables that lead
from the terminal blocks to the outside of the equipment.
Locate the PPCS branching unit (APBU-xx). Enable memory backup By default, memory backup is
battery by setting actuator 6 of switch S3 to ON. switched off to save the battery.
Connecting voltage to input terminals and auxiliary circuit
WARNING! When voltage is connected to the input terminals, voltage
may also be connected to the auxiliary circuits of the drive.
Make sure that it is safe to apply voltage. Ensure that:
• nobody is working on the unit or circuits that are wired from outside into
the cabinets
• cabinet doors are closed
• covers of motor terminal boxes are in place.
Open the earthing/grounding switch (if present). The earthing/grounding switch and
the main disconnecting device are
either mechanically or electrically
interlocked so that the earthing/
grounding switch can only be closed
when the main disconnecting switch
is open, and vice versa.
Close the supply (rectifier) unit switch-disconnector. On units with line contactors, the
supply unit charges the contactor
control capacitors (3 s at first start).
The supply unit performs a fault
status check.
Close the main breaker of the supply transformer.
Close the auxiliary circuit On/Off switch.
Installation checklist and start-up
101
Action Additional information
Starting the supply unit
WARNING! If the drive is equipped with a brake unit, make sure there If there is not enough capacitive load
are inverters connected to the intermediate circuit before start. As a rule at start, the DC voltage will overshoot
of thumb, the sum capacitance of the inverters connected must be at the controller voltage limit, causing
least 30% of the sum capacitance of all inverters. immediate start of braking. An
unloaded supply unit keeps the DC
voltage high and the chopper
remains conductive.
Units with line contactors: Close the contactors and start the supply unit
by turning the start switch on the cabinet door from 0 into START
position for 2 seconds.
Checks with the supply unit running
Activate and check the operation of the power loss ride-through See chapter Hardware description.
function. (Only if automatic restart is required/allowed after a short power
supply break.)
Check the settings of the earth fault (ground fault) monitoring device. See chapter Electrical installation.
Application program set-up
Follow the instructions in the Firmware Manual to start up the drive and
to set the drive parameters.
On-load checks
Check that the Prevention of Unexpected Start function (if installed) Optional function. See delivery
works: specific circuit diagrams.
• Start and Stop the drive and wait until the motor has stopped.
• Open the Prevention of Unexpected Start switch (mounted on a control
desk).
• Give a Start command. The drive should not start.
• Reset the drive.
Check that the cooling fans rotate freely in the right direction, and the air Check visually that the fans rotate in
flows upwards. the direction indicated by an arrow
on the fan housing.
Check the direction of rotation of the motor.
Check the correct operation of the emergency-stop circuits from each
operating location.
Installation checklist and start-up
102
Installation checklist and start-up
103
Maintenance
What this chapter contains
This chapter contains preventive maintenance instructions.
Safety instructions
Only a qualified electrician is allowed to perform the maintenance.
Before starting work inside the cabinet,
• isolate the drive from the supply (note that the switch-disconnector on the door
does not switch off the voltage from the input terminals)
• wait for 5 minutes to let the intermediate circuit capacitors discharge
• open the cabinet doors
• ensure there is no dangerous voltage present by measuring the voltage of the
input terminals and the intermediate circuit terminals.
Maintenance
104
Maintenance intervals
If installed in an appropriate environment, the drive requires very little maintenance.
This table lists the routine maintenance intervals recommended by ABB.
Interval Maintenance action Instructions
See document ACS 600/800 Capacitor Reforming
Every year of storage Capacitor reforming Guide (Code: 3BFE 64059629 [English]) and
Capacitors.
Every 6 to 12 months (depending Heatsink temperature
See Heatsinks.
on dustiness of environment) check and cleaning
Air filter check;
Every year (IP22 and IP42 units) See Replacing the PPCS branching unit (APBU-xx)
replacement if necessary
memory backup battery.
Every year (IP54 units) Air filter replacement
Cooling fan check;
Every 3 years See Cooling fans.
replacement if necessary
Power connections check
Every 3 years See Power connections.
and cleaning
Every 6 years Cooling fan change See Cooling fans.
PPCS branching unit Locate the APBU unit. See section Replacing the
Every 6 years (APBU-xx) – Memory PPCS branching unit (APBU-xx) memory backup
backup battery renewal battery on page 105.
Every 10 years (if drive subjected
Capacitor change See Capacitors.
to high ambient temperature)
Every 12 years Capacitor change See Capacitors.
Maintenance
105
Replacing the PPCS branching unit (APBU-xx) memory backup battery
1. Switch off the power to the unit.
2. Open the screws on the cover (3 pcs).
3. Slide off the cover.
4. Remove the battery.
5. Insert the new CR 2032 battery and reattach the cover.
2 3 4
Maintenance
106
Checking and replacing the air filters
1. Read and repeat the steps in Safety instructions above.
2. Open the cabinet doors.
3. Check the air filters and replace if necessary (see Technical data for the correct
filter types). The inlet (door) filters can be accessed by removing the fastener(s) at
the top of the grille, then lifting the grille and pulling it away from the door. The
outlet (roof) filter in IP54 units has a similar mechanism.
4. Check the cleanliness of the cabinet. Clean the interior of the cabinet if necessary
using a soft brush and a vacuum cleaner.
5. Close the cabinet doors.
Power connections
1. Read and repeat the steps in section Safety instructions above.
2. Open the cabinet doors.
3. Extract one supply or inverter module from the cabinet as described in the
connection procedures in the chapter Electrical installation.
4. Check the tightness of the cable connections at the quick connector. Use the
tightening torque table in Technical data.
5. Clean all contact surfaces of the quick connector and apply a layer of suitable joint
compound (e.g. Isoflex® Topas NB 52 from Klüber Lubrication) onto them.
6. Re-insert the supply/inverter module.
7. Repeat steps 3 to 6 for all remaining supply and inverter modules.
Maintenance
107
Cooling fans
Power module cooling fans
The lifespan of the cooling fans of the supply and inverter modules is about 50 000
hours. The actual lifespan depends on the running time of the fan, ambient
temperature and dust concentration. Each supply and inverter module has its own
cooling fan. Replacements are available from ABB. Do not use other than ABB
specified spare parts.
The application program keeps track of the running time of the cooling fan of the
inverter modules. See the Firmware Manual delivered with the drive for the actual
signal which indicates the running time.
Supply module fan replacement
1. Read and repeat the steps in section Safety instructions above.
2. Open the supply cubicle doors.
3. Loosen the locking screw (1).
4. Disconnect the fan wiring plug (2).
5. Pull out the fan (3).
6. Install a new fan in reverse order.
Maintenance
108
Inverter module fan replacement
1. Read and repeat the steps in section Safety instructions above.
2. Open the inverter cubicle doors.
3. Disconnect the fan wiring plug (1).
4. Remove the locking screws (2).
5. Pull the fan out along its sliding rails (3).
6. Install a new fan in reverse order.
Maintenance
109
Control and I/O cubicle cooling fans
The cooling fans inside the control and I/O cubicle can be replaced as follows:
1. Read and repeat the steps in section Safety instructions above.
2. Open the door of the control and I/O cubicle (or combined control, I/O and supply
cubicle).
3. Detach the wiring from each fan (AC plug and grounding wire).
4. Undo the four fastening screws of the fan assembly and pull the assembly
outwards to gain access to the fan fastening screws.
5. Undo the fastening screws of the fans (there are four for each fan) from below.
Remove the fans.
6. Install new fans in reverse order. Before fastening the fans, make sure the airflow
arrow on both fans is pointed up.
3 3
4
5
Maintenance
110
Air circuit breaker cubicle fans
Some IP2x/IP4x units with an air circuit breaker are also fitted with two fans at the air
outlet on the roof. The fans are fastened to the grating (1) which can be removed by
undoing the four screws (2). If necessary, undo the screws labelled (3) to remove the
airflow guide (4).
2
2 3
4
3
IP54 (UL type 12) fan replacement
1. Remove the front and back gratings of the fan cubicle by lifting them upwards.
2. Remove the shrouds by undoing the fastening screws.
3. Undo the fastening screws of the side/top cover of the fan.
4. Lift the side/top cover of the fan off.
5. Disconnect the fan supply wire connector from the cabinet roof (on top and
inside the cabinet).
6. Undo the fastening screws of the fan cassette at each corner.
7. Lift the fan cassette off.
8. Undo the cable ties on the top of the fan cassette.
9. Disconnect the cables (detachable terminals).
10. Remove the fan capacitor by undoing the fastening screw of the clamp.
11. Undo the fastening screws of the fan.
12. Pull the fan out.
13. Install the new fan and fan capacitor in reverse order to the above. Ensure that
the fan is centred and rotates freely.
Maintenance
111
2 2 4
1
3
2
2
3
7
6
5
5
10
9
8
8
9
8 8
12
11 11
Maintenance
112
Heatsinks
The heatsink fins of the power modules pick up dust from the cooling air. The module
runs into overtemperature warnings and faults if the heatsinks are not clean. In a
“normal” environment (not especially dusty nor clean) the heatsinks should be
checked annually, in a dusty environment more often.
Whenever necessary, clean the heatsinks as follows:
1. Remove the cooling fan (see section Cooling fans).
2. Blow dry clean compressed air from bottom to top and simultaneously use a
vacuum cleaner at the air outlet to trap the dust. Note: Prevent the dust from
entering adjoining equipment.
3. Refit the cooling fan.
Capacitors
The inverter modules employ several electrolytic capacitors. Their lifespan is at least
90 000 hours depending on the operating time of the drive, loading and ambient
temperature. Capacitor life can be prolonged by lowering the ambient temperature.
It is not possible to predict capacitor failure. Capacitor failure is usually followed by
damage to the unit and an input cable fuse failure, or a fault trip. Contact ABB if
capacitor failure is suspected.
Reforming
Reform (re-age) spare part capacitors once a year according to ACS 600/800
Capacitor Reforming Guide (code: 64059629 [English], available through your local
ABB representative.
Capacitor replacement
Contact an ABB service representative.
Other maintenance actions
Power module replacement
To replace power modules (i.e. supply and inverter modules), follow the instructions
on module removal and refitting given in the chapter Electrical installation.
Maintenance
113
Fault tracing
What this chapter contains
This chapter instructs in interpreting the LED indications of the ACS800-07.
Note: Information on warnings and faults reported by the application program (and
displayed on the CDP-312R drive control panel on the cabinet door) are contained
within the Firmware Manual delivered with the drive.
Supply unit status, fault and warning LEDs
LEDs on DSSB board LEDs on supply module front
(inside control and I/O cubicle)
, 0 , m 0 0 m, 0 m m m m
D C F u s , 0 e 0 , 0m F ,0 m m
0 ma m i l m u r e P o w e r
F a n F , a 0 0 i l mu rm e F a n F u ll S p e e d
,0 m m
O v e r T e m p F , 0a 0 i l m u m r e O v e rT e m p W a r n in g
P h a s e L 1 .1 M i, 0 s 0 s m i n m g P h a s e L 1 .2 M is s in g
P h a s e L 2 .1 M is s in g P h a s e L 2 .2 M is s in g
,0 m m
,0 m m
,1 3 m m
P h a s e L 3 .1 M is s in g P h a s e L 3 .2 M is s in g
C o d e : 6 x 4 x 6 x 9 x 4 x x8 x 8 x 3
, 0 0 ,m 0 m m m
LED Cause What to do
LEDs on the DSSB board
FAN FAILURE Cooling fan failure. Change fan.
SUPPLY MISSING LED blinks and Phase L_._ Missing Change main circuit AC fuse. Change fuse on DSAB
LED on module cover blinks: Main board or DSAB board. Check and tighten input
circuit AC fuse has blown, fuse on power terminals.
DSAB-01C board has blown, or input
power terminal is loose.
LED blinks but no Phase L_._ Missing Change blown auxiliary circuit AC fuse. Change
LED on module cover blinks: Auxiliary blown main circuit AC fuse. Check and tighten input
circuit AC fuse of Diode Supply Unit power terminals.
has blown, main circuit AC fuse of
branches L1.1, L2.1 or L3.1 of the first
DSU module has blown, or input power
terminal is loose.
LED on: DSU overload or faulty DSSB Check load. Are all parallel-connected supply
control board. modules in place? Decrease load or replace missing
module. Change faulty DSSB board.
Fault tracing
114
LED Cause What to do
OVER TEMP FAULT Supply unit has exceeded temperature Check ambient temperature. Check cooling air flows
fault limit. freely. Check fan operation. Check inlet and outlet air
filters. Check heatsink for dust pick-up.
DC FUSE DC fuse blown. Change DC fuse.
EXTERNAL FAULT Digital input indicates external fault. Fix external fault. Check status of digital input.
EM STOP / Blinking: Internal fault detected by DSU Check fuses on circuit boards.
OTHER FAULT control program, e.g:
- DSU charging failed or exceeded Reset DSU and restart.
allowed duration (5 s.).
- Module switch-disconnectors do not Check operation of switch-disconnectors (optional
open/close, or DSSB board receives equipment). Check status signal. Check/tighten
false switch-disconnector status signal signal connections. Replace module (or
(auxiliary contact). switchdisconnector.)
- Emergency stop circuit is open, or not Release emergency stop button. Check connections
connected correctly. of the emergency stop circuit.
- Loose connectors -X4 or -X8 on Check that connectors -X4 and -X8 are properly
DSSB board. fastened.
- 4A fuse(s) blown on DSSB board. Measure +/-24VDC from DSSB board connectors
-X4 and -X8. Change the 4A circuit board fuses F1
and F2 of DSSB board.
On: Check operation of contactors (optional). Check
- Module contactors do not open, or status signal. Check/tighten signal connections.
DSSB board receives false contactor Replace module (or contactor).
status signal (auxiliary contact). Reset DSU and restart.
EARTH FAULT Supply load imbalance due to earth Check motor, and motor cable. Ensure there are no
fault leakage current in drive, motor power factor correction capacitors or surge
cable or motor. absorbers connected to the system. If all of the
above are OK, raise earth fault trip level; see the
ACA631/633 User’s Manual for Cabinet-installed
Diode Supply Unit (code: 64735501 [English]).
OVER TEMP WARN Supply unit has exceeded temperature See OVER TEMP FAULT above.
warning limit.
READY Blinking: Supply module contactor is off Contactors off: Close contactors.
or module is charging intermediate Contactors on: Wait until supply unit has charged
circuit. Input terminals are live and intermediate circuit (i.e LED illuminates steadily) and
module switch-disconnectors are start to load the unit.
switched on. However, unit cannot be
loaded yet.
On: DSU is in operation and can be Load/control DSU.
loaded; Input terminals are live, module
switch-disconnectors and contactors
are on, intermediate circuit capacitors
have been charged.
LEDs on supply module front
DC Fuse Failure See DC FUSE above. See DC FUSE above.
Power See READY above. See READY above.
Fault tracing
115
LED Cause What to do
Fan Failure See FAN FAILURE above. See FAN FAILURE above.
Fan Full Speed Cooling fan rotates at maximum speed. -
Over Temp Fault See OVER TEMP FAULT above. See OVER TEMP FAULT above.
Over Temp Warning See OVER TEMP WARN above. See OVER TEMP FAULT above.
Phase L_._ Missing See SUPPLY MISSING above. See SUPPLY MISSING above.
Note: A fault indication LED normally stays lit after the fault is detected. However,
the LED will blink during an input power break to minimise back-up battery current
consumption. The battery discharge time is 30 … 60 minutes.
Other LEDs of the drive
Location LED Indication
RMIO board (RDCU drive control Red Drive in fault state.
unit)
Green The power supply on the board is OK.
Control panel mounting platform Red Drive in fault state
(with the control panel removed)
Green The main + 24 V power supply for the control panel and the
RMIO board is OK.
AINT board (visible through the V204 (green) +5 V voltage of the board is OK.
transparent cover on the front of the
V309 (red) Prevention of unexpected start is ON.
inverter modules)
V310 (green) IGBT control signal transmission to the gate driver control
boards is enabled.
Fault tracing
116
Fault tracing
117
Technical data
What this chapter contains
This chapter contains the technical specifications of the drive, e.g. ratings, frame
sizes and technical requirements, provisions for fulfilling the requirements for CE
and other markings, and warranty information.
Ratings
The ratings for the ACS800-07 with 50 Hz and 60 Hz supplies are given below. The
symbols are described below the table.
Nominal No-over- Light- Heavy-duty Heat dis- Noise
Air flow
ratings load use overload use use sipation level
ACS800-07 type
Icont.max Imax Pcont.max I2N PN I2hd Phd
A A kW A kW A kW kW m3/h dBA
Three-phase supply voltage 380 V, 400 V or 415 V
ACS800-07-0610-3 879 1315 500 844 500 657 400 13.0 3120 73
ACS800-07-0770-3 1111 1521 630 1067 630 831 450 17.2 3840 74
ACS800-07-0870-3 1255 1877 710 1205 710 939 500 18.5 3840 74
ACS800-07-1030-3 1452 1988 800 1394 800 1086 630 23.9 3840 74
ACS800-07-1230-3 1770 2648 1000 1699 1000 1324 710 27.5 5040 75
ACS800-07-1540-3 2156 2951 1200 2070 1200 1613 900 35.4 5760 76
ACS800-07-1850-3 2663 3894 1450 2556 1450 1992 1120 42.7 6960 76
Three-phase supply voltage 380 V, 400 V, 415 V, 440 V, 460 V, 480 V or 500 V
ACS800-07-0760-5 883 1321 630 848 630 660 500 14.0 3120 73
ACS800-07-0910-5 1050 1524 710 1008 710 785 560 17.2 3840 74
ACS800-07-1090-5 1258 1882 900 1208 900 941 630 19.9 3840 74
ACS800-07-1210-5 1372 1991 1000 1317 1000 1026 710 23.8 3840 74
ACS800-07-1540-5 1775 2655 1250 1704 1200 1328 900 29.4 5040 75
ACS800-07-1820-5 2037 2956 1450 1956 1400 1524 1120 35.0 5760 76
ACS800-07-2310-5 2670 3901 1900 2563 1850 1997 1400 45.4 6960 76
Three-phase supply voltage 525 V, 550 V, 575 V, 600 V, 660 V, or 690 V
ACS800-07-0750-7 628 939 630 603 630 470 500 13.9 3120 73
ACS800-07-0870-7 729 1091 710 700 710 545 560 17.1 3120 73
ACS800-07-1060-7 885 1324 800 850 800 662 630 18.4 3120 73
ACS800-07-1160-7 953 1426 900 915 900 713 710 20.8 3840 74
ACS800-07-1500-7 1258 1882 1200 1208 1200 941 900 27.0 5040 75
ACS800-07-1740-7 1414 2115 1400 1357 1400 1058 1000 32.5 5040 75
ACS800-07-2120-7 1774 2654 1700 1703 1700 1327 1250 40.1 6240 76
ACS800-07-2320-7 1866 2792 1900 1791 1800 1396 1400 43.3 6960 76
ACS800-07-2900-7 2321 3472 2300 2228 2200 1736 1600 51.5 8160 77
ACS800-07-3190-7 2665 3987 2600 2558 2500 1993 1900 58.0 9360 78
ACS800-07-3490-7 2770 4144 2800 2659 2700 2072 2100 63.6 10080 78
PDM-184674-0.36
Technical data
118
Symbols
Nominal ratings
Icont.max Continuous RMS output current. No overloadability at 40 °C.
Imax Maximum output current. Allowable for 10 seconds at start, otherwise as long as allowed
by drive temperature.
Typical ratings for no-overload use
Pcont.max Typical motor power. The power ratings apply to most IEC 34 motors at nominal voltage
(400, 500 or 690 V).
Typical ratings for light-overload use (10% overloadability)
I2N Continuous rms current. 10% overload is allowed for 1 minute every 5 minutes.
PN Typical motor power. The power ratings apply to most IEC 34 motors at nominal voltage
(400, 500 or 690 V).
Typical ratings for heavy-duty use (50% overloadability)
I2hd Continuous rms current. 50% overload is allowed for 1 minute every 5 minutes.
Phd Typical motor power. The power ratings apply to most IEC 34 motors at nominal voltage
(400, 500 or 690 V).
Derating
The load capacity (current and power) decreases if the installation site altitude exceeds 1000 metres
(3281 ft), or if the ambient temperature exceeds 40 °C (104 °F).
Temperature derating
In the temperature range +40 °C (+104 °F) to +50 °C (+122 °F), the rated output current is decreased
by 1% for every additional 1 °C (1.8 °F). The output current is calculated by multiplying the current
given in the rating table by the derating factor.
Example If the ambient temperature is 50 °C (+122 °F), the derating factor is 100 % - 1 % · 10 °C =
90% or 0.90. The output current is then 0.90 × I or 0.90 × I . °C
2N cont.max
Altitude derating
At altitudes from 1000 to 4000 m (3281 to 13123 ft) above sea level, the derating is 1% for every 100 m
(328 ft). For a more accurate derating, use the DriveSize PC tool. If the installation site is higher than
2000 m (6600 ft) above sea level, please contact your local ABB distributor or office for further
information.
Technical data
119
ACS800-07 frame sizes and power module types
Frame size Supply module(s) used Inverter modules used
ACS800-07 type (supply+inverter
modules) Qty Type Qty Type
Three-phase supply voltage 380 V, 400 V or 415 V
ACS800-07-0610-3 1×D4 + 2×R8i 1 ACS800-704-0910-7 2 ACS800-104-0390-3
ACS800-07-0770-3 2×D4 + 2×R8i 2 ACS800-704-0640-7 2 ACS800-104-0390-3
ACS800-07-0870-3 2×D4 + 2×R8i 2 ACS800-704-0640-7 2 ACS800-104-0510-3
ACS800-07-1030-3 2×D4 + 2×R8i 2 ACS800-704-0910-7 2 ACS800-104-0510-3
ACS800-07-1230-3 2×D4 + 3×R8i 2 ACS800-704-0910-7 3 ACS800-104-0510-3
ACS800-07-1540-3 3×D4 + 3×R8i 3 ACS800-704-0910-7 3 ACS800-104-0510-3
ACS800-07-1850-3 3×D4 + 4×R8i 3 ACS800-704-0910-7 4 ACS800-104-0510-3
Three-phase supply voltage 380 V, 400 V, 415 V, 440 V, 460 V, 480 V or 500 V
ACS800-07-0760-5 1×D4 + 2×R8i 1 ACS800-704-0910-7 2 ACS800-104-0460-5
ACS800-07-0910-5 2×D4 + 2×R8i 2 ACS800-704-0640-7 2 ACS800-104-0460-5
ACS800-07-1090-5 2×D4 + 2×R8i 2 ACS800-704-0640-7 2 ACS800-104-0610-5
ACS800-07-1210-5 2×D4 + 2×R8i 2 ACS800-704-0910-7 2 ACS800-104-0610-5
ACS800-07-1540-5 2×D4 + 3×R8i 2 ACS800-704-0910-7 3 ACS800-104-0610-5
ACS800-07-1820-5 3×D4 + 3×R8i 3 ACS800-704-0910-7 3 ACS800-104-0610-5
ACS800-07-2310-5 3×D4 + 4×R8i 3 ACS800-704-0910-7 4 ACS800-104-0610-5
Three-phase supply voltage 525 V, 550 V, 575 V, 600 V, 660 V, or 690 V
ACS800-07-0750-7 1×D4 + 2×R8i 1 ACS800-704-0640-7 2 ACS800-104-0440-7
ACS800-07-0870-7 1×D4 + 2×R8i 1 ACS800-704-0910-7 2 ACS800-104-0440-7
ACS800-07-1060-7 1×D4 + 2×R8i 1 ACS800-704-0910-7 2 ACS800-104-0580-7
ACS800-07-1160-7 2×D4 + 2×R8i 2 ACS800-704-0640-7 2 ACS800-104-0580-7
ACS800-07-1500-7 2×D4 + 3×R8i 2 ACS800-704-0640-7 3 ACS800-104-0580-7
ACS800-07-1740-7 2×D4 + 3×R8i 2 ACS800-704-0910-7 3 ACS800-104-0580-7
ACS800-07-2120-7 2×D4 + 4×R8i 2 ACS800-704-0910-7 4 ACS800-104-0580-7
ACS800-07-2320-7 3×D4 + 4×R8i 3 ACS800-704-0910-7 4 ACS800-104-0580-7
ACS800-07-2900-7 3×D4 + 5×R8i 3 ACS800-704-0910-7 5 ACS800-104-0580-7
ACS800-07-3190-7 3×D4 + 6×R8i 3 ACS800-704-0910-7 6 ACS800-104-0580-7
ACS800-07-3490-7 4×D4 + 6×R8i 4 ACS800-704-0910-7 6 ACS800-104-0580-7
PDM-184674-0.32
Technical data
120
Internal AC fuses
Input Rated I2t
ACS800-07… Type Voltage I2t
current Qty. current Clearing at
type (IEC/UL/CSA) (V) Pre-arc
(A) (A RMS) 660V
UN = 400 V (Range 380-415 V)
-0610-3 790 6
-0770-3 999 12
-0870-3 1128 12 170M4417
-1030-3 1305 12 700 690 69500 465000
Bussmann
-1230-3 1591 12
-1540-3 1938 18
-1850-3 2394 18
UN = 500 V (Range 380-500 V)
-0760-5 793 6
-0910-5 944 12
-1090-5 1131 12
170M4417
-1210-5 1233 12 700 690 69500 465000
Bussmann
-1540-5 1596 12
-1820-5 1831 18
-2310-5 2400 18
UN = 690 V (Range 525-690 V)
-0750-7 565 6
-0870-7 655 6
-1060-7 795 6
-1160-7 856 12
-1500-7 1131 12
170M4417
-1740-7 1271 12 700 690 69500 465000
-2120-7 1595 12 Bussmann
-2320-7 1678 18
-2900-7 2086 18
-3190-7 2396 18
-3490-7 2490 24
*If the drive is not equipped with internal AC fuses (option code +F260), install specified fuses externally at the AC
supply. See the diagram on page 73 for the cabling arrangement at each supply module.
Technical data
121
DC fuses at inverter module input
Input Rated
ACS800- current Type
Qty. Type (IEC) current Voltage (V)
07… type (UL/CSA)
(A) (A RMS)
UN = 400 V (Range 380-415 V)
-0610-3 790 4 170M8547 170M6216
1250 690
-0770-3 999 4 Bussmann Bussmann
-0870-3 1128 4
-1030-3 1305 4
170M8550 170M6219
-1230-3 1591 6 1600 690
Bussmann Bussmann
-1540-3 1938 6
-1850-3 2394 8
UN = 500 V (Range 380-500 V)
-0760-5 793 4 170M8547 170M6216
1250 690
-0910-5 944 4 Bussmann Bussmann
-1090-5 1131 4
-1210-5 1233 4
170M8550 170M6219
-1540-5 1596 6 1600 690
Bussmann Bussmann
-1820-5 1831 6
-2310-5 2400 8
UN = 690 V (Range 525-690 V)
-0750-7 565 4 170M8647 170M8637
800 1000
-0870-7 655 4 Bussmann Bussmann
-1060-7 795 4
-1160-7 856 4
-1500-7 1131 6
-1740-7 1271 6
170M8650 170M8639
-2120-7 1595 8 1000 1000
Bussmann Bussmann
-2320-7 1678 8
-2900-7 2086 10
-3190-7 2396 12
-3490-7 2490 12
Fuses for main circuit voltage measurement
Fuses F7 (2 pcs) and F8 (3 pcs) are used for DC voltage and AC supply voltage
measurement respectively. The recommended type for replacement is Ferraz
Shawmut A070GRB01T13 (1 A, 700 V, UL Recognized).
DC fuses for the DSU module
Each D4 type DSU module uses four fuses. The fuses are in two pairs, each pair
consisting of a 170M4417 (with a micro switch) and 170M4467 (with a red fuse
indicator) fuse connected in parallel.
Rated current
Qty. Type Voltage (V)
(A RMS)
2 170M4417 Bussmann 700 690
2 170M4467 Bussmann 700 690
Technical data
122
Input power connection
Voltage (U1) 380/400/415 VAC 3-phase ± 10 % for 400 VAC units
380/400/415/440/460/480/500 VAC 3-phase ± 10 % for 500 VAC units
525/550/575/600/660/690 VAC 3-phase ± 10 % for 690 VAC units
Prospective short-circuit Units without earthing/grounding switch:
current (IEC 60439-1,
UL508C) Icf
65 kA
Units with earthing/grounding switch:
Icw / 1 s Ipk
50 kA 105 kA
US/Canada: The drive is suitable for use in a circuit capable of delivering not more than
65,000 A rms symmetrical at drive nominal voltage when protected by T-class fuses.
Frequency 48 to 63 Hz, maximum rate of change 17 %/s
Imbalance Max. ± 3 % of nominal phase to phase input voltage
Fundamental power factor 0.98 (at nominal load)
(cos phi1)
Transformer for 12-pulse Connection Dy 11 d0 or Dyn 11 d0
supply
Phase shift between 30° electrical
secondaries
Voltage difference between < 0.5%
secondaries
Short-circuit impedance of > 5%
secondaries
Short-circuit impedance < 10% of short-circuit
difference between impedance
secondaries
Other No grounding of the secondaries allowed.
Static screen recommended
Input power cable lead- Units without load switch-disconnector or air circuit breaker:
throughs 4 × Ø60 mm (2.36”) at each supply module
Units with load switch-disconnector (+F253):
9 × Ø60 mm (2.36”) (frame 1×D4 + 2×R8i)
12 × Ø60 mm (2.36”) (frame 2×D4 + n×R8i)
18 × Ø60 mm (2.36”) (frame 3×D4 + n×R8i and 4×D4 + n×R8i)
Units with air circuit breaker (+F255):
18 × Ø60 mm (2.36”)
Technical data
123
Input terminals at each
supply module (units without Conductor size Max. no. and size of cable Lug hole Bolt Tightening
load switch-disconnector or air lugs per phase torque
circuit breaker) IEC Cabling
< 150 mm2 2 × 150 mm2 1 × 11 M10 40 Nm
185 … 240 mm2 OL 2 × 185-240 mm2 (with – – 15 Nm
dual-cable screw lug included
with delivery)
US Cabling
300 … 350 MCM 2 × 350 MCM 2 × 1¾” 7/16” 30 lbf.ft
Input terminals (units with
load switch-disconnector or air Busbar dimensions No. of Bolt size Tightening
circuit breaker) busbars 2) torque
13 [0.51] 40 [1.57]
M12 or 70 Nm
See below
½” (50 lb.ft)
50 [1.97]
Number of input busbars (6-pulse units)
No. of supply modules No. of busbars per connection point
(n×D4) 1L1 1L2 1L3
1 1 1 1
2 2 2 2
3 3 3 3
4 3 3 3
Number of input busbars (12-pulse units)
No. of supply modules No. of busbars per connection point
(n×D4) 1L1 1L2 1L3 2L1 2L2 2L3
1 1 1 1 1 1 1
2 2 2 2 2 2 2
3 3 3 3 3 3 3
4 3 3 3 3 3 3
Technical data
124
Motor connection
Voltage (U2) 0 to U1, 3-phase symmetrical, Umax at the field weakening point
Frequency DTC mode: 0 to 3.2 × fFWP. Maximum frequency 300 Hz.
UNmains
fFWP = · fNmotor
UNmotor
where fFWP = frequency at field weakening point; UNmains = mains (input power) voltage;
UNmotor = rated motor voltage; fNmotor = rated motor frequency
Frequency resolution 0.01 Hz
Current See section Ratings.
Power limit 2 × Phd. After approximately 2 minutes at 2 × Phd, the limit is set at Pcont.max.
Field weakening point 8 to 300 Hz
Switching frequency 2 kHz (average)
Motor cable lead-throughs 3 × Ø60 mm at each inverter module (units without common motor terminal cubicle)
Units with common motor terminal cubicle: See the chapter Dimensions.
Technical data
125
Output terminals at each R8i
Bottom exit Top exit
inverter module (units
without common motor Side view Side view
terminal cubicle) Bolt size: M12 or ½” Bolt size: M12 or ½”
Tightening torque: 70 Nm (52 lbf.ft) Tightening torque: 70 Nm (52 lbf.ft)
Cabling
direction
Cabling direction
68265631-A0 cabinet_400_generic.asm
Output terminals (units with 8 × Ø13 mm per phase. See the chapter Dimensions.
common motor terminal
cubicle)
Maximum recommended 100 m (328 ft). Motor cables up to 500 m (1640 ft) long are allowed but EMC filtering
motor cable length within the specified limits will not be realised.
Efficiency
Approximately 98% at nominal power level
Technical data
126
Cooling
Method Internal fans, flow direction from bottom to top
Filter material Inlet (door) Outlet (roof)
IP22/IP42 units Luftfilter airTex G150 –
IP54 units Luftfilter airComp 300-50 Luftfilter airTex G150
Free space around the unit See chapter Mechanical installation.
Cooling air flow See Ratings.
Degrees of protection
IP21; IP22; IP42; IP54, IP54R (with air outlet duct)
Ambient conditions
Environmental limits for the drive are given below. The drive must be used in a heated,
indoor controlled environment.
Operation Storage Transportation
installed for stationary use in the protective package in the protective package
Installation site altitude 0 to 4000 m (13123 ft) above - -
sea level [above 1000 m
(3281 ft), see section
Derating]
Air temperature -15 to +50 °C (5 to 122 °F), -40 to +70 °C (-40 to +158°F) -40 to +70 °C (-40 to +158°F)
no frost allowed. See section
Derating.
Relative humidity 5 to 95% Max. 95% Max. 95%
No condensation allowed. Maximum allowed relative humidity is 60% in the presence of
corrosive gases.
Contamination levels No conductive dust allowed.
(IEC 60721-3-3, IEC 60721-3- Boards without coating: Boards without coating: Boards without coating:
2, IEC 60721-3-1) Chemical gases: Class 3C1 Chemical gases: Class 1C2 Chemical gases: Class 2C2
Solid particles: Class 3S2 Solid particles: Class 1S3 Solid particles: Class 2S2
Boards with coating: Boards with coating: Boards with coating:
Chemical gases: Class 3C2 Chemical gases: Class 1C2 Chemical gases: Class 2C2
Solid particles: Class 3S2 Solid particles: Class 1S3 Solid particles: Class 2S2
Atmospheric pressure 70 to 106 kPa 70 to 106 kPa 60 to 106 kPa
0.7 to 1.05 atmospheres 0.7 to 1.05 atmospheres 0.6 to 1.05 atmospheres
Vibration (IEC 60068-2) Max. 1 mm (0.04 in.) Max. 1 mm (0.04 in.) Max. 3.5 mm (0.14 in.)
(5 to 13.2 Hz), (5 to 13.2 Hz), (2 to 9 Hz),
max. 7 m/s2 (23 ft/s2) max. 7 m/s2 (23 ft/s2) max. 15 m/s2 (49 ft/s2)
(13.2 to 100 Hz) sinusoidal (13.2 to 100 Hz) sinusoidal (9 to 200 Hz) sinusoidal
Shock (IEC 60068-2-29) Not allowed Max. 100 m/s2 (330 ft./s2), Max. 100 m/s2 (330 ft./s2),
11 ms 11 ms
Free fall Not allowed 100 mm (4 in.) for weight 100 mm (4 in.) for weight
over 100 kg (220 lb) over 100 kg (220 lb)
Technical data
127
Materials
Cabinet Hot-dip zinc-coated (thickness approx. 20 µm) steel sheet (thickness 1.5 mm) with
polyester thermosetting powder coating (thickness approx. 80 µm) on visible surfaces
except back panel. Colour: RAL 7035 (light beige, semigloss).
Busbars Tin- or silver-plated copper
Fire safety of materials Insulating materials and non-metallic items: Mostly self-extinctive
(IEC 60332-1)
Packaging Frame: Wood or plywood. Plastic wrapping: PE-LD. Bands: PP or steel.
Disposal The drive contains raw materials that should be recycled to preserve energy and natural
resources. The package materials are environmentally compatible and recyclable. All
metal parts can be recycled. The plastic parts can either be recycled or burned under
controlled circumstances, according to local regulations. Most recyclable parts are marked
with recycling marks.
If recycling is not feasible, all parts excluding electrolytic capacitors and printed circuit
boards can be landfilled. The DC capacitors (C1-1 to C1-x) contain electrolyte and the
printed circuit boards contain lead, both of which are classified as hazardous waste within
the EU. They must be removed and handled according to local regulations.
For further information on environmental aspects and more detailed recycling instructions,
please contact your local ABB distributor.
Tightening torques for power connections
Screw size Torque
M5 3.5 Nm (2.6 lbf.ft)
M6 9 Nm (6.6 lbf.ft)
M8 20 Nm (14.8 lbf.ft)
M10 40 Nm (29.5 lbf.ft)
M12 70 Nm (52 lbf.ft)
M16 180 Nm (133 lbf.ft)
Applicable standards
The drive complies with the following standards. The compliance with the European Low
Voltage Directive is verified according to standards EN 50178 and EN 60204-1.
• EN 50178 (1997) Electronic equipment for use in power installations.
• EN 60204-1 (1997) Safety of machinery. Electrical equipment of machines. Part 1: General requirements.
Provisions for compliance: The final assembler of the machine is responsible for installing
- an emergency-stop device
- a supply disconnecting device.
• EN 60529: 1991 (IEC 529) Degrees of protection provided by enclosures (IP code).
• IEC 60664-1 (1992) Insulation coordination for equipment within low-voltage systems. Part 1: Principles,
requirements and tests.
• EN 61800-3 (1996) + EMC product standard including specific test methods
Amendment A11 (2000)
• UL 508C UL Standard for Safety, Power Conversion Equipment, second edition
• CSA C22.2 No. 14-95 Industrial control equipment
Technical data
128
CE marking
A CE mark is attached to the drive 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).
Definitions
EMC stands for Electromagnetic Compatibility. It is the ability of electrical/electronic equipment to
operate without problems within an electromagnetic environment. Likewise, the equipment must not
disturb or interfere with any other product or system within its locality.
First environment includes establishments connected to a low-voltage network which supplies buildings
used for domestic purposes.
Second environment includes establishments connected to a network not supplying domestic premises.
Restricted distribution: mode of sales distribution in which the manufacturer restricts the supply of
equipment to suppliers, customers or users who separately or jointly have technical competence in the
EMC requirements of the application of drives.
Unrestricted distribution: mode of sales distribution in which the supply of equipment is not dependent
on the EMC competence of the customer or user for the application of drives.
Compliance with the EMC Directive
The EMC Directive defines the requirements for immunity and emissions of electrical equipment used
within the European Union. The EMC product standard (EN 61800-3 + Amendment A11 [2000]) covers
requirements stated for drives.
Compliance with the EN 61800-3 + Amendment A11 (2000)
First environment (restricted distribution)
The requirements of the EMC Directive can be met as follows for restricted distribution:
1. The drive is equipped with EMC filter +E202.
2. The motor and control cables are selected as specified in the Hardware Manual.
3. The drive is installed according to the instructions given in the Hardware Manual.
4. Maximum cable length is 100 metres (328 ft).
WARNING! The drive may cause radio interference if used in a residential or domestic environment.
The user is required to take measures to prevent interference, in addition to the requirements for CE
compliance listed above, if necessary.
Note: It is not allowed to install a drive equipped with EMC filter +E202 on IT (unearthed) systems. The
supply network becomes connected to earth potential through the EMC filter capacitors which may
cause danger or damage the unit.
Technical data
129
Second environment
The requirements of the EMC Directive can be met as follows:
1. The drive is equipped with EMC filter +E210. The filter is suitable for TN (earthed) and IT
(unearthed) networks.
2. The motor and control cables are selected as specified in the drive manuals.
3. The drive is installed according to the instructions given in the drive manuals.
4. Maximum cable length is 100 metres (328 ft).
If the above listed provisions cannot be met, the requirements of the EMC Directive can be met as
follows for restricted distribution:
1. It is ensured that no excessive emission is propagated to neighbouring low-voltage networks. In
some cases, the natural suppression in transformers and cables is sufficient. If in doubt, the supply
transformer with static screening between the primary and secondary windings can be used.
Medium voltage network
Supply transformer
Neighbouring network
Static screen
Point of measurement
Low voltage Low voltage
Equipment
Drive
(victim)
Equipment Equipment
2. An EMC plan for preventing disturbances is drawn up for the installation. A template is available
from the local ABB representative.
3. The motor and control cables are selected as specified in the drive manuals.
4. The drive is installed according to the instructions given in the drive manuals.
Machinery Directive
The drive complies with the European Union Machinery Directive (98/37/EC) requirements for an
equipment intended to be incorporated into machinery.
Technical data
130
“C-tick” marking
A “C-tick” mark is attached to each drive in order to verify compliance with the relevant standard
(IEC 61800-3 (1996) – Adjustable speed electrical power drive systems – Part 3: EMC product
standard including specific test methods), mandated by the Trans-Tasman Electromagnetic
Compatibility Scheme.
Definitions
EMC stands for Electromagnetic Compatibility. It is the ability of electrical/electronic equipment to
operate without problems within an electromagnetic environment. Likewise, the equipment must not
disturb or interfere with any other product or system within its locality.
The Trans-Tasman Electromagnetic Compatibility Scheme (EMCS) was introduced by the Australian
Communication Authority (ACA) and the Radio Spectrum Management Group (RSM) of the New
Zealand Ministry of Economic Development (NZMED) in November 2001. The aim of the scheme is to
protect the radiofrequency spectrum by introducing technical limits for emission from
electrical/electronic products.
First environment includes establishments connected to a low-voltage network which supplies buildings
used for domestic purposes.
Second environment includes establishments connected to a network not supplying domestic premises.
Restricted distribution: mode of sales distribution in which the manufacturer restricts the supply of
equipment to suppliers, customers or users who separately or jointly have technical competence in the
EMC requirements of the application of drives.
Unrestricted distribution: mode of sales distribution in which the supply of equipment is not dependent
on the EMC competence of the customer or user for the application of drives.
Compliance with IEC 61800-3
First environment (restricted distribution)
The drive complies with the limits of IEC 61800-3 with the following provisions:
1. The drive is equipped with EMC filter +E202.
2. The drive is installed according to the instructions given in the drive manuals.
3. The motor and control cables used are selected as specified in the drive manuals.
4. Maximum cable length is 100 metres.
Note: The drive must not be equipped with the EMC filter E202 when installed to IT (unearthed)
systems. The mains becomes connected to earth potential through the EMC filter capacitors. In IT
systems this may cause danger or damage the unit.
Technical data
131
Second environment
The drive complies with the limits of IEC 61800-3 with the following provisions:
1. It is ensured that no excessive emission is propagated to neighbouring low-voltage networks. In
some cases, the natural suppression in transformers and cables is sufficient. If in doubt, the supply
transformer with static screening between the primary and secondary windings is strongly
recommended.
Medium voltage network
Supply transformer
Neighbouring network
Static screen
Point of measurement
Low voltage Low voltage
Equipment
Drive
(victim)
Equipment Equipment
2. The drive is installed according to the instructions given in the drive manuals.
3. The motor and control cables used are selected as specified in the drive manuals.
Technical data
132
Technical data
133
Dimensions
Cabinet line-ups
The drive consists of cubicles built into a cabinet line-up. The tables below show the
composition of cabinet line-ups for each frame size and the standard combinations
of options. The dimensions are in millimetres.
Notes:
• The side panels increase the total line-up width by 30 millimetres (1.2”).
• The standard depth of the cabinet line-up is 650 mm (excluding door equipment
such as switches and air inlet gratings). This is increased by 130 millimetres
(5.1”) with top entry/exit models as well as units with cooling air intake through the
bottom of the cabinet.
• The measurements given apply to 6-pulse-input, non-UL/CSA units. For
dimensions of 12-pulse-input or UL/CSA units, contact your local ABB
representative.
The tables are followed by example dimensional drawings.
Dimensions
134
1×D4 + 2×R8i
*Brake chopper 1
*Brake chopper 2
*Brake chopper 3
*Brake resistor 1
*Brake resistor 2
*Brake resistor 3
terminal cubicle
Common motor
Joining cubicle
EMC/RFI filter
supply cubicle
Control, I/O &
Shipping split
Line-up width
disconnector
Load switch-
(kg approx.)
Inverter unit
Net weight
widths
700 600 1300 1300 890
700 300 400 600 2000 2000 1490
700 400 600 1700 1700 1190
700 600 300 1600 1600 1060
700 300 400 600 300 2300 2300 1660
700 400 600 300 2000 2000 1360
700 600 400 400 2100 2100 1250
700 300 400 600 400 400 2800 2800 1850
700 400 600 400 400 2500 2500 1550
700 600 300 400 400 2400 2400 1420
700 300 400 600 300 400 400 3100 3100 2020
700 400 600 300 400 400 2800 2800 1720
700 600 200 400 800 400 800 1500 + 2400 3900 980 + 800
700 300 400 600 200 400 800 400 800 2200 + 2400 4600 1580 + 800
700 400 600 200 400 800 400 800 1900 + 2400 4300 1280 + 800
700 600 300 400 800 400 800 1600 + 2400 4000 1060 + 800
700 300 400 600 300 400 800 400 800 2300 + 2400 4700 1660 + 800
700 400 600 300 400 800 400 800 2000 + 2400 4400 1360 + 800
700 600 400 400 400 2500 2500 1430
700 300 400 600 400 400 400 3200 3200 2030
700 400 600 400 400 400 2900 2900 1730
700 600 300 400 400 400 2800 2800 1600
700 300 400 600 300 400 400 400 3500 3500 2200
700 400 600 300 400 400 400 3200 3200 1900
700 600 200 400 800 400 800 400 800 1500 + 3600 5100 980 + 1200
700 300 400 600 200 400 800 400 800 400 800 2200 + 3600 5800 1580 + 1200
700 400 600 200 400 800 400 800 400 800 1900 + 3600 5500 1280 + 1200
700 600 300 400 800 400 800 400 800 1600 + 3600 5200 1060 + 1200
700 300 400 600 300 400 800 400 800 400 800 2300 + 3600 5900 1660 + 1200
700 400 600 300 400 800 400 800 400 800 2000 + 3600 5600 1360 + 1200
*The number of brake choppers depends on drive type. See the chapter Resistor braking.
Dimensions
135
2×D4 + 2×R8i
Air circuit breaker
*Brake chopper 1
*Brake chopper 2
*Brake chopper 3
*Brake resistor 1
*Brake resistor 2
*Brake resistor 3
terminal cubicle
Common motor
Joining cubicle
Shipping split
Line-up width
Control & I/O
disconnector
Load switch-
(kg approx.)
Inverter unit
Supply unit
Net weight
cubicle
widths
400 600 600 1600 1600 1200
400 500 600 600 2100 2100 1580
400 600 600 600 2200 2200 1900
400 600 600 300 1900 1900 1370
400 500 600 600 300 2400 2400 1750
400 600 600 600 300 2500 2500 2070
400 600 600 400 400 2400 2400 1560
400 500 600 600 400 400 2900 2900 1940
400 600 600 600 400 400 3000 3000 2260
400 600 600 300 400 400 2700 2700 1730
400 500 600 600 300 400 400 3200 3200 2110
400 600 600 600 300 400 400 3300 3300 2430
400 600 600 200 400 800 400 800 1800 + 2400 4200 1290 + 800
400 500 600 600 200 400 800 400 800 2300 + 2400 4700 1670 + 800
400 600 600 600 200 400 800 400 800 2400 + 2400 4800 1990 + 800
400 600 600 300 400 800 400 800 1900 + 2400 4300 1370 + 800
400 500 600 600 300 400 800 400 800 2400 + 2400 4800 1750 + 800
400 600 600 600 300 400 800 400 800 2500 + 2400 4900 2070 + 800
400 600 600 400 400 400 2800 2800 1740
400 500 600 600 400 400 400 3100 3100 2120
400 600 600 600 400 400 400 3400 3400 2440
400 600 600 300 400 400 400 3100 3100 1910
400 500 600 600 300 400 400 400 3600 3600 2290
400 600 600 600 300 400 400 400 3700 3700 2610
400 600 600 200 400 800 400 800 400 800 1800 + 3600 5400 1290 + 1200
400 500 600 600 200 400 800 400 800 400 800 2300 + 3600 5900 1670 + 1200
400 600 600 600 200 400 800 400 800 400 800 2400 + 3600 6000 1990 + 1200
400 600 600 300 400 800 400 800 400 800 1900 + 3600 5500 1370 + 1200
400 500 600 600 300 400 800 400 800 400 800 2400 + 3600 6000 1750 + 1200
400 600 600 600 300 400 800 400 800 400 800 2500 + 3600 6100 2070 + 1200
*The number of brake choppers depends on drive type. See chapter Resistor braking.
Dimensions
136
2×D4 + 3×R8i
Control & Load switch- Air circuit Common motor Shipping split Line-up Net weight
Supply unit Inverter unit
I/O cubicle disconnector breaker terminal cubicle widths width (kg approx.)
400 600 800 1800 1800 1350
400 500 600 800 2300 2300 1730
400 600 600 800 2400 2400 2050
400 600 800 400 2200 2200 1540
400 500 600 800 400 2700 2700 1920
400 600 600 800 400 2800 2800 2240
2×D4 + 4×R8i
Control & Load switch- Air circuit Supply Inverter Common motor Inverter Shipping split Line-up Net weight
I/O cubicle disconnector breaker unit unit (1) terminal cubicle unit (2) widths width (kg approx.)
400 600 600 600 2200 2200 1680
400 500 600 600 600 2700 2700 2060
400 600 600 600 600 2800 2800 2380
400 600 600 400 600 2600 2600 1870
400 500 600 600 400 600 3100 3100 2250
400 600 600 600 400 600 3200 3200 2570
3×D4 + 3×R8i
Control & Load switch- Air circuit Common motor Shipping split Line-up Net weight
Supply unit Inverter unit
I/O cubicle disconnector breaker terminal cubicle widths width (kg approx.)
400 800 800 2000 2000 1540
400 600 800 800 2600 2600 1940
400 600 800 800 2600 2600 2240
400 800 800 400 2400 2400 1730
400 600 800 800 400 3000 3000 2130
400 600 800 800 400 3000 3000 2430
3×D4 + 4×R8i
Control & Load switch- Air circuit Supply Inverter Common motor Inverter Shipping split Line-up Net weight
I/O cubicle disconnector breaker unit unit (1) terminal cubicle unit (2) widths width (kg approx.)
400 800 600 600 2400 2400 1870
400 600 800 600 600 3000 3000 2270
400 600 800 600 600 3000 3000 2570
400 800 600 400 600 2800 2800 2060
400 600 800 600 400 600 3400 3400 2460
400 600 800 600 400 600 3400 3400 2760
3×D4 + 5×R8i
Control & Load switch- Air circuit Supply Inverter Common motor Inverter Shipping split Line-up Net weight
I/O cubicle disconnector breaker unit unit (1) terminal cubicle unit (2) widths width (kg approx.)
400 800 800 600 2600 2600 2020
400 600 800 800 600 3200 3200 2420
400 600 800 800 600 3200 3200 2720
400 800 800 400 600 3000 3000 2210
400 600 800 800 400 600 3600 3600 2610
400 600 800 800 400 600 3600 3600 2910
Dimensions
137
3×D4 + 6×R8i
Control & Load switch- Air circuit Supply Inverter Common motor Inverter Shipping split Line-up Net weight
I/O cubicle disconnector breaker unit unit (1) terminal cubicle unit (2) widths width (kg approx.)
400 800 800 800 2800 2800 2170
400 600 800 800 800 3400 3400 2570
400 600 800 800 800 3400 3400 2870
400 800 800 600 800 3400 3400 2390
400 600 800 800 600 800 4000 4000 2790
400 600 800 800 600 800 4000 4000 3090
4×D4 + 6×R8i
Control & Load switch- Air circuit Inverter Common motor Inverter Shipping split Line-up Net weight
Supply unit
I/O cubicle disconnector breaker unit (1) terminal cubicle unit (2) widths width (kg approx.)
400 600 + 600 800 800 3200 3200 2520
400 600 600 + 600 800 800 3800 3800 2920
400 600 600 + 600 800 800 3800 3800 3220
400 600 + 600 800 600 800 3800 3800 2740
400 600 600 + 600 800 600 800 4400 4400 3840
400 600 600 + 600 800 600 800 4400 4400 4140
Dimensions
138
Frame size 1×D4 + 2×R8i
Dimensions
139
Frame size 1×D4 + 2×R8i (continued)
Dimensions
140
Frame size 1×D4 + 2×R8i (continued)
Dimensions
141
Frame size 1×D4 + 2×R8i (with load switch-disconnector)
Dimensions
142
Frame size 1×D4 + 2×R8i (with load switch-disconnector) (continued)
Dimensions
143
Frame size 1×D4 + 2×R8i (with load switch-disconnector) (continued)
Dimensions
144
Frame size 1×D4 + 2×R8i (with load switch-disconnector) (continued)
Dimensions
145
Frame size 1×D4 + 2×R8i (with load switch-disconnector) (continued)
Dimensions
146
Frame size 1×D4 + 2×R8i (with load switch-disconnector) (continued)
Dimensions
147
Frame size 1×D4 + 2×R8i (with top entry/exit)
Dimensions
148
Frame size 1×D4 + 2×R8i (with top entry/exit) (continued)
Dimensions
149
Frame size 1×D4 + 2×R8i (with top entry/exit) (continued)
Dimensions
150
Frame size 2×D4 + 2×R8i
Dimensions
151
Frame size 2×D4 + 2×R8i (continued)
Dimensions
152
Frame size 2×D4 + 2×R8i (continued)
Dimensions
153
Frame size 2×D4 + 2×R8i (with load switch-disconnector)
Dimensions
154
Frame size 2×D4 + 2×R8i (with load switch-disconnector) (continued)
Dimensions
155
Frame size 2×D4 + 2×R8i (with load switch-disconnector) (continued)
Dimensions
156
Frame size 2×D4 + 3×R8i
Dimensions
157
Frame size 2×D4 + 3×R8i (continued)
Dimensions
158
Frame size 2×D4 + 3×R8i (continued)
Dimensions
159
Frame size 2×D4 + 3×R8i (with load switch-disconnector)
Dimensions
160
Frame size 2×D4 + 3×R8i (with load switch-disconnector)
Dimensions
161
Frame size 2×D4 + 3×R8i (with load switch-disconnector)
Dimensions
162
Frame size 2×D4 + 3×R8i (with load switch-disconnector)
Dimensions
163
Frame size 2×D4 + 3×R8i (with air circuit breaker)
Dimensions
164
Frame size 2×D4 + 3×R8i (with air circuit breaker) (continued)
Dimensions
165
Frame size 2×D4 + 3×R8i (with air circuit breaker) (continued)
Dimensions
166
Frame size 2×D4 + 3×R8i (with air circuit breaker) (continued)
Dimensions
167
Frame size 3×D4 + 4×R8i
Dimensions
168
Frame size 3×D4 + 4×R8i (continued)
Dimensions
169
Frame size 3×D4 + 4×R8i (continued)
Dimensions
170
Frame size 3×D4 + 4×R8i (with load switch-disconnector)
Dimensions
171
Frame size 3×D4 + 4×R8i (with load switch-disconnector) (continued)
Dimensions
172
Frame size 3×D4 + 4×R8i (with load switch-disconnector) (continued)
Dimensions
173
Frame size 3×D4 + 4×R8i (with load switch-disconnector) (continued)
Dimensions
174
Frame size 3×D4 + 4×R8i (with air circuit breaker)
Dimensions
175
Frame size 3×D4 + 4×R8i (with air circuit breaker) (continued)
Dimensions
176
Frame size 3×D4 + 4×R8i (with air circuit breaker) (continued)
Dimensions
177
Frame size 3×D4 + 4×R8i (with air circuit breaker) (continued)
Dimensions
178
Common motor terminal cubicle
Depending on the drive size, the common motor terminal cubicle is either 300, 400
or 600 mm wide. Refer to the cabinet line-up tables at the beginning of this chapter.
300 mm
Dimensions
179
400 mm
Dimensions
180
600 mm
Dimensions
181
Resistor braking
What this chapter contains
This chapter describes the resistor braking options of the ACS800-07.
Resistor braking options
The following ACS800-07 (>500 kW) drives are available with brake choppers and
resistors. For information on braking equipment for other ACS800-07 types, or
custom resistor braking equipment, contact your local ABB representative.
UN ACS800-07 type Brake chopper type (+D150) Brake resistor type (+D151)
ACS800-07-0610-3 2 × NBRA-659 2 × (2 × SAFUR180F460)
ACS800-07-0770-3 2 × NBRA-659 2 × (2 × SAFUR180F460)
400 V
ACS800-07-0870-3 3 × NBRA-659 3 × (2 × SAFUR180F460)
ACS800-07-1030-3 3 × NBRA-659 3 × (2 × SAFUR180F460)
ACS800-07-0760-5 2 × NBRA-659 2 × (2 × SAFUR200F500)
ACS800-07-0910-5 2 × NBRA-659 2 × (2 × SAFUR200F500)
500 V
ACS800-07-1090-5 3 × NBRA-659 3 × (2 × SAFUR200F500)
ACS800-07-1210-5 3 × NBRA-659 3 × (2 × SAFUR200F500)
ACS800-07-0750-7 2 × NBRA-669 2 × (2 × SAFUR200F500)
ACS800-07-0870-7 2 × NBRA-669 2 × (2 × SAFUR200F500)
690 V
ACS800-07-1060-7 3 × NBRA-669 3 × (2 × SAFUR200F500)
ACS800-07-1160-7 3 × NBRA-669 3 × (2 × SAFUR200F500)
Resistor braking
182
Chopper/Resistor combinations – Technical data
The following table contains the technical data of some chopper/resistor
combinations.
Duty Cycle Duty Cycle
(10/60 s) (1/5 min)
R Pbrmax Pcont Imax
UN Chopper(s) Resistors
(ohm) (kW) (kW) (A)
Pbr Irms Pbr Irms
(kW) (A) (kW) (A)
1 × NBRA-659 2 × SAFUR180F460 1.2 353 54 545 287 444 167 257
400 V 2 × NBRA-659 2 × (2 × SAFUR180F460) 1.2 706 108 1090 575 888 333 514
3 × NBRA-659 3 × (2 × SAFUR180F460) 1.2 1058 162 1635 862 1332 500 771
1 × NBRA-659 2 × SAFUR200F500 1.35 403 54 605 287 355 167 206
500 V 2 × NBRA-659 2 × (2 × SAFUR200F500) 1.35 806 108 1210 575 710 333 412
3 × NBRA-659 3 × (2 × SAFUR200F500) 1.35 1208 162 1815 862 1065 500 618
1 × NBRA-669 2 × SAFUR200F500 1.35 404 54 835 287 355 167 206
690 V 2 × NBRA-669 2 × (2 × SAFUR200F500) 1.35 807 108 1670 575 514 333 298
3 × NBRA-669 3 × (2 × SAFUR200F500) 1.35 1211 162 2505 862 771 500 447
UN = Nominal voltage
R = Resistance of specified resistors (per chopper)
Pbrmax = Maximum short-term (1 min every 10 mins) braking power
Pcont = Maximum continuous braking power
Imax = Maximum peak current
Pbr = Braking power for the specified duty cycle
Irms = Corresponding RMS current
Brake resistors – Technical data
The following table contains the technical data for the resistors supplied by ABB.
UN R ER PRcont
Type
(V) (ohm) (kJ) (kW)
SAFUR125F500 500 4.0 3600 9.0
SAFUR210F575 575 3.4 4200 10.5
SAFUR200F500 500 2.7 5400 13.5
SAFUR180F460 460 2.4 6000 15.0
UN Nominal voltage
R Resistance
ER Short energy pulse that the resistor assembly will withstand each 400 seconds
PRcont Continuous power (heat) dissipation of the resistor when placed correctly. Energy ER dissipates in 400
seconds.
Resistor braking
183
Verifying the capacity of the braking equipment
1. Calculate the maximum power (Pmax) generated by the motor during braking.
2. Ensure the following condition is met:
Pbrmax > Pmax
The Pbrmax values specified in the technical data table above are for the reference braking cycle
(1 minute of braking, 9 minutes of rest). If the actual duty cycle does not correspond to the reference
cycle, the maximum allowed braking power Pbr must be used instead. In the technical data table,
Pbr is given for two additional braking cycles. See below for directions for calculating Pbr for other
braking cycles.
3. Check the resistors selection. The energy generated by the motor during a 400-
second period must not exceed the heat dissipation capacity ER.
If the ER value is not sufficient, it is possible to use a four-resistor assembly in which two standard
resistors are connected in parallel, two in series. The ER value of the four-resistor assembly is four
times the value specified for the standard resistor.
Custom resistors
Resistors other than the standard resistors can be used provided that:
• the resistance is not lower than with the standard resistors
WARNING! Never use a brake resistor with a resistance below the value specified
for the particular drive / brake chopper / resistor combination. The drive and the
chopper are not able to handle the overcurrent caused by the low resistance.
• the resistance does not restrict the braking capacity needed, i.e.,
2
UDC
Pmax <
R
where
Pmax maximum power generated by the motor during braking
UDC voltage over the resistor during braking, e.g.,
1.35 · 1.2 · 415 VDC (when supply voltage is 380 to 415 VAC),
1.35 · 1.2 · 500 VDC. (when supply voltage is 440 to 500 VAC) or
1.35 · 1.2 · 690 VDC (when supply voltage is 525 to 690 VAC).
R resistor resistance (ohm)
• the heat dissipation capacity (ER) of the resistors is sufficient for the application
(see step 3 above).
Resistor braking
184
Calculating the maximum braking power (Pbr)
• Braking energy transferred during any ten minute period must be less than or
equal to the energy transferred during the reference braking cycle.
• The braking power must not exceed the rated maximum value Pbrmax.
1. n × Pbr × tbr < Pbrmax × 60 s
2. Pbr < Pbrmax
n = Number of braking pulses during
a ten minute period
Pbr = Maximum allowed braking power (kW).
tbr = Braking time (s)
Pbrmax = Maximum Braking Power
for a reference cycle (kW)
Example 1
Duration of a braking cycle is 30 minutes. The braking time is
15 minutes.
Result: If the braking time exceeds 10 minutes, the braking is considered
continuous. The allowed continuous braking power is 10% of the Maximum Braking
Power (Pbrmax).
Example 2
Duration of a braking cycle is three minutes. The braking time is
40 seconds.
Pbrmax × 60 s
1. Pbr < = 0.375 × Pbrmax
4 × 40 s
Pbr
Pbrmax
t
tbr 600 s
T = Duration of braking cycle
2. Pbr < Pbrmax O.K.
Result: The maximum allowed braking power for the cycle is 37 % of the rated value
given for the reference cycle.
Resistor braking
185
Example 3
Duration of a braking cycle is three minutes. The braking time is 10 seconds.
Pbrmax × 60 s
1. Pbr < = 1.5 · Pbrmax
4 × 10 s
Pbr
Pbrmax
t
tbr 600 s
T = Duration of the braking cycle
2. Pbr > Pbrmax Not allowed.
Result: The maximum allowed braking power for the cycle is equal to the Maximum
Braking Power (Pbrmax) given for the reference cycle.
Resistor braking
186
Custom resistor installation and wiring
Effective cooling of the resistors must be ensured.
WARNING! All materials near the brake resistors must be non-flammable. The
surface temperature of the resistors is high. The temperature of the air rising from
the resistors is hundreds of degrees Celsius. Protect the resistors against contact.
For resistor cable, use the type specified for drive input cabling (specified under
chapter Technical Data) so the input fuses will protect the resistor cable also. Two-
conductor shielded cable with the same cross-sectional area can alternatively be
used. The maximum length of the resistor cable is 10 m.
For protection against overheating, resistors with thermal circuit breakers (standard
in ABB resistors) should be used. The circuit breakers should be wired to the
ENABLE inputs of the brake choppers.
WARNING! The ENABLE input terminal blocks of the choppers are at intermediate
circuit potential when the supply unit of the ACS800-07 is running. This voltage is
extremely dangerous and may cause serious damage or injuries if the isolation level
and protection conditions for the thermal circuit breakers are not sufficient. The
normally-closed breakers should always be properly isolated (over 2.5 kV) and
shrouded against contact.
Note: For the ENABLE input wiring, use cable rated as follows:
• twisted pair (screened type recommended)
• rated operating voltage between a core and earth (U0): ≥ 750 V
• insulation test voltage > 2.5 kV
Resistor braking
187
The following is a wiring diagram example of the resistor connection.
Brake chopper
X1
R+ R– 1 2
1 2 3
R+ R–
t°
Brake resistor
Brake circuit commissioning
In the drive application program, overvoltage control of the drive must be disabled for
correct operation of the brake chopper. This has been done at the factory for units
with brake choppers.
Resistor braking
188
Resistor braking
3AFE64731165 REV E EN
EFFECTIVE: 15.2.2008
ABB Oy ABB Inc. ABB Beijing Drive Systems Co. Ltd.
AC Drives Automation Technologies No. 1, Block D, A-10 Jiuxianqiao Beilu
P.O. Box 184 Drives & Motors Chaoyang District
FI-00381 HELSINKI 16250 West Glendale Drive Beijing, P.R. China, 100015
FINLAND New Berlin, WI 53151 Telephone +86 10 5821 7788
Telephone +358 10 22 11 USA Fax +86 10 5821 7618
Fax +358 10 22 22681 Telephone 262 785-3200 Internet http://www.abb.com
Internet http://www.abb.com 800-HELP-365
Fax 262 780-5135
ACS800
Firmware Manual
System Control Program 7.x
System Control Program 7.x
Firmware Manual
3AFE64670646 REV E
EN
EFFECTIVE: 05.12.2008
© 2008 ABB Oy. All Rights Reserved.
5
Table of contents
Table of contents
Introduction to the manual
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Reader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Product and service inquiries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Product training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Providing feedback on ABB Drives manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Start-up
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
How to start-up the drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Control panel
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Overview of the panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Identification display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Panel operation mode keys and displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Status row . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Drive control with the panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
How to start, stop and change direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
How to set speed reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Actual signal display mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
How to select actual signals to the display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
How to display the full name of the actual signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
How to view and reset the fault history . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
How to display and reset an active fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
About the fault history . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Parameter mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
How to select a parameter and change the value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
How to adjust a source selection parameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Function mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
How to copy parameters from one drive to other drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
How to set the contrast of the display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Drive selection mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
How to select a drive and change its panel link ID number . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Reading and entering packed boolean values on the display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Table of contents
6
Program features
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Local control vs. external control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Control modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
External control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Local control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Analogue inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Analogue outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Digital inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Digital outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Diagnostics and control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Fast analogue interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Fast digital interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
RMIO board connection diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Control through communication link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Control through I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Actual signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Motor identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Undervoltage control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Overvoltage control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Automatic start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Auto restart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Diagnostics and control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Emergency stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
If an emergency stop signal is activated when the motor is already stopped . . . . . . . . . . . . . . 67
If an emergency stop signal is activated when the motor is running . . . . . . . . . . . . . . . . . . . . . 67
Emergency stop through fieldbus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Table of contents
7
Diagnostics and control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Safe Torque Off function (STO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
DC magnetising . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Constant DC magnetising . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
DC hold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Flux braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Flux optimisation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Acceleration and deceleration ramps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Variable slope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Diagnostics and control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Oscillation damping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Speed filtering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Speed controller tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Low speed fine tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Run interlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Motor control, DTC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Scalar control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
IR compensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Hexagonal motor flux . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Parallel-connected inverters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Reduced run function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Removing a broken inverter module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Current measurement calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Programmable protection functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
AI<Min . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Panel loss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Table of contents
8
Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Motor temperature protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Motor thermal mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Temperature sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Thermal sensor connection through I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Thermal connection through analogue I/O extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
I/O configuration example 1 with motor temperature measurement . . . . . . . . . . . . . . . . . . . 90
I/O configuration example 2 with motor temperature measurement . . . . . . . . . . . . . . . . . . . 90
Alternative thermal connection for PTC thermistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Short time overload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Maximum current load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Stall protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Underload protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Motor phase loss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Earth fault and current unbalance protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Communication fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Master/Follower link communication fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Speed measurement fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Motor fan control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Preprogrammed faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Overcurrent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Table of contents
9
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
DC overvoltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
DC undervoltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Drive temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Short circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Run disable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Overfrequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Input phase loss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Control board temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
I/O monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Start inhibit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Overswitching frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
System fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Operation limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Parameter lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Adaptive programming with DriveAP 2.x . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Master/Follower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Diagnostics and control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Master drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Follower drive(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Data transfer from follower(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Load share function with speed controlled Follower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Process master on-line configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Master/Follower link specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Inverter fan speed control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
LSU communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Sine filter support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Inverter charging logic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Table of contents
10
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Monitoring panel NLMD-01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Pulse encoder, RTAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Position counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Position count . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Diagnostics and control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Firmware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Firmware loading package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Program boot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Memory handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Fault and event loggers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Time format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Data loggers 1 and 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Default signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Diagnostics and control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Backup and restore function with DriveWindow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
User macro save with DriveWindow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Software version update . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Actual signals and parameters
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Fieldbus equivalent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Fieldbus addresses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Modbus and Modbus Plus address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Terms and abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
01 ACTUAL SIGNALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
02 ACTUAL SIGNALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
03 ACTUAL SIGNALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
04 INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
05 LSU SIGNALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
07 CONTROL WORDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
07 CONTROL WORDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
08 STATUS WORDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
08 STATUS WORDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
09 FAULT WORDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
10 DIGITAL INPUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
11 REFERENCE SELECT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
12 FAST IO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
13 ANALOGUE INPUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
14 DIGITAL OUTPUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
15 ANALOGUE OUTPUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
Table of contents
11
16 SYSTEM CTR INPUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
17 DC HOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
18 LED PANEL CTRL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
19 DATA STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
20 LIMITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
21 START/STOP FUNC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
22 ACCEL/DECEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
23 SPEED REF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
24 SPEED CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
25 TORQUE REF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
26 TORQUE REF HANDLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
27 FLUX CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
28 MOTOR MODEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
29 SCALAR CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
30 FAULT FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
31 FAULT FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
34 BRAKE CHOPPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
35 MOTOR FAN CTRL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
36 MOTOR CABLE PROTECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
50 SPEED MEASUREMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
51 MASTER ADAPTER (fieldbus adapter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
52 STANDARD MODBUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
53 USER PARAMETERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
55 ADAPTIVE PROG1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
56 ADAPT PROG1 CNTRL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
57 ADAPTIVE PROG2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
58 ADAPT PROG2 CNTRL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
66 AP CONNECT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
70 DDCS CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
71 DRIVEBUS COMM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
90 D SET REC ADDR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
91 D SET REC ADDR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
92 D SET TR ADDR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
93 D SET TR ADDR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
95 LSU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
97 DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
98 OPTION MODULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
99 START-UP DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
Fault tracing
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
Alarm and fault indications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
How to reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
Fault history . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
Alarm messages generated by the drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
Alarm messages generated by the control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
Alarms by number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
Table of contents
12
Fault messages generated by the drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
Faults by number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
Application macros
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289
Overview of macros . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289
User macros . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290
How to create user macro 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290
How to recall user macro 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290
Fieldbus control
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291
System overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291
Redundant fieldbus control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
RDCO channels CH0...3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
Commissioning and supporting tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293
Setting up communication through fieldbus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293
Setting up communication through the standard Modbus link . . . . . . . . . . . . . . . . . . . . . . . . . . . 295
Modbus link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296
Setting up communication through Advant controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297
External control interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299
Data sets 1 and 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299
For type Nxxx fieldbus adapters and RMBA-01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299
For type Rxxx fieldbus adapters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299
Data sets 10...33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300
Data sets received from an external control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
Data set transmitted to an external control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
Use of mailbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
ABB Drives communication profile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
Control examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305
Control block diagrams
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309
Main control word control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310
I/O speed and torque references and motor temperature protection . . . . . . . . . . . . . . . . . . . . 311
Speed measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312
Speed reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313
Speed reference ramp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314
Speed control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315
Torque reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316
Flux and DTC control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318
Scalar control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 319
Terms
Table of contents
13
Introduction to the manual
What this chapter contains
This chapter describes the contents of the manual. In addition it contains information
about the compatibility, safety and intended audience.
Compatibility
The manual is compatible with ACS800 System Control Program version
AMXR7250 and later. See signal 04.01 SW PACKAGE VER.
Safety instructions
Follow all safety instructions delivered with the drive.
• Read the complete safety instructions before you install, commission, or use
the drive. For single drive the complete safety instructions are given at the
beginning of the hardware manual. For multidrive safety instructions, see
ACS800 Multidrive Safety Instructions [3AFE64760432 (English)].
• Read the software function specific warnings and notes before changing the
default settings of the function. For each function, the warnings and notes are
given in this manual in the section describing the related user-adjustable
parameters.
Reader
The reader of the manual is expected to know the standard electrical wiring
practices, electronic components, and electrical schematic symbols.
Introduction to the manual
14
Contents
The manual consists of the following chapters:
• Start-up instructs in setting up the application program.
• Control panel gives instructions for using the panel.
• Program features contains the feature descriptions and the reference lists of the
user settings and diagnostic signals.
• Actual signals and parameters describes the actual signals and parameters of the
drive.
• Fault tracing lists the alarm and fault messages with the possible causes and
remedies.
• Application macros contains a short description of each macro.
• Fieldbus control describes the communication through the serial communication
link.
• Control block diagrams contains control block diagrams.
• Terms lists the terms and abbreviation used in this manual.
Product and service inquiries
Address any inquiries about the product to your local ABB representative, quoting
the type code and serial number of the unit in question. A listing of ABB sales,
support and service contacts can be found by navigating to www.abb.com/drives and
selecting Drives – Sales, Support and Service network on the right pane.
Product training
For information on ABB product training, navigate to www.abb.com/drives and select
Drives – Training courses on the right pane.
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) on the right pane.
Introduction to the manual
15
Start-up
What this chapter contains
This chapter describes the basic start-up procedure of the drive.
How to start-up the drive
The drive can be operated:
• locally from control panel or DriveWindow PC tool
• externally via I/O connections or fieldbus interface.
The start-up procedure presented uses the DriveWindow program. Drive references
can be monitored with DriveWindow with data loggers or with an oscilloscope
(connect analogue output signals to an oscilloscope and check the scaling of the
signals). For instruction on how to use the DriveWindow PC tool, see DriveWindow
Online Help and DriveWindow 2 User’s Manual [3AFE64560981 (English)].
The start-up procedure includes actions which need to be performed only when the
drive is powered up for the first time (e.g. entering the motor data). After the first
start-up, the drive can be powered up without using these start-up functions. The
start-up procedure can be repeated later if start-up data needs to be changed.
If an alarm or a fault is generated during the start-up, see chapter Fault tracing for
the possible causes and remedies. If problems continue, disconnect the main power
and wait 5 minutes for the intermediate circuit capacitors to discharge and check the
drive and motor connections.
Start-up
16
Safety
The start-up may only be carried out by a qualified electrician.
The safety instructions must be followed during the start-up procedure. See the safety
instructions on the first pages of the appropriate hardware manual or for multidrive,
see ACS800 Multidrive Safety Instructions [3AFE64760432 (English)].
Check the installation. See the installation checklist in the appropriate hardware manual.
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 an incorrect direction of rotation, or
- a Standard ID run needs to be performed during the drive start-up. (ID run is essential only
in applications which require the ultimate in motor control accuracy.)
Connect fibre optic cables between DDCS channel CH3 (of the RDCO-0x module) and the
NDPC cable adapter connected to PCMCIA card in the PC.
Disconnect the external control system from channel CH0 of the RDCO-0x module or from
the fieldbus adapter module type Rxxx connected to Slot 1 of the RMIO board.
Power up
Switch the power on.
Start the DriveWindow program.
Switch the drive to local control mode.
Motor data entering
Open the parameter list (Parameters) from the DriveWindow menu.
Select the language. 99.01 LANGUAGE
Double-click the DriveWindow Parameters window to upload
parameters and signals.
Select the motor control mode. 99.08 MOTOR CTRL
MODE
DTC is suitable for most cases. The SCALAR control mode is
recommended
- for multimotor drives with variable number of motors
- when the nominal current of the motor is less than 1/6 of the nominal
output current of the drive (inverter)
- when the drive is used for test purposes with no motor connected.
Start-up
17
Enter the motor data from the motor nameplate: Note: Set the motor data to
exactly the same value as
ABB Motors on the motor nameplate. For
example, if the motor
3 motor M2AA 200 MLA 4
IEC 200 M/L 55
nominal speed is 1440 rpm
No on the nameplate, setting
Ins.cl. F IP 55 the value of parameter
V Hz kW r/min A cos IA/IN t E/s
690 Y 50 30 1475 32.5 0.83
99.05 MOTOR NOM
400 D 50 30 1475 56 0.83 SPEED to 1500 rpm results
660 Y 50 30 1470 34 0.83 380 V in wrong operation of the
380 D 50 30 1470 59 0.83 mains drive.
415 D 50 30 1475 54 0.83
440 D 35 1770 59 0.83
voltage
60
Cat. no 3GAA 202 001 - ADA
6312/C3 6210/C3 180
IEC 34-1
- motor nominal voltage
Allowed range: 1/2 × UN … 2 × UN of the drive. (UN refers to the highest voltage in
each of the nominal voltage ranges: 415 V AC for 400 V AC units, 500 V AC for 99.02 MOTOR NOM
500 V AC units and 690 V AC for 600 V AC units.) VOLTAGE
- motor nominal current 99.03 MOTOR NOM
Allowed range: approximately 1/6 × Ihd … 2 × Ihd of the drive (0…2 × Ihd if CURRENT
parameter 99.08 MOTOR CTRL MODE = SCALAR))
With multimotor drives, see section Multimotor drives on page 18.
- motor nominal frequency
99.04 MOTOR NOM FREQ
Enter the exact value on the motor nameplate to achieve adequate estimated
torque accuracy and linearity.
Range: 8…300 Hz
With multimotor drives, see section Multimotor drives on page 18. 99.05 MOTOR NOM
SPEED
- motor nominal speed
Range: 1…18000 rpm 99.06 MOTOR NOM
With multimotor drives, see section Multimotor drives on page 18. POWER
- motor nominal power
Range: 0…9000 kW 99.12 MOTOR NOM
With multimotor drives, see section Multimotor drives on page 18. COSFII
- motor nominal cosϕ
If the nominal cosϕ of the motor is unknown, set parameter 99.13 POWER IS GIVEN
to POWER.
After the motor parameters have been set, alarm ID MAGN REQ is ** ALARM **
displayed. ID MAGN REQ
Start-up
18
Multimotor drives
i.e. more than one motor is connected to one drive
Note: Scalar control mode is recommended with multimotor drives
1) if the load is not equally shared between the motors,
2) if the motors are of different sizes, or
3) if the motors are going to be changed after the motor identification.
Check that the motors have the same relative slip, nominal voltage
and number of poles. If the manufacturer motor data is insufficient,
use the following formulas to calculate the slip and the number of
poles:
⎛ fN ⋅ 60⎞ * * Round to the nearest integer value.
p = Int ⎜ -----------------⎟
⎝ nN ⎠
f ⋅ 60
n N
= ----------------
-
S p
n S – nN
s = --------------------- ⋅ 100%
n
S
where
p = number of pole pairs (= motor pole number / 2)
fN = motor nominal frequency [Hz]
nN = motor nominal speed [rpm]
s = motor slip [%]
nS = motor synchronous speed [rpm].
Set the sum of the motor nominal currents. 99.03 MOTOR NOM
CURRENT
Set the nominal motor frequencies. Frequencies must be the same. 99.04 MOTOR NOM FREQ
Note: If scalar control is used (parameter 99.08 MOTOR CTRL
MODE = SCALAR), this setting does not apply.
Set the sum of the motor nominal powers. 99.06 MOTOR NOM
POWER
If the motor powers are close to each other or the same but the
99.05 MOTOR NOM
nominal speeds vary slightly, parameter 99.05 MOTOR NOM
SPEED
SPEED can be set to an average value of the motor speeds.
Optional modules
Activate all optional modules connected to the RDCO-0x module. Parameter group 98
Select the connection interface and operation mode for the OPTION MODULES
modules.
I/O communication
Check the possible I/O signal selections. Parameter groups
10 DIGITAL INPUTS...
15 ANALOGUE OUTPUTS
Start-up
19
Run interlock
If RUN INTERLOCK function is needed (prevents motor start): 16.14 RUN INTERLOCK
Program the interlocking with adaptive programming. 08.01 MAIN STATUS
WORD bit 13
See ACS600 / ACS800 Application Guide Adaptive Program for
System Application Program 7.x [3AFE68420075 (English)].
Safe Torque Off function and emergency stop circuit
If there is a Safe Torque Off circuit in use, check the operation as 08.02 AUX STATUS WORD
follows: bit 8 START INHIBITION
- Open the control switch: 08.02 bit 8 = 1, AGPS (Gate Driver Power
supply board) 230/115 V AC circuit is open (active).
- Close the control switch: 08.02 bit 8 = 0, AGPS 230/115 V AC
circuit is closed (normal state).
Deactivate the logging of the Safe Torque Off alarm to the fault/ 31.02 START INHIBIT ALM
alarm logger if the function will be used frequently. Without
deactivation, the logger will be filled with START INHIBI alarms.
If there is an emergency stop circuit in use, check that the circuit 08.01 MAIN STATUS
functions (emergency stop signal is connected to digital input DI1 WORD bit 4 OFF 2 STA and
bit 5 OFF 3 STA
and the feedback signal is sent through digital output DO1). For
more information, see section Emergency stop on page 67.
Select the emergency stop mode. 21.04 EME STOP MODE
RMIO board supply
If the RMIO board is powered from an external supply, check that 16.07 CTRL BOARD
parameter 16.07 CTRL BOARD SUPPLY settings is EXTERNAL. SUPPLY
Inverter fan speed control
With R8i module equipped with speed controlled fan, check the fan 16.08 FAN SPD CTRL
speed control mode setting. MODE
Motor fan control
If the motor is equipped with an external cooling fan (controlled by 35.01 MOTOR FAN CTRL
the drive): 35.02 FAN ACK DELAY
- Check the motor fan control circuit and associated parameters. 35.03 FAN OFF DELAY
35.04 FAN ON DELAY
10.06 MOTOR FAN ACK
Optional DC switch
Activate the fuse switch control if R7i/R8i inverter is equipped with 98.12 FUSE SWITCH CTRL
a DC switch or if R7i inverter includes charging option +F272. 08.20 INV ENABLED
WORD
Start-up
20
Speed measurement
with pulse encoder
Check the speed scaling of the motor. 50.01 SPEED SCALING
Set parameter 50.03 SPEED FB SEL to INTERNAL. 50.03 SPEED FB SEL
Set the number of encoder pulses. 50.04 ENCODER PULSE
NR
Check other speed scaling and encoder settings. Parameter group 50 SPEED
MEASUREMENT
Reset the drive and start the motor.
During the first start the motor is magnetised for 20...60 s at zero
speed and the drive calculates the motor model (the stator
resistance and other electrical losses are identified and stored to the
FPROM memory). The motor shaft is not rotating during the first
start. ** ALARM **
Alarm message ID MAGN REQ is displayed.
Alarm ID MAGN is displayed during the identification. The motor ID MAGN REQ
stops after the identification magnetisation (ID MAGN) has been
performed. ID MAGN
Alarm message ID DONE is displayed after the identification is
completed. ID DONE
Start the motor again.
Enter a small speed reference value (for example 3% of the nominal
motor speed).
Check that the motor is running in the desired direction and the
polarity of the speed measurement is correct.
When the motor is rotating in the correct direction and the speed 01.03 SPEED MEASURED
reference is positive, the actual speed 01.03 SPEED MEASURED
must be positive and equal to 01.02 SPEED ESTIMATED. 01.02 SPEED ESTIMATED
Incorrect connection can be located as follows:
If the direction of the rotation is correct and 01.03 SPEED MEASURED is
negative, the phasing of the pulse encoder wires is reversed.
If the direction of the rotation is incorrect and 01.03 SPEED MEASURED is
negative, the motor cables are incorrectly connected.
If the direction of the rotation is incorrect and 01.03 SPEED MEASURED is
positive, both the motor and the pulse encoder are incorrectly connected.
Changing the connection:
Disconnect the main power, and wait for 5 minutes for the intermediate
circuit capacitors to discharge.
Do the necessary changes. Switch the power on and start the motor again.
Check that the actual speed value is positive.
Stop the motor.
Start-up
21
Set parameter 50.03 SPEED FB SEL to ENCODER. 50.03 SPEED FB SEL
Start the motor.
Check that SPEED ESTIMATED and SPEED MEASURED values 01.02 SPEED ESTIMATED
are the same. 01.03 SPEED MEASURED
08.02 AUX STATUS WORD
Check that signal 08.02 AUX STATUS WORD bit 12 (INTERNAL
bit 12
SPEED FB) value is zero.
Stop the motor.
Speed measurement
without pulse encoder
Check the speed scaling of the motor. 50.01 SPEED SCALING
Reset and start the motor.
During the first start the motor is magnetised for 20...60 s at zero
speed and the drive calculates the motor model (the stator
resistance and other electrical losses are identified and stored to the
FPROM memory). The motor shaft is not rotating during the first
start. ** ALARM **
Alarm message ID MAGN REQ is displayed.
Alarm ID MAGN is displayed during the identification. The motor ID MAGN
stops after the identification magnetisation (ID MAGN) has been
performed. ID MAGN
Alarm message ID DONE is displayed after the identification is
completed. ID DONE
Start the motor again.
Enter a small speed reference value (for example 3% of the nominal
motor speed).
Check that the motor is running in the desired direction.
If true motor speed is not equal to nominal value due to the motor 24.16 SLIP GAIN
construction, true speed can be fine tuned with slip gain.
Stop the motor.
Start-up
22
ID RUN (motor identification run)
WARNING! The motor will run at up to approximately 50…80% of the nominal speed
during the ID run. ENSURE THAT IT IS SAFE TO RUN THE MOTOR BEFORE
PERFORMING THE ID RUN!
Check the direction of rotation of the motor before starting the ID
run. During the run, the motor will rotate in the forward direction. forward
direction
Select the motor identification method by setting parameter 99.07
MOTOR ID RUN. During the Motor ID run, the drive will identify the
characteristics of the motor for optimum motor control. The ID run reverse
lasts a few minutes, depending on the motor size. direction
If 1 = NO (ID MAGN) is selected, ID run is not performed. When the start
command is given, the motor is magnetised for 20...60 s at zero speed and
the drive calculates the motor model.
Select the ID MAGN 99.07 MOTOR ID RUN
- for pump or fan application
- if there are drive sections in which more than one motor is connected to
one inverter. See section Multimotor drives on page 18.
The ID run (STANDARD or REDUCED) should be selected if
- the operation point is near zero speed, and/or
- the operation point is at a torque range above the motor nominal torque
within a wide speed range and no measured speed feedback is required.
The REDUCED ID run should be selected instead of the STANDARD if the
mechanical losses are higher than 20%, i.e. the motor cannot be
uncoupled from the driven equipment, or flux reduction is not allowed when
the motor is running, for example in a case of a braking motor in which a
mechanical brake is engaged when the flux falls below a certain level.
Note: The STANDARD Motor ID run may be performed even when
machinery is coupled if the machinery is not under load. However it is
always recommended to uncouple the driven equipment from the motor
with STANDARD Motor ID run.
WARNING! If STANDARD Motor ID run is to be performed with the
machinery coupled to the motor, make sure the machinery is able to
withstand the fast speed changes during the ID run.
With multimotor drives the ID run can be performed with the machinery
coupled or uncoupled.
Note: The Motor ID run (STANDARD or REDUCED) cannot be performed
if scalar control is selected (parameter 99.08 setting is SCALAR).
Start-up
23
Start the motor to activate the ID run. 16.01 RUN ENABLE
Note: RUN ENABLE must be active. 08.01 MAIN STATUS
When the ID run is started, alarm MOTOR STARTS is displayed. WORD bit 13
During the ID run, alarm ID RUN is displayed.
** ALARM **
After a successfully completed ID run, alarm ID DONE is displayed,
signal 08.02 AUX STATUS WORD bit 7 is set to 1 and parameter MOTOR STARTS
99.07 MOTOR ID RUN value is restored back to selection NO.
Note: If the Motor ID run has not been successfully completed, fault ID RUN
message ID RUN FAIL is displayed. See chapter Fault tracing.
ID DONE
Start function
Select the start function. 21.01 START FUNCTION
The fastest start is achieved when parameter 21.01 START
FUNCTION is set to AUTO (flying start).
The highest possible starting torque is achieved when parameter
21.01 START FUNCTION is set to DC MAGN (DC magnetising) or
CNST DC MAGN (constant DC magnetising).
Note: When parameter 21.01 START FUNCTION setting is
DC MAGN or CNST DC MAGN, flying start (start to a rotating motor)
is not possible.
When constant DC magnetising is used, the shaft movement during 21.11 START JERK COMP
the magnetising can be minimised:
Adjust parameter 21.11 START JERK COMP setting.
Set operation limits according to the process requirements. Parameter group 20 LIMITS
If there is a starting problem at zero speed with AUTO mode without 28.12 FLYSTART CUR REF
a pulse encoder, adjust parameters 28.12 FLYSTART CUR REF or 28.13 FLYSTART INIT DLY
28.15 RS20 [mOhm]
28.13 FLYSTART INIT DLY. See also effect of parameter 28.15
RS20 [mOhm] if starting torque is high.
Motor thermal model
Select the motor thermal model protection mode. 30.01 MOTOR THERM
PMODE
Note: DTC mode can only be used with ABB motors when the
nominal motor current IN < 800 A.
Select the thermal model protection function. 30.02 MOTOR THERM
PROT
When 30.01 MOTOR THERM P MODE setting is USER MODE:
- Set the time for the 63% temperature rise. 30.09 MOTOR THERM
TIME
- Set the maximum allowed operating load of the motor. 30.10 MOTOR LOAD
- Set the zero speed load. A higher value can be used if the motor CURVE
has an external motor fan to boost the cooling. 30.11 ZERO SPEED LOAD
- Set the break point frequency of the motor load curve. 30.12 BREAK POINT
Start-up
24
Set the thermal model alarm and fault limits. 30.28 THERM MOD ALM L
30.29 THERM MOD FLT L
Set the motor nominal temperature rise. 30.30 MOT NOM TEMP
RISE
Note: If the ABB motor rating plate includes temperature coefficient
value (MNTRC), multiply it by 80 °C to get the motor nominal
temperature rise.
Set the typical ambient temperature of the motor. 30.31 AMBIENT TEMP
Motor temperature measurement
If motor temperature measurement is connected, activate the motor 30.03/30.06 MOT1/2 TEMP
temperature measurement function for motor 1/2 and select the AI1/2 SEL
sensor type. 98.06 AI/O EXT MODULE 1
Sensor type Unit Scaling
Pt100 °C
PTC Ω normal 0...1.5 kΩ
overtemperature > 4 kΩ
KTY84-1xx Ω 90 °C = 936 Ω
110 °C = 1063 Ω
130 °C = 1197 Ω
150 °C = 1340 Ω
See control block diagram in section I/O speed and torque
references and motor temperature protection on page 311.
Set the temperature fault and alarm limits for motor 1/2. 30.04/30.07 MOT 1/2 TEMP
ALM L
30.05/30.08 MOT 1/2 TEMP
FLT L
Speed controller tuning
Note: These settings do not apply when parameter 99.08 MOTOR CTRL MODE setting is
SCALAR.
When tuning the drive, change one parameter at a time and monitor the response to the speed
reference step. To achieve the best possible result, the step response test should be carried out
with different speeds, from minimum speed up to the maximum speed.
The speed control values obtained depend mainly on
- the flux reference 27.03 FLUX REF
- the relationship between the motor power and the rotating mass
- backlashes in the drive's mechanical structure.
See control block diagram in section Speed control on page 315.
Note: Thyristor Supply Unit TSU should be in the normal operation mode during the step response
test (i.e. TSU signal 104.07 = 0). If TSU is in the diode bridge mode, an overvoltage alarm can trip
the drive when a step change down is given. Extra jumps may also appear in the step when the DC
voltage rises because no braking occurs.
The speed controller tuning can be performed automatically or manually:
Start-up
25
Automatic speed controller tuning
Activate the automatic tuning of the speed controller. Tuning is 24.01 PI TUNE
based on the estimated mechanical time constant. If automatic
tuning is not enough, use manual tuning.
Manual speed controller tuning
Select the following signals to be monitored with the DriveWindow
monitoring tool:
- 01.07 MOTOR TORQUE FILT2, actual torque
- 01.04 MOTOR SPEED, actual speed
- 02.03 SPEED ERROR NEG, filtered speed difference.
Start the motor with a small speed reference.
Give a speed reference step and monitor the response. Repeat the test for few speed reference
steps across the whole speed range:
Set the speed step: 1% or 2% of the maximum speed of the drive. 23.10 SPEED STEP
Optimise the P-part of the speed controller: Set the integration time 24.09 TIS
to its maximum value to change the PI (proportional integral)
controller into a P controller:
Give a step change up, for example 20 rpm. When the speed is 23.10 SPEED STEP
stabilised, give a step change down, for example -20 rpm.
Increase the relative gain until the response is sufficient: 24.03 KPS
y-axis = 02.09 TORQ REF 2
01.04 MOTOR
SPEED
KPS too low KPS too high KPS optimal
Start-up
26
Reduce the integration time until an overshoot is observed in the 24.09 TIS
response.
Adjust the integration time so that there is no overshoot or only
a slight overshoot (depending on the drive application). The integral
part is used to correct the error between the reference and the
actual value (which is caused by the proportional control) as quickly
as possible.
If the drive is stable and allows a high relative gain (KPS),
an overcompensated step response is obtained if the integration
time is set short.
y-axis = 02.09 TORQ REF 2
01.04 MOTOR
SPEED
TIS too long TIS too short TIS optimal
Low speed fine tuning
Eliminate potentially harmful oscillation at low speeds (e.g. during 50.13 ZERO DETECT
start): DELAY
50.14 SPEED HOLD TIME
- Set the time the speed controller saves the last reference value.
- Set the time delay for the proportional part of the speed controller.
The larger the mass of the driven equipment, the higher the value of
parameter 50.13 ZERO DETECT DELAY should be. Parameter
50.14 SPEED HOLD TIME should be set to approximately 60% of
the value of parameter 50.13.
For example, typical settings for a drive rotating a dryer section of
a paper machine are: par 50.13 = 50 ms and par. 50.14 = 30 ms.
Start-up
27
Speed filtering
The measured speed always has a small ripple because of mechanical interference and couplings.
A small ripple is acceptable as long as it does not affect the speed control chain. Reducing the
ripple with filters may cause speed controller tuning problems. A long filter time constant and fast
acceleration time contradict one other.
If the speed measurement shows rapid oscillation, it can be filtered 23.06 SPEED ERROR FILT
with a speed error filter: 50.06 SP ACT FILT TIME
- Set the speed error filter time constant.
- Set the time constant of the first order actual speed filter.
If there is no gear box and no pulse encoder feedback and if fast
oscillation is observed:
- Decrease the time constant of the first order actual speed filter to
its minimum.
See control block diagrams in sections Speed measurement on
page 312 and Scalar control on page 319.
If there is a substantial backlash in the drive, and the drive oscillates 24.04 KPSMIN
at low torque due to the mechanism: 24.05 KPS WEAKPOINT
- Set the adaptive speed control parameters. 24.06 KPS WP FILT TIME
If the adaptability has to be made abrupt (i.e. par. 24.03 KPS value
is high, and par. 24.04 value is low) the drive can start to oscillate as
the load varies. Use a speed step to test the adaptability (for
example 50 rpm). See section Manual speed controller tuning on
page 25.
If mechanical oscillation at a certain frequency is observed (narrow 26.04 OSC
frequency band), reduce oscillation: COMPENSATION
26.05 OSCILLATION FREQ
See section Oscillation damping on page 74.
26.06 OSCILLATION
PHASE
26.08 OSCILLATION GAIN
Scalar control and IR compensation
It is recommended to activate the scalar control mode in the following special applications:
- with multimotor drives:
1) if the load is not equally shared between the motors,
2) if the motors are of different sizes, or
3) if the motors are going to be changed after the motor identification.
- if the nominal current of the motor is less than 1/6 of the nominal output current of the inverter.
- if the drive is used without a motor connected (for example for test purposes).
- if the drive runs a medium voltage motor via a step-up transformer.
Magnetise the drive: 99.08 MOTOR CTRL
MODE
Start the drive in DTC control mode (par. 99.08 = DTC and par.
99.07 MOTOR ID RUN
99.07 = NO) before switching to the scalar control mode.
Start-up
28
Select the scalar control mode. Parameter group 29 SCALAR 99.08 MOTOR CTRL
CONTROL becomes visible. Parameters 29.02 FREQUENCY MAX MODE
and 29.03 FREQUENCY MIN are updated by the software
according to parameter 20.02 MAXIMUM SPEED and 20.01
MINIMUM SPEED values.
See control block diagram in section Scalar control on page 319.
When IR compensation is activated, the drive gives an extra voltage boost to the motor at low
speeds. IR compensation is useful in applications that require high breakaway torque or in
applications where the motor must rotate slowly, i.e. at a low frequency.
Set the relative output voltage boost at zero speed (IR 29.04 IR COMPENSATION
compensation).
Value can be set to 0...30% of the motor nominal voltage. Select
a value at which the motor is able to start and run at constant speed
over the whole speed range.
U/UN
(%) Relative output voltage. IR compensation
is set to 15%.
100%
15% Relative output voltage. No IR
compensation.
f (Hz)
Field weakening point
Test the IR compensation with actual load
Note: Supervise the temperature rise of the motor during the IR
compensation. With high IR compensation voltage values the motor
can be overheated.
Fieldbus control
The drive can be controlled from an external control system by using data sets 1, 2 or 10…33.
For more information on the external control, see chapter Fieldbus control.
Activate the external serial communication and select the interface. 98.02 COMM. MODULE
When parameter 98.02 = FIELDBUS, see parameter settings in
section Setting up communication through fieldbus on page 293.
When parameter 98.02 = ADVANT/N-FB, see parameter settings in
section Setting up communication through Advant controller on
page 297 or in section Setting up communication through fieldbus
on page 293.
When parameter 98.02 = STD MODBUS, see parameter settings in
section Setting up communication through the standard Modbus link
on page 295.
Start-up
29
Connect the external control system to channel CH0 of the
RDCO-0x module or to a fieldbus adapter module type Rxxx
connected to Slot 1 of the RMIO board.
Set the channel CH3 node address (DriveWindow PC tool 70.15 CH3 NODE ADDR
connection). Use addresses 1…75 and 124…254. Other addresses
are reserved for the NDBU branching units.
If CH3 channels of several drives are connected with a branching
unit, each one must be given a unique node address.
Note: The new node address becomes valid after the next power-up
of the RMIO board.
Select the topology of the channel CH3 link. Default value STAR is 70.20 CH3 HW
typically used with branching units. RING is used when the CH3 CONNECTION
channels of the RMIO boards are connected in a ring.
Test that the communication functions.
I/O control
The drive can be controlled by using I/O signals.
Select the I/O control mode (par. 98.02 = NO). 98.02 COMM. MODULE
Set the digital input parameters. Parameter group 10
DIGITAL INPUTS
For analogue signal, set the analogue input parameters. 11.01 EXT REF1 SEL
98.06 AI/O EXT MODULE 1
Parameter group 13
ANALOGUE INPUTS
Switching between I/O and external control can be controlled via 10.07 HAND/AUTO
a digital input.
Voltage control
If the DC voltage drops due to input power cut off, the undervoltage controller will automatically
decrease the motor torque in order to keep the voltage above the lower limit.
To prevent the DC voltage from exceeding the overvoltage control limit, the overvoltage controller
automatically decreases the generating torque when the limit is reached.
Activate the undervoltage and overvoltage controllers. 30.22 UNDERVOLTAGE
CTL
30.23 OVERVOLTAGE CTL
Deactivate the adaptive DC voltage measurement if undervoltage 20.14 ADAPTIVE UDC
control is used when several drives are connected to the same DC MEAS
link.
20.16 UNDERVOLT TORQ
Limit the maximum torque during undervoltage control. DN
Limit the minimum torque during undervoltage control to tune the 20.15 UNDERVOLT TORQ
generating torque level. UP
Start-up
30
AUTO RESTART function
It is possible to restart the drive automatically after a short power supply failure (max. 5 seconds)
using the AUTO RESTART function if
- the RMIO board is powered through an UPS (Uninterruptible Power System).
- digital input DI2 circuit remains closed during the power supply failure.
Activate the auto restart function. 21.09 AUTO RESTART
Set the maximum allowed power supply failure time. 21.10 AUTO RESTART
TIME
Activate the fault mask to prevent PPCC link fault indications. 30.24 PPCC FAULT MASK
Check that the auxiliary control circuit functions correctly during
power supply failure.
Master/Follower communication
Ensure the ID Run has been performed individually on all drives.
For more information on the Master/Follower applications, see section Master/Follower on page
104.
Select the Master/Follower mode. 70.08 CH2 M/F MODE or
07.03 AUX CTRL WORD 2
bits 6, 10 and 11
Select the data to be sent from the Master drive to the Follower. Master drive parameters
Example: Speed and torque references are sent from the Master 70.10 MASTER SIGNAL 2
drive to the Follower drive: 70.11 MASTER SIGNAL 3
Follower drive parameters
Master drive par. 70.10 = 2301 (23.01 SPEED REF).
70.17 FOLL SPEED REF
Master drive par. 70.11 = 210 (02.10 TORQ REF 3).
70.18 FOLL TORQ REF
Speed reference source:
Follower drive par. 70.17 = MASTER (or controlled by 07.03 AUX
CTRL WORD 2 bits 6 and 7).
Torque reference source:
Follower drive par. 70.18 = MASTER (or controlled by 07.03 AUX
CTRL WORD 2 bits 6 and 8).
Note: If parameter 70.08 CH2 M/F MODE is set to FOLLOWER,
parameter 70.10 MASTER SIGNAL 2 and 70.11 MASTER
SIGNAL 3 settings are not effective.
Load share function with speed controlled Follower drive (activated 07.03 AUX CTRL WORD 2
by 07.03 AUX CTRL WORD 2 bit 9): bit 9
23.18 FOLL SPD CTRL
Select the correction mode (23.19 FOLL SPD COR MODE) and
COR
increase the correction term (23.18 FOLL SPD CTRL COR) until the
23.19 FOLL SPD COR
Follower follows the Master torque accurately enough. MODE
Test the load sharing in practice by changing the load share value 25.03 LOAD SHARE
(within allowed range of the drive application) while the system is
running.
Start-up
31
Test that the emergency stop functions with the Master/Follower 21.04 EME STOP MODE
application.
Flying start tuning and flux correction
If flying start fails (21.01 START FUNCTION = AUTO), adjust the 28.12 FLYSTART CUR REF
flying start tuning parameters. [%]
28.13 FLYSTART INIT DLY
If required start torque is not achieved, i.e. motor will not start to 28.15 RS20 [mOhm]
rotate, decrease the stator resistance of the motor model.
Start-up
32
Start-up
33
Control panel
What this chapter contains
This chapter describes how to use the control panel CDP 312R. The control panel is
used to control the drive(s), read status data, and adjust parameters. The drive is
programmable through a set of parameters.
The communication between the CDP 312R control panel and the drive uses the
Modbus protocol. Modbus is a common bus protocol for ABB Drives products. The
communication speed of the bus is 9600 bit/s. 31 drives and one panel can be
connected to the bus. Each station must have a unique ID number.
Overview of the panel
The LCD type display has 4 lines of 20 characters.
The language is selected at start-up (parameter 99.01
LANGUAGE).The control panel has four operation
modes:
- Actual Signal Display Mode (ACT key)
1 L -> 0.0 rpm 0 - Parameter Mode (PAR key)
LED PANE 0 %
MOTOR SP 0.0 rpm - Function Mode (FUNC key)
MOTOR TO 0.00 %
- Drive Selection Mode (DRIVE key)
The use of single arrow keys, double arrow keys and
ENTER depend on the operation mode of the panel.
ACT PAR FUNC DRIVE
The drive control keys are:
No. Use
ENTER 1 Start
2 Stop
7 6 3 1 3 Activate reference setting
LOC RESET REF
REM 4 Forward direction of rotation
5 Reverse direction of rotation
I 0
4 5 2 6 Fault reset
7 Change between Local/Remote (external)
control
Control panel
34
Identification display
When the control panel is connected to the panel link for the first time, or when the
drive is powered up, the identification display shows the panel software version:
CDP312 PANEL V5.30
After the Identification Display, the panel enters the Drive Selection Mode and
displays the inverter type:
ACS 800 0005_3 SR
ID NUMBER 1
Inverter type is constructed as follows:
ACS800 0210_3SR
kVA rating (210 kVA)
Part of the inverter type code
Voltage rating UN (400 V)
3 = 400 V
5 = 500 V
7 = 690 V
SR = Single drive, air cooled
NR = Multidrive, air cooled
MR = 4Q or 2Q low harmonic drive
LC = Liquid cooled multidrive
LS = Liquid cooled single drive (4Q or 2Q)
After two seconds, the display will clear, and the Actual Signal Display Mode will
appear.
Note: The panel can be connected to the drive while power is applied to the drive.
Control panel
35
Panel operation mode keys and displays
With control panel keys the user can select status data, parameters and change
parameter settings. The figure below shows the mode selection keys of the panel,
and the basic operations and displays in each mode.
Actual Signal Display Mode
Act. signal / Fault history
ACT
selection
1 L -> 0.0 rpm 0 Status row
LED PANEL 0 % Actual signal names
MOTOR SP 0.0 rpm and values
Act. signal / Fault message
scrolling MOTOR TO 0.00 %
Enter selection mode
ENTER Accept new signal
Parameter Mode
Group selection 1 L -> 0.0 rpm 0 Status row
PAR Fast value change
99 START-UP DATA Parameter group
01 LANGUAGE Parameter
Parameter selection
Slow value change ENGLISH Parameter value
Enter change mode
ENTER Accept new value
Function Mode
1 L -> 0.0 rpm 0 Status row
FUNC Row selection
UPLOAD <=<=
Page selection
DOWNLOAD =>=> List of functions
CONTRAST 4
ENTER Function start
Drive Selection Mode
DRIVE
Drive selection ACS 800 0005_3 Device type
ID number change
DRYER SECTION 1
Enter change mode AMAM15D3 980605 SW version / application
ENTER Accept new value version and ID number
ID NUMBER 1
Status row
The figure below describes the status row digits.
Drive ID number Drive status
1 L -> 1242.0 rpm I I = Running
Drive control status
O = Stopped
L = Local control Direction of rotation Drive reference “ “ = Run disabled
“ “ = External control -> = Forward
<- = Reverse
Control panel
36
Drive control with the panel
The user can control the drive with the panel as follows:
• start, stop, and change direction of the motor
• give the motor speed reference or torque reference
• give a process reference
• reset the fault and alarm messages
• change between local and external drive control.
The panel can be used for drive control always when the drive is under local control
and the status row is visible on the display. L indicates local control on the panel
display. External control (through I/O or fieldbus interface) is indicated by a blank on
the panel display.
Operational (e.g. start/stop) commands cannot be given from the panel when the
drive is in remote control. Actual signal monitoring, parameter setting, parameter
upload and ID number setting are allowed in remote control.
How to start, stop and change direction
Step Action Press Key Display
1. To show the status row. 1 -> 0.0 rpm 0
ACT PAR LED PANE 0 %
MOTOR SP 0.0 rpm
FUNC
MOTOR TO 0.00 %
2. To switch to local control. 1 L -> 0.0 rpm 0
LOC
(Only if the drive is not under local control, i.e. there is no L LED PANE 0 %
REM
on the first row of the display.) MOTOR SP 0.0 rpm
MOTOR TO 0.00 %
3. To stop. 1 L -> 0.0 rpm 0
LED PANE 0 %
MOTOR SP 0.0 rpm
MOTOR TO 0.00 %
4. To start. 1 L -> 0.0 rpm I
LED PANE 0 %
MOTOR SP 0.0 rpm
MOTOR TO 0.00 %
5. To change the direction to reverse. 1 L <- 0.0 rpm 0
0 LED PANE 0 %
MOTOR SP 0.0 rpm
MOTOR TO 0.00 %
6. To change the direction to forward. 1 L -> 0.0 rpm 0
I LED PANE 0 %
MOTOR SP 0.0 rpm
MOTOR TO 0.00 %
Control panel
37
How to set speed reference
Step Action Press Key Display
1. To show the status row. 1 -> 1242.0 rpm 0
ACT PAR LED PANE 0 %
MOTOR SP 0.0 rpm
FUNC
MOTOR TO 0.00 %
2. To switch to local control. 1 L -> 1242.0 rpm 0
LOC
(Only if the drive is not under local control, i.e. there is no L LED PANE 0 %
REM
on the first row of the display.) MOTOR SP 0.0 rpm
MOTOR TO 0.00 %
3. To enter the Reference Setting function. REF
1 L -> [1242.0 rpm] 0
LED PANE 0 %
MOTOR SP 0.0 rpm
MOTOR TO 0.00 %
4. To change the reference. 1 L -> [1325.0 rpm] 0
(slow change) LED PANE 0 %
MOTOR SP 0.0 rpm
MOTOR TO 0.00 %
(fast change)
5. To save the reference. 1 L -> 1325.0 rpm 0
ENTER
(The value is stored in the permanent memory; it is LED PANE 0 %
restored automatically after power switch-off.) MOTOR SP 0.0 rpm
MOTOR TO 0.00 %
Actual signal display mode
The Actual Signal Display mode includes two displays: the Actual Signal Display and
the Fault History Display. In this Mode, the user can:
• show three actual signals on the display at a time
• select the actual signals to be displayed
• view the fault history
• reset the fault history.
The panel enters the Actual Signal Display Mode when the user presses the ACT
key, or if he does not press any key within one minute. If a fault is active, the Fault
History Display will be shown before the panel enters the Actual Signal Display
Mode. If the Drive Selection Mode is active, the Status Display of the Drive Selection
Mode is shown.
Control panel
38
How to select actual signals to the display
Step Action Press key Display
1. To enter the Actual Signal Display Mode. 1 L -> 0.0 rpm 0
ACT LED PANE 0 %
MOTOR SP 0.0 rpm
MOTOR TO 0.00 %
2. To select a row (a blinking cursor indicates the selected 1 L -> 0.0 rpm 0
row). LED PANE 0 %
MOTOR SP 0.0 rpm
MOTOR TO 0.00 %
3. To enter the actual signal selection function. ENTER
1 L -> 0.0 rpm 0
1 ACTUAL SIGNALS
01 MOTOR SPEED FILT
0.0 rpm
4. To select an actual signal. 1 L -> 0.0 rpm 0
2 ACTUAL SIGNALS
01 SPEED REF 2
To change the actual signal group.
0 rpm
5. To accept the selection and to return to the Actual Signal 1 L -> 0.0 rpm 0
ENTER
Display Mode. LED PANE 0 %
SPEED RE 0.0 rpm
MOTOR TO 0.00 %
6. To cancel the selection and keep the original selection. 1 L -> 0.0 rpm 0
ACT PAR LED PANE 0 %
MOTOR SP 0.0 rpm
The selected keypad mode is entered.
FUNC DRIVE MOTOR TO 0.00 %
How to display the full name of the actual signals
Step Action Press key Display
1. To display the full name of the three actual signals. Hold 1 L -> 0.0 rpm 0
LED PANEL OUTP
ACT MOTOR SPEED FILT
MOTOR TORQUE FILT
2. To return to the Actual Signal Display Mode. Release 1 L -> 0.0 rpm 0
LED PANE 0 %
ACT MOTOR SP 0.0 rpm
MOTOR TO 0.00 %
Control panel
39
How to view and reset the fault history
Note: The fault history cannot be reset if there are active faults or alarms.
Step Action Press key Display
1. To enter the Actual Signal Display Mode. 1 L -> 0.0 rpm 0
ACT LED PANE 0 %
MOTOR SP 0.0 rpm
MOTOR TO 0.00 %
2. To enter the Fault History Display. 1 L -> 0.0 rpm
The time of occurrence can be seen either as total power- 2 LAST FAULT
on time or in the date format if an external control system + PANEL LOSS
(for example AC 80, AC 800M) has been connected to 20 H 49 MIN 56 S
control the drive.
3. To select the previous (UP) or the next fault/alarm 1 L -> 0.0 rpm
(DOWN). 2 LAST FAULT
H MIN S
To clear the Fault History. RESET 1 L -> 0.0 rpm
2 LAST FAULT
+ OVERCURRENT
12 H 49 MIN 10 S
4. To return to the Actual Signal Display Mode. 1 L -> 0.0 rpm 0
LED PANE 0 %
MOTOR SP 0.0 rpm
MOTOR TO 0.00 %
How to display and reset an active fault
Step Action Press Key Display
1. To display an active fault. 1 L -> 0.0 rpm 0
ACT ACS 800 75 kW
*** FAULT ***
2. To reset the fault. RESET 1 L -> 0.0 rpm 0
LED PANE 0 %
MOTOR SP 0.0 rpm
MOTOR TO 0.00 %
Control panel
40
About the fault history
The fault history restores information on the 16 latest events (faults, alarms and
resets) of the drive. The table below shows how the events are stored in the fault
history.
Event Information on display
Drive detects a fault and Sequential number of the event and
A Fault History View generates a fault message. LAST FAULT text
Sign Name and Name of the fault and a “+” sign in front
code of the name
Sequential number Power- Total power-on time
(1 is the most recent event) on time User resets the fault message. Sequential number of the event and
LAST FAULT text
1 L -> 0.0 rpm RESET FAULT text
2 LAST FAULT Total power-on time
+ OVERCURRENT
12 H 49 MIN 10 S Drive generates an alarm Sequential number of the event and
message. LAST ALARM text
Name of the alarm and a “+” sign in
front of the name
Total power-on time
Drive deactivates the alarm Sequential number of the event and
message. LAST ALARM text
Name of the alarm and a “-” sign in
front of the name
Total power-on time
Parameter mode
In the Parameter Mode, the user can:
• view parameter values
• change parameter settings.
The panel enters the Parameter Mode when the user presses the PAR key.
Note: Certain parameters do not allow changes. If tried, no change is accepted, and
the following warning is displayed:
**WARNING**
WRITE ACCESS DENIED
PARAMETER SETTING
NOT POSSIBLE
Control panel
41
How to select a parameter and change the value
Step Action Press key Display
1. To enter the Parameter Mode. 1 L -> 0.0 rpm O
PAR 13 ANALOGUE INPUTS
01 AI1 HIGH VALUE
10000
2. To select a group. 1 L -> 0.0 rpm O
When the arrow button is pressed down, only the 10 DIGITAL INPUTS
parameter group name is displayed. When the button is 01 START/STOP
released also the first parameter of the group is displayed. NO
3. To select a parameter within a group. 1 L -> 0.0 rpm O
When the arrow button is pressed down, only the 10 DIGITAL INPUTS
parameter name is displayed. When the button is released 02 DIRECTION
also the parameter value is displayed.
4. To enter the parameter setting function. ENTER 1 L -> 0.0 rpm O
10 DIGITAL OUTPUTS
02 DIRECTION
[FORWARD]
5. To change the parameter value. 1 L -> 0.0 rpm O
(slow change for numbers and text) 10 DIGITAL OUTPUTS
02 DIRECTION
[DI3]
(fast change for numbers only)
6a. To save the new value. ENTER 1 L -> 0.0 rpm O
10 DIGITAL OUTPUTS
02 DIRECTION
DI3
6b. To cancel the new setting and keep the original value, 1 L -> 0.0 rpm O
ACT PAR
press any of the mode selection keys. 10 DIGITAL OUTPUTS
The selected mode is entered. 02 DIRECTION
FUNC DRIVE FORWARD
Control panel
42
How to adjust a source selection parameter
Most parameters define values that are used directly in the drive application
program. Source selection parameters are exceptions: They point to the value of
another parameter. The parameter setting procedure differs somewhat from that of
the other parameters.
Step Action Press Key Display
1. See the table above to 1 L -> 0.0 rpm O
- enter the Parameter Mode PAR 55 ADAPTIVE PROG1
06 INPUT1
- select the correct parameter group and parameter
[±000.000.00]
- enter the parameter setting mode.
ENTER
2. To scroll between the inversion, group, index and bit 1 L -> 0.0 rpm O
fields.1) 55 ADAPTIVE PROG1
06 INPUT1
[±000.000.00]
3. To adjust the value of a field. 1 L -> 0.0 rpm O
55 ADAPTIVE PROG1
06 INPUT1
[±000.018.00]
4. To accept the value.
ENTER
1)
1 L -> 0.0 rpm O Inversion field inverts the selected parameter
55 ADAPTIVE PROG1 value. Plus sign (+): no inversion, minus (-) sign:
06 INPUT1 inversion.
[±001.018.00] Bit field selects the bit number (relevant only if the
Inversion field parameter value is a packed boolean word).
Group field Index field selects the parameter index.
Index field
Group field selects the parameter group.
Bit field
Note: Instead of pointing to another parameter, it is also possible to define a
constant by the source selection parameter. Proceed as follows:
• Change the inversion field to C. The appearance of the row changes. The rest of
the line is now a constant setting field.
• Give the constant value to the constant setting field.
• Press ENTER to accept.
Control panel
43
Function mode
In the Function Mode, the user can:
• Upload group 10...98 parameter values from the drive to the panel.
• Download group 10...97 parameter values from the panel to the drive.1)
• Copy group 10...97 parameter values from one drive to another by using the
upload and download functions.
• Adjust the contrast of the display.
The panel enters the Function Mode when the user presses the FUNC key.
The upload function can be performed also when the drive is running. During upload,
only a STOP command can be given to the drive.
The download function can only be performed, when the drive is stopped.
1)
The parameter groups 98, 99 and the results of the motor identification are not included.
How to copy parameters from one drive to other drives
Note:
• Upload before downloading.
• Ensure the firmware (e.g. system firmware) and its version are the same in both
drives. See signals 04.02 DTC SW VERSION and 04.03 APPLIC SW VERSION.
• Before removing the panel from a drive, ensure the panel is in remote operating
mode (selected with the LOC/REM key).
• Stop the drive before downloading.
• Parameter groups 98 and 99 will not be copied.
Before upload, repeat the following steps for each drive:
• Setup the motors. Enter the motor data from the motor nameplate (parameter
group 99 START-UP DATA) and if required, perform the identification run. For
instructions, see ID RUN (motor identification run) on page 22.
• Activate the communication to the optional equipment. See parameter group 98
OPTION MODULES.
Before upload, do the following steps for the drive from which the copies are to be
taken:
• Set the parameters in groups 10...97 as preferred.
• Proceed to the upload and download sequences (below).
Control panel
44
Step Action Press Key Display
1. To enter the Function Mode. 1 L -> 0.0 rpm O
FUNC UPLOAD <=<=
DOWNLOAD =>=>
CONTRAST 0
2. To enter the page that contains the upload, download and 1 L -> 0.0 rpm O
contrast functions. UPLOAD <=<=
DOWNLOAD =>=>
CONTRAST 0
3. To select the upload function (a flashing cursor indicates 1 L -> 0.0 rpm O
the selected function). UPLOAD <=<=
DOWNLOAD =>=>
CONTRAST 0
4. To enter the upload function. ENTER 1 L -> 0.0 rpm O
UPLOAD <=<=
5. To switch to external control. 1 -> 0.0 rpm O
LOC
(No L on the first row of the display.) UPLOAD <=<=
REM
DOWNLOAD =>=>
CONTRAST 0
6. Disconnect the panel and reconnect it to the drive to which
the data will be downloaded.
7. Connect the panel containing the uploaded data to the
drive.
8. Ensure the drive is in local control (L shown on the first row 1 L -> 0.0 rpm 0
LOC
of the display). If necessary, press the LOC/REM key to LED PANE 0 %
REM
change to local control. MOTOR SP 0.0 rpm
MOTOR TO 0.00 %
9. To enter the Function Mode. 1 L -> 0.0 rpm O
FUNC UPLOAD <=<=
DOWNLOAD =>=>
CONTRAST 0
10. To enter the page that contains the upload, download and 1 L -> 0.0 rpm O
contrast functions. UPLOAD <=<=
DOWNLOAD =>=>
CONTRAST 0
11. To select the download function (a flashing cursor 1 L -> 0.0 rpm O
indicates the selected function). UPLOAD <=<=
DOWNLOAD =>=>
CONTRAST 0
12. To start the download. ENTER 1 L -> 0.0 rpm O
DOWNLOAD =>=>
Control panel
45
How to set the contrast of the display
Step Action Press Key Display
1. To enter the Function Mode. 1 L -> 0.0 rpm O
FUNC UPLOAD <=<=
DOWNLOAD =>=>
CONTRAST 0
2. To enter the page that contains the upload, download and 1 L -> 0.0 rpm O
contrast functions. UPLOAD <=<=
DOWNLOAD =>=>
CONTRAST 0
3. To select a function (a flashing cursor indicates the 1 L -> 0.0 rpm O
selected function). UPLOAD <=<=
DOWNLOAD =>=>
CONTRAST 0
4. To enter the contrast setting function. ENTER 1 L -> 0.0 rpm O
CONTRAST [0]
5. To adjust the contrast. 1 L -> 0.0 rpm O
CONTRAST [7]
6.a To accept the selected value. ENTER 1 L -> 0.0 rpm O
UPLOAD <=<=
DOWNLOAD =>=>
CONTRAST 7
6.b To cancel the new setting and retain the original value by 1 L -> 0.0 rpm 0
pressing any of the mode selection keys. ACT PAR LED PANE 0 %
MOTOR SP 0.0 rpm
MOTOR TO 0.00 %
The selected mode is entered. FUNC DRIVE
Drive selection mode
In normal use the features available in the Drive Selection Mode are not needed; the
features are reserved for applications where several drives are connected to one
panel link. (For more information, see the Installation and Start-up Guide for the
Panel Bus Connection Interface Module, NBCI, [3AFY58919748 (English)].
In the Drive Selection Mode, the user can:
• Select the drive with which the panel communicates through the panel link.
• Change the identification number of a drive connected to the panel link.
• View the status of the drives connected to the panel link.
The panel enters the Drive Selection Mode when the user presses the DRIVE key.
Each on-line station must have an individual identification number (ID). By default,
the ID number of the drive is 1.
Note: The default ID number setting of the drive should not be changed unless the
drive is to be connected to the panel link with other drives on-line.
Control panel
46
How to select a drive and change its panel link ID number
Step Action Press key Display
1. To enter the Drive Selection Mode. ACS800 0003_3 SR
DRIVE DRIVE NAME
AMXR7200
ID NUMBER 1
2. To select the next drive/view. ACS800 0003_3 SR
The ID number of the station is changed by first pressing DRIVE NAME
ENTER (the brackets round the ID number appear) and AMXR7200
then adjusting the value with arrow buttons. The new value
ID NUMBER 1
is accepted with ENTER. The power of the drive must be
switched off to validate its new ID number setting.
The status display of all devices connected to the Panel 1o
Link is shown after the last individual station. If all stations
do not fit on the display at once, press the double-arrow up
Status Display Symbols:
to view the rest of them.
o = Drive stopped, direction
forward
= Drive running, direction
reverse
F = Drive tripped on a fault
3. To connect to the last displayed drive and to enter another 1 L -> 0.0 rpm 0
mode, press one of the mode selection keys. ACT PAR LED PANE 0 %
MOTOR SP 0.0 rpm
FUNC MOTOR TO 0.00 %
The selected mode is entered.
Reading and entering packed boolean values on the display
Some actual values and parameters are packed boolean, i.e. each individual bit has
a defined meaning (explained at the corresponding signal or parameter). On the
control panel, packed boolean values are read and entered in hexadecimal format.
In this example, bits 1, 3 and 4 of the packed boolean value are ON:
Bit 15 Bit 0
Boolean 0000 0000 0001 1010
Hex 0 0 1 A
Control panel
47
Program features
What this chapter contains
This chapter describes the typical functions of the drive.
Local control vs. external control
The drive can receive start, stop and direction commands and reference values from
the control panel or through digital and analogue inputs. An optional fieldbus adapter
enables control over an open fieldbus link. A PC equipped with DriveWindow can
also control the drive.
Local control ACS800 External control
Standard I/O
Control panel Fieldbus Slot 1
adapter
RTAC/RDIO/RAIO Slot 1 or Slot 2
module
RDCO CH0 Fieldbus adapter
CH3 module (DDCS) Nxxx
DriveWindow
(DDCS) or
Advant controller
(e.g. AC 80, AC 800M)
CH1 AIMA-01 I/O RTAC/RDIO/RAIO
(DDCS) adapter module module
Control modes
The System Application Program has two main control modes: remote (external
control) and local (local control). The control mode is selected with the LOC/REM
key on the CDP 312R control panel or with the DriveWindow PC tool.
Program features
48
External control
When the drive is in external control, commands are given through a serial link
(connected to option module in Slot 1/2 of the drive or to DDCS channel CH0 of the
RDCO module) or the I/O terminals (digital and analogue inputs). The desired
alternative is selected by parameter 98.02 COMM. MODULE.
A HAND/AUTO function is suitable for applications requiring alternation between
serial communication control and I/O control. A digital input can be selected for
changing the control location. The function is activated by parameter
10.07 HAND/AUTO.
It is possible to use two serial communication interfaces with one drive. See section
Redundant fieldbus control on page 292.
I/O extension modules are connected to option Slot 1/2 of the drive or to DDCS
channel CH0 of the RDCO module. All I/O extension units connected to DDCS
channel CH1 are connected in ring topology. Channel CH1 acts as a master in the
communication link.The RMIO is the actual master of the communication link. Each
I/O unit has an individual address, set with DIP switches on the unit. Before use,
each I/O unit must be activated by parameter group 98 OPTION MODULES.
External control is indicated by a blank on the panel display.
1 ->1242 rpm I
Local control
When the drive is in local control, the control commands are given from the control
panel keypad or from a PC equipped with DriveWindow. When control panel is used,
L indicates local control on the panel display.
1 L ->1242 rpm I
Local control mode is mainly used during commissioning and maintenance. The
control panel always overrides the external control signal sources when used in local
mode. Changing the control location to local can be disabled by parameter
16.04 LOCAL LOCK.
In local control, the emergency stop activation signal source can be selected by
parameter 21.12 LOCAL EM STOP MODE.
Settings
Parameter Additional information
10.07 HAND/AUTO Activation of the HAND/AUTO function
16.04 LOCAL LOCK Activation of the local control lock
21.12 LOCAL EM STOP MODE Selection of the source for the emergency stop activation signal in
local control mode
98 OPTION MODULES Activation of the optional I/O and serial communication
Program features
49
The following diagram presents the external control interface and I/O connections.
Fieldbus RDIO-01 RAIO-01 RTAC-01 2)
RMIO adapter or or or
Slot 1 Rxxx (e.g.
RPBA-01
1) Installed in Slot 1 or Slot 2 2) Recommended to be
RDNA-01
RMBA-01 1) connected to AIMA-01
Slot 2 RDIO-01 or RAIO-01 or RTAC-01 2) or RMBA-011)
RDCO-0x POF (Plastic optic fibre)
- Fieldbus CH0 or or or
- ABB controllers
Fieldbus CI858 ModuleBus
4) Used
with adapter Nxxx
RDCO-01, 10 MBd (used with AC80 (4 AC 800M (4
AC 800M (4
RDCO-02
- I/O extensions
CH1 POF (Plastic optic fibre)
- Pulse encoder
NTAC-02 CH1 1A AIMA-01 CH1 1A AIMA-01 ISU
Node addr. DSU
= 16 Slot 1 Slot 2 Slot 3 Slot 1 Slot 2 Slot 3 (single drive
interface)
RDIO/RAIO/RTAC RDIO/RAIO/RTAC
0...2 AIMA-01 adapters according to the
- Master/Follower link HCS (Hard Silica Fibre with RDCO-01/02) number of RDIO, RAIO and RTAC modules
POF (Plastic optic fibre with RDCO-01/02/03)
CH2 or
Broadcast This option
module can NAIO-03F
CH0/CH2 CH0/CH2 CH0/CH2 CH0/CH2
be used, if (Fast AI)
RDCO-0x RDCO-0x RDCO-0x RDCO-0x no other Node addr = 1
devices
ACS800 ACS800 ACS800 ACS800 connected
Follower 1 Follower 2 Follower 3 Follower 4 in the CH2.
- PC tools POF (Plastic optic fibre) RDCO-0x CH0 or CH3
- NETA-0x HCS (Hard Silica Fibre with RDCO-01/02) NETA-01
or NBDU MSTR
CH3
or
NDBU
-85/95
NDBU
CH0 -85/95 DDCS/PC card
cable
MSTR CH0
or NDPC-12
CH1 MSTR or
CH2 CH1
ACS800 PCMCIA PCMCIA
drives board and board and
CH3 ACS800 CH2
... NDPA-02 NDPA-02
drives
CH8 CH3 Laptop PCI
... PC adapter
ACS800 CH8
Desktop
PC
Program features
50
Analogue inputs
The drive has three programmable non-galvanically isolated analogue inputs on
the RMIO board: one voltage input (0/2...10 V or -10...10 V) and two current inputs
(0/4...20 mA). The accuracy of the analogue inputs is +/-0.5%.
Two extension inputs are available if an optional Analogue I/O Extension 1 module,
RAIO, is used. The input signal range is selected with DIP switches. The hardware
filter time constant of the RMIO analogue inputs is approximately 1 ms.
For more information, see RAIO-01 Analogue I/O Extension User's Manual
[3AFE64484567 (English)].
Each input can be filtered, and the maximum and minimum values can be adjusted.
Analogue inputs can be used
• for motor temperature measurement
• as I/O speed or torque reference source
• as a communication interface for an external control system (e.g. fieldbus control)
• in adaptive programming using function blocks.
Analogue input speed reference can be summed with the fieldbus adapter speed
reference if parameter 11.02 AI+FBA SPEED REF is activated and parameter
98.02 COMM. MODULE is set to FIELDBUS.
See control block diagram in section I/O speed and torque references and motor
temperature protection on page 311.
Two extra inputs are also available for adaptive block programming if an optional
Analogue I/O Extension 2 module, RAIO, is used. (See blocks EXT2_AI1...2 in the
ACS600 / ACS800 Application Guide Adaptive Program for System Application
Program 7.x [3AFE68420075 (English)].)
The analogue input update cycle is 10 ms.
Program features
51
RMIO board
AI Input type Resolution Signal Additional information
(1
AI1 0...+/-10 11 bits MOTOR 1 TEMP Motor temperature measurement with 1...3 PTC thermistor,
V DC + sign or Pt100 or KTY84-1xx sensors.
Ri = 200 kΩ I/O speed reference Speed reference for I/O control or HAND/AUTO function (Par.
10.07 HAND/AUTO).
AI2 0/4...20 mA 11 bits I/O speed reference Speed reference (mA) for I/O control or HAND/AUTO function
Ri = 100 Ω + sign or (Par. 10.07 HAND/AUTO)
used in the adaptive
programming
AI3 0/4...20 mA 11 bits I/O torque reference Torque reference for I/O control or HAND/AUTO function
Ri = 100 Ω + sign or (Par. 10.07 HAND/AUTO)
used in the adaptive
programming
RAIO module: Unipolar mode (2
AI Input type Resolution Signal Additional information
AI1 0(4)...20 mA 12 bits MOTOR 1 TEMP Motor 1 temperature measurement with 1...3 PTC thermistor,
Ri = 100 Ω Pt100 or KTY84-1xx sensors
0...2 V DC 12 bits or Speed reference for I/O control.
0...10 V DC I/O speed reference Isolated from analogue outputs, power supply and earth.
Ri > 200 κΩ Test voltage: 1.5 kV AC, 1 minute.
AI2 0(4)...20 mA 12 bits MOTOR 2 TEMP Motor 2 temperature measurement with 1...3 PTC thermistor,
Ri > 100 Ω Pt100 or KTY84-1xx sensors
0...2 V DC 12 bits or Torque reference for I/O control.
0...10 V DC I/O torque reference B Isolated from analogue outputs, power supply and earth.
Ri > 200 kΩ Test voltage: 1.5 kV AC, 1 minute.
RAIO module: Bipolar mode (3
AI Input type Resolution Signal Additional information
AI1 -20...+20 mA 11 bits MOTOR 1 TEMP Motor 1 temperature measurement with 1...3 PTC thermistor,
0(4)...20 mA + sign Pt100 or KTY84-1xx sensors
Ri = 100 Ω
-2...+2 V DC 11 bits or Speed reference for I/O control.
-10...10 V DC + sign I/O speed reference Isolated from analogue outputs, power supply and earth.
Ri = 200 kΩ Test voltage: 1.5 kV AC, 1 minute.
AI2 -20...+20 mA 11 bits MOTOR 2 TEMP Motor 2 temperature measurement with 1...3 PTC thermistor,
0(4)...20 mA + sign Pt100 or KTY84-1xx sensors
Ri = 100 Ω
-2...+2 V DC 11 bits or Torque reference for I/O control.
-10...10 V DC + sign I/O torque reference B Isolated from analogue outputs, power supply and earth.
Ri = 200 kΩ Test voltage: 1.5 kV AC, 1 minute.
(1 If
analogue input AI1 has been selected for speed reference and motor temperature measurement, motor temperature
measurement is valid and the speed reference is switched to zero and alarm I/O SP REF is activated (see chapter Fault
tracing).
(2
Unipolar mode is selected by setting parameter 98.06 AI/O EXT MODULE 1 (with analogue I/O extension module 1) or
by setting parameters 98.13 AI1 EXT2 MODE and 98.14 AI2 EXT2 MODE (with analogue I/O extension module 2).
(3
With bipolar speed reference signal, the speed scaling is defined by parameters 13.01/13.04 AI1/2 HIGH VALUE and
13.02/13.05 AI1/2 LOW VALUE. See also parameter 13.12/13.06 MINIMUM AI1/2.
Program features
52
Example:
-10...+10 V bipolar speed reference signal:
• Set parameter 13.01 AI1 HIGH VALUE to 20000 and 13.02 AI1 LOW VALUE to
-20000.
• Select -10 V by parameter 13.12 MINIMUM AI1.
• Set speed scaling: Parameter 50.01 SPEED SCALING defines the speed
reference in rpm which corresponds to value 20000.
Settings
Parameter Additional information
10.07 HAND/AUTO Switching between I/O control and serial communication control
through a digital input
11 REFERENCE SELECT Selection of analogue input as a reference source
13 ANALOGUE INPUTS Processing of the analogue inputs
30.27 AI<MIN FUNC Selection of the supervision with analogue input signal loss
98 OPTION MODULES Activation of the optional I/O and serial communication.
Definition of the analogue input signal type (bipolar or unipolar).
Diagnostics
Actual value Additional information
01.16, 01.17 MOTOR 1 TEMP Values of analogue inputs AI1...AI2 with motor temperature
measurement
01.19...01.21 Non-scaled values of analogue inputs AI1...AI3
01.41 EXT2 AI1, 01.42 EXT2 AI2 Non-scaled values of analogue inputs AI1...AI2 of I/O extension
module EXT2
02.25 ADDITIVE SP REF Sum of the analogue input speed reference and fieldbus adapter
reference
Program features
53
Analogue outputs
The drive has two programmable non-galvanically isolated current outputs
(0/4...20 mA) on the RMIO board. Two outputs can be added by using an optional
Analogue I/O Extension module, RAIO. For more information, see RAIO-01
Analogue I/O Extension User's Manual [3AFE64484567 (English)].
Analogue output signals can be inverted and filtered. The analogue output signals
can be proportional to motor speed, process speed (scaled motor speed), output
frequency, output current, motor torque, motor power, etc. It is possible to write
a value to an analogue output through a serial communication link (e.g. fieldbus
link).
The resolution of the RMIO board analogue outputs is 10 bits and the accuracy is
+/-1%. The resolution of the RAIO module analogue outputs is 12 bits and the
accuracy is +/-0.5%.
The analogue output update cycle is 10 ms.
Two extra outputs are also available for adaptive block programming if an optional
Analogue I/O Extension 2 module, RAIO, is used.
RMIO board
AO Input type Resolution Signal Additional information
AO1 0(4)...20 mA 10 bits AO1_OUT The output can be used as a constant current source
Ri = to supply temperature measurement sensor Pt100,
max. 700 Ω PTC or KTY84-1xx. The current is set automatically
according to the type of the sensor.
AO2 0(4)...20 mA 10 bits AO2_OUT The output can be controlled by an external control
Ri = system.
max. 700 Ω
RAIO module
AO Input type Resolution Signal Additional information
AO3 0(4)...20 mA 12 bits AO3_OUT See parameter 98.06 AI/O EXT MODULE 1 and
Ri = parameter group 15 ANALOGUE OUTPUTS.
max. 700 Ω Isolated from analogue inputs, power supply and
AO4 0(4)...20 mA 12 bits AO4_OUT earth. Test voltage: 1.5 kV AC, 1 minute.
Ri =
max. 700 Ω
(isolated from
the power
supply)
Program features
54
Settings
Parameter Additional information
15 ANALOGUE OUTPUTS Selection and processing of analogue output values
98 OPTION MODULES Activation of optional I/O and serial communication
Diagnostics
Actual value Additional information
01.23 AO1 [mA] Values of analogue outputs AO1...AO2
01.24 AO1 [mA]
One of the NAIO-03F current outputs (0(4)…20 mA) can be used as a fast analogue
output. The output can be connected to any parameter with an appropriate scaling
value. Signal can also be inverted.
Program features
55
Digital inputs
The drive has seven digital inputs on the RMIO board. Digital input DI1 is reserved
for the emergency stop signal and digital input DI2 is reserved for the run enable
signal. Digital inputs DI3...DI7 are freely programmable. Six inputs can be added by
using optional Digital I/O Extension modules, RDIOs. RDIO modules can also be
used to replace the RMIO board digital inputs. For more information, see RDIO-01
Digital I/O Extension User's Manual [3AFE64485733 (English)].
All digital inputs can be read through a serial communication link (e.g. fieldbus link).
The maximum number of digital inputs is 13. The analogue input update cycle time is
10 ms.
DI RMIO board RDIO module 1 RDIO module 2 Par. setting
I/O name DI1 DI2 DI3 DI4 DI5 DI6 DI7 Ext1 Ext1 Ext1 Ext2 Ext2 Ext2
in software DI1 DI2 DI3 DI1 DI2 DI3
DI1 1 2
DI2 1 2 1: Par. 98.03 1)
DI3 1 2 and Par. 98.04
= NO
DI4 1 3
2: Par. 98.03 1)
DI5 1 3
= REPLACE
DI6 1 3 3: Par. 98.04 =
DI7(DIIL) 2) 1 REPLACE
EXT1 DI1 5 5: Par. 98.03 1)
= EXTEND
EXT1 D12 5
6: Par. 98.04 =
EXT1 DI3 5
EXTEND or
EXT2 DI1 3) 6 STEP-UP
3)
EXT2 DI2 6
3)
EXT2 DI3 6
I/O extension module 1/2 is activated by parameters 98.03/98.04 and 98.09/98.10.
1)
98.03 DI/O EXT MODULE 1: NO = No RDIO module 1 used, REPLACE = RDIO replaces RMIO
DI1, DI2, DI3.
2) DI7 is a normal input, which is not connected to interlock circuit.
3) See parameter group 10 DIGITAL INPUTS.
Settings
Parameter Additional information
10 DIGITAL INPUTS Selection and processing of digital input values
98 OPTION MODULES Activation of the optional I/O and serial communication
Diagnostics
Actual value Additional information
01.15 DI6-1 STATUS Values of RMIO digital inputs
08.05 DI STATUS WORD Values of RMIO and extended digital inputs
Program features
56
Digital outputs
The drive has three programmable digital outputs on the RMIO board. Four outputs
can be added by using optional Digital I/O Extension modules, RDIOs. RDIO
modules can also be used to replace the RMIO board digital outputs. For more
information, see RDIO-01 Digital I/O Extension User's Manual [3AFE64485733
(English)].
The maximum number of digital outputs is 7. The analogue output update cycle time
is 10 ms.
It is possible to write a value to a digital output through a serial communication link
(e.g. fieldbus link).
DO RMIO board RDIO RDIO Parameter setting
module 1 module 2
I/O name DO1 DO2 DO3 Ext1 Ext1 Ext2 Ext2
in software DO1 DO2 DO1 DO2
DO1 1 2 1: Par. 98.03 (1 and Par. 98.04 = NO
2: Par. 98.03 (1 = REPLACE
DO2 1 2
3: Par. 98.04 = REPLACE
DO3 1 3
5: Par. 98.03 (1 = EXTEND
EXT1 DO1 2, 5 (controlled by signal 07.03 AUX
EXT1 DO2 2, 5 CONTRL WORD 2)
EXT2 DO1 6 6: Par. 98.04 = EXTEND or STEP-UP
EXT2 DO2 3, 6
I/O extension module 1/2 is activated by parameters 98.03/98.04 and 98.09/98.10.
(1 98.03
DI/O EXT MODULE 1: NO = No RDIO module 1 used, REPLACE = RDIO replaces RMIO
DO1 and DO2.
Settings
Parameter Additional information
14 DIGITAL OUTPUTS Processing of the RMIO and RDIO digital outputs
30.26 COM LOSS RO Selection of the supervision of fieldbus controlled RMIO and RDIO
digital outputs DO1...3 in a communication break
98 OPTION MODULES Activation of optional I/O and serial communication
Diagnostics and control
Actual value Additional information
01.22 RO3-1 STATUS Values of standard digital outputs
07.02 AUX CTRL WORD 1 RMIO DO1...DO2 control
07.03 AUX CTRL WORD 2 RDIO DO1...DO2 control
Program features
57
Fast analogue interface
The fast analogue interface can be used for speed and torque references. A fast
analogue input module (NAIO-03F) should be connected to channel 2 on the RDCO
DDCS communication option module. When the fast analogue I/O module is
enabled, no other modules are allowed on channel 2. See option I/O, fieldbus and
PC tool configuration chart at the end of the sub chapter.
The fast analogue interface is NOT active if any of the following conditions is true:
• Drive ID run is in progress
• Parameter 99.07 MOTOR ID RUN value is other than “NO”. This means that the
ID run is selected to be run at the next start.
• There is no active start command.
The NAIO-03F module uses address 1. The address is selected by DIP switches on
the NAIO-03F module. Bipolar mode must be used; it is also set by DIP switches.
See the Installation and Start-up Guide (3AFY58919730 [English]) for the NAIO-0x
modules for more information.
NAIO-03F DIP switch settings
21
The System Control program supports two external fast analogue inputs and one
output, thus the other analogue output of NAIO-03F module is not used. See the
Installation and Start-up Guide [3AFY58919730 (English)] option module for extra
information and for instructions on how to adjust the input ranges.
Settings
Parameter Additional information
12.12 FAST AI1 REF SEL Signal source for fast analogue input AI1
12.13 FAST AI1 SPD SCL Scaling of fast analogue signal AI1 for speed reference chain.
12.14 FAST AI1 TORQ SCL Scaling of fast analogue signal AI1 for torque reference chain.
12.15 FAST AI2 REF SEL Signal source for fast analogue input AI2.
12.16 FAST AI2 SPD SCL Scaling of fast analogue input AI2 for speed reference chain.
12.17 FAST AI2 TORQ SCL Scaling of fast analogue AI2 for torque reference chain.
Settings
Parameter Additional information
12.21 FAST EXT AO1 SEL Signal source for fast analogue output AO1
12.22 FAST EXT AO1 INV Inverts fast AO1
12.23 FAST EXT AO1 MIN Minimum value for AO1
12.24 FAST EXT AO1 SCL Scaling for AO1
Program features
58
Diagnostics
Actual value Additional information
09.06 FAULT WORD 3 B8 Fast AI module fault FAST EXT AI
Fast digital interface
The standard DI5 can be used as fast DI. The fast DI is read on 1 ms timelevel and it
can be used to:
• (dis)connect the SPEED CORRECTION to / from speed reference chain (see
control block diagram in section Speed reference ramp on page 314.)
or
position synchronisation see section Position counter on page 120.
Settings
Parameter Additional information
12.03 FAST DI5 SEL Connect DI5 to SPEED CORRECTION or Position counter
Extracted from complete speed and torque control chain. See control block
diagrams Control block diagrams on page 309.
F A S T A I1 R E F S E L
1 2 .1 2
F A S T A I1 S C A L IN G 2 6 .0 4 T O R Q U E S T E P
F A S T A I1 S P D S C L 2 5 .0 4 T O R Q U E R E F B
1 2 .1 3 2 5 .0 1 T O R Q U E R E F A
F A S T A I1 T O R Q S C L 2 3 .0 4 S P E E D C O R R
1 2 .1 4 2 .2 5 A D D S P E E D
N O A I R E F
F A S T A I2 R E F S E L
1 2 .1 5
F A S T A I2 2 6 .0 4 T O R Q U E S T E P
S C A L IN G
F A S T A I2 S P D S C L 2 5 .0 4 T O R Q U E R E F B
1 2 .1 6 2 5 .0 1 T O R Q U E R E F A
F A S T A I2 T O R Q S C L 2 3 .0 4 S P E E D C O R R
1 2 .1 7
2 .2 5 A D D S P E E D
N O A I R E F
Program features
59
RMIO board connection diagrams
For RDCU Drive Control Unit (includes an RMIO board) installation instructions and
technical information, see RDCU-02(C) Drive Control Unit Hardware Manual
[3AFE64636324 (English)].
Program features
60
Control through communication link
The figure below shows the RMIO Motor Control and I/O board default connections
when the drive is controlled through a serial communication link.
Motor temperature X20
measurement 1...3 1 VREF Reference voltage -10 V DC, max. 10 mA
Pt100, PTC or 2 GND 1 kΩ < RL < 10 kΩ
KTY84-1xx X21
1 VREF Reference voltage 10 V DC, max. 10 mA
AI1+ 2 GND 1 kΩ < RL < 10 kΩ
AI1-
3 AI1+ Analogue input (voltage -10 V ... 0 ... +10 V)
4 AI1- Rin > 200 kΩ
5 AI2+ Analogue input (current 0(4)...20 mA)
AO1- 6 AI2- Rin = 100 Ω
AO1+
7 AI3+ Analogue input (current 0(4)...20 mA
8 AI3- Rin = 100 Ω
If parameter 30.03 =
% 9 AO1+ Motor torque 0…20 mA = 0…motor nom.
1...3 × PT100 or PTC
10 AO1- torque, RL < 700 Ω
11 AO2+ Motor speed 0…20 mA = 0…motor nom.
rpm
12 AO2- speed, RL < 700 Ω
X22
1 DI1 No Emergency Stop
2 DI2 Run Enabled
3 DI3 By default not in use
4 DI4 By default not in use
5 DI5 By default not in use
6 DI6 By default not in use
7 +24 V +24 V DC, max. 100 mA
8 +24 V
9 DGND1 Digital ground
10 DGND2 Digital ground
11 DI7(DIIL) By default not in use
X23
Use external power supply if the total current 1 +24 V Auxiliary voltage input or output 24 V DC, 250
consumption exceeds 250 mA. 2 GND mA or 130 mA if an NLMD-01 panel is
included.
X25
1 RO11 Relay output 1
2 RO12 Emergency Stop (default)
3 RO13
X26
1 RO21 Relay output 2
2 RO22 Running (default)
3 RO23
X27
1 RO31 Relay output 3
2 RO32 Fault (default)
3 RO33
Program features
61
Control through I/O
The figure below shows the RMIO Motor Control and I/O board default signals when
the drive is controlled from the I/O: parameter 98.02 COMM. MODULE is set to NO
or HAND/AUTO function is used (Par. 10.07 HAND/AUTO).
X20
Motor temperature 1 VREF Reference voltage -10 V DC, max 10 mA
measurement 1...3 2 GND 1 kΩ < RL < 10 kΩ
Pt100, PTC or X21
KTY84-1xx 1 VREF Reference voltage 10 V DC, max 10 mA
2 GND 1 kΩ < RL < 10 kΩ
AI1+ 3 AI1+ Speed reference unipolar (default) (range for
AI1- AI1: -10 V… 0 ...10 V, Rin > 200 kΩ
4 AI1-
5 AI2+ Speed reference (current 0(4)…20 mA),
6 AI2- alternative, see Par. 11.01, Rin = 100 Ω
mA-type of alternative
AO1- for references 7 AI3+ Torque reference, (current 0(4)…20 mA)
AO1+ 8 AI3- (TORQ REF B), Rin = 100 Ω
% 9 AO1+ Motor torque 0…20 mA = 0 … motor nom.
If parameter 30.03 = 10 AO1- torque, RL < 700 Ω
1...3 × PT100 or PTC rpm 11 AO2+ Motor speed 0…20 mA = 0 … motor nom.
12 AO2- speed, RL < 700 Ω
X22
1 DI1 No Emergency Stop
2 DI2 Run Enabled
3 DI3 1)
4 DI4 1)
5 DI5 Reset
6 DI6 1)
1)See parameter group 10 7 +24 V +24 V DC, max. 100 mA
DIGITAL INPUTS for Start/ 8 +24 V
Stop/Direction control. 9 DGND1 Digital ground
10 DGND2 Digital ground
11 DI7 (DIIL) 1)
X23
Use external power supply if the total current
1 +24 V Auxiliary voltage input or output 24 V DC, 250
consumption exceeds 250 mA.
2 GND mA or 130 mA if an NLMD-01 panel is
included.
X25
1 RO11 Relay output 1
DO3: Motor fan control. See 2 RO12 Emergency Stop (default)
parameter 10.06 MOTOR FAN 3 RO13
ACK and parameter groups X26
14 DIGITAL OUTPUTS and 1 RO21 Relay output 2
35 MOTOR FAN CTRL. 2 RO22 Run (default)
3 RO23
X27
1 RO31 Relay output 3
2 RO32 Fault (default)
3 RO33
Program features
62
Actual signals
Several actual signals are available:
• drive output frequency, current, voltage and power
• motor speed and torque
• intermediate circuit DC voltage
• drive temperature
• operating time counter (h), kWh counter, fan-on time counter (h) and motor run time
counter (h)
• digital I/O and analogue I/O status.
Three signals can be shown simultaneously on the control panel display. It is also
possible to read the values through a serial communication link or through analogue
outputs.
Settings
Parameter Additional information
15 ANALOGUE OUTPUTS Selection of an actual signal to an analogue output
16.09 RESET COUNTER Resetting of the cooling fan running time counter
51 MASTER ADAPTER (fieldbus Settings of the fieldbus adapter used in serial communication
adapter)
92 D SET TR ADDR Selection of an actual signal to a data set (serial communication)
93 D SET TR ADDR
Diagnostics
Actual value Additional information
01 ACTUAL SIGNALS... Lists of actual signals
09 FAULT WORDS
Motor identification
The performance of Direct Torque Control is based on an accurate motor model
determined during the motor start-up. A motor Identification Magnetisation is
automatically done the first time the start command is given. During this first start-up,
called ID MAGN, the motor is magnetised at zero speed for several seconds to allow
the motor model to be created. This identification method is suitable for most
applications. In demanding applications, a separate identification run can be
performed.
Settings
Parameter Additional information
99.07 MOTOR ID RUN Selection of the motor identification run
Program features
63
Undervoltage control
If the incoming supply voltage is cut off, the drive will continue to operate by utilising
the kinetic energy of the rotating motor. The drive will be fully operational as long as
the motor rotates and generates energy to the drive. The drive can continue the
operation after the break if the main contactor remained closed.
Undervoltage control limit is 0.82 · 1.35 · U1min, where U1min is the minimum value of
the input voltage range.
See control block diagram in section Torque reference on page 316.
Note: Cabinet assembled units equipped with main contactor option must be
equipped with a hold circuit (e.g. UPS) which keeps the contactor control circuit
closed during a short supply break.
Umains
TM fout UDC
(Nm) (Hz) (V DC) UDC
160 80 520
120 60 390
fout
80 40 260
TM
40 20 130
t(s)
1.6 4.8 8 11.2 14.4
UDC= intermediate circuit voltage of the drive, fout = output frequency of the drive,
TM = motor torque
Loss of supply voltage at nominal load (fout = 40 Hz). The intermediate circuit DC voltage drops to the
minimum limit. The controller keeps the voltage steady as long as the mains is switched off. The drive
runs the motor in generator mode. The motor speed falls but the drive is operational as long as the
motor has enough kinetic energy.
Note: The undervoltage controller is able to adjust the torque in all operating
quadrants without limitations, if the following parameter values are set high enough:
- power limits: 20.17, 20.18,
- torque limits: 20.05, 20.06 and
- maximum current: 20.04.
Program features
64
Settings
Parameter Additional information
20.04 MAXIMUM CURRENT Maximum current
20.05 MAXIMUM TORQUE and Torque limits
20.06 MINIMUM TORQUE
20.14 ADAPTIVE UDC MEAS Deactivation of the adaptive UDC measurement. Measurement
should be deactivated if undervoltage control is in use in
a application with several drives connected to the same DC bus.
20.15 UNDERVOLT TORQ UP and Limitation of the maximum/minimum torque during undervoltage
20.16 UNDERVOLT TORQ DN control, when adaptive UDC measurement is deactivated.
20.17 P MOTORING LIM and Power limits
20.18 P GENERATING LIM
30.22 UNDERVOLTAGE CTL Activation of the undervoltage controller
Diagnostics
Actual value Additional information
08.03 LIMIT WORD 1, bit 12 DC undervoltage limit
Program features
65
Overvoltage control
Overvoltage control of the intermediate DC link is needed with two-quadrant
line-side converters when the motor operates within the generating quadrant.
To prevent the DC voltage from exceeding the overvoltage control limit, the
overvoltage controller automatically decreases the generating torque when the limit
is reached.
The overvoltage control limit is 1.24 × 1.35 × U1max, where U1max is the maximum
value of the input voltage range.
See control block diagram in section Torque reference on page 316.
Settings
Parameter Additional information
30.23 OVERVOLTAGE CTL Activation of the overvoltage controller
Diagnostics
Actual value Additional information
08.03 LIMIT WORD 1, bit 13 DC overvoltage limit
Automatic start
Since the drive can detect the state of the motor within a few milliseconds,
the starting is immediate under all conditions. For example the starting of turbining
pumps or windmilling fans is easy.
Settings
Parameter Additional information
21.01 START FUNCTION Selection of the start function
Program features
66
Auto restart
It is possible to restart the drive automatically after a short power supply failure (max.
5 seconds) using the AUTO RESTART function if
- the RMIO board is powered through an UPS (Uninterruptible Power System)
- digital input DI2 circuit remains closed during the power supply failure
- the inverter is allowed to run for max. 5 seconds without inverter fans.
The maximum time for a power failure for the auto restart function is adjustable
(21.10 AUTO RESTART TIME). The factory setting is five seconds.
Note: Check that the auxiliary control circuit functions correctly during a power
supply failure.
When a power supply failure occurs
• 08.01 MAIN STATUS WORD is frozen and DC UNDERVOLT fault (signal 09.02
Fault Word 2 bit 2) is masked. DC UNDERVOLT fault is internally reset.
• DC UNDERVOLT alarm is activated (signal 09.05 Alarm Word 2 bit 14 value is 1).
• 07.01 MAIN CONTROL WORD bit 0 (ON) changes from 1 to 0 and back to 1.
• Start function is forced temporarily to the flying start mode (parameter 21.01
START FUNCTION setting is AUTO).
• After a successful restart, alarm RESTARTED is activated (signal 09.05 Alarm
Word 2 bit 15 value is 1).
Note: If the power supply failure lasts over 5 seconds: Auto restart function is
cancelled, 08.01 Main Status Word is restored and DC UNDERVOLT fault (signal
09.02 Fault Word 2 bit 2) is unmasked.
PPCC fault indications can be masked when auto restart function has been selected.
Settings
Parameter Additional information
21.09 AUTO RESTART Selection of the auto restart function
21.10 AUTO RESTART TIME Maximum duration of the power failure
30.24 PPCC FAULT MASK Activation of the fault mask (prevents PPCC fault indications)
Diagnostics and control
Actual value Additional information
07.01 MAIN CTRL WORD, bit 0 State ON/OFF1 control
08.01 MAIN STAUS WORD Main Status Word
09.02 FAULT WORD 2, bit 2 / DC undervoltage fault/alarm
09.05 ALARM WORD 2, bit 14
09.05 ALARM WORD 2, bit 15 Motor restart alarm
Program features
67
Emergency stop
ACS800 hardware and System Control Program fulfil the following emergency stop
category classes:
• Class 0 Immediate removal of power
• Class 1 Controlled emergency stop.
The emergency stop signal is connected to digital input DI1 of the RMIO board or
DI1 of the RDIO I/O Extension module 1 (Par. 98.03 DI/O EXT MODULE 1 setting
must be REPLACE). The function is activated by digital input DI1 or by setting 07.01
Main Control Word bit 2 (OFF3) to 0.
The emergency stop feedback signal is sent through relay output RO1 of the drive
RMIO board (or the RDIO I/O Extension module1) to the Auxiliary Control Unit,
which contains the control relays for the common emergency stop circuit.
The purpose of the feedback signal is to confirm that the emergency stop function
has been received and the drive program is running. If no feedback is received, the
main AC supply will be switched off after a short delay defined by the Auxiliary
Control Unit’s adjustable relays.
Note: During emergency stop, torque selector parameter 26.01 TORQUE
SELECTOR is internally set to speed control when parameter 21.04 EME STOP
MODE setting is STOP RAMPING or STOP TORQ.
Note: When an emergency stop signal is detected, the emergency stop function
cannot be cancelled even though the signal is cancelled.
If an emergency stop signal is activated when the motor is already stopped
- 07.01 Main Control Word bit 2 is set to 0 (= emergency stop), 08.01 Main Status
Word bit 5 is set to 0 (emergency stop active) and 09.04 Alarm Word 1 bit 1 is set
to 1 (= EM STOP alarm). Motor run and motor magnetisation commands are
disabled.
- Relay output RO1 (of the RMIO/RDIO) is energised until 07.01 Main Control Word
bit 0 value is set to 0 (i.e. when the drive is ready to proceed to READY TO SWITCH
ON state).
If an emergency stop signal is activated when the motor is running
- 07.01 Main Control Word bit 2 is set to 0 (= emergency stop), 08.01 Main Status
Word bit 5 is set to 0 (= emergency stop active) and 09.04 Alarm Word 1 bit 1 is set
to 1 (= EM STOP alarm). The drive is stopped according to the emergency stop
mode defined by parameter 21.04 EME STOP MODE.
- Emergency stop function is locked by the application, (i.e. it cannot be cancelled).
Relay output RO1 is energised until the motor has reached zero speed and
07.01 Main Control Word bit 0 value is set to 0. Control program supervises that the
drive deceleration rate is within the window defined by parameters 21.05 EMSTOP
DER MIN L and 21.06 EMSTOP DER MAX L. The supervision starts after the time
delay defined by parameter 21.07 EM STOP DEC MON DEL. If the drive is not able
to decelerate the motor within the window, it coasts to stop and 08.02 Auxiliary
Status Word bit 2 is set to 1 (= EMERG STOP COAST).
Program features
68
Emergency stop through fieldbus
Emergency stop can be activated by fieldbus via 07.01 Main Control Word bit 1 or 2.
Emergency stop control through fieldbus functions also in local control if parameter
21.12 LOCAL EMSTOP MODE setting is DI+FIELDBUS.
Emergency Stop Emergency off
OFF3 (MCW Bit2=0) OFF2 (MCW Bit1=0)
OFF3 OFF2
ACTIVE OFF_3_STA ACTIVE OFF_2_STA
(MSW Bit5=0) (MSW Bit4=0)
n(f)=0 / I=0
SWITCH-ON
INHIBITED ON_INHIBIT
(MSW Bit6=1)
ON (MCW Bit0=0)
Settings
Parameter Additional information
21.04 EME STOP MODE Selection of the emergency stop mode
21.05 EMSTOP DER MAX L Maximum deceleration rate for the emergency stop
21.06 EMSTOP DER MIN L Minimum deceleration rate for the emergency stop
21.07 EM STOP DEC MON DEL Time delay between the emergency stop signal and the start
of the deceleration monitoring
21.12 LOCAL EMSTOP MODE Selection of the source for the emergency stop activation
signal in local control mode
98.03 DI/O EXT MODULE 1 Activation of the RDIO I/O Extension module 1
Diagnostics and control
Actual value Additional information
07.01 MAIN CTRL WORD, bit 0 State ON/OFF1 control
07.01 MAIN CTRL WORD, bits 1 and 2 Emergency stop control
08.01 MAIN STATUS WORD, bits 4 Emergency stop activation status
and 5
08.02 AUX STATUS WORD, bit 2 Emergency stop failure
09.04 ALARM WORD 1, bit 1 Emergency stop alarm
Program features
69
Safe Torque Off function (STO)
Safe Torque Off (STO) function used to be called Prevention of Unexpected Start-up.
The operation of both function is identical.
Safe Torque Off function disconnects the control voltage from the inverter power
semiconductors, i.e. the drive output voltage is cut off. See the circuit diagrams
delivered with the drive for the wirings to be made by the user.
WARNING! The Safe Torque Off function does not disconnect the voltage of the
main and auxiliary circuits from the drive. Therefore, maintenance work on electrical
parts may only be carried out after disconnecting the drive system from the input
power line.
The Safe Torque Off function operates as follows:
- The operator activates the Safe Torque Off function with a switch mounted on the
control desk.
- The drive application program receives an internal signal from the AINT board that
Safe Torque Off function has been activated.
- The voltage supply of the AGPS-0x (Gate Driver Power Supply) board is
disconnected.
- If the Safe Torque Off function has been activated during run, the drive coasts to
stop.
- Alarm START INHIBI is activated (09.04 Alarm Word 1 bit 0 value is 1).
- 08.02 AUX STATUS WORD bit 8 value is set to 1 (= Safe Torque Off function is
active) within 3 seconds.
Note: Fault START INHIBI is generated (09.06 Fault Word 3 bit 5 value is 1) if the
Safe Torque Off function is activated during motor run or if motor start command is
given when the Safe Torque Off function is already active.
Settings
Parameter Additional information
31.02 START INHIBIT ALM Deactivation of the logging of START INHIBI alarm into the
fault/alarm logger.
Diagnostics
Actual value Additional information
08.02 AUX STATUS WORD, bit 8 Safe Torque Off function activation status
09.04 ALARM WORD 1, bit 0 / Safe Torque Off function alarm/fault
09.06 FAULT WORD 3, bit 5
Program features
70
DC magnetising
When DC magnetising is activated, the drive automatically magnetises the motor
before starting. This feature guarantees the highest possible breakaway torque, up
to 200% of the motor nominal torque.
The automatic start feature (section Auto restart on page 66) and DC magnetising
cannot be activated at the same time.
Settings
Parameter Additional information
21.01 START/STOP FUNC Selection of the DC magnetising
Constant DC magnetising
When constant DC magnetising is activated, the drive automatically magnetises the
motor for the defined magnetising time before starting. Constant DC magnetising
guarantees the highest possible breakaway torque when the pre-magnetising time is
set long enough. By adjusting the premagnetising time, it is possible to synchronise
the motor start and for example mechanical brake release.
The automatic start feature (section Auto restart on page 66) and DC magnetising
cannot be activated at the same time.
Settings
Parameter Additional information
21.01 START/STOP FUNC Selection of the constant DC magnetising
21.02 CONST MAGN TIME Magnetising time
DC hold
By activating the motor DC hold feature it is possible to lock the rotor at zero speed.
When both the reference and the motor speed fall below the preset DC hold speed,
the drive stops the motor and starts to inject DC into the motor. When the reference
speed again exceeds the DC hold speed, normal drive operation resumes.
Motor
Speed
DC hold
DC hold
speed
t
Speed
Reference
DC hold
speed
t
Program features
71
Settings
Parameter Additional information
17.01 DC HOLD Activation of the DC hold function
17.02 DC HOLD SPEED DC hold speed
17.03 DC HOLD CURRENT DC hold current
Flux braking
The drive can provide greater deceleration by raising the level of magnetisation in
the motor. By increasing the motor flux, the energy generated by the motor during
braking can be converted to motor thermal energy. This feature is useful in motor
power ranges below 15 kW.
Motor
speed
No flux braking
Flux braking
t (s)
The drive monitors the motor status continuously, also during flux braking.
Therefore, flux braking can be used both for stopping the motor and for changing the
speed. The other benefits of flux braking are:
• The braking starts immediately after a stop command is given. The function does
not need to wait for the flux reduction before it can start the braking.
• The cooling of the motor is efficient. The stator current of the motor increases
during the flux braking, not the rotor current. The stator cools much more
efficiently than the rotor.
Settings
Parameter Additional information
27.02 FLUX BRAKING Activation of the flux braking function
Flux optimisation
Flux optimisation reduces the total energy consumption and motor noise level when
the drive operates below the nominal load. The total efficiency (motor and the drive)
can be improved by 1% to 10%, depending on the load torque and speed.
Note: Flux optimisation limits the dynamic control performance of the drive because
with a small flux reference the drive torque cannot be increased fast.
Settings
Parameter Additional information
27.01 FLUX OPTIMIZATION Activation of the flux optimisation function
Program features
72
Acceleration and deceleration ramps
Acceleration and deceleration ramp can be defined by the user.
It is also possible to scale external ramp time references: With very fast or very slow
acceleration and deceleration times, the scaling from 16-bit data to integer value
might not be accurate enough. The accuracy can be improved by using acceleration/
deceleration ramp time scaling (22.03 ACC/DEC TIME SCLE).
See control block diagram in section Speed reference ramp on page 314.
If several constant ramp times are needed in the application, they can be easily
programmed with adaptive programming. For more information, see ACS600/
ACS800 Application Guide Adaptive Program for System Application Program 7.x
[3AFE68420075 (English)].
The following block diagram shows an adaptive programming example, where
acceleration and deceleration times are selected by digital input DI6:
DI6 = 0: Numeric 1 defines the acceleration time 1 and Numeric 3 defines the
deceleration time 1.
DI6 = 1: Numeric 2 defines the acceleration time 2 and Numeric 4 defines the
deceleration time 2.
Acceleration and deceleration values are then written to parameters
22.01 ACCELER TIME and 22.02 DECELER TIME.
The available ramp shape alternatives are Linear and S-curve.
Linear: Suitable for drives requiring steady or slow acceleration/deceleration.
Program features
73
S-curve: Ideal for conveyors carrying fragile loads, or other applications where
a smooth transition is required when changing the speed.
Motor
speed
Linear
S-curve
2 t (s)
Emergency stop ramp time can be defined by parameter 22.04 EME STOP RAMP.
See section Emergency stop on page 67.
Variable slope
When variable slope is activated by parameter 22.06 VARIABLE SLOPE, the slope
of the speed ramp is controlled during a speed reference change.
If the updating time interval for the external control system and the time for the
speed reference change defined by 22.07 VAR SLOPE RATE are equal,
02.02 SPEED REF 3 is a straight line.
This function is active only in the REMOTE control mode.
Speed ref
SPEED REF
A SPEED REF 3 (02.02)
t = updating time interval of the external control system
A = speed reference change during time t
Settings
Parameter Additional information
22 ACCEL/DECEL Settings of the ramp function
Program features
74
Diagnostics and control
Actual value Additional information
02.02 SPEED REF 3 Limited speed reference
07.01 MAIN CTRL WORD, bits 4 and 5 Ramp Function Generator control
07.01 MAIN CTRL WORD, bit 6 Speed ramp input control
07.02 AUX CTRL WORD 1, bit 2 Speed reference ramp bypass
Oscillation damping
The oscillation damping function damps mechanical or DC voltage oscillations of the
intermediate circuit. The oscillation source is selected between speed error and DC
voltage by parameter 26.08 OSC COMP INPUT. As an output the oscillation
damping algorithm produces a sine wave. This sine wave can be summed with the
torque reference with a suitable gain and phase.
Tuning procedure of the oscillation damping
Select the input by Par. 26.08 OSC COMP INPUT
Set 26.04 OSC COMPENSATION bit 0 to ON.
Set 26.07 OSCILLATION GAIN to 0%.
Calculate the oscillation frequency from the signals
monitored with the DriveWindow PC tool.
Set 26.05 OSCILLATION FREQ.
Set 26.06 OSCILLATION PHASE.
Increase 26.07 OSCILLATION GAIN gradually so that the
algorithm affects the system. (2%, 4%, 6%...)
Oscillation amplitude decreases: Oscillation amplitude increases:
Increase 26.07 OSCILLATION GAIN and change Try other values for 26.06 OSCILLATION PHASE.
26.06 OSCILLATION PHASE (if necessary).
Increase 26.07OSCILLATION GAIN to suppress the
oscillation totally.
If the DC voltage oscillation phase cannot be determined by measurements, the
value of 0 deg is usually a suitable initial value.
Note: Changing the speed error lowpass filter time constant and integration time of
the speed controller can affect the tuning of the oscillation damping algorithm. It is
recommended to tune the speed controller before tuning this algorithm. Speed
controller gain can be altered after the tuning of the oscillation damping algorithm.
Program features
75
See control block diagram in section Torque reference on page 316.
Settings
Parameter Additional information
26.04 OSC COMPENSATION Activation of the torsional vibration or DC voltage oscillation
damping
26.05 OSCILLATION FREQ Oscillation frequency
26.06 OSCILLATION PHASE Phase angle of the sine wave
26.07 OSCILLATION GAIN Oscillation gain
26.08 OSC COMP INPUT Selection of algorithm input
Speed filtering
The measured speed always has a small ripple because of mechanical interference
and couplings. A small ripple is acceptable as long as it does not affect the speed
control loops. Reducing the ripple with filters may cause tuning problems. A long
filter time constant and fast acceleration time contradict each other.
If the speed measurement shows rapid oscillation, it can be filtered with a speed
error filter and by setting the time constant of the first order actual speed filter.
If fast oscillation is observed and the application has no gear box and no pulse
encoder feedback: decrease the time constant of the first order actual speed filter to
its minimum value.
If there is a substantial backlash in the drive, and the drive oscillates at low torque
due to the mechanism, adaptive speed control can be used (parameters 24.05 KPS
WEAKPOINT and 24.06 KPS WP FILT TIME). If the adaptivity has to be made
abrupt, the drive can start to oscillate as the load varies: Use a speed step to test the
adaptivity (for example 50 rpm).
For adaptive speed control as a function of the motor frequency, see parameters
24.17...24.20.
Settings
Parameter Additional information
23.06 SPEED ERROR FILT Speed error filter time constant
24.04 KPS MIN Gain when speed controller output is zero.
24.05 KPS WEAKPOINT Speed controller output when gain is KPS.
24.06 KPS WP FILT TIME Rate of change of the gain
24.17...24.20 Adaptive speed control as a function of the motor frequency
50.06 SP ACT FILT TIME Time constant of the first order actual speed filter
Program features
76
Speed controller tuning
Speed controller tuning can be performed manually or automatically. Tuning
procedure is described in section Speed controller tuning on page 24.
The figure below is a simplified block diagram of the speed controller. The controller
output is the reference for the torque controller. For a more detailed block diagram,
see section Speed control on page 315.
Derivative
acceleration
compensation
Proportional,
integral + Torque
Speed + Error +
reference - value + reference
Derivative
Calculated or measured
actual speed
The figure below shows speed responses at a speed reference step (typically,
1 to 20%).
n
nN
%
A B C D
A: Undercompensated t
B: Normally tuned (PI tuning)
C: Normally tuned (manually). Better dynamic performance than with B
D: Overcompensated speed controller
Settings
Parameter Additional information
23.10 SPEED STEP Additional speed step given to the speed controller
24.01 PI TUNE Activation of the automatic speed controller tuning
24.09 TIS Integration time of the speed controller
24.03 KPS Relative gain of the speed controller
Program features
77
Diagnostics
Actual value Additional information
08.03 LIMIT WORD 1, bits 1 and 2 Speed control torque minimum and maximum limits
Low speed fine tuning
Low speed fine tuning can be used when a pulse encoder is used for the speed
measurement. In order to eliminate potentially harmful oscillations at low speeds (for
example, during start), parameters 50.13 ZERO DETECT DELAY and 50.14 SPEED
HOLD TIME should be adjusted. The larger the mass of the driven equipment,
the higher the value of the zero detect delay should be. Parameter 50.14 should be
set to approximately 60% of the value of parameter 50.13. For example, typical
values for a drive rotating a dryer section of a paper machine would be 50 ms and
30 ms respectively.
Settings
Parameter Additional information
50.03 SPEED FB SEL Definition of the used speed feedback value
50.13 ZERO DETECT DELAY Adjusting the low speed fine tuning
50.14 SPEED HOLD TIME
Run interlock
Drive run can be prevented by the run interlock function. If the function is active,
motor start is prevented or motor is stopped if it was already running.
Note: Run interlock does not reset the start request.
Run interlock can be controlled either digital input DI2 by parameter 16.01 RUN
ENABLE = INTERLOCK or by adaptive programming.
Example: Run interlock is activated by digital input DI3:
Program features
78
DI3 = 1: No run interlock (normal state)
DI3 = 0: Run interlock active
RUN INTERLOCK
RUN INTERLOCKED = 0 BLOCK 2
DI3 WR-I
BLOCK 1
C16 GROUP
SWITCH-B
8.05.2 -8.05.2
OUT ACT C14 INDEX
57.09 +57.09
X22:3 C1 NO INPUT
C0 NC
Parameter settings with DriveWindow:
TIME LEVEL 2
BLOCK 1: BLOCK 2:
57.05 = SWITCH-B 57.10 = WR-I
57.06 = -8.05.2 57.11 = C16
57.07 = C1 57.12 = C14
57.08 = C0 57.13 =+57.09
Settings
Parameter Additional information
16.14 RUN INTERLOCK Activation of the run interlock function
16.01 RUN ENABLE Activation of the run interlock function
Diagnostics
Actual value Additional information
08.01 MAIN STATUS WORD, bit 13 Run interlock function status
Run interlock function does not activate any alarm or fault.
Motor control, DTC
The motor control of the frequency converter is based on direct torque control, DTC.
The inverter power semiconductors (switches) are regulated to achieve the required
stator flux and motor torque. The switching frequency is changed only if the actual
torque and the stator flux values differ from their reference values more than the
allowed hysteresis. The reference value for the torque controller comes from the
speed controller or directly from an external source.
Motor control requires measurement of the DC voltage and two motor phase
currents. Stator flux is calculated by integrating the motor voltage in vector space.
Motor torque is calculated as a cross product of the stator flux and the rotor current.
By utilising the identified motor model, the stator flux estimate is improved. Actual
motor shaft speed is not needed for the motor control.
The main difference between traditional control and DTC is that the torque control
has the same time level as the power switch control (25 microseconds). There is no
separate voltage and frequency controlled PWM modulator. All selections of the
switches are based on the electromagnetic state of the motor.
Program features
79
The DTC can only be applied by using high speed signal processing technology.
Digital signal processors are used in ACS800.
Note: In demanding applications a separate identification run is to be performed to
achieve the best motor control accuracy with DTC. See section ID RUN (motor
identification run) on page 22.
Settings
Parameter Additional information
99.08 MOTOR CTRL MODE Selection of the motor control mode
99.07 MOTOR ID RUN Selection of the motor identification run
Program features
80
Program features
3 P H A S E S U P P L Y
3
B lo c k d ia g r a m o f th e D ir e c t T o r q u e C o n tr o l m e th o d
A C S 8 0 0
F R E Q U E N C Y R E F S P E E D a n d D IR E C T T O R Q U E A S IC
2 9 .0 1 F R E Q U E N C Y a n d F L U X
C O N T R O L T O R Q U E U S E D R E F H Y S T E R E S IS T o r q b its
S P E E D R E F C O N T R O L
2 3 .0 1 2 .1 3 O p tim a l
F lu x b its S w itc h in g
M O T O R S P E E D
1 .0 4 F L U X U S E D R E F C o n tro l
C o n tr o l b its
F R E Q U E N C Y 2 .1 4
1 .0 5
M O T O R C T R L M O D E C O N T R O L
M O D E
9 9 .0 8
F L U X A C T 2 .1 5 1 .0 8 M O T O R T O R Q U E
M O T O R M O D E L D C V O L T A G E
C U R R E N T
C A L C U L A T E M
A C T U A L V A L U E S
E S T IM A T E a n d
C A L C U L A T E
81
Scalar control
It is possible to select scalar control as the motor control method instead of Direct
Torque Control (DTC). In the scalar control mode, the drive is controlled with
a frequency reference. The outstanding performance of the default motor control
method, Direct Torque Control, is not achieved with scalar control.
It is recommended to activate the scalar control mode in the following special
applications:
• Multimotor drives: 1) if the load is not equally shared between the motors, 2) if the
motors are of different sizes, or 3) if the motors are going to be changed after the
motor identification.
• If the nominal current of the motor is less than 1/6 of the nominal output current of
the drive.
• If the drive is used without a motor connected (for example for test purposes).
• If the drive runs a medium voltage motor via a step-up transformer.
See control block diagram in section Scalar control on page 319.
See also the start-up procedure with scalar control in section Scalar control and IR
compensation on page 27.
Settings
Parameter Additional information
99.08 MOTORCTRL MODE Selection of the motor control mode
IR compensation
IR compensation is active only when the motor control mode is scalar (see section
Scalar control on page 81). When IR compensation is activated, the drive gives
an extra voltage boost to the motor at low speeds. IR compensation is useful in
applications that require high breakaway torque or in applications where the motor
must rotate slowly, i.e. at a low frequency. In Direct Torque Control, no IR
compensation is possible/needed.
Motor voltage
IR compensation
Umax
No compensation
f (Hz)
Field weakening point
Settings
Parameter Additional information
29.04 IR COMPENSATION Activation of the IR compensation
Program features
82
Hexagonal motor flux
Typically the drive controls the motor flux in such a way that the rotating flux vector
follows a circular pattern. This is ideal in most applications. When operated above
the field weakening point (FWP, typically 50 or 60 Hz), it is, however, not possible to
reach 100% of the output voltage. The peak load capacity of the drive is lower than
with the full voltage.
If hexagonal flux control is selected, the motor flux is controlled along a circular
pattern below the field weakening point, and along a hexagonal pattern in the field
weakening range. The applied pattern is changed gradually as the frequency
increases from 100% to 120% of the FWP. Using the hexagonal flux pattern,
the maximum output voltage can be reached. The peak load capacity is higher than
with the circular flux pattern but the continuous load capacity is lower in the
frequency range of FWP to 1.6 · FWP, due to increased losses.
Settings
Parameter Additional information
27.08 HEX FIELD WEAKEN Selection of the motor flux control
Parallel-connected inverters
2 to 12 inverters can be connected parallel with branching unit APBU. AINT 1 is
connected to APBU CH1, AINT 2 to CH2 etc.
Inverter block diagram
RMIO Motor Control and I/O Board
Upper-leg IGBTs AINT Main Circuit Interface Board
RMIO AINT APBU PPCS Link Branching Unit
Lower-leg IGBTs
U V W
Inverter unit block diagram (2 to 12 parallel inverters)
APBU CH3
RMIO
CH1 CH2
1 2 3
INT INT INT
U V W U V W U V W ...
Program features
83
Reduced run function
Reduced run function is available for parallel-connected R8 inverters, 2...12 × R8i.
Reduced run function makes it possible to continue the operation with limited current
if an inverter module(s) is out of order. If one of the modules is broken, it must be
removed from the cabinet. Parameter change is needed to continue the run with
reduced current.
Removing a broken inverter module
WARNING! The safety instructions must be followed. See the safety instructions on
the first pages of the appropriate hardware manual or the safety manual.
• Disconnect the supply voltage and all auxiliary voltages from the drive.
• Remove the broken inverter module from the cabinet. See appropriate hardware
manual.
• Fasten the air baffle provided with the unit to the top module guide to block airflow
through the empty module space.
• Disable the charging monitoring of the isolated module, i.e. set switch S1...S3
of the ASFC-01 board to DIS (= disabled).
• Switch on the supply voltage. INT COFIG fault (09.06 Fault Word 3 bit 7 value
is 1) now indicates that the number of the connected inverter modules has
changed.
• If the operation is continued with limited current, number of existing inverter
modules must be set by parameter 16.10 INT CONFIG USER.
• Reset the fault and start the drive. PPCS link is reconfigured automatically and
the maximum current is limited (internally) in relation to the new inverter
configuration and inverter nominal current.
Note: If INT CONFIG fault reappears, the number of parallel-connected inverters
defined by parameter 16.10 INT CONFIG USER is incorrect. See signal 08.22 INT
CONFIG WORD.
Note: When the isolated module is reconnected, set switch S1/S2/S3 of the
ASFC-01 board back to the enabled position.
Program features
84
Note: If all switches S1, S2 and S3 of the ASFC-01 board are set to DIS
(= disabled), the main contactors of the DC switches will not close.
When inverter hardware configuration is changed back to the original, parameter
16.10 INT CONFIG USER value automatically restores back to the original value.
Settings
Parameter Additional information
16.10 INT CONFIG USER Number of parallel-connected inverter modules (R8i) in the drive
20.04 MAXIMUM CURRENT Maximum motor current
Diagnostics
Actual value Additional information
08.22 INT CONFIG WORD Inverters recognized by the application program
09.06 FAULT WORD 3, bit 7 Number of recognized inverters
Current measurement calibration
The current measurement is calibrated automatically during the ID run.
Calibration can also be activated by setting 99.07 MOTOR ID RUN to CURRENT
CAL and starting a drive. It is recommended to perform calibration when inverter
module(s) hardware configuration has been changed. An alarm indication CALIBRA
REQ is activated during the calibration and alarm CALIBRA DONE when completed.
Settings
Parameter Additional information
99.07 MOTOR ID RUN Activation of current measurement calibration
Programmable protection functions
AI<Min
AI<Min function defines the drive operation if an analogue input signal falls below the
preset minimum limit.
Settings
Parameter Additional information
30.27 AI<MIN FUNC Selection of the supervision with analogue input signal loss
Diagnostics
Alarm Signal
AI<MIN FUNC Signal 09.05 Alarm Word 2 bit 10 value is 1.
Fault Signal
AI<MIN FUNC Signal 09.02 Fault Word 2 bit 10 value is 1.
Program features
85
Panel loss
Panel loss function defines the operation of the drive if the control panel or
DriveWindow selected as control location for the drive stops communicating.
Settings
Parameter Additional information
30.21 PANEL LOSS Selection of the supervision in control panel or DriveWindow
communication break
Diagnostics
Alarm Signal
PANEL LOSS Signal 09.05 Alarm Word 2 bit 13 value is 1.
Fault Signal
PANEL LOSS Signal 09.02 Fault Word 2 bit 13 value is 1.
Motor temperature protection
The motor can be protected against overheating by
• activating the motor thermal protection function and by selecting one of the motor
thermal protection modes available (DTC motor thermal model or User Model).
See section Motor thermal mode on page 86.
• measuring the motor temperature with Pt100, PTC or KTY84-1xx sensors. See
sections Temperature sensors on page 87 and Alternative thermal connection for
PTC thermistor on page 91.
• detecting the state of the motor overload protection switch in the motor supply by
digital input. See input selector parameter 10.11 MOT PROT SWITCH and fault
function parameter 31.04 MOT PROT FLT SEL. If the contact opens, fault or
alarm indication MPROT SWITCH is activated (09.01 Fault Word 1 bit 10 or 09.04
Alarm Word 1 bit 12 value is set to 1).
• detecting the state of the thermal switch or thermistor relay by a digital input. See
section Alternative thermal connection for PTC thermistor on page 91.
The motor thermal model can be used parallel with other temperature protections
(PTC, Pt100, KTY84-1xx, thermistor relay or thermal switch).
T / °C Motor insulation classes according to IEC 85
180 15
155
10
130
Hot spot temperature margin 10
120
80 Allowed temperature rise 80 105 125
40
Maximum ambient temperature 40 40 40
Insulation class B F H
Maximum winding temperature 130°C 155°C 180°C
Program features
86
Motor thermal mode
The drive calculates the temperature of the motor on the basis of the following
assumptions:
1) The motor is at the estimated temperature (value of 01.18 MOTOR TEMP EST
saved at power switch off) when power is applied to the drive. When power is
applied for the first time, the motor is at the ambient temperature (30°C).
2) Motor temperature is calculated using either the user-adjustable or automatically
calculated motor thermal time and motor load curve (see the figures below).
The load curve should be adjusted in case the ambient temperature exceeds 30°C.
Alarm/Fault MOTOR TEMP is activated when the limit defined by parameter 30.28
THERM MOD ALM L / 30.29 THERM MOD FLT L has been reached.
Note: If thermal protection according to UL requirements for NEMA class motors is
needed, the thermal model fault trip limit must be 110°C (30.29 THERM MOD FLT L)
and the thermal time (30.09 MOTOR THERM TIME) for Class 10 trip curve must be
350 s, for Class 20 trip curve 700 s and for Class 30 trip curve 1050 s.
Motor Motor Break point
load current 150
100% (%) Motor load curve
100
50
Temp. t Zero speed load
rise
Speed
100%
63%
t
Motor thermal time
Settings
Parameter Additional information
30.01 MOT THERM P MODE Selection of the motor thermal protection mode
30.02 MOTOR THERM PROT Selection of the supervision with motor overtemperature
30.09...30.12 Definition of the user-defined thermal model
30.28...30.29 Fault and alarm limits
30.30 MOT NOM TEMP RISE Nominal temperature rise
30.31 AMBIENT TEMP Ambient temperature
Diagnostics
Alarm Signal
MOTOR TEMP Signal 09.04 Alarm Word 1 bit 3 value is 1.
Fault Signal
MOTOR TEMP Signal 09.01 Fault Word 1 bit 6 value is 1.
Program features
87
Temperature sensors
It is possible to detect motor overtemperature by connecting a motor temperature
sensor to analogue inputs and outputs of the drive.
Analogue output feeds constant current through the sensor. The sensor resistance
increases as the motor temperature rises, as does the voltage over the sensor.
The temperature measurement function reads the voltage through analogue input
and converts it to degrees centigrade. The System Application program supports two
measurement channels: AI1 (of the RMIO or RAIO) and AI2 (of the RAIO) for
motor 1 and motor 2 temperature measurements. The constant current level is
automatically set by the application program according to the sensor type selection.
Sensor type Unit Scaling
Pt100 °C
PTC Ω normal 0...1.5 kΩ
overtemperature > 4 kΩ
KTY84-1xx, Ω 90 °C = 936 Ω
(silicon 110 °C = 1063 Ω
temperature 130 °C = 1197 Ω
sensor)
150 °C = 1340 Ω
Motor overtemperature can also be detected by connecting a PTC thermistor to
a digital input.
The alarm and fault (MOTOR TEMP M) limits are defined by parameters 30.04 MOT
1 TEMP ALM L and 30.05 MOT 1 TEMP FLT L for motor 1 and by parameters 30.07
MOT 2 TEMP ALM L and 30.08 MOT 2 TEMP FLT L for motor 2.
Parameter 31.03 TEMP MEAS FLT SEL selects whether a fault or alarm is
generated when a fault is detected in the temperature measurement circuit.
Two additional temperature measurements can be programmed with adaptive
programming if an optional analogue I/O extension module 2 (EXT2 AIO) is used.
For more information, see ACS600 / ACS800 Application Guide Adaptive Program
for System Application Program 7.x [3AFE68420075 (English)].
WARNING! According to IEC 664, the connection of the motor temperature sensor
to the RMIO board, requires double or reinforced insulation between motor live parts
and the sensor. Reinforced insulation entails a clearance and creepage distance of
8 mm (400 / 500 V AC equipment). If the assembly does not fulfil the requirement:
the RMIO board terminals must be protected against contact and they may not be
connected to other equipment
or
the temperature sensor must be isolated from the RMIO board terminals.
Program features
88
Thermal sensor connection through I/O
The figure below shows a motor temperature measurement of one motor when
RMIO board is used as the connection interface.
RMIO board
One sensor
AI1+
Motor
AI1-
T
AO1+
AO1-
Three sensors RMIO board
AI1+
Motor AI1-
T T T
AO1+
AO1-
Settings
Parameter Additional information
30.03 MOT1 TEMP AI1 SEL Activation of the motor 1 temperature measurement function and
selection of the sensor type
30.04...30.05 Alarm and fault limits
31.03 TEMP MEAS FLT SEL Selection of the supervision with motor temperature measurement
circuit fault
Diagnostics
Actual value Additional information
01.16 MOTOR 1 TEMP Measured temperature of motor 1
Alarm Signal
MOTOR TEMP M Signal 09.04 Alarm Word 1 bit 2 value is 1.
T MEAS CIRC Signal 09.04 Alarm Word 1 bit 6 value is 1.
Fault Signal
MOTOR TEMP M Signal 09.01 Fault Word 1 bit 5 value is 1.
T MEAS CIRC Signal 09.06 Fault Word 3 bit 4 value is 1.
Program features
89
Thermal connection through analogue I/O extension
The figure below shows a motor temperature measurement of one motor when
analogue input AI1 of an optional Analogue I/O Extension module, RAIO, is used as
the connection interface.
RAIO module
One sensor
AI1+
Motor
AI1-
T
AO1+
AO1-
Three sensors RAIO module
AI1+
Motor AI1-
T T T
AO1+
AO1-
Settings
Parameter Additional information
30.03 MOT1 TEMP AI1 SEL / Activation of the motor 1/2 temperature measurement function and
30.06 MOT2 TEMP AI2 SEL selection of the sensor type
30.04...30.05 / 30.07...30.08 Alarm and fault limits
31.03 TEMP MEAS FLT SEL Selection of the supervision with motor temperature measurement
circuit fault
98.06 AI/O EXT MODULE 1 Activation of the motor temperature measurement with analogue I/O
extension module
98.11 AI/O EXT1 LOCATION Activation of the communication to the optional analogue I/O
extension module
Diagnostics
Actual value Additional information
01.16 MOTOR 1 TEMP / Measured temperature of motor 1/2
01.17 MOTOR 2 TEMP
Alarm Signal
MOTOR TEMP M Signal 09.04 Alarm Word 1 bit 2 value is 1.
T MEAS CIRC Signal 09.04 Alarm Word 1 bit 6 value is 1.
Fault Signal
MOTOR TEMP M Signal 09.01 Fault Word 1 bit 5 value is 1.
T MEAS CIRC Signal 09.06 Fault Word 3 bit 4 value is 1.
Program features
90
I/O configuration example 1 with motor temperature measurement
The following figure presents motor temperature measurement with RMIO board.
RMIO
+ RMIO RMIO +
Motor 1 temperature measurement and
AI1 AO1
protection
AI2
AI3 1.21 AI3
PTC /
Pt100 / KTY84-1xx
Parameter Setting
30.03 MOT1 TEMP AI1 SEL 1xPT100
2xPT100
3xPT100
or
1…3 PTC or EXT TEMP
I/O configuration example 2 with motor temperature measurement
The following figure presents the RMIO and RAIO analogue I/O connections, when
RAIO Analogue I/O Extension module is used for motor temperature measurement.
RMIO
SPEED REF if
RMIO 98.02 = NO or
RMIO
AI1 1.19 AI1 HAND/AUTO AO1 AO1 mA
AI2 1.20 AI2 signals
AI3 TORQUE REF if for AO AO2 AO2
1.21 AI3 mA
98.02 = NO or
HAND/AUTO
PTC /
Pt100 / KTY84-1xx
+ RAIO RAIO +
AI1 Motor 1 temperature measurement and AO1
protection
+ +
AI2 Motor 2 temperature measurement and AO2
protection
Parameter Setting
30.03 MOT1 TEMP AI1 SEL and 1xPT100
30.06 MOT2 TEMP AI2 SEL 2xPT100
3xPT100
or
1...3 PTC
98.06 AI/O EXT MODE TEMP MEAS
98.11 AI/O EXT1 LOCATION Select according to the hardware configuration.
Program features
91
Alternative thermal connection for PTC thermistor
It is also possible to connect a PTC thermistor between the +24 V DC voltage supply
of the RMIO board and a digital input.
The figure below shows the alternative thermistor connections:
Alternative 1
Thermistor * or thermistor switch
relay*
RMIO board, X22
6 DI6
7 +24 V DC
T
Motor
Alternative 2 RMIO board, X22
6 DI6
7 +24 V DC
T
Motor
In normal motor operation temperature, the thermistor resistance should be less
than 1.5 kohm (current 5 mA). The drive stops the motor and gives alarm/fault
indication KLIXON if the thermistor resistance exceeds 4 kohm.
When a thermistor relay or a thermistor switch is used in the connection, alarm/fault
indication KLIXON is activated when the contact opens.
Digital input for the thermal switch or for the thermistor relay can be selected freely.
PTC thermistor can only be connected to digital input DI6.
Note: The installation must meet the regulations for protection against contact.
Settings
Parameter Additional information
10.05 KLIXON Selection of an interface for the motor overtemperature protection
31.01 KLIXON MOT OVER T Selection of the supervision when a thermistor relay or a thermistor
switch connected to digital input opens.
Diagnostics
Alarm Signal
KLIXON Signal 09.04 Alarm Word 1 bit 2 value is 1.
Fault Signal
KLIXON Signal 09.01 Fault Word 1 bit 5 value is 1.
Program features
92
Short time overload
See ACS800 catalogue for light-overload and heavy-duty use ratings.
Settings
Parameter Additional information
20.04 MAXIMUM CURRENT Maximum motor current
Diagnostics
Signal Additional information
08.07 LIMIT WORD INV Information on the internal current limits
Maximum current load
Drive switching frequency is limited, if the motor is continuously loaded with
maximum current and
- the IGBT temperature exceeds 116 °C (e.g. due to unclean inverter) or
- the ambient temperature exceeds the nominal limit specified in the technical
catalogue.
If the drive is still loaded with maximum current in extreme environmental conditions,
alarm ACS800 TEMP is activated, and eventually the drive trips on fault ACS800
TEMP.
Note: With standard drives, frame types R7 and R8, maximum current is limited
when ACS800 TEMP alarm is active.
The frequency reduction and temperature supervision limits are drive type-specific.
Settings
Parameter Additional information
20.04 MAXIMUM CURRENT Maximum motor current
Diagnostics
Alarm Signal
ACS800 TEMP Signal 09.04 Alarm Word 1 bit 4 value is 1.
Fault Signal
ACS800 TEMP Signal 09.01 Fault Word 1 bit 3 value is 1.
Program features
93
Stall protection
The drive protects the motor in a stall situation. It is possible to adjust the supervision
limits (torque, frequency, time) and choose how the drive reacts to a motor stall
condition (alarm indication / fault indication & stop the drive / no reaction).
Stall limit is defined by parameters 20.04 MAXIMUM CURRENT...20.10 TREF
TORQMIN. Torque and current limits must be set according to the maximum load of
the used application.
Note: Stall limit is restricted by internal current limit TORQ_INV_CUR_LIM.
When the application reaches the stall limit and the output frequency of the drive is
below the stall frequency: Fault MOTOR STALL is activated after the stall time delay.
Settings
Parameter Additional information
20.04...20.10 Stall limit
30.13 STALL FUNCTION Selection of the supervision in a stall situation
30.14 STALL FREQ HI Frequency limit for the stall protection
30.15 STALL TIME Delay time for the stall protection
Diagnostics
Actual value Additional information
08.03 LIMIT WORD 1 Torque limits and user-defined current limit
Alarm Signal
MOTOR STALL Signal 09.05 Alarm Word 2 bit 9 value is 1.
Fault Signal
MOTOR STALL Signal 09.02 Fault Word 2 bit 14 value is 1.
Program features
94
Underload protection
Loss of motor load may indicate process malfunction. The drive provides
an underload function to protect the machinery and process in such a serious fault
condition. Supervision limits - underload curve and underload time - can be chosen
as well as the action taken by the drive upon the underload condition (alarm
indication / fault indication & stop the drive / no reaction).
The protection is activated if all the following conditions are fulfilled at the same time:
• Motor load is below the underload curve selected by the user.
• Motor load has been below the selected underload curve longer than the time set
by the user.
• Output frequency of the drive is more than 10% of the motor nominal frequency.
Settings
Parameter Additional information
30.16 UNDERLOAD FUNC Selection of the supervision in a underload condition
30.17 UNDERLOAD TIME Time limit
30.18 UNDERLOAD CURVE Selection of the load curve
Diagnostics
Alarm Signal
UNDERLOAD Signal 09.05 Alarm Word 2 bit 1 value is 1.
Fault Signal
UNDERLOAD Signal 09.01 Fault Word 1 bit 8 value is 1.
Motor phase loss
The phase loss function monitors the status of the motor cable connection.
The function is useful especially during the motor start: The drive detects if any of
the motor phases is not connected and refuses to start. The phase loss function also
supervises the motor connection status during normal operation.
The action taken by the drive upon phase loss can be chosen (fault indication & stop
the drive / no reaction).
Settings
Parameter Additional information
30.19 MOTOR PHASE LOSS Activation of the phase loss function
Diagnostics
Fault Signal
MOTOR PHASE Signal 09.02 Fault Word 2 bit 15 value is 1.
Program features
95
Earth fault and current unbalance protection
The earth fault protection detects earth faults in the motor, motor cable or inverter
output. The protection is based on the sum current measurement (100 microsecond
time level).
The action taken by the drive upon earth fault can be chosen with non-parallel-
connected inverters (fault indication & stop the drive / alarm indication).
The earth fault trip level can be chosen with non-parallel-connected inverter
modules. The level is defined as inverter output current unbalance (measured by the
AINT board).
Note: With parallel-connected inverters modules, the protection monitors the
inverter output current unbalance (e.g. short circuit) and the fault indication is CUR
UNBAL x instead of EARTH FAULT. The action taken by the drive upon current
unbalance cannot be chosen (only fault indication). See chapter Fault tracing.
Settings
Parameter Additional information
30.20 EARTH FAULT Selection of the supervision in an earth fault condition (with
non-parallel-connected inverters)
30.25 EARTH FAULT LEVEL Selection of the earth fault level
Diagnostics
Alarm Signal
EARTH FAULT Signal 09.04 Alarm Word 1 bit 14 value is 1.
Fault Signal
EARTH FAULT Signal 09.01 Fault Word 1 bit 4 value is 1.
CUR UNBAL x * Signal 09.01 Fault Word 1 bit 4 value is 1.
See also signal 09.13 CURRENT UNBALANCE.
* For parallel-connected inverter modules
Communication fault
The communication fault function supervises the messages received from DDCS
channel CH0 or fieldbus adapter module type Rxxx. The action taken by the drive
upon the communication fault (alarm indication / fault indication & stop the drive) can
be chosen.
Note: If the data update time to data set 10 is less than 2 s (data sets 10...33 are
activated by setting parameter 98.02 to ADVANT-N/FB), both alarm and fault
indications are activated.
Note: When COMM MODULE fault is activated, torque selector (26.01 TORQUE
SELECTOR) is set to speed control.
Settings
Parameter Additional information
70.04 CH0 TIME OUT Delay time for communication supervision
70.05 CH0 COM LOSS CTRL Selection of the supervision with communication fault
Program features
96
Diagnostics
Alarm Signal
COMM MODULE Signal 09.05 Alarm Word 2 bit 11 value is 1.
Fault Signal
COMM MODULE Signal 09.02 Fault Word 2 bit 12 value is 1.
Master/Follower link communication fault
The Follower drive supervises the received broadcast data (data set 41). The action
taken by the drive upon a Master/Follower communication fault (alarm indication /
fault indication & stop the drive) can be chosen. The protection is activated after the
time delay defined by the user.
Settings
Parameter Additional information
70.13 CH2 TIMEOUT Delay time for CH2 communication supervision
70.14 CH2 COM LOSS CTRL Selection of the supervision with CH2 communication fault
Diagnostics
Alarm Signal
CH2 COM LOSS Signal 09.04 Alarm Word 1 bit 11 value is 1.
Fault Signal
CH2 COM LOSS Signal 09.01 Fault Word 1 bit 11 value is 1.
Speed measurement fault
Speed measurement fault is activated when any of the following conditions is
fulfilled:
• No pulses are received from the encoder within the time defined by parameter
50.11 ENCODER DELAY and the drive is simultaneously at current or torque
limit.
• There is a 20% difference between the estimated speed and the measured speed
received from the pulse encoder (parameter 50.03 SPEED FB SEL =
ENCODER).
• There is no communication between the pulse encoder module and the RMIO
board.
• The pulse frequency of the pulse encoder changes considerably during a time
interval of 1 ms.
If an alarm function has been selected and speed measurement error is detected
(i.e. the pulse frequency of the pulse encoder changes considerably during a time
interval of 1 ms), the drive automatically starts to use estimated speed (08.02 AUX
STATUS WORD bit12 value is 1). The drive uses estimated speed as long as the
difference between the estimated and the measured speed is more than 1%. The
difference is checked every five seconds. When the difference is smaller than 1%,
the drive starts to use measured speed again.
The protection is activated after the time delay defined by the user.
Program features
97
Settings
Parameter Additional information
50.03 SPEED FB SEL Selection of the speed feedback
50.05 ENCODER ALM/FLT Selection of the supervision with speed measurement error
50.11 ENCODER DELAY Delay time for speed measurement supervision
Diagnostics
Actual value Additional information
08.02 AUX STATUS WORD, Internal speed feedback is followed.
bit12
Alarm Signal
ENCODER ERR Signal 09.04 Alarm Word 1 bit 5 value is 1.
Fault Signal
ENCODER ERR Signal 09.02 Fault Word 2 bit 5 value is 1.
Motor fan control
If the motor has an external cooling fan, it is possible to control the starter of the fan
motor via a digital output.
• During motor start: If the motor fan acknowledge signal is not received by the
selected digital input within the time defined by parameter 35.02 FAN ACK
DELAY, a fault is generated and the drive is tripped.
• During motor run: If the acknowledge signal is lost, an alarm is generated. If the
acknowledge signal is still lost after 35.02 FAN ACK DELAY, a fault is generated
and the drive is tripped. If the acknowledge time is zero, only an alarm is
displayed.
When fault is activated, fan off delay time (35.02 FAN ACK DELAY) is cleared.
Settings
Parameter Additional information
10.06 MOTOR FAN ACK Selection of the motor fan acknowledgement signal source
14 DIGITAL OUTPUTS Settings of the digital outputs
35 MOTOR FAN CTRL Settings of the motor fan control
Diagnostics
Alarm Signal
MOTOR FAN Signal 09.05 Alarm Word 2 bit 0 value is set to 1.
Fault Signal
MOTOR FAN Signal 09.06 Fault Word 3 bit 0 value is set to 1.
Program features
98
Preprogrammed faults
Overcurrent
The overcurrent trip limit is 3.5 × Ihd, where Ihd is the nominal motor current for
heavy-duty use.
There are two sources for the overcurrent fault:
• RMIO software trip level (97% of the measurement range, time level
100 microseconds)
• hardware trip level with parallel-connected units (overcurrent is detected by the
APBU board logic).
Note: With parallel-connected inverters the overcurrent fault indication is
OVERCURR x.
Diagnostics
Actual value Additional information
09.14 OVERCURRENT FAULT Overcurrent
Fault Signal
OVERCURRENT Signal 09.01 Fault Word 1 bit 1 value is 1.
OVERCURR x * Signal 09.01 Fault Word 1 bit 1 value is 1.
* For parallel-connected inverter modules
DC overvoltage
The DC overvoltage trip limit is 1.3 × 1.35 × U1max, where U1max is the maximum
value of the input voltage range.
Unom of the inverter unit U1max UDC overvoltage trip limit
400 V 415 V 728 V DC
500 V 500 V 877 V DC
690 V 690 V 1210 V DC
DC voltage control and trip limits
High voltage trip limit (130% of U1max)
High voltage control limit (124%)
Brake chopper limit (120%)
Low voltage control limit (82%)
Charging limit (79%)
Low voltage tripping limit (60% of U1min)
Program features
99
Diagnostics
Fault Signal
DC OVERVOLT Signal 09.01 Fault Word 1 bit 2 value is 1.
DC undervoltage
The DC undervoltage trip limit is 0.60 × 1.35 × U1min, where U1min is the minimum
value of the input voltage range.
Unom of the inverter unit U1min UDC undervoltage trip limit
400 V 380 V 308 V DC
500 V 380 V 308 V DC
690 V 525 V 425 V DC
Diagnostics
Fault Signal
DC UNDERVOLT Signal 09.02 Fault Word 2 bit 2 value is 1.
Drive temperature
The drive supervises the inverter module temperature. There are two supervision
limits: alarm limit and fault trip limit. These limits are inverter type-specific.
Note: The temperature difference between several parallel-connected inverter
modules is also monitored. If the temperature of one module compared to the
average temperature of the rest of the modules exceeds the limit, alarm/fault is
activated.
Diagnostics
Alarm Signal
ACS800 TEMP Signal 09.04 ALARM WORD 1 bit 4 value is 1.
TEMP DIF xy * Signal 09.18 TEMP DIF ALM WORD
Fault Signal
ACS800 TEMP Signal 09.01 FAULT WORD 1 bit 3 value is 1.
ACS TEMP xy * Signal 09.16 OVERTEMP WORD
TEMP DIF xy * Signal 09.17 TEMP DIF FLT WORD
* For parallel-connected inverter modules
Program features
100
Short circuit
Short circuit protection is based on the power semiconductor (IGBT) voltage
measurement (100 microsecond time level). If voltage Uce (collector-emitter voltage)
will not rise within an application-specific time, short circuit fault is activated. This
supervision is active also when no switch-off command has been issued to the IGBT.
The supervision is used for the inverter output circuit protection. If a short circuit
occurs, the drive will not start and a fault is activated.
Diagnostics
Fault Signal
SHORT CIRC Signal 09.01 FAULT WORD 1 bit 0 value is 1.
SC INV xy * Signal 09.15 SHORT CIRC FAULT
* For parallel-connected inverter modules
Run disable
To activate the RUN ENABLE signal, a voltage signal must be connected to digital
input DI2. If the voltage drops to 0 V, the drive coasts to stop and fault RUN ENABLE
is generated. The drive will not start before the RUN ENABLE signal is active.
RUN ENABLE signal is also used to control the inverter charging. See section
Inverter charging logic on page 119.
Diagnostics
Fault Signal
RUN DISABLE Signal 09.02 Fault Word 2 bit 4 and 08.02 Auxiliary Status Word
bit 4 values are 1.
Overfrequency
If the drive output frequency exceeds the preset level (20.11 FREQ TRIP MARGIN),
for example in overshooting of the speed control, the drive is stopped and a fault
indication is given.
Diagnostics
Fault Signal
OVERFREQ Signal 09.01 Fault Word 1 bit 9 value is 1.
Input phase loss
Input phase loss protection circuits supervise the main power cable connection by
detecting intermediate circuit ripple. If a phase is lost, the ripple increases. The drive
is stopped and a fault indication is given if the ripple exceeds 13%.
Diagnostics
Fault Signal
SUPPLY PHASE Signal 09.02 Fault Word 2 bit 0 value is 1.
Program features
101
Control board temperature
The drive supervises the control board temperature. A fault indication is given if the
temperature exceeds 88 °C.
Diagnostics
Fault Signal
CTRL B TEMP Signal 09.02 FAULT WORD 2 bit 7 value is 1.
I/O monitoring
If there is a communication break or signal read error with the RMIO Control board
I/O or with the I/O extension module or I/O extension link, alarm is activated.
Diagnostics
Alarm Signal
DIO ALARM Signal 09.04 ALARM WORD 1 bit 7 value is 1.
AIO ALARM Signal 09.04 ALARM WORD 1 bit 8 value is 1.
EXT DIO ALM Signal 09.04 ALARM WORD 1 bit 9 value is 1.
EXT AIO ALM Signal 09.04 ALARM WORD 1 bit 10 value is 1.
Start inhibit
When Safe Torque Off function is activated, the voltage supply of the AGPS-0x
(Gate Driver Power Supply) board is disconnected and
- alarm START INHIBI is generated if the drive was stopped
- fault START INHIBI is generated if the Safe Torque Off function is activated during
motor run or if motor start command is given while the Safe Torque Off function is
active.
The logging of START INHIBI alarm to the fault/alarm logger can be deactivated by
parameter 31.02 START INHIBIT ALM.
For more information, see Safe Torque Off function (STO) on page 69.
Settings
Parameter Additional information
31.02 START INHIBIT ALM Deactivation of the logging of START INHIBI alarm into the
fault/alarm logger
Diagnostics
Alarm Signal
START INHIBI Signal 09.04 ALARM WORD1 bit 0 value is 1.
Fault Signal
START INHIBI 08.21 START INHIBI WORD.
09.06 Fault Word 3 bit 5 value is 1.
Program features
102
Overswitching frequency
If the inner DTC control loop exceeds the maximum switching frequency, a fault is
generated.
Diagnostics
Fault Signal
OVER SWFREQ Signal 09.02 Fault Word 2 bit 9 value is 1.
System fault
If an RMIO board software error causes a communication break, a system fault is
activated.
Diagnostics
Actual value Additional information
09.03 SYSTEM FAULT WORD System fault information
Fault Signal
SYSTEM FAULT Signal 09.01 FAULT WORD 1 bit 7 value is 1.
Operation limits
The drive has adjustable limits for speed, current (maximum), torque (maximum),
power and DC voltage.
Settings
Parameter Additional information
20 LIMITS Drive limits
Parameter lock
The user can prevent parameter changes to the flash memory (EPROM) by
activating the parameter lock. The lock prevents parameter changing from the
CDP 312R control panel. From an external control system (e.g. fieldbus control
system) parameter changes to the RAM memory are allowed, even when the lock is
active.
Settings
Parameter Additional information
16.02 PARAMETER LOCK Selection of the state of the parameter lock
16.03 PASS CODE Selection of the pass code
Program features
103
Adaptive programming with DriveAP 2.x
Conventionally, the user can control the operation of the drive by parameters. Each
parameter has a fixed set of choices or a setting range. The parameters make the
programming easy, but the choices are limited. The user cannot customise the
operation any further. The adaptive program makes free customising possible
without the need of a special programming tool or language:
• The program is built of standard function blocks included in the drive application
program.
• The DriveAP 2.x or the control panel is the programming tool.
• The user can document the program by drawing it on block diagram template
sheets (maximum of 10 sheets).
The maximum size of the adaptive program is 26 function blocks (6 for 10 ms time
level and 20 for 100 ms time level) and 22 I/O blocks (DI/AI/AO/...). The program
may consist of several separate functions.
With the WRITE block, the adaptive program can easily be connected to any of
the parameters in the drive application program.
Note: If adaptive program (originally done with DriveAP 2.x programming tool) is
modified with control panel, the function block view with DriveAP 2.x will be different,
since the location of the function blocks cannot be determined by the panel.
For more information, see ACS600/ACS800 Application Guide Adaptive Program for
System Application Program 7.x [3AFE68420075 (English)] and DriveAP 2.1 User
Manual [3AFE64540998 (English)].
Program features
104
Master/Follower
In a Master/Follower application, the system is run by several drives and the motor
shafts are coupled to each other (via gears, chains, belts etc.). The Master drive
controls the Follower drive(s) via a fibre optic link: The Master sends a broadcast
message to the Follower. Its also possible to receive three selectable feedback
signals from maximum three followers via optic link.
Program features
U S E D M O T O R S P E E D T O R Q U E S E L E C T O R = S P E E D
S P E E D S P E E D S P E E D
F O L L S P E E D 7 0 .1 7 R E F 2 R E F 3 S P E E D 2 6 .0 1
R E F
R E F C O N T R O L T O R Q U E R E F 2
2 . 21 79 2 . 01 19 2 . 01 29 2 . 01 9 T O R Q U E R E F 3
S P E E D R E F 2 3 .0 1
P ID 2 . 1 09
T O R Q U E
M /F M O D E = 7 0 .0 8 C O N F IG U R A T IO N R E F A 2 5 .0 1
M A S T E R
M A S T E R S IG N A L 1 M A S T E R S IG N A L 2 M A S T E R S IG N A L 3
7 0 .0 9 M /F R E F E R E N C E S 7 0 .1 0 M /F R E F E R E N C E S 7 0 .1 1 M /F R E F E R E N C E S
D a ta s e t 4 1 .1 D a ta s e t 4 1 .2 D a ta s e t 4 1 .3
M C W S P E E D R E F T O R Q U E R E F
X
M A S T E R D R IV E M A S T E R S G N 3 S C A L E 7 0 .3 0
D S M C W F O L L O W E R
D S 4 1 . 12 2 . 21 9 S G N 3 D S 4 1 .3
M /F M O D E = 7 0 .0 8 C O N F IG U R A T IO N D S T O R Q R E F A
S C A L E
F O L L O W E R D S S P E E D R E F X
7 0 .3 1 2 .2 0
2 .1 9 D S 4 1 .2
A block diagram for torque controlled Follower:
S P E E D S H A R E 2 3 .0 5
W IN D O W W ID T H P O S 2 3 .0 8
F O L L O W E R
L O A D S H A R E 2 5 .0 3 L O A D S H A R E
F O L L S P D C T R L C O R 2 3 .1 8
F O L L S P D C O R R E N A = F A L S E 7 .0 3 b 9
T O R Q U E S E L E C T O R = 3 6
F O L L S P E E D U S E D F O L L S P D C O R R O U T 2 .3 0 (n o t S P E E D o r Z E R O )
R E F M O T O R S P E E D
S P E E D S P E E D
7 0 .1 7 R E F 2 S P E E D 2 6 .0 1
R E F
C O N T R O L T O R Q U E R E F 2
2 . 21 79 2 . 01 19 2 . 01 9 T O R Q U E R E F 3
S P E E D R E F 2 3 .0 1
P ID 2 . 1 09
D R O O P R A T E 2 4 .0 2 T O R Q U E R E F A 2 5 .0 1
= 0
F O L L T O R Q R E F 7 0 .1 8
F O L L O W E R D R IV E = D S T O R Q R E F A
M A S T E R - F O L L O W E R A P P L IC A T IO N P R IN C IP L E : T O R Q U E C O N T R O L L E D F O L L O W E R
105
Program features
106
Program features
U S E D M O T O R S P E E D T O R Q U E S E L E C T O R = S P E E D
S P E E D S P E E D S P E E D
F O L L S P E E D 7 0 .1 7 R E F 2 R E F 3 S P E E D 2 6 .0 1
R E F
R E F C O N T R O L T O R Q U E R E F 2
2 . 21 79 2 . 01 19 2 . 01 29 2 . 01 9 T O R Q U E R E F 3
S P E E D R E F 2 3 .0 1
P ID 2 . 1 09
T O R Q U E
M /F M O D E = 7 0 .0 8 C O N F IG U R A T IO N R E F A 2 5 .0 1
M A S T E R
M A S T E R S IG N A L 1 M A S T E R S IG N A L 2 M A S T E R S IG N A L 3
7 0 .0 9 M /F R E F E R E N C E S 7 0 .1 0 M /F R E F E R E N C E S 7 0 .1 1 M /F R E F E R E N C E S
D a ta s e t 4 1 .1 D a ta s e t 4 1 .2 D a ta s e t 4 1 .3
M C W S P E E D R E F T O R Q U E R E F
X
M A S T E R D R IV E M A S T E R S G N 3 S C A L E 7 0 .3 0
D S M C W F O L L O W E R
D S 4 1 . 12 2 . 21 9 S G N 3 D S 4 1 .3
M /F M O D E = 7 0 .0 8 C O N F IG U R A T IO N D S T O R Q R E F A
S C A L E
F O L L O W E R D S S P E E D R E F X
7 0 .3 1 2 .2 0
2 .1 9 D S 4 1 .2
S P E E D S H A R E 2 3 .0 5
W IN D O W W ID T H P O S 2 3 .0 8
F O L L O W E R
L O A D S H A R E 2 5 .0 3 L O A D S H A R E
F O L L S P D C T R L C O R 2 3 .1 8
F O L L S P D C O R R E N A = T R U E 7 .0 3 b 9
T O R Q U E S E L E C T O R = 3 6
F O L L S P E E D U S E D F O L L S P D C O R R O U T 2 .3 0 (n o t S P E E D o r Z E R O )
R E F M O T O R S P E E D
S P E E D S P E E D
7 0 .1 7 R E F 2 S P E E D 2 6 .0 1
R E F
C O N T R O L T O R Q U E R E F 2
2 . 21 79 2 . 01 19 2 . 01 9 T O R Q U E R E F 3
S P E E D R E F 2 3 .0 1
P ID 2 . 1 09
A block diagram for speed controlled Follower with load share function:
D R O O P R A T E 2 4 .0 2 T O R Q U E R E F A 2 5 .0 1
= 0
F O L L O W E R D R IV E F O L L T O R Q R E F 7 0 .1 8
M A S T E R - F O L L O W E R A P P L IC A T IO N P R IN C IP L E : S P E E D C O N T R O L L E D F O L L O W E R W IT H L O A D S H A R E F U N C T IO N
107
Parameter selection (70.08 CH2 M/F MODE) defines whether the drive is the Master
or the Follower in the communication link. Parameter selection can be changed
on-line through an external control system (e.g. fieldbus control system via 07.03
bits 6, 10 and 11). Typically the speed controlled process master drive is configured
also as the Master of the communication.
The Master station is typically speed controlled and the other drives follow its torque
or speed reference. In general, torque control of the Follower should be used when
the motor shafts of the Master and Follower drives are coupled to each other and no
speed difference between the drives is possible. Pulse encoders are recommended
to be used in all of the torque controlled Followers.
The source for the Follower torque/speed reference is selected by parameter 70.17
FOLL SPEED REF / 70.18 FOLL TORQ REF. The Follower reference can also be
selected through external control by 07.03 Auxiliary Control Word 2 bits 6...8.
The selected bits of MCW sent by master can be used in the followers MCW. The
bits are selected by parameter 70.34 FOLLOWER MCW MASK in the follower. The
other bits of the followers MCW are for example sent by fieldbus.
The load sharing between the Master and the Follower can be adjusted by
a parameter (par. 25.03 LOAD SHARE of the Follower drive).
A Master/Follower link is formed by connecting the DDCS CH2 channels of two or
more drives in a ring or star configuration (NDBU branching unit is required with star
configuration).
Ring configuration:
T = Transmitter; R = Receiver; RMIO = I/O and Control Board
Please note that channels CH0/CH2/CH3 are located on the optional RDCO-0x module.
Master Follower Follower
ACS800 ACS800 ACS800
RMIO-XX RMIO-XX RMIOXX
CH2 RDCO-0X CH2 RDCO-0X CH2 RDCO-0X
V17
V17
V17
V18
V18
V18
T R T R T R
Program features
108
Star configuration:
T = Transmitter; R = Receiver; RMIO = I/O and Control Board
Please note that channels CH0/CH2/CH3 are located on the optional RDCO-0x module.
Master
ACS800
RMIO-XX
CH2 RDCO-0X
V17
V18
T R
Follower 1 Follower n
ACS800 Master
ACS800
MASTER
CH0 NDBU CHX
RMIO-XX RMIOXX
...
CH2 RDCO-0X CH2 RDCO-0X
V17
V18
V17
V18
T R T R
See control block diagrams in sections Speed reference on page 313 and Torque
reference on page 316.
Program features
109
T = Transmitter; R = Receiver; RMIO = I/O and Control Board
Please note that channels CH0/CH2/CH3 are located on the optional RDCO-0x module.
Follower 1 Follower n
ACS800 MASTER ACS800
NDBU
X13 = REGEN
CHX CHX CHX
RMIO-XX RMIOXX
...
CH2 RDCO-0X CH2 RDCO-0X
V17
V18
V17
V18
T R T R
Master
ACS800
RMIO-XX
CH2 RDCO-0X
V17
V18
T R
Program features
110
Settings
Parameter Additional information
23.07...23.09 Definition of the speed supervision function for
a torque-controlled Follower drive
25.03 LOAD SHARE Load share (i.e. scaling factor for torque reference 02.28 USED
TORQ REF)
25.03 LOAD SHARE Load share function with speed controlled Follower
23.18 FOLL SPD CTRL COR,
23.19 FOLL SPD COR MODE
26.01 TORQUE SELECTOR Selection of the torque reference
70.07...70.14, 70.17, 70.18, Settings of the Master/Follower link
70.30...70.37
Diagnostics and control
Actual value Additional information
02.30 FOLL SPD CORR OUT Output of the load share function used with speed controlled
Follower
03.33…03.42 Signal values received from followers
07.02 AUX CONTROL WORD 1, Speed supervision for a torque controlled Follower drive
bit 7
07.03 AUX CTRL WORD 2, Follower reference from external control
bits 6...8
07.03 AUX CTRL WORD 2, bit 9 Activation of the load share function with speed controlled
Follower
07.03 AUX CTRL WORD 2, Role of the drive in the Master/Follower link
bits 6, 10 and 11
Master drive
The torque reference source address is defined in the Master drive by parameter
70.11 MASTER SIGNAL 3 to be sent as data set 41 to the Follower drives. Main
Control Word 70.09 MASTER SIGNAL 1 and speed reference 70.10 MASTER
SIGNAL 2 can also be sent through the link in the same DDCS message.
Typical Master drive parameter settings are:
Master drive parameter Setting
70.08 CH2 M/F MODE MASTER
70.09 MASTER SIGNAL 1 07.01 MAIN CTRL WORD / 02.31 FOLLOWER MCW
70.10 MASTER SIGNAL 2 23.01 SPEED REF
70.11 MASTER SIGNAL 3 02.10 TORQ REF 3
70.35 FOLLOWER SEL NOT USED (No data read from followers)
The Master drive sends master references 1...3 in one DDCS broadcast message
(cyclic communication) every 2 ms.
70.11 MASTER SIGNAL 3 can be scaled by parameter 70.30 MASTER SGN3
SCALE before it is sent to the Follower drive. Rescaling is done by parameter 70.31.
FOLLOW SGN3 SCALE. Scaling is useful e.g. when torque reference received from
the Master needs to be relative to the power of the motor connected to the Follower.
Program features
111
Follower drive(s)
In the Follower mode the speed and torque references are read from data set 41.
The Follower mode includes only fast data read from data set 41. Therefore Follower
mode can also be used with an external control system connected to DDCS channel
CH0 by sending a message to data set 41 from the control system. This is useful
when fast communication is required but there is no need for a real Master/Follower
application.
Data set # Data word # Default parameter address Follower signal
41 1 02.31 FOLLOWER MCW 02.29 DS MCW
2 23.01 SPEED REF 02.18 DS SPEED REF
3 25.01 TORQ REF A 02.20 DS TORQ REF A
Typical Follower drive parameter settings are:
Follower drive parameter Setting
70.08 CH2 M/F MODE FOLLOWER
70.17 FOLL SPEED REF MASTER (if the speed reference is read from the Master drive)
(or controlled by 07.03 bits 6 and 7)
70.18 FOLL TORQ REF MASTER (if the torque reference is read from the Master drive)
(or controlled by 07.03 bits 6 and 8)
70.34 FOLLOWER MCW MASK 0 (MCW sent by master is not used)
25.03 LOAD SHARE Default: 100%. Set according to the application requirements.
26.01 TORQUE SELECTOR SPEED/TORQUE (depending on the reference used in the
motor torque control)
In some applications, both speed and torque control of the Followers are required.
For example if it is necessary to accelerate all drives along the same speed ramp up
to a certain speed before torque control can be started, switching between the speed
and torque control is required. The switching is done by controlling parameter 26.01
TORQ SELECTOR from an external control system (e.g. fieldbus control system) or
via adaptive programming.
A speed supervision function for a torque controlled Follower drive is available. See
parameters 23.07 WINDOW INTG ON … 23.09 WINDOW WIDTH NEG and signal
07.02 AUX CTRL WORD 1 bit 7.
The Follower drive is able to detect a communication break. The action taken by the
drive upon a communication brake is defined by parameters 70.13 CH2 TIMEOUT
and 70.14 CH2 COM LOSS CTRL.
See also section Master/Follower communication on page 30 for Master/Follower
configuration during drive start-up.
Program features
112
Data transfer from follower(s)
It is possible to receive three selectable feedback signals from a maximum of three
followers via optic link. The followers from which data is read are selected by
parameter 70.35 FOLLOWER SEL in master. The feedback signals are selected by
parameters 70.09 MASTER SIGNAL 1 … 70.11 MASTER SIGNAL 3 in the follower
drive. The received signals from followers can be read from signals 03.33
FOLLOWER2 MSW … 03.42 FOLLOWER4 ACT3 in master drive. The signal
values are transferred as integer values.
This communication can also be used for status monitoring of followers in the master
drive. The master’s start can be interlocked for status of followers. The enable signal
of the followers is selected by parameter 70.37 FOLL ENABLE SEL. The Master’s
reaction to followers faulting is selected by parameter 70.36 FOLL FAULT SEL. If
70.09 MASTER SIGNAL 1 is not 801 (MSW), the parameter 70.36 FOLL FAULT
SEL must set to NO REACTION and parameter 70.37 FOLL ENABLE SEL to
ALLWAYS.
The example of parameter settings for speed controlled master / follower application
where
• master is controlled by external control system (Command word and speed
reference)
• two followers are controlled by master’s MCW and references.
Master’s start is interlocked to the status of the followers by parameters
70.35…70.37 in the master drive.
E x te rn a l C o n tro l S y s te m (e .g . P L C )
) + 5 & ) + 5 &
M A S T E R F O L L O W E R 2
P a ra m e te r s e ttin g s : P a ra m e te r s e ttin g s :
5 0 .0 1 S P E E D S C A L IN G 2 0 0 0 rp m
C H 2
5 0 .0 1 S P E E D S C A L IN G 2 0 0 0 rp m
C H 2
7 0 .0 8 C H 2 M /F M O D E M A S T E R 7 0 .0 7 C H 2 N O D E A D D R 2
7 0 .0 9 M A S T E R S IG N A L 1 2 2 6 7 0 .0 8 C H 2 M /F M O D E F O L L O W E R
7 0 .1 0 M A S T E R S IG N A L 2 2 3 0 1 7 0 .0 9 M A S T E R S IG N A L 1 8 0 1
7 0 .1 1 M A S T E R S IG N A L 3 2 0 9 7 0 .1 0 M A S T E R S IG N A L 2 1 0 1
7 0 .3 2 C H 2 H W C O N N E C T IO N R IN G 7 0 .1 1 M A S T E R S IG N A L 3 1 0 7
7 0 .3 5 F O L L O W E R S E L F O L L O W E R 2 + 3 7 0 .0 7 C H 2 N O D E A D D R 2
7 0 .3 6 F O L L F A U L T S E L F A U L T 7 0 .1 7 F O L L S P E E D R E F M A S T E R
7 0 .3 7 F O L L E N A B L E S E L M S W B IT 0 7 0 .3 2 C H 2 H W C O N N E C T IO N R IN G
7 0 .3 4 F O L L O W E R M C W M A S K F F F F
9 8 .0 2 C O M M . M O D U L E N O
R in g o r S ta r ) + 5 &
T o p o lo g y in M /F lin k F O L L O W E R 3
P a ra m e te r s e ttin g s :
5 0 .0 1 S P E E D S C A L IN G 2 0 0 0 rp m
7 0 .0 7 C H 2 N O D E A D D R 3
C H 2
7 0 .0 8 C H 2 M /F M O D E F O L L O W E R
7 0 .0 9 M A S T E R S IG N A L 1 8 0 1
7 0 .1 0 M A S T E R S IG N A L 2 1 0 1
7 0 .1 1 M A S T E R S IG N A L 3 1 0 7
7 0 .0 7 C H 2 N O D E A D D R 3
7 0 .1 7 F O L L S P E E D R E F M A S T E R
7 0 .3 2 C H 2 H W C O N N E C T IO N R IN G
7 0 .3 4 F O L L O W E R M C W M A S K F F F F
9 8 .0 2 C O M M . M O D U L E N O
Program features
113
The example of paraneter settings for torque controlled master / follower application,
where
• master is controlled by external control system (Command word and speed
reference)
• two followers, MCW is received from external control system and references
from the master.
Master start is interlocked to the status of the followers by parameters 70.35…70.37
in the master drive.
E x te rn a l C o n tro l S y s te m (e .g . P L C )
M C W
M C W a n d S P E E D R E F M C W
) + 5 & ) + 5 &
M A S T E R T O R Q R E F
F O L L O W E R 2
P a ra m e te r s e ttin g s : S P E E D R E F P a ra m e te r s e ttin g s :
2 6 .0 1 T O R Q U E S E L E C T O R T O R Q U E / A D D
C H 2
2 6 .0 1 T O R Q U E S E L E C T O R S P E E D
C H 2
7 0 .0 8 C H 2 M /F M O D E M A S T E R 7 0 .0 7 C H 2 N O D E A D D R 2
7 0 .0 9 M A S T E R S IG N A L 1 0 7 0 .0 8 C H 2 M /F M O D E F O L L O W E R
7 0 .1 0 M A S T E R S IG N A L 2 2 3 0 1 7 0 .0 9 M A S T E R S IG N A L 1 8 0 1
7 0 .1 1 M A S T E R S IG N A L 3 2 0 9 7 0 .1 0 M A S T E R S IG N A L 2 1 0 1
7 0 .3 2 C H 2 H W C O N N E C T IO N R IN G 7 0 .1 1 M A S T E R S IG N A L 3 1 0 7
7 0 .3 5 F O L L O W E R S E L F O L L O W E R 2 + 3 7 0 .0 7 C H 2 N O D E A D D R 2
7 0 .3 6 F O L L F A U L T S E L F A U L T 7 0 .1 7 F O L L S P E E D R E F M A S T E R
7 0 .3 7 F O L L E N A B L E S E L M S W B 0 7 0 .1 8 F O L L T O R Q R E F M A S T E R
7 0 .3 2 C H 2 H W C O N N E C T IO N R IN G
7 0 .3 4 F O L L O W E R M C W M A S K 0
9 8 .0 2 C O M M . M O D U L E F IE L D B U S /
A D V A N T
) + 5 &
F O L L O W E R 3
P a ra m e te r s e ttin g s :
2 6 .0 1 T O R Q U E S E L E C T O R T O R Q U E / A D D
7 0 .0 7 C H 2 N O D E A D D R 3
C H 2
7 0 .0 8 C H 2 M /F M O D E F O L L O W E R
7 0 .0 9 M A S T E R S IG N A L 1 8 0 1
F O L L 2 a n d 3 S W 7 0 .1 0 M A S T E R S IG N A L 2 1 0 1
7 0 .1 1 M A S T E R S IG N A L 3 1 0 7
7 0 .1 7 F O L L S P E E D R E F M A S T E R
7 0 .1 8 F O L L O W E R T O R Q R E F M A S T E R
7 0 .3 2 C H 2 H W C O N N E C T IO N R IN G
7 0 .3 4 F O L L O W E R M C W M A S K 0
9 8 .0 2 C O M M . M O D U L E F IE L D B U S /
A D V A N T
The Main Control Word (02.26 USED MCW), speed reference (02.18 SPEED REF
4) and torque reference at the output of speed regulator (02.09 TORQUE REF 2) are
sent from the master to the followers. The Main Status Words (08.01 MAIN STATUS
WORD), actual speed (01.01 MOTOR SPEED FILT) and actual torque (01.07
MOTOR TORQ FILT2) are sent from the followers to the master. The master start is
prevented if the bit 0 of follower’s MSW is OFF and if one of the follower has a fault,
then also master is tripped to FOLLOWER FLT fault.
If master drive is faulted, it sends coast stop command also to followers.
Program features
114
Load share function with speed controlled Follower
Load sharing between Master drive and speed controlled Follower drives can be
used in several applications. The load share function is implemented by fine tuning
the speed reference with an additional term which is based on the torque reference
of the Master drive.
Load share is adjusted by parameter 25.03 LOAD SHARE and activated by 07.03
AUX CTRL WORD 2 bit 9. Parameters 23.18 FOLL SPD CTRL COR and 23.19
FOLL SPD COR MODE define how the Follower drives follow the Master torque.
The output of the load share function, 02.30 FOLL SPD CORR OUT, is added to
speed reference 02.02 SPEED REF3.
Note: The Master and Follower drives should have the same speed control tuning
values.
Note: Drooping (24.02 DROOP RATE) must be disabled when load share is used
with speed controlled Follower drives.
Note: The window control also limits the parameter 02.30 FOLL SPD CORR OUT.
See control block diagrams on page 106 and in section Speed reference ramp on
page 314.
Process master on-line configuration
If the on-line configurable master is required the separate CACP board has to be
used. CACP works as communication master and 1 or 2 of drives can be process
masters and other drives are process followers. The process master can be
changed on-line without any interrupts in the process. For more information, see
chapter Program features for Master/Follower in ACS800 Configuration and Control
Program for ABB Industrial Drives Firmware Manual (3AUA0000021158 [English]).
Master/Follower link specification
Size of the link: One master and maximum of 10 Follower drives. If more than 10
Followers are required, an ABB representative should be consulted. The maximum
length of the fibre optic cables depends on the type of the used cable:
With RDCO-01 or RDCO-02:
- POF (Plastic Optic Fibre): Maximum cable length is 30 m.
- HCS (Hard-Clad Silica Fibre): Maximum cable length is 200 m.
For distances up to 1000 m: Use two Optical Converter/Repeater boards (NOCR-01)
with glass optic cable (GOF, 6.25 um, Multi-Mode).
With RDCO-03:
- POF (Plastic Optic Fibre): Maximum cable length is 10 m.
- HCS (Hard-Clad Silica Fibre): Not supported.
Transmission rate: 4 Mbit/s
Configuration: The role of the drive in the Master/Follower link can be changed
on-line through an external control system (connected to DDCS CH0) by parameter
Program features
115
70.08 CH2 M/F MODE or adaptive programming and thus there is no need for
hardware reconfiguration.
Total performance of the link: < 5 ms to transfer references between the Master
and Follower drives.
Protocol: DDCS (Distributed Drives Communication System)
Inverter fan speed control
Parallel-connected inverter modules can be equipped with an optional inverter fan.
The fan speed can be controlled by adjusting the fan speed control parameters.
The following figures present the different fan speed control curves.
Fan speed / Hz 16.08 is set to CONST 50 HZ
Drive Drive
stopped modulating
50
Fan Fan
acceleration deceleration
time time
IGBT temperature / °C
Charging
Fan speed / Hz 16.08 is set to RUN/STOP
Drive Drive
stopped modulating
50
Fan Fan
acceleration deceleration
time time
10
IGBT temperature / °C
Charging
Fan speed / Hz
16.08 is set to CONTROLLED
Drive
Drive modulating
stopped
55
Fan deceleration time
25 Fan acceleration time
10
Charging IGBT temperature / °C
90 112
Settings
Parameter Additional information
16.08 FAN SPD CTRL MODE Selection of the inverter fan speed control
Program features
116
LSU communication
Fibre optic link can be connected between line-side converter unit (LSU) and the
inverter unit (INU) in 4Q, low harmonic and liquid cooled single drives. Fibre optic
cable is connected between LSU control board CH0 and INU control board CH1 or
CH2. LSU's start, stop and reset commands can be given via INU and the actual
values can be read from LSU to INU, as well as DC and reactive power references
can be written from INU to LSU. If INU is faulted, also ISU is stopped. For further
details, see description of signals and parameters in groups 5 and 95.
Start by overriding system, when ISU starting is controlled by INU.
2Q
6WDUW(QDEOHG+: 9 2II
$X[LOLDU\3RZHU21 2Q
VHFRQGV 2II
)LHOGEXV&RPPVWDUWV 2Q
2II
&ORVHG
(PHUJHQF\6WRSEXWWRQV 2SHQ
&KDUJLQJ
'LVFKDUJHG
'&9ROWDJH ,68,18
,680DLQ&RQWDFWRU &ORVHG
2SHQ
V
2Q
,680RGXODWLRQ 2II
,180RGXODWLRQ 2Q
2II
7RUTXHUHIHUHQFH 6WRS
6HTXHQFH
&RQWUROIURPWKH2YHUULGLQJ6\VWHP
21
2))
2))
0&:ELWV
581
5$03287=(52
5$03+2/'
5$03,1=(52
1HHGHGRQO\LIIDXOWVLWXDWLRQ
5(6(7
,1&+,1*
,1&+,1*
5(027(B&0'
5'<B21
6WDWXV:RUGWR2YHUULGLQJ6\VWHP
5'<B581
5'<B5()
06:ELWV
75,33('
2))67$
2))67$
$/$50
$76(732,17
5(027(
WLPH
*) Starting of modulation can be separated to free bit of MCW with parameter 95.06
LSU RUN MCW BIT.
Program features
117
There are several alternative for communication between the INU and LSU. This can
be selected by user’s parameter 95.05 LSU COMM SEL and it is not a HW
dependent like single drive or multidrive.
Settings
Parameter Additional information
95.01...95.02 References for LSU
95.03...95.04 Selection parameters for actual signals read from LSU.
95.05 LSU COMM SEL Selection for communication type
95.06 LSU RUN MCW BIT Selection for the start bit of LSU modulation
Diagnostics
Actual value Additional information
05.01...05.09 Actual values read from LSU
05.10..05.11 LSU status, fault and alarm words
05.13 LSU CONTROL WORD Main control word of LSU
05.21...26 Special signals of Wind Turbine Application
Sine filter support
The sine filters are low-pass filters that suppress the high frequency components of
the drive output. The sine filters available for the ACS800 consist of single- or three-
phase reactors and delta- or star-connected capacitors.
The following diagram shows a drive system with a sine filter.
M
3~
Drive Sine filter
The sine filters are used in conjunction with the ACS800 System Control Program.
The Scalar motor control mode (instead of DTC mode) is used with a sine filter. See
User’s Manual Sine Filters (3AFE68389178 [English]).
The sine filter function is activated by parameter 98.04 DI/O EXT MODULE 2
(selection (4) STEP UP). This selection activates scalar mode and sets internal
parameters for sine filter use. The function requires an RDIO extension module. This
Program features
118
activates scalar control mode with internal parameter settings. The following sine
filter protections are available.
Input Additional information
DI/O EXT2:DI1 0 = CHOKE OTEMP, overtemperature of sine filter.
1 = no fault
DI/O EXT2:DI2 0 = FAN OVERTEMP, cooling fan overtemperature of sine filter.
1 = no fault
DI/O EXT2:DI3 Not in use.
DI/O EXT2:RO1
DI/O EXT2:RO2
Settings
Parameter Additional information
29.04 IR COMPENSATION Defines relative output voltage boost at zero speed.
29.06 IR STEP-UP FREQ Defines the frequency at which the step-up IR compensation reachers
the IR compensation
29.07 ENA INC SW FREQ Minimum switching frequency limitation
98.04 DI/O EXT MODULE 2 Activation of sine filter support
99.02 MOTOR NOM Using nominal supply voltage instead of motor rating plate value
VOLTAGE
98.10 DI/O EXT2 LOCATION Location for DI/O EXT2 extension module
Diagnostics
Alarm Signal
FAN OVERTEMP Signal 09.05 ALARM WORD2 bit 5 value is 1
Fault Signal
CHOKE OTEMP Signal 09.06 FAULT WORD3 bit 8 value is 1
Program features
119
Inverter charging logic
With R2i…R5i and R7i inverters digital input DI2 is used to indicate the position of
an optional DC switch.
Three conditions must be fulfilled before the charging relay is energised:
• DC charging level has reached 79% of the nominal DC voltage.
• Voltage derivative is 0 (i.e. voltage is not changing any longer).
• Digital input DI2 value is 1, i.e. RUN ENABLE (see signal 08.05 DI STATUS
WORD).
When the DC switch opens, the inverter IGBT control is disabled and the charging
relay is de-energized. If undervoltage is detected in the supply voltage, the charging
relay is de-energized after the DC UNDERVOLT fault trip.
DC bars
DC switch
DI2
charging charging
logic relay
M
With R8i inverters equipped with an optional DC switch, the charging logic is
controlled by the Switch Fuse Control Board, ASFC.
Settings
Parameter Additional information
98.12 FUSE SWITCH CTRL Activation of the inverter DC switch monitoring (with R8i inverters
equipped with an optional DC switch)
Diagnostics
Actual value Additional information
08.05 DI STATUS WORD Digital input status
08.20 INV ENABLED WORD Inverter module operation status
Program features
120
Monitoring panel NLMD-01
The cabinet door of the drive can be equipped with Led Monitoring Display panel
NLMD-01 to indicate a selected signal. The unit of the selected signal must be
percent (%).
NLMD-01 can be used with or without the CDP 312R control panel.
Settings
Parameter Additional information
18 LED PANEL CTRL Settings of the Led Monitoring Display panel
Pulse encoder, RTAC
RTAC-01 pulse encoder module is connected to Slot 1 or Slot 2 of the drive or via
an optional AIMA-01 I/O Module Adapter connected to RMIO board DDCS channel
CH1.
Position counter
The number of pulse encoder pulses can be counted by using signal 07.02 Auxiliary
Control Word 1 bits 9...11. The calculation has three output modes: number of
pulses, number of revolutions and motor shaft position in degrees.
When faster synchronising is required, see parameter 10.04 SYNC CMD.
Program features
F A S T D I5 S E L = P O S C N T S Y N C
D I5 1 2 .0 3
S Y N C C M D
Position count
S Y N C C M D D I S Y N C C O M M A N D
1 0 .0 4 > 1 &
S S
S Y N C C O M M A N D 7 .0 2 b 9 8 .0 2 b 5 S Y N C R D Y
R R
S Y N C D IS A B L E 7 .0 2 b 1 0
F A U L T 8 .0 1 b 3
> 1 1
R E S E T S Y N C R D Y 7 .0 2 b 1 1
3 .0 7 P O S C O U N T L O W
3 .0 8 P O S C O U N T H IG H
P O S C O U N T IN IT L O W 5 0 .0 8
P O S C O U N T IN IT H IG H 5 0 .0 9 3 .0 9 P O S C O U N T D E G R E E S
P U L S E S F R O M E N C O D E R
3 .1 0 P O S C O U N T R O U N D S
A D D
P O S C O U N T M O D E = R O U N D & D E G 5 0 .0 7
P O S IT IO N C O U N T : L O G IC A N D C A L C U L A T IO N D IA G R A M
121
Program features
122
Example:
A basic position count function can be seen in the following figure. When
synchronisation is enabled (07.02 bit 10 SYNC DISABLE value is 0) and the next
positive edge of the SYNC CMD (07.02 bit 9) is encountered, the initial values of
POS COUNT INIT LOW and POS COUNT INIT HIGH (par. 50.08 and 50.09) are
loaded into the counter. (Initial values can only be used in the pulse edge count
mode.) Status signal SYNC RDY (08.02 bit 5) is set to indicate position counter
synchronisation. When the positioning has been completed by an external control
system (i.e. the motor can be stopped or some other sequence started), signal
SYNC RDY can be reset by RESET SYNC RDY (07.02 bit 11).
SYNC CMD 7.02 B9
SYNC DISABLE 7.02 B10
SYNC RDY 8.02 B5
RESET SYNC RDY 7.02 B11
ENCODER PULSES
POS COUNT LO 3.07
POS COUNT HI 3.08
or
POS COUNT ROUNDS 3.10
POS COUNT DEGREES 3.09
POS COUNT INIT LO 50.08
POS COUNT INIT HI 50.09
Settings
Parameter Additional information
10.04 SYNC CMD Synchronisation of the position count
50 SPEED MEASUREMENT Settings of the encoder and processing of the position counter
(50.07...50.09)
98.01 ENCODER MODULE Activation of the RTAC module
Diagnostics and control
Actual value Additional information
01.03 SPEED MEASURED Measured motor speed
03.07...03.10 Position counter values
07.02 AUX CONTROL Commands for the position count
WORD 1, bits 9...11
08.02 AUX STATUS WORD Speed feedback: 0 = Pulse encoder is used.
1 = Internal speed feedback is used.
Program features
123
Firmware
Firmware loading package
Each drive product has a product specific loading package, which contains all
necessary software files to be downloaded to the RMIO board. The loading
packages define for example the inverter ratings which are different for AC and DC
supplied inverters. The type information of the loading package can be identified
from signal 04.01 SW PACKAGE VER. The downloaded application program
version can be identified from signal 04.03 APPLIC SW VERSION.
Program boot
The application program of the RMIO board is saved to the FPROM memory. After
switching on the auxiliary power, the program starts routines for initialisation and
loading of all tasks, parameters and the application program from the FPROM to the
RAM memory. This takes 8 seconds. A fault reset is given at the end of the boot
procedure and the control mode of the drive is changed to remote.
Memory handling
Parameter value changes through DriveWindow or CDP 312R control panel are
stored to the RAM and FPROM memories. Parameter value changes through
an external control system are stored only to the RAM memory. However, if
parameter changes made through external control need to be saved to the FPROM,
saving can be executed by setting parameter 16.06 PARAMETER BACKUP to
SAVE.
DriveWindow parameter
or CDP 312R change
RAM memory
Par. 16.06
POWER-UP
USER 1
USER 1 Parameter file SAVE
LOAD
USER MACRO 1 file USER 2
USER 2
SAVE
LOAD
USER MACRO 2 file
FACTORY
FACTORY FILE
FPROM memory
When the power is turned off, 16 latest faults or alarms are saved to the FPROM
memory.
Settings
Parameter Additional information
16.06 PARAMETER BACKUP Saving of parameters from the RAM memory to the FPROM
memory
Program features
124
Diagnostics
Actual value Additional information
04.01 SW PACKAGE VER Type and version of the firmware package
04.03 APPLIC SW VERSION Type and the version of the application program
Diagnostics
Drive diagnostics is informed by signals, data loggers and event and fault loggers.
Fault and event loggers
The fault logger collects 64 of the most recent faults into the fault buffer in the RAM
memory. The latest 16 faults are stored to the flash memory at the beginning of
an auxiliary power supply loss when an internal +24 V power supply is used.
The fault logger records all available information from the drive including fault, alarm,
reset and system messages.
Time format
Fault logger time is taken from the power-on counter and can be seen on the
CDP 312R control panel in format xx H zz MIN yy S = hours, minutes seconds (with
DriveWindow the format is xxxx:zz: yy.yyyy = hours:minutes:seconds). The counter
can be updated cyclically from an external control system if the system includes
a controller with a clock master (for example AC 80 / AC 800M). In this case the
DriveWindow and the CDP 312R control panel show the real date and time.
Data loggers 1 and 2
Data loggers are used to monitor selected signals and to store them for later retrieval
and analysis. The contents of the data loggers are stored to the RAM memory. There
are two data loggers on the RMIO board. Both data loggers consist of 1...4 channels.
The minimum sample interval is 1 ms. The total memory size of a data logger is 1024
bytes. The maximum number of samples depends on the data type:
• Integer type signal or parameters reserve 1 byte.
• Real type values reserve 2 bytes.
Example: Four real type signals are measured with data logger 1. The maximum
number of samples is 1024 / (2 bytes · 4 channels) = 128.
Data loggers store the selected signals to the RAM memory every 5 milliseconds
Default signals
Data logger 1 default signals Data logger 2 default signals
01.01 MOTOR SPEED FILT 01.02 SPEED ESTIMATED
01.07 MOTOR TORQUE FILT 01.10 DC VOLTAGE
23.01 SPEED REF 01.12 PP TEMP
25.01 TORQUE REF A 02.15 FLUX ACT
The default trigger mode for data loggers is a fault condition. Data logger 1 can also
be triggered by an external control system (e.g. fieldbus) or adaptive programming
via 07.02 Auxiliary Control Word 1 (bits 0 and 1).
Program features
125
Example: Triggered by rising edge:
07.02 bit 0: Restart data logger 1.
07.02 bit 1: Data logger 1 triggered
Diagnostics and control
Actual value Additional information
03.11 DATALOG1 STATUS Status Word of data logger 1
07.02 AUX CTRL WORD 1 bits 0 and 1 Data logger 1 control
Backup and restore function with DriveWindow
It is recommended to take a backup copy of the parameters and Motor ID run results
at the end of the commissioning of the drive. The data can be restored later, e.g.
downloaded into a spare board of the same type. The backup is done with the
DriveWindow PC tool (or with the CDP 312R control panel: the backup is stored to
the EEPROM memory of the panel).
The DriveWindow backup file (*.BPG) stores all the information from the drive
FPROM to the PC. For instructions on how to make a backup, see DriveWindow 2
User’s Manual [3AFE64560981 (English)].
DriveWindow backup file (*.BPG) is normally downloaded if the RMIO board is
replaced.
The backup can be restored to a spare board in which CH3 node address is 1. One
spare RDCU-02C unit or ACS800 drive module R2i/.../R5i/R2/.../R6 including an
RMIO board, is needed for each application software type (for example System,
Standard, Crane etc.). The spare board and the original board must have the same
firmware. See signal 04.01 SOFTWARE VERSION. The inverter type for a spare
RMIO board (defined usually during software download) can be of any type
(selection NONE can also be used).
Note: The DriveWindow backup can be restored only if the destination firmware
(e.g. spare board firmware) and the original firmware (which was backed up) have
the same channel CH3 node addresses (70.15 CH3 NODE ADDR) or if the
destination firmware node address is 1. With other node addresses, the following
message is displayed.
Note that the new node address becomes valid only after the next power-up of the
drive.
Program features
126
Note: If backup restore function does not restore all the information (e.g. ID run
results), restore the backup again. Use DriveWindow version 2.21 or newer or
update your older version using service pack available in ABB Library.
Note: The DriveWindow backup cannot be executed in local control mode.
Note: Remember to save the backup file after the backup is completed.
Settings
Parameter Additional information
70.15 CH3 NODE ADDR Definition of the channel CH3 node address
Diagnostics
Actual value Additional information
04.01 SOFTWARE VERSION Firmware package type and version
User macro save with DriveWindow
When user macros are saved to the PC with DriveWindow, both macros must be
saved separately:
1) Activate user macro 1 by setting parameter 99.11 APPLICATION MACRO to
USER1 LOAD and save it:
• Select remote control mode.
• Select the drive from the list.
• Select from the File menu: Parameters - Save as (parameter file name *.dwp).
2) Activate user macro 2 by setting parameter 99.11 APPLICATION MACRO to
USER2 LOAD and save it according to the instruction given above.
The files should be named logically and clearly to identify the corresponding drive
and the macro, e.g. Unwinder 1 macro 1. The process name of the drive can be
typed into parameter 97.01 DEVICE NAME, e.g. Unwinder 1, and it can be seen on
the DriveWindow main menu and on the second row of the control panel display.
For more information on user macros, see section User macros on page 290.
Settings
Parameter Additional information
97.01 DEVICE NAME Definition of the drive name
99.11 APPLICATION MACRO Activation of user macro 1/2
Program features
127
Software version update
A version update restores parameters (groups 10...98) and ID run results from the
old drive firmware version to the new firmware version.
1) Before downloading the new software to the RMIO board, save parameters and
both user macros (if used) of the old software into a file in the PC:
• Select remote control mode.
• Select the drive from the list:
• Select from the File menu: Parameters - Save as (parameter file name *.dwp).
• Save both user macros (if used) to the PC: Parameters - Save as (parameter file
name *.dwp). (User macros are activated by setting parameter 99.11
APPLICATION MACRO to USER1/2 LOAD.)
• Create a DriveWindow backup file (*.BPG) to PC. For instructions, see
DriveWindow 2 User’s Manual [3AFE64560981 (English)].
• Upload DriveAP 2.x application to PC (if used) from the DriveAP drive menu:
Upload - Save as (file name *.ap).
Program features
128
2) Download the new software version to the RMIO board from the DOS loading
package according to the software downloading instructions.
3) Restore parameters (groups 10...98) and ID run results from the old software
version to the new software version:
• Select remote control mode.
• Open the parameter file of the old software by selecting from the File menu:
Parameters - Open - (parameter file name *.dwp) - Open.
• Select the appropriate drive.
• Select from the File menu: Parameters - Download.
Note: When user macros are restored, save the stored user macro files (*.dwp) as
user macro 1 and 2 of the new software.
• A version conflict notification appears. Proceed by clicking the YES button.
• Select parameters and ID run results and click the OK button.
Program features
129
• A user macro notification appears. If it is safe to proceed, click the YES button.
• Restart the drive software by clicking the YES button.
• Use compare function (File -Parameters -Compare) to check the parameter
differences between the drive and file.
• Check the settings of the new parameters.
For more information on DriveWindow, see DriveWindow 2 User’s Manual
[3AFE64560981 (English)].
Note: If adaptive programming is used and it has been created by the CDP 312R
control panel or DriveWindow, connections and blocks are activated automatically
when the parameter file is restored (parameter groups 53...66). If adaptive program
has been created by DriveAP 2.x, the program must be opened as follows:
• Open the DriveAP 2.x application into the RMIO board by selecting from the File
menu: Open - (block application file *.ap).
• Check that the DriveAP version is 2.1 or later.
• Select from the DriveAP Drive menu: Download.
• Start the adaptive program tasks by DriveAP 2.x.
Program features
130
Program features
131
Actual signals and parameters
What this chapter contains
The chapter describes the actual signals and parameters. Parameter groups 10...99
are user-adjustable. Actual signal groups 1...9 are only for monitoring (read-only, i.e.
no user setting is possible), though data can be written into the Control Words
(parameter group 7) through an external control system. Parameter changes
through DriveWindow or CDP 312R control panel are stored to the FPROM memory
and changes through external control system are stored to the RAM memory.
Note: Some parameters cannot be changed when the drive is running.
Fieldbus equivalent
Serial communication data between fieldbus adapter and drive is transferred in
integer format. Thus the drive actual and reference signal values must be scaled to
16-bit integer values. Fieldbus equivalent defines the scaling between the signal
value and the integer used in serial communication.
All the read and sent values are limited to 16 bits (-32768...32767).
Example 1: If 20.09 TREF TORQMAX is set from external control system, an integer
value of 100 corresponds to 1%.
Example 2: Speed reference is defined by parameter 23.01 SPEED REF. Parameter
50.01 SPEED SCALING defines the motor speed (in rpm) at maximum reference
(20000 for external control system). Thus, sending a value 20000 from an external
control system into parameter 23.01 sets the speed reference to the rpm value
defined by parameter 50.01.
Fieldbus addresses
Type Rxxx adapter modules (such as RPBA, RCAN, RDNA, etc.): See the
appropriate user’s manual.
PROFIBUS-DP NPBA-12 module: See column PB in the following signal and
parameter tables. (Add 4000 in FMS Mode.)
Interbus-S NIBA-01 module:
xxyy · 100 + 12288 converted into hexadecimal (xx = parameter number and
yy = subindex)
Example: The index for drive parameter 13.09 AI3 LOW VALUE is 1309 + 12288 =
13597 = 351D (hex).
Actual signals and parameters
132
Modbus and Modbus Plus address
The drive parameters, data words, references and actual values are mapped into the
4xxyy register area. This holding register can be read from an external device, which
can modify the register values by writing into them.
There are no setup parameters for mapping the data into the 4xxyy register area.
The mapping is pre-defined and corresponds directly to the drive parameter
grouping which is being used by the local drive panel.
The parameters and signals are mapped into the area 4xxxx so that:
• 40001...40096 are reserved for data sets: 40001 = data set 1 data word 1,
40002 = data set 1 data word 2, 40003 = data set 1 data word 3,
40004 = data set 2 data word 1 etc.
• 40101...40999 are reserved for drive actual signals 01.01...09.99.
• 41000...49999 are reserved for drive parameters 10.01...99.99. (E.g. 41002 is
parameter 10.02). In this mapping, the thousands and hundreds correspond to
the group number, while the tens and ones correspond to the parameter number
within a group.
Terms and abbreviations
Term Definition
Actual signal Signal measured or calculated by the drive. Can be monitored by the
user. No user setting possible.
B Boolean
C Character string
Def. Default value
FbEq Fieldbus equivalent: The scaling between the value shown on the panel
and the integer used in serial communication.
I Integer
P Pointer
Parameter A user-adjustable operation instruction of the drive
Pb Packed boolean
PB PROFIBUS equivalent for drive parameters communicating through the
NPBA-12 PROFIBUS Adapter. (Add 4000 in FMS Mode.)
R Real
T Data type (see B, C, I, R, Pb)
Actual signals and parameters
133
Index Name/Value Description FbEq PB T
01 ACTUAL SIGNALS Basic signals for monitoring the drive
01.01 MOTOR SPEED FILT Filtered actual speed. Used speed feedback is defined by See par. 1 R
parameter 50.03 SPEED FB SEL. 50.01.
Filter time constant can be adjusted by parameter 50.12 MOTOR
SP FILT TIME.
rpm Speed
01.02 SPEED ESTIMATED Calculated motor speed See par. 2 R
50.01.
rpm Speed
01.03 SPEED MEASURED Measured motor speed See par. 3 R
50.01.
rpm Speed
01.04 MOTOR SPEED Actual speed used for the speed error calculation See par. 4 R
50.01.
rpm Speed
01.05 FREQUENCY Calculated drive output frequency 100 = 1 Hz 5 R
Hz Frequency
01.06 MOTOR CURRENT Measured motor current (absolute value) 10 = 1 A 6 R
A Current
01.07 MOTOR TORQ FILT2 Filtered motor torque. Filter time constant can be adjusted by 100 = 1% 7 R
parameter 25.07 TORQ ACT FILT TIM.
% Torque in percent of the rated motor torque
01.08 MOTOR TORQUE Motor torque 100 = 1% 8 R
% Torque in percent of the rated motor torque
01.09 POWER Motor power 10 = 1% 9 R
% Power in percent of the rated motor power
01.10 DC VOLTAGE Measured intermediate circuit voltage 1=1V 10 R
V Voltage
01.11 MOTOR VOLTAGE Calculated motor output voltage 1=1V 11 R
V Voltage
01.12 ACS800 TEMP IGBT temperature 1 = 1°C 12 R
°C Temperature
01.13 TIME OF USAGE Elapsed time counter. Runs when the control board is powered. 1=1h 13 R
h Time
01.14 KILOWATT HOURS kWh counter 1= 14 R
100 kWh
kWh Counter value
01.15 DI7-1 STATUS Status of digital inputs. 1=1 15 I
00000000…1111111 Example: 0001001 = DI1 and DI4 are on.
0001001
DI7 DI1
DI6 DI2
DI5 DI3
DI4
Actual signals and parameters
134
Index Name/Value Description FbEq PB T
01.16 MOTOR 1 TEMP Measured temperature of motor 1. See parameter 30.03 MOT1 1 = 1°C or 16 R
TEMP AI1 SEL. 1Ω
°C or Ω °C = Pt100 measurement, Ω = PTC / KTY84-1xx measurement
01.17 MOTOR 2 TEMP Measured temperature of motor 2. See parameter 30.06 MOT2 1 = 1°C or 17 R
TEMP AI2 SEL. 1Ω
°C or Ω °C = Pt100 measurement, Ω = PTC / KTY84-1xx measurement
01.18 MOTOR TEMP EST Estimated motor temperature when thermal model (DTC or USER 1 = 1°C 18 R
MODE) is used for motor overtemperature protection. See
parameter 30.01 MOT THERM MODE.
°C Temperature
01.19 AI1 [V] Non-scaled value of analogue input AI1. See parameters 13.01 AI1 10000 = 19 R
HIGH VALUE and 13.02 AI1 LOW VALUE. 10 V or
20 mA
-10...10 V Voltage
01.20 AI2 [mA] Non-scaled value of analogue input AI2. See parameters 13.04 AI2 20000 = 20 R
HIGH VALUE and 13.05 AI2 LOW VALUE. 20 mA, 2 V
or 10 V
-20...20 mA Current
01.21 AI3 [mA] Non-scaled value of analogue input AI3. See parameters 13.08 AI3 20000 = 21 R
HIGH VALUE and 13.09 AI3 LOW VALUE. 20 mA
-20...20 mA Current
01.22 RO3-1 STATUS Status of relay outputs 1=1 22 I
0000000…1111111 Example: 0000110 = RO2 and RO3 are energised.
0000110
RO1
RO2
RO3
01.23 AO1 [mA] Value of analogue output AO1. See parameter group 15 20000 = 23 R
ANALOGUE OUTPUTS for signal selection and scaling. 20 mA
0...22 mA Current
01.24 AO2 [mA] Value of analogue output AO2. See parameter group 15 20000 = 24 R
ANALOGUE OUTPUTS for signal selection and scaling. 20 mA
0...22 mA Current
01.25 CONTROL MODE Active control mode 25 I
1 Speed control
2 Torque control
01.26 LED PANEL OUTPUT NLMD-01 LED panel output. See parameter group 18 LED PANEL 1 = 1 26 R
CTRL.
% Panel output
01.27 CABLE Motor cable thermal model output monitoring. See parameter 1=1 27 R
TEMPERATURE group 36 MOTOR CABLE PROTECTION.
% 102% corresponds to the trip limit.
01.28 IU Measured output current of phase U 1=1 28 R
0...300 A Current
01.29 IV Calculated output current of phase V 1=1 29 R
0...300 A Current
Actual signals and parameters
135
Index Name/Value Description FbEq PB T
01.30 IW Measured output current of phase W 1=1 30 R
0...300 A Current
01.31 FAN-ON-TIME Running time of the drive cooling fan 1 = 10 h 31 R
Note: Resetting of the counter is recommended when the fan is
replaced. See parameter 16.09 RESET COUNTER.
h Time
01.37 GENER TORQ FILT2 Filtered generating torque in percent of the rated motor or 100 = 1% 37 R
generator torque. Same as 01.07 MOTOR TORQ FILT2, but with
opposite sign. Filter time constant can be adjusted by parameter
25.07 TORQ ACT FILT TIM.
% Torque in percent of the rated motor torque
01.38 MOTOR RUN-TIME Running time of the motor fan 1=1 38 R
Note: The counter can be reset by parameter 16.09 RESET
COUNTER.
h Time
01.41 EXT2 AI1 Non-scaled value of analogue input AI1 of I/O extension module 1=1 41 I
EXT 2
-20000...20000 Integer value. 20000 corresponds to the maximum analogue input
signal value.
01.42 EXT2 AI2 Non-scaled value of analogue input AI2 of I/O extension module 1=1 42 I
EXT 2
-20000...20000 Integer value. 20000 corresponds to the maximum analogue input
signal value.
01.43 kWh Kilowatt hour counter. After 999999 kWh, 0143 kWh is reset and 1 = 100 R
01.44 GWh counter is incremented. kWh
0…999999 Counter value
01.44 GWh Gigawatt hour counter 1=1 R
0…999999 Counter hour
02 ACTUAL SIGNALS Speed and torque reference monitoring signals
02.01 SPEED REF 2 Limited speed reference See par. 51 R
50.01.
-18000...18000 rpm Speed
02.02 SPEED REF 3 Speed reference after the speed ramp See par. 52 R
50.01.
-18000...18000 rpm Speed
02.03 SPEED ERROR NEG Difference between speed reference and actual speed. See par. 53 R
If parameter 23.07 WINDOW INTG ON is active, 02.03 SPEED 50.01.
ERROR NEG is filtered through the window function.
% Difference
02.04 TORQUE PROP REF Output of the proportional part (P-part) of the PID controller 100 = 1% 54 R
% Output value
02.05 TORQUE INTEG REF Output of the integral part (I-part) of the PID controller 100 = 1% 55 R
% Output value
02.06 TORQUE DER REF Output of the derivative part (D-part) of the PID controller 100 = 1% 56 R
Actual signals and parameters
136
Index Name/Value Description FbEq PB T
% Output value
02.07 TORQ ACC COMP Output of the acceleration compensation 100 = 1% 57 R
REF
% Output value
02.08 TORQUE REF 1 Limited torque reference 100 = 1% 58 R
% Value in percent of the nominal motor torque
02.09 TORQUE REF 2 Speed controller output 100 = 1% 59 R
% Value in percent of the nominal motor torque
02.10 TORQUE REF 3 Torque reference after the torque selector 100 = 1% 60 R
% Value in percent of the nominal motor torque
02.11 TORQUE REF 4 Torque reference: sum of 02.10 TORQUE REF 3 and 26.02 LOAD 100 = 1% 61 R
COMPENSATION
% Torque
02.12 TORQUE REF 5 Torque reference: sum of 02.11 TORQUE REF 4 and 26.03 100 = 1% 62 R
TORQUE STEP
% Torque
02.13 TORQ USED REF Limited torque reference after frequency, voltage and torque 100 = 1% 63 R
limiters
% Value in percent of the nominal motor torque
02.14 FLUX USED REF Flux reference 10 = 1% 64 R
% Flux
02.15 FLUX ACT Actual flux 10 = 1% 65 R
% Flux
02.16 dv/dt Speed reference change after the speed ramp generator See par. 66 R
50.01.
rpm/s Speed change
02.18 SPEED REF 4 Speed reference before speed error calculation See par. 68 R
50.01.
-18000...18000 rpm Speed
02.19 DS SPEED REF Speed reference in a Master/Follower application See par. 69 R
50.01.
-18000...18000 rpm Speed
02.20 DS TORQ REF A Torque reference in a Master/Follower application 100 = 1% 70 R
% Value in percent of the nominal motor torque
02.21 FIELDWK POINT ACT Actual field weakening point 100 = 1Hz 71 R
Hz Frequency
02.22 TORQ FREQ LIM REF Torque reference after the frequency limiter 100 = 1% 72 R
% Value in percent of the nominal motor torque
02.23 TORQ DC LIM REF Torque reference after the DC voltage limiter 100 = 1% 73 R
% Value in percent of the nominal motor torque
02.24 TORQ POW LIM REF Torque reference after the power limiter 10 = 1% 74 R
-600.00...600.00% Value in percent of the nominal motor torque
Actual signals and parameters
137
Index Name/Value Description FbEq PB T
02.25 ADDITIVE SP REF Analogue input speed reference when AI+FBA SPEED REF See par. 75 R
function has been activated by parameter 11.02 REFERENCE 50.01.
SELECT. This additional speed reference can also be updated by
the Application Program if AI+FBA SPEED REF is not selected.
-18000...18000 rpm Speed
02.26 USED MCW Internal command word used by the application program. Control - Pb
commands which are actually used can be monitored with this
signal.
0...65535 Control word value
02.27 USED SPEED REF Speed reference. See control block diagram in section Speed See par. R
reference on page 313. 50.01.
-18000...18000 rpm Speed
02.28 USED TORQ REF A Torque reference. See control block diagram in section Torque 100 = 1% R
reference on page 316.
% Value in percent of the nominal motor torque
02.29 DS MCW Main control word used in a Master/Follower application - Pb
0...65535 Control word value
02.30 FOLL SPD CORR Speed output correction of the load share function with speed See par. R
OUT controlled Follower drive. See section Load share function with 50.01.
speed controlled Follower on page 114.
-18000...18000 rpm Speed
02.31 FOLLOWER MCW Actual signal is sent by the Master to the Follower. Same as 02.26
USED MCW except bit 3 is replaced by masters MODULATING
STATUS. Selected by parameter 70.09 MASTER SIGNAL 1.
03 ACTUAL SIGNALS Monitoring signals
03.02 APPLICATION OVERL Overload monitoring 1=1 77 Pb
-32768...32767 Bit 0 = Application Task 1 overload
Bit 1 = Application Task 2 overload
Bit 2 = Application Task 3 overload
Bit 3 = Application Task 4 overload
Bit 4 = Application Task 5 overload
Bit 5 = Application Task 6 overload
03.03 RS Estimated stator resistance RS (consists of the resistance value 28676 = 78 R
estimated during ID run and the temperature dependence of the 1Ω
resistance).
mohm Resistance
03.04 LS Estimated stator inductance LS 100 = 1 mH 79 R
mH Inductance
03.05 SIGMALS Estimated value of leakage factor σLS 100 = 1 mH 80 R
mH Leakage factor
03.06 TR Estimated time constant of the rotor 1 = 1 ms 81 R
ms Time constant
03.07 POS COUNT LO Position counter value in pulses (16 least significant bits) 1=1 82 I
0...65536 Integer value
03.08 POS COUNT HI 1=1
Position counter value in pulses (16 most significant bits) 83 I
0...65536 Integer value
Actual signals and parameters
138
Index Name/Value Description FbEq PB T
03.09 POS COUNT Position counter value. Parameter 50.07 POS COUNT MODE 1 = 1 deg 84 R
DEGREES must be set to ROUND&DEG. This signal is used together with
signal 03.10 POS COUNT ROUNDS.
-360...360 deg Position
03.10 POS COUNT Position counter value in total shaft revolutions. Parameter 50.07 1=1 85 R
ROUNDS POS COUNT MODE must be set to ROUND&DEG. This signal is
used together with signal 03.09 POS COUNT DEGREES.
-8388608...8388608 Integer value
03.11 DATALOG1 STATUS Status Word of data logger 1. See section Data loggers 1 and 2 on 86 Pb
page 124.
-32768...32767 B0 = triggered on fault
B1 = triggered on set level
B2 = triggered on alarm
B3 = triggered on limit
B4 = triggered by user
B5 = triggered from level
B6 = trend triggered from difference
B7 = initialising
B8 = overwrite
B9 = filled
B10 = running
B11 = initialised
B12 = not initialised
03.12 PP 1 TEMP Measured IGBT temperature of inverter module no. 1 1=1 87 R
ºC Temperature
03.13 PP 2 TEMP Measured IGBT temperature of inverter module no. 2 1=1 88 R
ºC Temperature
03.14 PP 3 TEMP Measured IGBT temperature of inverter module no. 3 1=1 89 R
ºC Temperature
03.15 PP 4 TEMP Measured IGBT temperature of inverter module no. 4 1=1 90 R
ºC Temperature
03.16 CTRL BOARD TEMP Control board (RMIO) temperature 1 = 1ºC 91 R
ºC Temperature
03.18 TEMP DIF MAX Maximum phase temperature difference 1 = 1ºC 93 R
ºC Temperature
03.19 PHASE U TEMP DIF Temperature difference between individual module phase U and 1 = 1ºC 94 R
the average temperature of the rest of the modules
ºC Temperature
03.20 PHASE V TEMP DIF Temperature difference between individual module phase V and 1 = 1ºC 95 R
the average temperature of the rest of the modules
ºC Temperature
03.21 PHASE W TEMP DIF Temperature difference between individual module phase W and 1 = 1ºC 96 R
the average temperature of the rest of the modules
ºC Temperature
03.31 LSU ACT SIGNAL 1 Line-side converter signal selected by parameter 95.03 LSU PAR1 1 = 1 I
SEL. This signal is active only when parameter 95.05 LSU COMM
SEL = LIMITED.
Actual signals and parameters
139
Index Name/Value Description FbEq PB T
-32768...32767 Signal value
03.32 LSU ACT SIGNAL 2 Line-side converter signal selected by parameter 95.04 LSU PAR2 1 = 1 I
SEL. This signal is active only when parameter 95.05 LSU COMM
SEL = LIMITED.
-32768...32767 Signal value
03.33 FOLLOWER2 MSW 08.01 MAIN STATUS WORD of Follower 2 drive. 1=1 Pb
0...65535 Signal value
03.34 FOLLOWER2 ACT2 Actual value 2 of Follower 2 drive. Signal source is selected by 1=1 I
parameter 70.10 MASTER SIGNAL 2 in the Follower 2 drive.
-32768...32767 Signal value
03.35 FOLLOWER2 ACT3 Actual value 3 of Follower 2 drive. Signal source is selected by 1=1 I
parameter 70.11 MASTER SIGNAL 3 in the Follower 2 drive.
-32768...32767 Signal value
03.36 FOLLOWER3 MSW 08.01 MAIN STATUS WORD of Follower 3 drive. 1=1 Pb
0...65535 Signal value
03.37 FOLLOWER3 ACT2 Actual value 2 of Follower 3 drive. Signal source is selected by 1=1 I
parameter 70.10 MASTER SIGNAL 2 in the Follower 3 drive.
-32768...32767 Signal value
03.38 FOLLOWER3 ACT3 Actual value 3 of Follower 3 drive. Signal source is selected by 1=1 I
parameter 70.11 MASTER SIGNAL 3 in the Follower 3 drive.
-32768...32767 Signal value
03.39 FOLLOWER4 MSW 08.01 MAIN STATUS WORD of Follower 4 drive. 1=1 Pb
0...65535 Signal value
03.40 FOLLOWER4 ACT2 Actual value 2 of Follower 4 drive. Signal source is selected by 1=1 I
parameter 70.10 MASTER SIGNAL 2 in the Follower 4 drive.
-32768...32767 Signal value
03.41 FOLLOWER4 ACT3 Actual value 2 of Follower 4 drive. Signal source is selected by 1=1 I
parameter 70.11 MASTER SIGNAL 3 in the Follower 4 drive.
-32768...32767 Signal value
03.42 FOLL234 MSW Main Status Word of Followers 2…4 combined together. See bit 1=1 Pb
definitions from signal 08.01 MAIN STATUS WORD.
Following bits of Main Status Words have OR function:
- bit 3 TRIPPED
- bit 6 ON INHIB
- bit 7 ALARM
- bit 13 RUN INTERLOCK
- bit 15
Rest of the bits have then AND function and result of these is
written to this signal 03.42 FOLL234 MSW.
Example:
Follower 2: 08.01 MSW 0101 0101 0011 0111
Follower 3: 08.01 MSW 0000 0000 0011 1000
Master: 03.42 FOLL234 MSW 0000 0000 0011 1000
0...65535 Signal value.
Actual signals and parameters
140
Index Name/Value Description FbEq PB T
04 INFORMATION Program versions
04.01 SW PACKAGE VER Displays the type and the version of the firmware package in the - C
drive.
AMXR72x0
Product
A = Inverter software
D = DC drives software
I = Input bridge software
L = Large Drives software
Software application
B = Multi Block Programming Application
J = Cascade Control
M = System Control
N = PMSM System Control
P = Motion Control
S = Standard Control
T = FCB Application Template
U = Liquid Cooling Unit Application
Inverter hardware type
A = Custom Application Software
X = Multiple hardware (single drive & multidrive)
7 = ACS800-07/11/14/17LC (liquid cooled)
Control board type
A = NAMC-03 or NAMC-04 control board
M =NAMC-03 or NAMC-04 control board
B = NAMC-2x control board
C = AMC 3 control board
D = N2AC AMC board
E = NAMC-11 control board
G = NAMC-51 control board
R = RMIO control board
Software version number
04.02 DTC SW VERSION Motor control software version. This fixed part of the application - C
program consists of motor control, operational system,
communication control of the DDCS channels and Modbus
software for the control panel.
04.03 APPLIC SW VERSION Displays the type and the version of the application program. - C
04.04 APBU EPLD Displays the APBU logic software version. APBU branching unit is C
VERSION used with parallel connected inverter modules. Signal value is
updated only after the PPCC link has been successful established.
04.09 INVERTER TYPE Displays the downloaded inverter type. - C
04.11 BOARD TYPE Displays the RMIO board type. - C
04.12 PARAMETER CRC Calculated checksum of parameter values. No actual signals are 1=1 Pb
included in checksum calculation.
0…65535
Actual signals and parameters
141
Index Name/Value Description FbEq PB T
05 LSU SIGNALS These Line Supply Unit signals and inputs are visible with WIDE
and WTA selection in parameter 95.05 LSU COMM SEL when
optic fibre communication link is connected between inverter RMIO
control board CH1 and LSU RMIO control board CH0. Data sets
are used to transfer information in communication. See parameter
group 95 LSU.
05.01 MAINS VOLTAGE [V] Line to line voltage calculated by the line converter and sent to INU 1 = 1 V I
every 100 ms. The value of parameter 92.05 D SET 13 VAL 2 must
be 111 in LSU.
V Voltage
05.02 LINE CURRENT [A] Line current measured by the line supply unit and sent to INU every 1 = 1 A I
100 ms. The value of parameter of 92.06 D SET 13 VAL 3 must be
106 in LSU.
A Current
05.03 POWER [kW] Grid power calculated by the line supply unit and sent to INU every 1 = 1 kW I
10 ms. The value of parameter 92.02 D SET 11 VAL 2 must be 108
in LSU.
kW Power in kilowatts.
05.04 REACT POWER Reactive grid power calculated by the line supply unit and sent to 1 = 1 kVAr I
[kVAr] INU every 10ms. Positive value = capacitive, negative = reactive.
The value of parameter 92.03 D SET 11 VAL 3 must be 107 in LSU.
kVAr Reactive power
05.05 LSU PP TEMP Power plate temperature of line supply unit, sent to INU every 500 1 = 1 °C I
ms. The value of parameter 92.12 D SET 17 VAL 3 must be 112 in
LSU.
°C Temperature
05.06 LSU DI STATUS Status of line converter digital inputs DI7…DI1, sent to INU every 1=1 I
100 ms. The value of parameter 92.04 D SET 13 VAL 1 must be
115 in LSU.
0...127 (bin) Example: 0001001 = DI1 and DI4 are on.
0001001
DI7 DI1
DI6 DI2
DI5 DI3
DI4
05.07 LSU ACT1 Programmable signal by LSU parameter 92.07 D SET 15 VAL 1, 1=1 I
sent to INU every 100 ms.
-32768...32767
05.08 LSU ACT2 Programmable signal by LSU parameter 92.08 D SET 15 VAL 2, 1=1 I
sent to INU every 100 ms.
-32768...32767
05.09 LSU ACT3 Programmable signal by LSU parameter 92.09 D SET 15 VAL 3, 1=1 I
sent to INU every 100 ms.
-32768...32767
05.10 LSU STATUS WORD Signal 08.01 MAIN STATUS WORD in LSU. 1=1 Pb
Actual signals and parameters
142
Index Name/Value Description FbEq PB T
0...65535 Main status word of the line converter, sent to INU every 10 ms.
The parameter 92.01 D SET 11 VAL 1 must be 801 in LSU.
Bit Name Value Description
0 RDY_ON 1 Ready to switch on = no fault
0 Not ready to switch on = fault
1 RDY_RUN 1 Ready to operate = DC bus charged
0 Not ready to opearate
2 RDY_REF 1 Operation enabled
0 -
3 TRIPPED 1 Fault
0 No fault
4…6 Not in use
7 ALARM 1 Warning
0 No warning
8 MODULATING 1 Converter modulates.
0 Converter is not modulating.
9 REMOTE 1 Drive control location: REMOTE
0 Drive control location: LOCAL
10 NET OK 1 Network voltage is OK.
0 Network voltage is lost.
11…12 Not in use
13 CHARGING Combines bits 14 and 1.
OR RDY_RUN
1 Ready to operate = DC bus charged
or
Charging contactor closed
0 Not ready to operate
or
Charging contactor open
14 CHARGING 1 Charging contactor closed
0 Charging contactor open
15 Not in use
05.11 LSU FAULT WORD Supply fault word of the line converter, sent to INU every 500 ms. 1=1 PbI
The parameter 92.10 D SET 17 VAL 1 must be 911 in LSU.
Actual signals and parameters
143
Index Name/Value Description FbEq PB T
0...65535
Bit Name Description
0 CHARGING FLT DC link short-circuit during charging
1 OVERCURRENT Overcurrent
2 EXT EVENT DI5 External fault indicated via digital
input DI5
3 ACS 800 TEMP IGBT overtemperature
4 EXT EVENT DI4 External fault indicated via digital
input DI4
5 DI1 Fan failure. Fault is activated 5
seconds after failure.
6 MAIN CNT FLT Main contactor failure
7 SHORT CIRC Short-circuit in the main circuit
8 Internal fault Internal fault. If this bit is 1, write down
the fault message from the fault
logger and contact your local ABB
representative.
9 NET VOLT FLT Supply voltage out of range during
synchronisation
10 COMM MODULE Communication error between drive
and type Rxxx fieldbus module or
between drive and external control
system..
11 EXT EVENT DI7 External fault indicated via digital
input DI7
12 EARTH FAULT Internally detected earth (ground)
fault
13 SYNCHRO FLT Synchronisation to supply failed
14 DC UNDERVOLT Intermediate circuit DC undervoltage
15 DC OVERVOLT Intermediate circuit DC overvoltage
05.12 LSU ALARM WORD Supply alarm word of the line converter, sent to INU every 500 ms. 1 = 1 Pb
The parameter 92.11 D SET 17 VAL 2 must be 912 in LSU.
Actual signals and parameters
144
Index Name/Value Description FbEq PB T
0...65535
Bit Name Description
0 COMM MODULE Communication break detected
1 PANEL LOST Local control lost
2 DI1 DI1 alarm. Alarm is activated 0.5
seconds after failure.
3 AI<MIN FUNC Current below 4 mA (4 mA minimum
selected)
4 ACS 800 TEMP IGBT overtemperature
5 CURRENT LIM Current limit exceeded
6…9 Not in use
10 NET LOST Network voltage lost
11 EXT EVENT DI7 External fault indicated via digital input
DI7
12 Not in use
13 EARTH FAULT Internally detected earth (ground) fault
EXT EVENT DI4 External fault indicated via digital input
DI4
14 EXT EVENT DI5 External fault indicated via digital input
DI5
15 Not in use
05.13 LSU CONTROL Main control word of the line converter, sent to LSU every 10 ms. 1=1 Pb
WORD The parameter 90.01 D SET 10 VAL 1 must be 701 in LSU.
0...65535
Bit Name Value Description
0 ON/OFF 0 -> 1 Start charging (close charging contactor).
0 Open main contactor (switch power off).
1…2 Not in use
3 START 1 Start modulation
0 Stop modulation
4…6 Not in use
7 RESET 0 -> 1 Reset
0 -
8…15 Not in use
05.21 LSU REF1 Writes an additional reference to data set 12.1 of LSU or WTA. 1=1 I
Sent to LSU every 100 ms.
-32768...32767
05.22 LSU REF2 Writes an additional reference to data set 12.2 of LSU or WTA. 1=1 I
Sent to LSU every 100 ms.
-32768...32767
05.23 LSU REF3 Writes an additional reference to data set 12.3 of LSU or WTA. 1=1 I
Sent to LSU every 100 ms.
Actual signals and parameters
145
Index Name/Value Description FbEq PB T
-32768...32767
05.24 LSU ACT4 Reads a data value from data set 19.01 of LSU or WTA every 500 1 = 1 I
ms. Programmable signal by LSU or WTA parameter 92.13 D SET
19 VAL 1.
-32768...32767
05.25 LSU ACT5 Reads a data value from data set 19.02 of LSU or WTA every 500 1 = 1 I
ms. Programmable signal by LSU or WTA parameter 92.13 D SET
19 VAL 1.
-32768...32767
05.26 LSU ACT6 Reads a data value from data set 19.3 of LSU or WTA every 500 1=1 I
ms. Programmable signal by LSU or WTA parameter 92.13 D SET
19 VAL 1.
-32768...32767
07 CONTROL WORDS ABB Drive Profile Control Words. See chapter Fieldbus control.
07.01 MAIN CTRL WORD Main Control Word (MCW). A 16-bit data word. - Pb
0...65535 Control word value
MAIN CONTROL WORD (MCW)
Bit Name Value Enter state / Description
0 ON 1 Enter RDY RUN state (08.01 MSW bit 1). IGBT or diode supply unit is started (supported
only with ACS800 multidrive and liquid cooled single drives.)
OFF1 0 Enter OFF state (08.01 MSW bit 0): Stop along the deceleration ramp defined by
parameter 22.02 DECELER TIME. Control pulses are removed at zero speed. Proceed to
READY TO SWITCH ON state unless other interlocks (OFF2, OFF3) are active.
IGBT or diode supply unit is stopped (supported only with ACS800 single drives).
Note: Restart is not possible before the drive has decelerated to zero speed.
1 OFF2 1 OFF2 inactive (08.01 MSW bit 4)
0 Emergency OFF: Coast to stop. Enter OFF2 ACTIVE (08.01 MSW bit 4); proceed to ON
INHIB (08.01 MSW bit 6).
Stator and flux currents are set to zero and control pulses are removed.
2 OFF3 1 OFF3 inactive (08.01 MSW bit 5).
0 Emergency Stop: Stop along the deceleration ramp defined by parameter 21.04 EME
STOP MODE (fast stop). Stator and flux currents are set to zero and control pulses are
removed. Enter OFF3 ACTIVE (08.01 MSW bit 5); proceed to ON INHIB (08.01 MSW
bit 6).
Warning: Ensure motor and driven machine can be stopped using this stop mode.
See also section Emergency stop on page 67.
3 RUN 1 Enable operation. Enter RDY REF (08.01 MSW bit 2). Enable stator/armature pulses.
Raise flux to the nominal reference value, accelerate along speed ramp to the given
speed reference (Par. 23.01 SPEED REF).
Note: The Run Enable signal must be activated via digital input DI2 and the RUN
INTERLOCK function must deactivated by parameter 16.14 RUN INTERLOCK (08.01
MSW bit 13).
0 Inhibit operation, coast to stop. Enter operation inhibited (08.01 MSW bit 2 RDY REF
value is 0). Continue to RDY RUN state (08.01 MSW bit 1).
Actual signals and parameters
146
MAIN CONTROL WORD (MCW)
Bit Name Value Enter state / Description
4 RAMP OUT 1 Enter RFG: OUTPUT ENABLED.
ZERO See control block diagram in section Speed reference ramp on page 314.
0 Force Ramp Function Generator output to zero. Stop along ramp (current and DC voltage
limits are in force).
See control block diagram in section Speed reference ramp on page 314.
5 RAMP HOLD 1 Enable ramp function. Enter RFG: ACCELERATOR ENABLED.
See control block diagram in section Speed reference ramp on page 314.
0 Stop Ramp Function Generator (Ramp Function Generator output held).
See control block diagram in section Speed reference ramp on page 314.
6 RAMP IN 1 Enter OPERATING.
ZERO See control block diagram in section Speed reference ramp on page 314.
0 Inhibit setpoint (= speed or frequency reference). Input of the speed ramp is forced to
zero.
See control block diagram in section Speed reference ramp on page 314.
7 RESET 1 Fault reset (0 -> 1) if an active fault exists. Enter ON INHIB (08.01 MSW bit 6).
0 Continue normal operation.
8 INCHING 1 1 Accelerate to inching setpoint 1 (defined by parameter 23.02 CONST SPEED 1).
The following conditions must be fulfilled:
- bit 4 RAMP OUT ZERO = 0
- bit 5 RAMP HOLD = 0
- bit 6 RAMP IN ZERO = 0
See control block diagram in section Speed reference ramp on page 314.
0 Decelerate to zero speed.
9 INCHING 2 1 Accelerate to inching setpoint 2 (defined by parameter 23.03 CONST SPEED 2).
The following conditions must be fulfilled:
- bit 4 RAMP OUT ZERO = 0
- bit 5 RAMP HOLD = 0
- bit 6 RAMP IN ZERO = 0
See control block diagram in section Speed reference ramp on page 314.
0 Decelerate to zero speed.
10 REMOTE 1 External control enabled
CMD 0 No control from external system (exception: OFF1, OFF2 and OFF3 commands)
11...15 Not in use
Actual signals and parameters
147
Index Name/Value Description FbEq PB T
07 CONTROL WORDS ABB Drive Profile Control Words. See chapter Fieldbus control.
07.02 AUX CTRL WORD 1 Auxiliary Control Word 1 (ACW 1). A 16-bit data word. - Pb
Bit Name Description
0 RESTART Data logger 1 control: restart.
DLOG
1 TRIGG Data logger 1 control: trigger.
LOGGER
2 RAMP BYPASS Speed reference ramp is bypassed.
3 BAL RAMP Force speed ramp output to the value defined by
OUT parameter 22.08 BAL RAMP REF.
4 FLUX ON DC DC flux ON. (DC flux OFF: 07.02 ACW 1 bit 4
and 07.01 MCW bit 3, RUN, values must be 0.)
5 FLUX ON Flux ON (zero torque).
6 HOLD NCONT Hold integral part of the PI controller.
7 WINDOW Activate window control.
CTRL
8 BAL NCONT Force external value to the output of the speed
controller.
9 SYNC Position counter control: synchronise command
COMMAND
10 SYNC Position counter control: synchronise command
DISABLE disabled
11 RESET SYNC Position counter control: synchronous ready
RDY command reset
12 ENABLE Speed reference select: 23.17 RAMPED INCH
RAMPED INCH REF. See control block diagram in section
REF Speed reference on page 313.
13 DO1 CONTROL RMIO digital output DO1 control. See
parameters 14.01 DO1 CONTROL, 14.02 DO1
GROUP+INDEX and 98.03 DI/O EXT
MODULE 1.
14 DO2 CONTROL RMIO digital output DO2 control. See
parameters 14.04 DO2 GROUP+INDEX and
98.03 DI/O EXT MODULE 1.
15 DO3 CONTROL RMIO digital output DO3 control. See
parameters 14.06 DO3 GROUP+INDEX and
98.04 DI/O EXT MODULE 2.
0...65535 Control word value
Actual signals and parameters
148
Index Name/Value Description FbEq PB T
07.03 AUX CTRL WORD 2 Auxiliary Control Word 2 (ACW 2). A 16-bit data word. - Pb
Bit Name Description
0 EXT1 DO1 RDIO Extension module 1 digital output DO1
CONTROL control
1 EXT1 DO2 RDIO Extension module 1 digital output DO2
CONTROL control
2 EXT2 DO1 RDIO Extension module 2 digital output DO1
CONTROL control
3 EXT2 DO2 RDIO Extension module 2 digital output DO2
CONTROL control
4...5 Not in use
6 FOLL REF SEL 1 = Follower speed and torque reference
ACW2 according to bits 7 (FOLL SPEED REF) and
8 (FOLL TORQ REF).
0 = Follower speed and torque reference
sources according to parameters 70.17
FOLL SPEED REF and 70.18 FOLL TORQ
REF. See control block diagrams in sections
Speed reference on page 313 and Torque
reference on page 316.
7 FOLL SPEED 1 = Follower speed reference is 02.19 DS
REF SPEED REF.
0 = Follower speed reference is 23.01
SPEED REF.
Used speed reference is indicated by signal
02.27 USED SPEED REF.
See control block diagram in section Speed
reference on page 313.
8 FOLL TORQ 1 = Follower torque reference is 02.20 DS
REF TORQ REF A.
0 = Follower torque reference is 25.01
TORQUE REF A.
Used torque reference is indicated by signal
02.28 USED TORQ REF A.
See control block diagram in section Torque
reference on page 316.
9 FOLL SPD 1 = Load share function with speed
CORR ENA controlled Follower drive is active. See
control block diagram in section Speed
reference ramp on page 314. 0 = Inactive
10 MASTER 1 = Drive is the Master of the channel CH2
communication link if value of bit 6 FOLL
REF SEL ACW2 is 1. 0 = Inactive
11 FOLLOWER 1 = Drive is the Follower of the channel CH2
communication link if value of bit 6 FOLL
REF SEL ACW2 is 1. 0 = Inactive
12 USER MACRO Macro change: 1 = macro 2, 0 = macro 1
CTRL See activation parameter 16.05 USER
MACRO CHG.
13 OSC See parameter 26.04 OSC
COMPENSATION COMPENSATION.
14...15 Not in use
Actual signals and parameters
149
Index Name/Value Description FbEq PB T
0...65535 Control word value
08 STATUS WORDS ABB Drive Profile Status Words. See chapter Fieldbus control.
08.01 MAIN STATUS WORD Main Status Word (MSW). A 16-bit data word. - Pb
0...65535 Status word value
MAIN STATUS WORD (MSW)
Bit Name Value Description
0 RDY ON 1 Ready to switch on. If the inverter unit has an internal control link to the start/stop
control of the IGBT supply unit or diode bridge unit: power supply is switched on.
OFF 0 Not ready to switch on. This state is active as long as the Emergency OFF or
Emergency Stop commands are active (OFF2 or OFF3). See par. 98.02 COMM
PROFILE.
If the inverter unit has an internal control link to the start/stop control of the IGBT
supply unit or diode bridge unit: power supply is switched off.
1 RDY RUN 1 Ready to operate
0 Not ready to operate
2 RDY REF 1 Operation enabled: RUNNING. The drive follows the given reference.
0 Operation inhibited
3 TRIPPED 1 Fault. The TRIPPED state is active until the fault is RESET.
Activate SWC ON INHIB state.
0 No fault
4 OFF2 STA 1 OFF2 inactive
0 OFF2 active
5 OFF3 STA 1 OFF3 inactive
0 OFF3 active
6 ON INHIB 1 Switch on inhibited. State is activated after Emergency OFF or Emergency Stop or
TRIPPED state. Enter OFF state.
0 No switch on inhibition
7 ALARM 1 Alarm
0 No alarm
8 AT SETPOINT 1 OPERATING. 01.04 MOTOR SPEED equals 02.18 SPEED REF4 within tolerance
limits. Default setting for the tolerance is 10% of the motor nominal speed.
0 01.04 MOTOR SPEED differs from 02.18 SPEED REF4, i.e. the difference is outside
the tolerance limits. Default setting for the tolerance is 10% of the motor nominal
speed.
9 REMOTE 1 Drive control location: remote
0 Drive control location: local
10 ABOVE LIMIT 1 Actual speed or frequency value equals or is greater than the supervision limit
defined by parameter 50.10 SPEED ABOVE LIMIT. Valid in both rotation directions
regardless of parameter 50.10 value.
0 Actual frequency or speed value is within supervision limit.
11 SELECTABLE MAIN STATUS WORD parameter 66.06
12 INTERNAL 1 Motor parameters have been set and Safe Torque Off function is active.
INTERLOCK 0 Motor parameters have not been set and/or Safe Torque Off function is inactive.
Actual signals and parameters
150
MAIN STATUS WORD (MSW)
Bit Name Value Description
13 RUN 1 RUN INTERLOCK. Run Interlock can be activated by parameter 16.14 RUN
INTERLOCK INTERLOCK using e.g. adaptive programming or by opening DI2, if parameter 16.01
RUN ENABLE = INTERLOCK.
0 No RUN INTERLOCK.
14 MODULATING 1 Modulating: IGBTs are controlled, i.e. the drive is RUNNING.
0 No modulation: IGBTs are not controlled.
15 Not in use
Index Name/Value Description FbEq PB T
08 STATUS WORDS ABB Drive Profile Status Words. See chapter Fieldbus control.
08.02 AUX STATUS WORD Auxiliary Status Word (ASW). A 16-bit data word. - Pb
Bit Name Description
0 LOGG DATA 1 = Data logger 1 is triggered.
READY 0 = Data logger 1 is running.
1 OUT OF WINDOW Speed difference is out of the allowed
window.
2 EMERG STOP Emergency stop function has failed.
COAST
3 MAGNETIZED Flux has been formed in the motor.
If parameter 21.01 START FUNCTION =
CNST DC MAGN magnetisation time has
elapsed.
4 RUN DISABLE Operation disabled. RUN ENABLE signal
connected to digital input DI2 is not active.
5 SYNC RDY Position counter is synchronised.
6 1 START NOT FIRST START has not been performed after
DONE the motor parameters in group 99 START-UP
DATA have been changed.
7 IDENTIF RUN Motor ID run is successfully completed.
DONE
8 START Safe Torque Off is active.
INHIBITION
9 LIMITING Control is at a limit. See actual signals 08.03
LIMIT WORD 1 and 08.04 LIMIT WORD 2.
10 TORQ CONTROL Torque reference is being followed.
11 ZERO SPEED Absolute value of motor actual speed is
below the zero speed limit defined by
parameter 20.03 ZERO SPEED LIMIT
(default: 4% of the synchronous speed).
12 INTERNAL Internal speed feedback is being followed.
SPEED FB
13 CH2 COMM LOSS Channel CH2 (Master/Follower link)
communication error
14 USER MACRO 1 User macro 1 is activate.
15 USER MACRO 2 User macro 2 is activate.
0...65535 Status word value
Actual signals and parameters
151
Index Name/Value Description FbEq PB T
08.03 LIMIT WORD 1 Limit word. A 16-bit data word. - Pb
Bit Name Active Limit
0 TORQ MOTOR LIM Pull-out limit
1 SPC TORQ MIN LIM Speed control torque minimum limit
2 SPC TORQ MAX LIM Speed control torque maximum limit
3 TORQ USER CUR LIM User-defined current limit
4 TORQ INV CUR LIM Internal current limit
5 TORQ MIN LIM Any torque minimum limit
6 TORQ MAX LIM Any torque maximum limit
7 TREF TORQ MIN LIM Torque reference minimum limit
8 TREF TORQ MAX LIM Torque reference maximum limit
9 FLUX MIN LIMIT Flux reference minimum limit
10 FREQ MIN LIMIT Speed/Frequency minimum limit
(valid in torque control)
11 FREQ MAX LIMIT Speed/Frequency maximum limit
(valid in torque control)
12 DC UNDERVOLT LIM DC undervoltage limit
13 DC OVERVOLT LIM DC overvoltage limit
14 TORQUE LIMIT Any torque limit
15 FREQ LIMIT Any speed/frequency limit
0...65535 Limit word value
08.04 LIMIT WORD 2 Limit word. A 16-bit data word. - Pb
Bit Name Active Limit
0 P MOTORING LIM Power limit (motoring)
1 P GENERATING LIM Power limit (generating)
2 FOLL SPD COR MIN Output of the signal FOLL SPD
CORR OUT is at minimum limit.
3 FOLL SPD COR MAX Output of the signal FOLL SPD
CORR OUT is at maximum limit.
4...15 Not in use
0...65535 Limit word value
Actual signals and parameters
152
Index Name/Value Description FbEq PB T
08.05 DI STATUS WORD Digital input status word. A 16-bit data word. - Pb
Bit Name Description
0 DI1 RMIO board digital input DI1 status
1 DI2 RMIO board digital input DI2 status
2 DI3 RMIO board digital input DI3 status
3 DI4 RMIO board digital input DI4 status
4 DI5 RMIO board digital input DI5 status
5 DI6 RMIO board digital input DI6 status
6 EXT1_DI1 Optional Digital I/O Extension Module 1 RDIO
digital input DI1 status *
7 EXT1_DI2 Optional Digital I/O Extension Module 1 RDIO
digital input DI2 status *
8 EXT1_DI3 Optional Digital I/O Extension Module 1 RDIO
digital input DI3 status *
9 EXT2_DI1 Optional Digital I/O Extension Module 2 (RDIO)
digital input DI1 status *
10 EXT2_DI2 Optional Digital I/O Extension Module 2 (RDIO)
digital input DI2 status *
11 EXT2_DI3 Optional Digital I/O Extension Module 2 (RDIO)
digital input DI3 status *
12 DI7 (DIIL) RMIO digital input DI7 status
13... Not in use
15
*See parameters 98.03...98.04 and section Digital inputs on page 55.
0...65535 Status word value
08.06 AUX STATUS Auxiliary Status Word 2 (ACW 2). A 16-bit data word. - Pb
WORD 2 Bit Name Description
0 FAN ON Motor fan control via digital output. See parameter
CMD group 35 MOTOR FAN CTRL.
1...15 Not in use
0...65535 Status word value
Actual signals and parameters
153
Index Name/Value Description FbEq PB T
08.07 LIMIT WORD INV A 16-bit data word. The LIMIT WORD INV includes information on - Pb
the internal current limits. If any of the bit values are 1, signal
08.03 LIMIT WORD 1 bit 4 TORQ INV CUR LIM is set to 1.
Bit Name Description
0...1 Not in use
2 INT LOW FREQ Current limit at high IGBT temperature with
low output frequency (<10 Hz). Temperature
model is not active.
3 INTG PP TEMP Current limit at high IGBT temperature.
Temperature model is not active.
4 PP OVER Current limit at high IGBT temperature.
TEMP Temperature model is active.
5 PP OVERLOAD Current limit at high IGBT junction to case
temperature. Temperature model is active. If
the IGBT junction to case temperature
continues to rise in spite of the current
limitation, PP OVERLOAD alarm or fault
occurs.
6 INV POW LIM Current limit at inverter output power limit
7 INV TRIP CUR Current limit at inverter overcurrent trip limit
8 OVERLOAD Maximum inverter overload current limit. See
CUR parameter 20.04 MAXIMUM CURRENT.
9 CONT DC CUR Continuous DC current limit
10 CONT OUT Continuous output current limit (Icont.max)
CUR
11 CONT DC CUR Maximum continuous output current limited
due to reduced run function
12 CONT OUT Maximum output current limited due to
CUR reduced run function
13... Not in use
15
0...65535 Limit word value
08.10 MAIN STATUS Main Status Word 2. A 16-bit data word. Bits 0…7, 9, 11…13 are - Pb
WORD2 same as 08.01 MAIN STATUS WORD.
Bit Name Description
8 LIMITING Some torque limit is active.
10 GRID ALARM If LSU is used, this bit indicates active grid
alarm.
14 TOGGLE BIT 100 ms toggle bit for communication
supervision.
0...65535 Status word value
Actual signals and parameters
154
Index Name/Value Description FbEq PB T
08.20 INV ENABLED WORD A 16-bit data word. The INV ENABLED WORD includes - Pb
information on the inverter module operation status. The inverters
are ready for operation (i.e. all bit values are 1) when inverter
module DC switches are closed, DC intermediate circuit is
charged and the modules are allowed to start modulation.
The DC switch monitoring must be activated by parameter 98.12
FUSE SWITCH CTRL.
Bit Name Description
0 INV1 ENABLED Inverter module 1 ready for operation
1 INV2 ENABLED Inverter module 2 ready for operation
2 INV3 ENABLED Inverter module 3 ready for operation
3 INV4 ENABLED Inverter module 4 ready for operation
4 INV5 ENABLED Inverter module 5 ready for operation
5 INV6 ENABLED Inverter module 6 ready for operation
6 INV7 ENABLED Inverter module 7 ready for operation
7 INV8 ENABLED Inverter module 8 ready for operation
8 INV9 ENABLED Inverter module 9 ready for operation
9 INV10 ENABLED Inverter module 10 ready for operation
10 INV11 ENABLED Inverter module 11 ready for operation
11 INV12 ENABLED Inverter module 12 ready for operation
12... Not in use
15
08.21 START INHIBI WORD A 16-bit data word. The START INHIBI WORD includes - Pb
information on the status of the Safe Torque Off circuit.
Bit Name Description
0 INV1 START INHIB Start of the inverter module 1 is inhibited
1 INV2 START INHIB Start of the inverter module 2 is inhibited
2 INV3 START INHIB Start of the inverter module 3 is inhibited
3 INV4 START INHIB Start of the inverter module 4 is inhibited
4 INV5 START INHIB Start of the inverter module 5 is inhibited
5 INV6 START INHIB Start of the inverter module 6 is inhibited
6 INV7 START INHIB Start of the inverter module 7 is inhibited
7 INV8 START INHIB Start of the inverter module 8 is inhibited
8 INV9 START INHIB Start of the inverter module 9 is inhibited
9 INV10 START INHIB Start of the inverter module 10 is inhibited
10 INV11 START INHIB Start of the inverter module 11 is inhibited
11 INV12 START INHIB Start of the inverter module 12 is inhibited
12... Not in use
15
0...65535 Status word value
Actual signals and parameters
155
Index Name/Value Description FbEq PB T
08.22 INT CONFIG WORD A 16-bit data word. The INT CONFIG WORD includes information - Pb
on the number of inverter modules connected to the APBU
branching unit. INT CONFIG fault is activated if the number of R8i
inverter modules recognized by application program during PPCC
link initialisation is not equal to original number of inverters. See
section Reduced run function on page 83.
Bit Name Description
0 INT1 Inverter module 1 INT board is recognised by the
application program during PPCC link initialisation
1 INT2 Inverter module 2 INT board is recognised by the
application program during PPCC link initialisation
2 INT3 Inverter module 3 INT board is recognised by the
application program during PPCC link initialisation
3 INT4 Inverter module 4 INT board is recognised by the
application program during PPCC link initialisation
4 INT5 Inverter module 5 INT board is recognised by the
application program during PPCC link initialisation
5 INT6 Inverter module 6 INT board is recognised by the
application program during PPCC link initialisation
6 INT7 Inverter module 7 INT board is recognised by the
application program during PPCC link initialisation
7 INT8 Inverter module 8 INT board is recognised by the
application program during PPCC link initialisation
8 INT9 Inverter module 9 INT board is recognised by the
application program during PPCC link initialisation
9 INT10 Inverter module 10 INT board is recognised by the
application program during PPCC link initialisation
10 INT11 Inverter module 11 INT board is recognised by the
application program during PPCC link initialisation
11 INT12 Inverter module 12 INT board is recognised by the
application program during PPCC link initialisation
12... Not in use
15
0...65535 Status word value
Actual signals and parameters
156
Index Name/Value Description FbEq PB T
08.23 LSU STATUS WORD A 16-bit data word. The LCU (= IGBT or diode supply unit) Status - Pb
Word includes information on the line-side converter status.
Bit Name Description
0 RDY_ON Ready to switch on (no fault)
1 RDY_RUN Ready to operate
2 RDY_REF Operation enabled
3 TRIPPED Fault
4...6 Not in use
7 ALARM Alarm
8 MODULATING Modulating
9 REMOTE Drive control: remote
10 NET OK Network voltage is OK.
11...13 Not in use
14 CHARGING Charging contactor is closed.
15 Not in use
0...65535 Status word value
Actual signals and parameters
157
Index Name/Value Description FbEq PB T
09 FAULT WORDS ABB Drive Profile Fault Words. For the possible causes and
remedies, see chapter Fault tracing.
09.01 FAULT WORD 1 A 16-bit data word. - Pb
Bit Name Description
0 SHORT CIRC Short-circuit in the main circuit
1 OVERCURRENT Overcurrent
2 DC OVERVOLT Intermediate circuit DC overvoltage
3 ACS800 TEMP IGBT overtemperature
4 EARTH FAULT Earth (ground) fault or excessive output
current unbalance in inverter unit of several
parallel connected inverter modules.
5 MOTOR TEMP M Measured motor overtemperature
6 MOTOR TEMP Calculated motor overtemperature
7 SYSTEM FAULT System fault indicated by 09.03 SYSTEM
FAULT WORD
8 UNDERLOAD Underload
9 OVERFREQ Overspeed
10 MPROT SWITCH Motor protection switch has opened.
11 CH2 COMM LOSS Channel CH2 (Master/Follower link)
communication error
12 SC (INU1) Short circuit in inverter unit 1 of several
parallel connected inverter modules
13 SC (INU2) Short circuit in inverter unit 2 of several
parallel connected inverter modules
14 SC (INU3) Short circuit in inverter unit 3 of several
parallel connected inverter modules
15 SC (INU4) Short circuit in inverter unit 4 of several
parallel connected inverter modules
0...65535 Fault word value
Actual signals and parameters
158
Index Name/Value Description FbEq PB T
09.02 FAULT WORD 2 A 16-bit data word - Pb
Bit Name Description
0 SUPPLY PHASE DC voltage ripple in intermediate circuit is too
high.
1 NO MOTOR Motor data is not given or motor data does not
DATA match with inverter data (parameter group 99
START-UP DATA).
2 DC UNDERVOLT Intermediate circuit DC undervoltage
3 CABLE TEMP Motor cable overtemperature
4 RUN DISABLE No RUN ENABLE signal
5 ENCODER ERR Encoder communication error
6 IO COMM ERR I/O communication error
7 CTRL B TEMP RMIO control board overtemperature
8 SELECTABLE FAULT WORD2 parameter 66.41
9 OVER SWFREQ Switching frequency is too high
10 AI<MIN FUNC Analogue control signal is below minimum
allowed value.
11 PPCC LINK AINT board current measurement or
communication error between RMIO and AINT
12 COMM MODULE Communication error between drive and
R-type fieldbus module or between drive and
external control system
13 PANEL LOSS Control panel or DriveWindow selected as
active control location for drive has ceased
communicating.
14 MOTOR STALL Motor stall
15 MOTOR PHASE Motor phase loss
0...65535 Fault word value
Actual signals and parameters
159
Index Name/Value Description FbEq PB T
09.03 SYSTEM FAULT A 16-bit data word. - Pb
WORD Bit Name Description
0 FLT (F1_7) Factory default parameter file error
1 USER MACRO User macro file error
2 FLT (F1_4) FPROM operating error
3 FLT (F1_5) FPROM data error
4 FLT (F2_12) Internal time level 2 overflow (100 µs)
5 FLT (F2_13) Internal time level 3 overflow (1ms)
6 FLT (F2_14) Internal time level 4 overflow (50 ms)
7 FLT (F2_15) Internal time level 5 overflow (1 s)
8 FLT (F2_16) State machine overflow
9 FLT (F2_17) Application program execution error
10 FLT (F2_18) Application program execution error
11 FLT (F2_19) Illegal instruction
12 FLT (F2_3) Register stack overflow
13 FLT (F2_1) System stack overflow
14 FLT (F2_0) System stack underflow
15 Not in use
0...65535 Fault word value
09.04 ALARM WORD 1 A 16-bit data word - Pb
Bit Name Description
0 START INHIBI Safe Torque Off function
1 EM STOP Emergency stop
2 MOTOR TEMP M Measured motor overtemperature
3 MOTOR TEMP Calculated motor overtemperature
4 ACS800 TEMP IGBT overtemperature
5 ENCODER ERR Encoder communication error
6 T MEAS CIRC Motor temperature measurement circuit error
7 DIGITAL IO RMIO digital input error
8 ANALOG IO RMIO analogue input error
9 EXT DIGITAL IO RDIO digital I/O error
10 EXT ANALOG IO RAIO analogue I/O error
11 CH2 COMM Channel CH2 (Master/Follower link)
LOSS communication error
12 MPROT SWITCH Motor protection switch has opened.
13 EM STOP DEC Emergency stop deceleration error
14 EARTH FAULT Earth (ground) fault
15 SAFETY SWITC Safety switch is open.
0...65535 Alarm word value
Actual signals and parameters
160
Index Name/Value Description FbEq PB T
09.05 ALARM WORD 2 A 16-bit data word. - Pb
Bit Name Description
0 MOTOR FAN No external motor fan acknowledgement
signal
1 UNDERLOAD Underload
2 INV OVERLOAD Inverter overload ACS 600
3 CABLE TEMP Motor cable overtemperature
4 ENCODER A<>B Wrong pulse encoder phasing
5 FAN OVERTEMP Fan fault of sine filter
6 Not in use
7 POWFAIL FILE Error in restoring powerfail.ddf file
8 POWDOWN FILE Error in restoring powerdown.ddf file
9 MOTOR STALL Motor stall
10 AI<MIN FUNC Analogue control signal is below minimum
allowed value.
11 COMM MODULE Communication error between drive and
R-type fieldbus module or between drive
and external control system
12 BATT FAILURE APBU branching unit memory backup
battery error
13 PANEL LOSS Control panel or DriveWindow selected as
active control location for drive has ceased
communicating.
14 DC UNDERVOLT Intermediate circuit DC undervoltage
15 RESTARTED Motor has been restarted with AUTO
RESTART after a short power failure
0...65535 Alarm word value
Actual signals and parameters
161
Index Name/Value Description FbEq PB T
09.06 FAULT WORD 3 A 16-bit data word. - Pb
Bit Name Description
0 MOTOR FAN No external motor fan acknowledgement
signal
1 (Not in use) Only with ACS 600: Start inhibit HW event
2 SAFETY Safety switch is open in the motor circuit.
SWITCH
3 LINE CONV ERR Line-side converter error
4 T MEAS CIRC Motor temperature measurement circuit error
5 START INHIBI Safe Torque Off function is activated during
run or start command is given when Safe
Torque Off function is active. See section
Safe Torque Off function (STO) on page 69.
6 GD DISABLED X One of the AGPS power supply of the R8i
inverter module has been switched off during
drive run.
7 INT CONFIG Number of R8i inverter modules recognized
by application program during PPCC link
initialisation is not equal to original number of
inverters.
8 CHOKE OTEMP Excessive temperature of drive output filter
9 Not in use
10 ENCODER A<>B Wrong pulse encoder phasing
11 DC HIGH RUSH Excessive drive supply voltage
12 INV OVERTEMP Excessive temperature of inverter module
13 MOD CHOKE T Overtemperature in choke of liquid cooled
R8i inverter module
14 MOD BOARD T Overtemperature in AINT board of inverter
module.
15 TEMP DIFF Temperature difference. See 09.17 TEMP
DIF FLT WORD.
0...65535 Fault word value
09.07 FAULT WORD 4
Bit Name Description
0 EM STOP DEC Emergency stop deceleration fault.
Actual signals and parameters
162
Index Name/Value Description FbEq PB T
09.11 ALARM WORD 3 A 16-bit data word. - Pb
Bit Name Description
0...8, Not in use
10,11
9 SELECTABLE ALM WORD3 parameter 66.04
12 INV OVERTEMP Temperature alarm of inverter module
13 MOD CHOKE T Overtemperature in choke of liquid cooled
R8i inverter module
14 MOD BOARD T Overtemperature in AINT board of inverter
module.
15 TEMP DIFF Temperature difference. See 09.18 TEMP
DIF ALM WORD.
0...65535 Fault word value
Actual signals and parameters
163
Index Name/Value Description FbEq PB T
09.13 CURRENT UNBAL A 16-bit data word. Pb
FW Bit Name Description
0 CUR UNBAL 1 Excessive output current unbalance in inverter
module 1 of several parallel connected inverter
modules
1 CUR UNBAL 2 Excessive output current unbalance in inverter
module 2 of several parallel connected inverter
modules
2 CUR UNBAL 3 Excessive output current unbalance in inverter
module 3 of several parallel connected inverter
modules
3 CUR UNBAL 4 Excessive output current unbalance in inverter
module 4 of several parallel connected inverter
modules
4 CUR UNBAL 5 Excessive output current unbalance in inverter
module 5 of several parallel connected inverter
modules
5 CUR UNBAL 6 Excessive output current unbalance in inverter
module 6 of several parallel connected inverter
modules
6 CUR UNBAL 7 Excessive output current unbalance in inverter
module 7 of several parallel connected inverter
modules
7 CUR UNBAL 8 Excessive output current unbalance in inverter
module 8 of several parallel connected inverter
modules
8 CUR UNBAL 9 Excessive output current unbalance in inverter
module 9 of several parallel connected inverter
modules
9 CUR UNBAL 10 Excessive output current unbalance in inverter
module 10 of several parallel connected
inverter modules
10 CUR UNBAL 11 Excessive output current unbalance in inverter
module 11 of several parallel connected
inverter modules
11 CUR UNBAL 12 Excessive output current unbalance in inverter
module 12 of several parallel connected
inverter modules
12... Not in use
15
0...65535 Fault word value
Actual signals and parameters
164
Index Name/Value Description FbEq PB T
09.14 OVERCURRENT FW A 16-bit data word. 1=1 Pb
Bit Name Description
0 OVERCURR 1 Excessive input current in inverter module 1 of
several parallel connected inverter modules
1 OVERCURR 2 Excessive input current in inverter module 2 of
several parallel connected inverter modules
2 OVERCURR 3 Excessive input current in inverter module 3 of
several parallel connected inverter modules
3 OVERCURR 4 Excessive input current in inverter module 4 of
several parallel connected inverter modules
4 OVERCURR 5 Excessive input current in inverter module 5 of
several parallel connected inverter modules
5 OVERCURR 6 Excessive input current in inverter module 6 of
several parallel connected inverter modules
6 OVERCURR 7 Excessive input current in inverter module 7 of
several parallel connected inverter modules
7 OVERCURR 8 Excessive input current in inverter module 8 of
several parallel connected inverter modules
8 OVERCURR 9 Excessive input current in inverter module 9 of
several parallel connected inverter modules
9 OVERCURR 10 Excessive input current in inverter module 10
of several parallel connected inverter modules
10 OVERCURR 11 Excessive input current in inverter module 11
of several parallel connected inverter modules
11 OVERCURR 12 Excessive input current in inverter module 12
of several parallel connected inverter modules
12... Not in use
15
0...65535 Fault word value
Actual signals and parameters
165
Index Name/Value Description FbEq PB T
09.15 SHORT CIRC FW A 16-bit data word. 1=1 Pb
Bit Name Description
0 SC INV1 Short circuit in inverter module 1.
1 SC INV2 Short circuit in inverter module 2 of several
parallel connected inverter modules
2 SC INV3 Short circuit in inverter module 3 of several
parallel connected inverter modules
3 SC INV4 Short circuit in inverter module 4 of several
parallel connected inverter modules
4 SC INV5 Short circuit in inverter module 5 of several
parallel connected inverter modules
5 SC INV6 Short circuit in inverter module 6 of several
parallel connected inverter modules
6 SC INV7 Short circuit in inverter module 7 of several
parallel connected inverter modules
7 SC INV8 Short circuit in inverter module 8 of several
parallel connected inverter modules
8 SC INV9 Short circuit in inverter module 9 of several
parallel connected inverter modules
9 SC INV10 Short circuit in inverter module 10 of several
parallel connected inverter modules
10 SC INV11 Short circuit in inverter module 11 of several
parallel connected inverter modules
11 SC INV 12 Short circuit in inverter module 12 of several
parallel connected inverter modules
12 SC PHASE U Short circuit in phase U of the faulted inverter
module
13 SC PHASE V Short circuit in phase V of the faulted inverter
module
14 SC PHASE W Short circuit in phase W of the faulted inverter
module
15 Not in use
0...65535 Fault word value
Actual signals and parameters
166
Index Name/Value Description FbEq PB T
09.16 OVERTEMP FW A 16-bit data word. 1=1 Pb
Bit Name Description
0 ACS TEMP INV1 Overtemperature in inverter module 1 of
several parallel connected inverter modules
1 ACS TEMP INV2 Overtemperature in inverter module 2 of
several parallel connected inverter modules
2 ACS TEMP INV3 Overtemperature in inverter module 3 of
several parallel connected inverter modules
3 ACS TEMP INV4 Overtemperature in inverter module 4 of
several parallel connected inverter modules
4 ACS TEMP INV5 Overtemperature in inverter module 5 of
several parallel connected inverter modules
5 ACS TEMP INV6 Overtemperature in inverter module 6 of
several parallel connected inverter modules
6 ACS TEMP INV7 Overtemperature in inverter module 7 of
several parallel connected inverter modules
7 ACS TEMP INV8 Overtemperature in inverter module 8 of
several parallel connected inverter modules
8 ACS TEMP INV9 Overtemperature in inverter module 9 of
several parallel connected inverter modules
9 ACS TEMP INV10 Overtemperature in inverter module 10 of
several parallel connected inverter modules
10 ACS TEMP INV11 Overtemperature in inverter module 11 of
several parallel connected inverter modules
11 ACS TEMP INV12 Overtemperature in inverter module 12 of
several parallel connected inverter modules
12 OVERTEMP Overtemperature in phase U of the faulted
PHASE U inverter module
13 OVERTEMP Overtemperature in phase V of the faulted
PHASE V inverter module
14 OVERTEMP Overtemperature in phase W of the faulted
PHASE W inverter module
15 Not in use
0...65535 Fault word value
Actual signals and parameters
167
Index Name/Value Description FbEq PB T
09.17 TEMP DIF FW A 16-bit data word. 1=1 Pb
Bit Name Description
0 TEMP DIF INV1 Temperature difference fault in inverter
module 1 of several parallel connected
inverter modules
1 TEMP DIF INV2 Temperature difference fault in inverter
module 2 of several parallel connected
inverter modules
2 TEMP DIF INV3 Temperature difference fault in inverter
module 3 of several parallel connected
inverter modules
3 TEMP DIF INV4 Temperature difference fault in inverter
module 4 of several parallel connected
inverter modules
4 TEMP DIF INV5 Temperature difference fault in inverter
module 5 of several parallel connected
inverter modules
5 TEMP DIF INV6 Temperature difference fault in inverter
module 6 of several parallel connected
inverter modules
6 TEMP DIF INV7 Temperature difference fault in inverter
module 7 of several parallel connected
inverter modules
7 TEMP DIF INV8 Temperature difference fault in inverter
module 8 of several parallel connected
inverter modules
8 TEMP DIF INV9 Temperature difference fault in inverter
module 9 of several parallel connected
inverter modules
9 TEMP DIF INV10 Temperature difference fault in inverter
module 10 of several parallel connected
inverter modules
10 TEMP DIF INV11 Temperature difference fault in inverter
module 11 of several parallel connected
inverter modules
11 TEMP DIF INV12 Temperature difference fault in inverter
module 12 of several parallel connected
inverter modules
12 TEMP DIF PHASE Temperature difference fault in phase U of the
U faulted inverter module
13 TEMP DIF PHASE Temperature difference fault in phase V of the
V faulted inverter module
14 TEMP DIF PHASE Temperature difference fault in phase W of the
W faulted inverter module
15 Not in use
0...65535 Fault word value
Actual signals and parameters
168
Index Name/Value Description FbEq PB T
09.18 TEMP DIF AW A 16-bit data word. 1=1 Pb
Bit Name Description
0 TEMP DIF INV1 Temperature difference alarm in inverter
module 1 of several parallel connected inverter
modules
1 TEMP DIF INV2 Temperature difference alarm in inverter
module 2 of several parallel connected inverter
modules
2 TEMP DIF INV3 Temperature difference alarm in inverter
module 3 of several parallel connected inverter
modules
3 TEMP DIF INV4 Temperature difference alarm in inverter
module 4 of several parallel connected inverter
modules
4 TEMP DIF INV5 Temperature difference alarm in inverter
module 5 of several parallel connected inverter
modules
5 TEMP DIF INV6 Temperature difference alarm in inverter
module 6 of several parallel connected inverter
modules
6 TEMP DIF INV7 Temperature difference alarm in inverter
module 7 of several parallel connected inverter
modules
7 TEMP DIF INV8 Temperature difference alarm in inverter
module 8 of several parallel connected inverter
modules
8 TEMP DIF INV9 Temperature difference alarm in inverter
module 9 of several parallel connected inverter
modules
9 TEMP DIF INV10 Temperature difference alarm in inverter
module 10 of several parallel connected
inverter modules
10 TEMP DIF INV11 Temperature difference alarm in inverter
module 11of several parallel connected
inverter modules
11 TEMP DIF INV12 Temperature difference alarm in inverter
module 12 of several parallel connected
inverter modules
12 TEMP DIF Temperature difference alarm in phase U of
PHASE U the faulted inverter module
13 TEMP DIF Temperature difference alarm in phase V of the
PHASE V faulted inverter module
14 TEMP DIF Temperature difference alarm in phase W of
PHASE W the faulted inverter module
15 Not in use
0...65535 Alarm word value
09.20 AP AFW Alarm and Fault word. This word can be used with adaptive 1=1 Pb
programming (typically for fieldbus information). See ACS600/
ACS800 Application Guide Adaptive Program for System
Application Program 7.x [3AFE68420075 (English)].
Actual signals and parameters
169
Index Name/Value Description FbEq PB T
0...65535 Alarm and fault word value
09.30 FAULT CODE 1 LAST Fieldbus code of the latest fault. See chapter Fault tracing for the 1=1 I
codes.
0...FFFF (hex) Fieldbus code
09.31 FAULT CODE 2 LAST Fieldbus code of the 2nd latest fault 1=1 I
0...FFFF (hex) Fieldbus code
09.32 FAULT CODE 3 LAST Fieldbus code of the 3rd latest fault 1=1 I
0...FFFF (hex) Fieldbus code
09.33 FAULT CODE 4 LAST Fieldbus code of the 4th latest fault 1=1 I
0...FFFF (hex) Fieldbus code
09.34 FAULT CODE 5 LAST Fieldbus code of the 5th latest fault 1=1 I
0...FFFF (hex) Fieldbus code
09.35 WARN CODE 1 LAST Fieldbus code of the latest alarm 1=1 I
0...FFFF (hex) Fieldbus code
09.36 WARN CODE 2 LAST Fieldbus code of the 2nd latest alarm 1=1 I
0...FFFF (hex) Fieldbus code
09.37 WARN CODE 3 LAST Fieldbus code of the 3rd latest alarm 1=1 I
0...FFFF (hex) Fieldbus code
09.38 WARN CODE 4 LAST Fieldbus code of the 4th latest alarm 1=1 I
0...FFFF (hex) Fieldbus code
09.39 WARN CODE 5 LAST Fieldbus code of the 5th latest alarm 1=1 I
0...FFFF (hex) Fieldbus code
Actual signals and parameters
170
Index Name/Selection Description FbEq Def. PB T
10 DIGITAL INPUTS Digital input functions. See section Digital inputs on page 55.
10.01 START/STOP Defines the source for the start and stop commands when 1 101 I
I/O control is activated either by setting parameter 98.02
COMM. MODULE to NO or by setting parameter 10.07 HAND/
AUTO to HAND.
1 = NO No start or stop command source
2 = DI3 Start and stop through digital input DI3. Stop by falling edge of
digital input 1 -> 0. Start by rising edge of digital input 0 -> 1.
3 = DI4 See selection DI3.
4 = DI5 See selection DI3.
5 = DI6 See selection DI3.
6 = EXT2 DI1 Start and stop through RDIO I/O Extension module 2.
Parameter 98.04 DI/O EXT MODULE 2 must be set to
EXTEND. Stop by falling edge of digital input: 1 -> 0. Start by
rising edge of digital input: 0 -> 1.
7 = EXT2 DI2 See selection EXT2 DI1.
8 = EXT2 DI3 See selection EXT2 DI1.
9 = DI7 See selection DI3.
10.02 DIRECTION Defines the source for the direction command. 1 102 I
Unipolar speed reference is selected by parameter 13.12
MINIMUM AI1.
I/O control is activated either by setting parameter 98.02
COMM. MODULE to NO or by setting parameter 10.07 HAND/
AUTO to HAND.
1 = FORWARD Fixed to forward
2 = DI3 Direction command through digital input DI3. 1 = reverse,
0 = forward.
3 = DI4 See selection DI3.
4 = DI5 See selection DI3.
5 = DI6 See selection DI3.
6 = EXT2 DI1 Direction command through RDIO I/O Extension module 2.
Parameter 98.04 DI/O EXT MODULE 2 must be set to
EXTEND. 1 = reverse, 0 = forward.
7 = EXT2 DI2 See selection EXT2 DI1.
8 = EXT2 DI3 See selection EXT2 DI1.
9 = DI7 See selection DI3.
10.03 RESET Defines the source for the reset signal. 4 103 I
I/O control is activated either by setting parameter 98.02
COMM. MODULE to NO or by setting parameter 10.07 HAND/
AUTO to HAND.
1 = NO No reset source
2 = DI3 Reset by rising edge of digital input DI3. 0 -> 1.
3 = DI4 See selection DI3.
4 = DI5 See selection DI3.
5 = DI6 See selection DI3.
Actual signals and parameters
171
Index Name/Selection Description FbEq Def. PB T
6 = EXT2 DI1 Reset through RDIO I/O Extension module 2. Reset by rising
edge of digital input: 0 -> 1. Parameter 98.04 DI/O EXT
MODULE 2 must be set to EXTEND.
7 = EXT2 DI2 See selection EXT2 DI1.
8 = EXT2 DI3 See selection EXT2 DI1.
9 = DI7 See selection DI3.
10.04 SYNC CMD Selects an interface for the position count. Active in all control 1 104 I
modes. By using this parameter, faster position count
synchronisation is achieved than by using 07.02 AUX CTRL
WORD 1 bit 9.
See section Position counter on page 120.
1 = NO No position count enabled
2 = DI3 Position count through DI3. 1 = active, 0 = inactive.
3 = DI4 See selection DI3.
4 = DI5 See selection DI3.
5 = DI6 See selection DI3.
6 = EXT2 DI1 Position count through RDIO I/O Extension module 2.
Parameter 98.04 DI/O EXT MODULE 2 must be set to
EXTEND. 1 = active, 0= inactive.
7 = EXT2 DI2 See selection EXT2 DI1.
8 = EXT2 DI3 See selection EXT2 DI1.
9 = DI7 See selection DI3.
10.05 KLIXON Selects an interface for motor overtemperature protection. 1 105 I
Digital input for the thermal switch (KLIXON) or for the
thermistor relay can be selected freely. PTC thermistor can only
be connected to digital input DI6. See section Alternative
thermal connection for PTC thermistor on page 91.
1 = NO No motor overtemperature protection selected
2 = DI3 Motor overtemperature protection through digital input DI3.
1 = no fault, 0 = fault trip.
3 = DI4 See selection DI3.
4 = DI5 See selection DI3.
5 = DI6 See selection DI3.
6 = EXT2 DI1 Motor overtemperature protection through RDIO I/O Extension
module 2. Parameter 98.04 DI/O EXT MODULE 2 must be set
to EXTEND. 1 = no fault, 0 = fault trip.
7 = EXT2 DI2 See selection EXT2 DI1.
8 = EXT2 DI3 See selection EXT2 DI1.
9 = DI7 See selection DI3.
10.06 MOTOR FAN ACK Selects the source for the motor fan acknowledgement signal. 1 106 I
An acknowledgement signal indicates that the contactor of the
fan motor is closed and the fan is ready to function. If the
contactor is open, no acknowledgement signal is received and
a fault indication is created. See parameter group 35 MOTOR
FAN CTRL and section Motor fan control on page 97.
1 = NO No motor fan acknowledgement selected
Actual signals and parameters
172
Index Name/Selection Description FbEq Def. PB T
2 = DI3 Acknowledgement signal through digital input DI3.
1 = acknowledgement.
3 = DI4 See selection DI3.
4 = DI5 See selection DI3.
5 = DI6 See selection DI3.
6 = EXT2 DI1 Acknowledgement signal through RDIO I/O Extension
module 2. Parameter 98.04 DI/O EXT MODULE 2 must be set
to EXTEND. 1 = acknowledgement.
7 = EXT2 DI2 See selection EXT2 DI1.
8 = EXT2 DI3 See selection EXT2 DI1.
9 = DI7 See selection DI3.
10.07 HAND/AUTO Enables switching between I/O control (HAND) and serial 1 107 I
communication control (AUTO) through digital input. This
parameter has a higher priority than parameter 98.02 COMM.
MODULE setting.
1 = NO No HAND/AUTO function selected
2 = DI3 Switching through digital input DI3. 1 = HAND, 0 = AUTO.
3 = DI4 See selection DI3.
4 = DI5 See selection DI3.
5 = DI6 See selection DI3.
6 = EXT2 DI1 Switching through RDIO I/O Extension module 2. Parameter
98.04 DI/O EXT MODULE 2 must be set to EXTEND.
1 = HAND, 0 = AUTO.
7 = EXT2 DI2 See selection EXT2 DI1.
8 = EXT2 DI3 See selection EXT2 DI1.
9 = DI7 See selection DI3.
10.08 START INHIB DI ACS 600 specific function to interlock run command. Use RUN 1 108 I
ENABLE or RUN INTERLOCK functions with ACS800.
This parameter defines the source for the start inhibition.
1 = NO No START INHIBITION function selected
2 = DI3 Start inhibition monitoring through digital input DI3. 0 = start
interlocked, 1 = start not interlocked.
3 = DI4 See selection DI3.
4 = DI5 See selection DI3.
5 = DI6 See selection DI3.
6 = EXT2 DI1 Start inhibition monitoring through RDIO I/O Extension module
2. Parameter 98.04 DI/O EXT MODULE 2 must be set to
EXTEND.
0 = start interlocked, 1 = start not interlocked.
7 = EXT2 DI2 See selection EXT2 DI1.
8 = EXT2 DI3 See selection EXT2 DI1.
9 = DI7 See selection DI3.
10.09 SAFETY SWITCH Defines the source for the motor safety switch monitoring. Fault 1 = NO 109 I
is created if the switch was opened during run. An alarm is
created if the drive was already stopped.
1 = NO No safety switch monitoring selected
Actual signals and parameters
173
Index Name/Selection Description FbEq Def. PB T
2 = DI3 Safety switch monitoring through digital input DI3. 1 = no fault,
0 = fault trip.
3 = DI4 See selection DI3.
4 = DI5 See selection DI3.
5 = DI6 See selection DI3.
6 = EXT2 DI1 Safety switch monitoring through RDIO I/O Extension
module 2. Parameter 98.04 DI/O EXT MODULE 2 must be set
to EXTEND. 1 = no fault, 0 = fault trip.
7 = EXT2 DI2 See selection EXT2 DI1.
8 = EXT2 DI3 See selection EXT2 DI1.
9 = DI7 See selection DI3.
10.10 I/O MACRO Enables the change of the user macro through a digital input, 1=NO 110 I
CHANGE when parameter 16.05 USER MACRO CHG setting is I/O
CHANGE. See also parameter 99.11 APPLICATION MACRO.
The change is allowed only when the drive is stopped. During
the change, the drive will not start.
Note: Always save the user macro by parameter 99.11 after
changing any parameter settings, or reperforming the motor
identification run. The last settings saved by the user are
loaded into use whenever the power is switched off and on
again or the macro is changed. Any unsaved changes will be
lost.
Note: The value of this parameter is not included in the user
macro. A setting once made remains despite of the user macro
change.
1 = NO User macro change is not possible through a digital input.
2 = DI3 User macro change through digital input DI3.
Falling edge of digital input DI3 (1 -> 0): User macro 1 is loaded.
Rising edge of digital input DI3 (0 -> 1): User macro 2 is loaded.
3 = DI4 See selection DI3.
4 = DI5 See selection DI3.
5 = DI6 See selection DI3.
6 = EXT2 DI1 User macro change through RDIO I/O Extension module 2.
Parameter 98.04 DI/O EXT MODULE 2 must be set to
EXTEND.
Falling edge of extension digital input DI1 (1 -> 0): User macro
1 is loaded.
Rising edge of extension digital input DI1 (0 -> 1): User macro 2
is loaded.
7 = EXT2 DI2 See selection EXT2 DI1.
8 = EXT2 DI3 See selection EXT2 DI1.
9 = DI7 See selection DI3.
10.11 MOT PROT Selects a digital input for motor overload protection. (Input for 1 = NO I
SWITCH the motor thermal protection device can be selected freely.)
1 = NO No overload protection
2 = DI3 Motor overload protection through digital input DI3.
1 = no fault, 0 = fault trip.
3 = DI4 See selection DI3.
Actual signals and parameters
174
Index Name/Selection Description FbEq Def. PB T
4 = DI5 See selection DI3.
5 = DI6 See selection DI3.
6 = EXT2 DI1 Motor overload protection through RDIO I/O Extension module
2. Parameter 98.04 DI/O EXT MODULE 2 must be set to
EXTEND. 1 = no fault, 0 = fault trip.
7 = EXT2 DI2 See selection EXT2 DI1.
8 = EXT2 DI3 See selection EXT2 DI1.
9 = DI7 See selection DI3.
11 REFERENCE Speed reference sources.
SELECT If analogue I/O extension module is used, see switch
configuration in parameter 98.06 AI/O EXT MODULE 1.
11.01 EXT REF1 SELECT Selects the speed reference through analogue input or external 1 126 I
reference.
1 = STD AI1 0…10 V speed reference input
2 = STD AI2 0(4)…20 mA speed reference input
3 = EXT REF The reference is given through parameter 11.03 EXT
REFERENCE, which can be written e.g. by Adaptive program.
11.02 AI+FBA SPEED Activates the AI+FBA SPEED REF function. Analogue input 1 1=1 OFF 127 B
REF or 2 speed reference can be summed with fieldbus adapter
reference if this parameter is activated and 98.02 COMM.
MODULE is set to FIELDBUS. Reference value can be
monitored with signal 02.25 ADDITIVE SP REF.
0 = OFF Inactive
1 = ON Active
11.03 EXT REFERENCE This external reference is used to speed or frequency reference See par. 0 128 I
in case of I/O control, if EXT REF(3) is selected by parameter 50.01
11.01 EXT REF1 SELECTED. This parameter is typically
written by adaptive program.
-32768...32767 Integer value
12 FAST IO Fast IO interface
12.03 FAST DI5 SEL Selects connection for fast interface of DI5.
0 = NO FAST DI5 No fast DI5 used. The connection for DI5 can be selected in
group 10.
1 = POS CNT Fast DI5 is used for the position count. See section Position
SYNC counter on page 120.
2 = SPEED CORR Fast DI connects 23.04 SPEED CORRECTION to speed
reference chain.
0 = disconnected
1 = connected
The speed connection is connected to reference chain if the
parameter value is not SPEED CORR.
Actual signals and parameters
175
Index Name/Selection Description FbEq Def. PB T
12.11 FAST EXT AIO SEL Interface for selection of fast analogue input module. 1=1 NO I,F
Fast AI is NOT active if any of the following conditions is true:
- drive ID run is in progress
- parameter 99.07 MOTOR ID RUN value is other than “NO”.
This means that the ID run is selected to be run at the next
start.
- there is no active start command.
Note: No other modules are allowed on CH2 if FAST AI module
is enabled.
0 = NO FAST AI No fast analogue input module.
1 = NAIO NAIO-03F module activated.
2 = FIO FIO-11 module not supported.
12.12 FAST AI1 REF SEL Signal source for analogue input AI1. 1=1 0 I,F
0 = NO AI REF No connections for AI1 of fast NAIO-03F.
1 = ADD SPEED AI1 of the fast AI module is connected internally to input 02.25
ADDITIVE SPEED REF.
2 = SPEED CORR AI1 of the fast AI module is connected internally to input 23.04
SPEED CORRECTION.
3 = TORQ REF A AI1 of the fast AI module is connected internally to input 25.01
TORQUE REFERENCE A.
Note: For fast analogue input response, ensure that parameter
25.02 TORQ REF A FTC is set to zero.
4 = TORQ REF B AI1 of the fast AI module is connected internally to input 25.04
TORQUE REFERENCE B.
Note: Ensure that the torque reference chain parameter 25.05
TORQ RAMP UP and 25.06 TORQ RAMP DOWN are set to
zero.
5 = TORQ STEP AI1 of the fast AI module is connected internally to input 26.03
TORQUE STEP.
12.13 FAST AI1 SPD SCL Scaling of fast analogue signal AI1 signal in the speed R,
reference chain. The value of this parameter corresponds to the F
nominal signal level of fast AI module (+10 V or 20 mA).
-8 × sync. speed … Speed scaling factor
8 × sync. speed
12.14 FAST AI1 TORQ Scaling of fast analogue signal AI1 signal in the torque 100 = 0% R,
SCL reference chain. The value of this parameter corresponds to the 1 % F
nominal signal level of fast AI module (+10 V or 20 mA).
-x% … x% Torque scaling. Maximum and minimum values depend on the
defined motor parameters (99 START-UP DATA).
12.15 FAST AI2 REF SEL Signal source for analogue input AI2. 1=1 0 rpm I,F
0 = NO AI REF No connections for AI2 of fast AI module.
1 = ADD SPEED AI2 of the fast AI module is connected internally to input 02.25
ADDITIVE SPEED REF.
2 = SPEED CORR AI2 of the fast AI module is connected internally to input 23.04
SPEED CORRECTION.
Actual signals and parameters
176
Index Name/Selection Description FbEq Def. PB T
3 = TORQ REF A AI2 of the fast AI module is connected internally to input 25.01
TORQUE REFERENCE A.
Note: For fast analogue input response, ensure that parameter
25.02 TORQ REF A FTC is set to zero.
4 = TORQ REF B AI2 of the fast AI module is connected internally to input 25.04
TORQUE REFERENCE B.
Note: Ensure that the torque reference chain parameters 25.05
TORQ RAMP UP and 25.06 TORQ RAMP DOWN are set to
zero.
5 = TORQ STEP AI2 of the fast AI module is connected internally to input 26.03
TORQUE STEP.
12.16 FAST AI2 SPD SCL Scaling of fast analogue input AI2 signal in the speed reference See Par. R,
chain. The value of this parameter corresponds to the nominal 50.01 F
signal level of fast AI module (+10 V or 20 mA).
-8 × sync. speed … Speed scaling factor.
8 × sync. speed
12.17 FAST AI2 TORQ Scaling of fast analogue input AI2 signal in the torque reference 100 = 0% R,
SCL chain. The value of this parameter corresponds to the nominal 1% F
signal level of fast AI module (+10 V or 20 mA).
-x% … x% Torque scaling. Maximum and minimum values depend on the
defined motor parameters (99 START-UP DATA).
12.21 FAST EXT AO1 Connects a measured signal to fast external analogue output 101 I
SEL AO1.
An external control system can also control the output. The data
set in which the signal is transmitted to the drive is directed into
one of the data parameters 19.01…19.08 using parameters
90.01…90.18. The data parameter is then coupled to the
analogue output with this parameter.
0 … 9999 Parameter index in (x)xyy format, where (x)x= parameter group,
yy = parameter number. For example value 2301 denotes
parameter 23.01.
12.22 FAST EXT AO1 INV Selects fast external analogue output AO1 signal inversion. 1=1 NO B
0 = NO Minimum signal value corresponds to the minimum output
value.
1 = YES Maximum signal value corresponds to the minimum output
value.
12.23 FAST EXT AO1 Defines the offset value for fast external analogue output AO1. 0 mA I
MIN
1 = 0 mA 0 mA
2 = 4 mA 4 mA
3 = 10 mA With bipolar signals the defined minimum value 10 mA is in the
middle of the range 0...20 mA. For example:
-1000 rpm = 0 mA and 1000 rpm = 20 mA
Bipolar signals indicate the direction of torque, speed etc.
Bipolar signals are also needed for testing purposes.
12.24 FAST EXT AO1 Defines the nominal value of the signal connected to fast 20000 R
SCL external analogue output AO1. See parameter 12.21 FAST EXT
AO1 SEL. The value corresponds to 20 mA at the output.
0 … 65536 Nominal value
Actual signals and parameters
177
Index Name/Selection Description FbEq Def. PB T
13 ANALOGUE Analogue input signal processing. See section Analogue inputs
INPUTS on page 50.
13.01 AI1 HIGH VALUE Defines the integer value that corresponds to the maximum 20000 176 I
value of analogue input AI1.
With I/O control, value 20000 corresponds the speed defined by
parameter 50.01 SPEED SCALING.
Note: Parameter is not active if AI1 is used for motor 1
temperature measurement. See parameter 30.03 MOT1 TEMP
AI1 SEL.
-32768...32767 Integer value
13.02 AI1 LOW VALUE Defines the integer value that corresponds to the minimum 0 177 I
value of analogue input AI1.
With I/O control, when bipolar I/O reference is used, value
-20000 corresponds the maximum negative speed defined by
parameter 50.01 SPEED SCALING.
Note: Parameter is not active if AI1 is used for motor 1
temperature measurement. See parameter 30.03 MOT1 TEMP
AI1 SEL.
-32768...32767 Integer value
13.03 FILTER AI1 Defines the filter time constant for analogue input AI1. 1000 178 I
The hardware filter time constant of the RMIO analogue input is
1 ms.
0...30000 ms Filter time constant
13.04 AI2 HIGH VALUE Defines the integer value that corresponds to the maximum 0 179 I
value of analogue input AI2.
-32768...32767 Integer value
13.05 AI2 LOW VALUE Defines the integer value that corresponds to the minimum 0 180 I
value of analogue input AI2.
-32768...32767 Integer value
13.06 MINIMUM AI2 Defines the minimum value for analogue input AI2. 1 181 I
1 = 0 mA 0 mA (range 0...20 mA)
2 = 4 mA 4 mA (range 4...20 mA)
3 = -20 mA -20 mA (range -20…20 mA). Used with a bipolar type of an
analogue input.
13.07 FILTER AI2 Defines the filter time constant for analogue input AI2. 1000 182 I
The hardware filter time constant of the RMIO analogue input is
1 ms.
0...30000 ms Filter time constant
13.08 AI3 HIGH VALUE Defines the integer value that corresponds to the maximum 10000 183 I
value of analogue input AI3.
-32768...32767 Integer value
13.09 AI3 LOW VALUE Defines the integer value that corresponds to the minimum 0 184 I
value of analogue input AI3.
-32768...32767 Integer value
13.10 MINIMUM AI3 Defines the minimum value for analogue input AI3. 1 185 I
1 = 0 mA 0 mA
2 = 4 mA 4 mA
Actual signals and parameters
178
Index Name/Selection Description FbEq Def. PB T
13.11 FILTER AI3 Defines the filter time constant for analogue input AI3. 1000 186 R
The hardware filter time constant of the RMIO analogue input is
1 ms.
0...30000 ms Filter time constant
13.12 MINIMUM AI1 Defines the minimum value for analogue input AI1. 1 187 I
1 = 0 mA 0 mA (range 0…20 mA)
2 = 4 mA 4 mA (range 4…20 mA)
3 = -20 mA -20 mA (range -20…20 mA). Used with a bipolar type of an
analogue input.
13.13 EXT2 AI1 CONV Selects the scaling for extension module 2 analogue input AI1. 1=1 1 I
MODE Scaling applies for unipolar and bipolar signals.
1 = NORMAL Normal scaling:
-20 mA / -2 V / -10 V…0…20 mA / 2 V / 10 V = -20000…20000
2 = 4 mA 4…20 mA = 0…20000
3 = PT100 Scaling with Pt100 temperature measurement:
200°C = 20000 if analogue output feeds the following constant
current to the Pt100 sensor:
with 1xPT100: 10 mA
with 2xPT100: 5 mA
with 3xPT100: 3.3 mA.
13.14 EXT2 AI1 FILTER Defines the filter time constant for extension module 2 analogue 1 = 1 ms 1000 I
input AI1.
0...30000 ms Filter time constant
13.15 EXT2 AI2 CONV Selects the scaling for extension module 2 analogue input AI2.
MODE Scaling applies for unipolar and bipolar signals.
See parameter 13.13 EXT2 AI1 CONV MODE.
13.16 EXT2 AI2 FILTER Defines the filter time constant for extension module 2 analogue 1 = 1 ms 1000 I
input AI2.
0...30000 ms Filter time constant
14 DIGITAL OUTPUTS Control of the digital outputs. See section Digital outputs on
page 56.
14.01 DO1 CONTROL Activates digital output DO1 control. 1=1 0= 201 B
OFF
0 = OFF Emergency stop command controls digital output DO1.
The emergency stop function is activated by parameter 21.04
EME STOP MODE.
1 = ON Digital output DO1 control. Control signal is selected by
parameters 14.02 DO1 GROUP+INDEX and 14.03 DO1 BIT
NUMBER.
14.02 DO1 Selects digital output DO1 control signal when parameter 14.01 801 202 I
GROUP+INDEX DO1 CONTROL setting is ON. Output is controlled with
a selectable bit (see parameter 14.03 DO1 BIT NUMBER) of
the signal selected by this parameter. If the parameter is set
to 0, the output is controlled from an external control system by
07.02 AUX CTRL WORD 1 bit 13.
-9999…9999 Parameter index in (-)xyy format, where (-1) = inversion,
x = parameter group, yy = parameter number. For example
value 801 denotes signal 08.01.*
Actual signals and parameters
179
Index Name/Selection Description FbEq Def. PB T
14.03 DO1 BIT NUMBER Defines the bit number of the signal selected by parameter 1 203 I
14.02 DO1 GROUP+INDEX.
0…23 Bit number
14.04 DO2 Selects digital output DO2 control signal. Output is controlled 801 204 I
GROUP+INDEX with a selectable bit (see parameter 14.05 DO2 BIT NUMBER)
of the signal selected by this parameter. If the parameter is set
to 0, the output is controlled from an external control system by
07.02 AUX CTRL WORD 1 bit 14. See also parameter 14.12
DO2 GRP+INDEX MOD.
-9999…9999 Parameter index in (-)xyy format, where (-1) = inversion,
x = parameter group, yy = parameter number. For example
value 801 denotes signal 08.01.*
14.05 DO2 BIT NUMBER Defines the bit number of the signal selected by parameter 2 205 I
14.04 DO2 GROUP+INDEX.
0…23 Bit number
14.06 DO3 Selects digital output DO3 control signal. Output is controlled 801 206 I
GROUP+INDEX with a selectable bit (see parameter 14.07 DO3 BIT NUMBER)
of the signal selected by this parameter. If the parameter is set
to 0, DO3 is controlled from an external control system by 07.02
AUX CTRL WORD 1 bit 15.
-9999…9999 Parameter index in (-)xyy format, where (-1) = inversion,
x = parameter group, yy = parameter number. For example
value 801 denotes signal 08.01.*
14.07 DO3 BIT NUMBER Defines the bit number of the signal selected by parameter 3 207 I
14.06 DO3 GROUP+INDEX.
0...23 Bit number
14.08 EXT2 DO1 Selects extension module 2 digital output DO1 control signal. 801 208 I
GR+INDEX Output is controlled with a selectable bit (see parameter 14.09
EXT2 DO1 BIT NR) of the signal selected by this parameter. If
parameter is set to 0, DO1 is controlled from an external control
system by 07.03 AUX CTRL WORD 2 bit 2. To activate the
extension module see parameter 98.04 DI/O EXT MODULE 2.
-9999…9999 Parameter index in (-)xyy format, where (-1) = inversion,
x = parameter group, yy = parameter number. For example
value 801 denotes signal 08.01.*
14.09 EXT2 DO1 BIT NR Defines the bit number of the signal selected by parameter 1 209 I
14.08 EXT2 DO1 GR+INDEX.
0...23 Bit number
14.10 EXT2 DO2 Selects extension module 2 digital output DO2 control signal. 806 210 I
GR+INDEX Extension module 2 digital output DO2 is controlled with
a selectable bit (see parameter 14.11 EXT2 DO2 BIT NR) of the
signal selected with this parameter. If parameter is set to 0,
DO2 can be controlled from an external control system by
07.03 AUX CTRL WORD 2 bit 3. To activate the extension
module see parameter 98.04 DI/O EXT MODULE 2.
-9999…9999 Parameter index in (-)xyy format, where (-1) = inversion,
x = parameter group, yy = parameter number. For example
value 801 denotes signal 08.01.*
14.11 EXT2 DO2 BIT NR Defines the bit number of the signal selected by parameter 0 211 I
14.10 EXT2 DO2 GR+INDEX.
0...23 Bit number
Actual signals and parameters
180
Index Name/Selection Description FbEq Def. PB T
14.12 DO2 GR+IND Defines digital output DO2 control in local and remote control 1=1 0 212 B
MODE modes.
0 = REM/LOCAL Parameters 14.04 DO2 GROUP+INDEX and 14.05 DO2 BIT
NUMBER are effective in remote and local control modes.
1 = LOCAL Parameters 14.04 DO2 GROUP+INDEX and 14.05 DO2 BIT
NUMBER are effective only in local control mode. In remote
control mode signal 07.02 AUX CTRL WORD 1 bit 14 controls
DO2.
*Example: If parameters 14.02 and 14.03 are set to 801 and 1, DO1 is active when 08.01 Main Status Word bit 1 is
1 = READY. If parameters 14.02 and 14.03 are set to -801 and 3, DO1 is active when 08.01 Main Status Word bit 3 is 0.
15 ANALOGUE Analogue output signal processing. The outputs are updated
OUTPUTS every 10 ms. See section Analogue outputs on page 53.
15.01 ANALOGUE Connects a measured signal to analogue output AO1. 106 226 I
OUTPUT1 If temperature measurement (parameter 30.03 MOT1 TEMP
AI1 SEL) is selected, analogue output AO1 is used for
supplying constant current for the sensor.
An external control system can also control the output. The data
set in which the signal is transmitted to the drive is directed into
one of the data parameters 19.01...19.08 using parameters
90.01...90.18. The data parameter is then coupled to the
analogue output with this parameter.
0…9999 Parameter index in (x)xyy format, where (x)x= parameter group,
y = parameter number. For example value 2301 denotes
parameter 23.01.
15.02 INVERT AO1 Selects analogue output AO1 signal inversion. 1=1 NO 227 B
0 = NO Minimum signal value corresponds to the minimum output
value.
1 = YES Maximum signal value corresponds to the minimum output
value.
15.03 MINIMUM AO1 Defines the offset value for analogue output AO1. 1 228 I
Note: Parameter is not effective if motor 1 temperature
measurement is activated by parameter 30.03 MOT1 TEMP AI1
SEL.
1 = 0 mA 0 mA
2 = 4 mA 4 mA
3 = 10 mA With bipolar signals the defined minimum value 10 mA is in the
middle of the range 0...20 mA. For example:
-1000 rpm = 0 mA and 1000 rpm = 20 mA
Bipolar signals indicate the direction of torque, speed etc.
Bipolar signals are also needed for testing purposes.
15.04 FILTER AO1 Defines the filter time constant for analogue output AO1. 100 = 0.1 229 R
1s
0...10 s Filter time constant
15.05 SCALE AO1 Defines the nominal value of the signal connected to analogue 1=1 100 230 R
output AO1. See parameter 15.01 ANALOGUE OUTPUT1.
The value corresponds to 20 mA at the output.
0...65536 Nominal value
Actual signals and parameters
181
Index Name/Selection Description FbEq Def. PB T
15.06 ANALOGUE Connects a measured signal to analogue output AO2. 101 231 I
OUTPUT2
0...9999 Parameter index in (x)xyy format, where (x)x= parameter group,
y = parameter number. For example value 1506 denotes
parameter 15.06.
15.07 INVERT AO2 Selects analogue output AO2 signal inversion. 1=1 NO 232 B
0 = NO Minimum signal value corresponds to the minimum output
value.
1 = YES Maximum signal value corresponds to the minimum output
value.
15.08 MINIMUM AO2 Defines the offset value for analogue output AO2. 1 233 I
1 = 0 mA 0 mA
2 = 4 mA 4 mA
3 = 10 mA With bipolar signals the defined minimum value 10 mA is in the
middle of the range 0...20 mA. For example:
-1000 rpm = 0 mA and 1000 rpm = 20 mA
Bipolar signals indicate the direction of torque, speed etc.
Bipolar signals are also needed for testing purposes.
15.09 FILTER AO2 Defines the filter time constant for analogue output AO2. 100 = 0.1 234 R
1s
0...10 s Filter time constant
15.10 SCALE AO2 Defines the nominal value of the signal connected to analogue 1=1 3000 235 R
output AO2. See parameter 15.06 ANALOGUE OUTPUT2.
The value corresponds to 20 mA at the output.
0...65536 Nominal value
15.11 ANALOGUE Connects a measured signal to analogue output AO3. 101 236 I
OUTPUT3 If temperature measurement (parameter 30.03 MOT1 TEMP
AI1 SEL) is selected, analogue output AO3 is used for
supplying constant current for the sensor.
Analogue outputs AO3 and AO4 are available when RAIO I/O
Extension module is used and parameter 98.06 AI/O EXT
MODULE 1 is set to UNIPOLAR AI or BIPOLAR AI. See also
parameters 98.06 AI/O EXT MODULE 1 and 98.11 AI/O EXT1
LOCATION.
0...9999 Parameter index in (x)xyy format, where (x)x= parameter group,
y = parameter number. For example value 2301 denotes
parameter 23.01.
15.12 INVERT AO3 Selects analogue output AO3 signal inversion. 1=1 NO 237 B
0 = NO Minimum signal value corresponds to the minimum output
value.
1 = YES Maximum signal value corresponds to the minimum output
value.
15.13 MINIMUM AO3 Defines the offset value for analogue output AO3. 1 238 I
1 = 0 mA 0 mA
2 = 4 mA 4 mA
Actual signals and parameters
182
Index Name/Selection Description FbEq Def. PB T
3 = 10 mA With bipolar signals the defined minimum value 10 mA is in the
middle of the range 0...20 mA. For example:
-1000 rpm = 0 mA and 1000 rpm = 20 mA
Bipolar signals indicate the direction of torque, speed etc.
Bipolar signals are also needed for testing purposes.
4 = 12 mA Used with 4…20 mA signals with meters which have zero point
in the middle of the range, e.g. -1000…0…1000 rpm.
15.14 FILTER AO3 Defines the filter time constant for analogue output AO3. 100 = 0.1 239 R
1s
0...10 s Filter time constant
15.15 SCALE AO3 Defines the nominal value of the signal connected to analogue 1=1 3000 240 R
output AO3. See parameter 15.11 ANALOGUE OUTPUT3.
The value corresponds to 20 mA at the output.
0...65536 Nominal value
15.16 ANALOGUE Connects a measured signal to analogue output AO4. 101 241 I
OUTPUT4 If temperature measurement (par. 30.06 MOT2 TEMP AI2 SEL)
is selected, analogue output AO4 is used for supplying constant
current for the sensor.
Analogue outputs AO3 and AO4 are available when I/O
extension is used and parameter 98.06 AI/O EXT MODULE 1 is
set to UNIPOLAR AI or BIPOLAR AI. See also parameters
98.06 AI/O EXT MODULE 1 and 98.11 AI/O EXT1 LOCATION.
0...9999 Parameter index in (x)xyy format, where (x)x= parameter group,
y = parameter number. For example value 2301 denotes
parameter 23.01.
15.17 INVERT AO4 Selects analogue output AO4 signal inversion. 1=1 NO 242 B
0 = NO Minimum signal value corresponds to the minimum output
value.
1 = YES Maximum signal value corresponds to the minimum output
value.
15.18 MINIMUM AO4 Defines the offset value for analogue output AO4. 1 243 I
1 = 0 mA 0 mA
2 = 4 mA 4 mA
3 = 10 mA With bipolar signals the defined minimum value 10 mA is in the
middle of the range 0...20 mA. For example:
-1000 rpm = 0 mA and 1000 rpm = 20 mA
Bipolar signals indicate the direction of torque, speed etc.
Bipolar signals are also needed for testing purposes.
4 = 12 mA Used with 4…20 mA signals with meters which have zero point
in the middle of the range, e.g. -1000…0…1000 rpm.
15.19 FILTER AO4 Defines the filter time constant for analogue output AO4. 100 = 0.1 244 R
1s
0...10 s Filter time constant
15.20 SCALE AO4 Defines the nominal value of the signal connected to analogue 1=1 3000 245 R
output AO4. See parameter 15.16 ANALOGUE OUTPUT4.
The value corresponds to 20 mA at the output.
0...65536 Nominal value
15.21 EXT2 AO1 OFFSET Defines the offset value for extension module 2 analogue 1 mA = 0 R
output AO1. 1000
Actual signals and parameters
183
Index Name/Selection Description FbEq Def. PB T
0...20 mA Offset
15.22 EXT2 AO1 SCALE Scales the extension module 2 analogue output AO1 signal. 20000 I
0...30000 20000 = 20 mA
15.23 EXT2 AO2 OFFSET Defines the offset value for extension module 2 analogue 1 mA = 0 R
output AO2. 1000
0...20 mA Offset
15.24 EXT2 AO2 SCALE Scales the extension module 2 analogue output AO2 signal. 20000 I
0...30000 20000 = 20 mA
16 SYSTEM CTR Run Enable, parameter lock etc.
INPUTS
16.01 RUN ENABLE Activates the RUN ENABLE signal. 1=1 2= 251 I
FAULT
1 = INTERLOCK To activate the RUN ENABLE signal, a voltage signal must be
connected to digital input DI2. If the voltage drops to 0 V, the
drive coasts to stop and RUN INTERLOCK bit is activated in
08.01 MSW bit 13.
2 = FAULT If the DI2 voltage drops to 0 V, the drive coasts to stop and fault
RUN DISABLE is generated.
3 = ALARM If the DI2 voltage drops to 0 V, the drive coasts to stop and
alarm RUN DISABLE is generated.
16.02 PARAMETER Selects the state of the parameter lock. The lock prevents 1=1 OPEN 252 B
LOCK parameter changing.
0 = OPEN The lock is open. Parameter values can be changed.
1 = LOCKED Locked. Parameter values cannot be changed from the control
panel. The lock can be opened by entering the valid code to
parameter 16.03 PASS CODE.
16.03 PASS CODE Selects the pass code for the parameter lock. See parameter 0 253 I
16.02 PARAMETER LOCK.
0...30000 Setting 358 opens the lock. The value reverts back to 0
automatically.
16.04 LOCAL LOCK Disables entering local control mode (LOC/REM key of the 1=1 FALSE 254 B
panel).
WARNING! Before activating, ensure that the control
panel is not needed for stopping the drive!
0 = FALSE Local control allowed
1 = TRUE Local control disabled
Actual signals and parameters
184
Index Name/Selection Description FbEq Def. PB T
16.05 USER MACRO Enables the change of the user macro. See parameter 99.11 1 255 I
CHG APPLICATION MACRO. The change is allowed only when the
drive is stopped. During the change, the drive will not start.
Note: Always save the user macro by parameter 99.11 after
changing any parameter settings, or reperforming the motor
identification. The last settings saved by the user are loaded
into use whenever the power is switched off and on again or the
macro is changed. Any unsaved changes will be lost.
Note: The value of this parameter is not included in the user
macro. A setting once made remains despite of the user macro
change.
For more information, see section User macros on page 290.
1 = NOT SEL User macro change is not possible.
2 = ACW2 BIT 12 User macro change by 07.03 AUX CTRL WORD 2 bit 12. 1 =
macro 2, 0 = macro 1.
3 = I/O CHANGE User macro change defined by parameter 10.10 I/O MACRO
CHANGE.
16.06 PARAMETER Saves parameters from the RAM memory to the FPROM DONE 256 B
BACKUP memory. Saving of parameters is needed only when parameter
changes through external control system have to be stored to
the FPROM memory.
Note: Parameter changes by CDP 312R control panel or
DriveWindow are immediately saved to the FPROM memory.
0 = DONE Parameter saving has been completed.
1 = SAVE Parameters are being saved to the FPROM memory.
16.07 CTRL BOARD Defines the source of the RMIO control board power supply. 1=1 1 B
SUPPLY Note: If an external supply is used but this parameter has value
INTERNAL, the drive trips on a fault when the power is
switched off.
1 = INTERNAL 24V The RMIO control board is supplied from internal power supply
from the inverter module. After power fail saving function the
RMIO board is booted.
2 = EXTERNAL 24V The RMIO control board is powered from an external supply.
After power fail saving function the RMIO is not automatically
booted.
16.08 FAN SPD CTRL Selects the inverter fan speed control. Parallel connected 2 I
MODE inverter modules 1…12 × R8i equipped with an optional
inverter fan have adjustable speed control as a function of IGBT
temperature. See section Inverter fan speed control on page
115.
During the charging of the inverter unit, the fan speed is
internally ramped to zero. When the charging is completed, the
speed accelerates to the selected speed.
0 = CONST 50HZ Fan is running always at constant frequency of 50 Hz when
powered.
1 = RUN/STOP Drive stopped: Fan is running at constant frequency of 10 Hz.
Drive started: Fan is running at constant frequency of 50 Hz.
2 = CONTROLLED Fan speed is determined from the IGBT temperature vs. the fan
speed curve.
Actual signals and parameters
185
Index Name/Selection Description FbEq Def. PB T
16.09 RESET COUNTER Resets the motor cooling fan or drive cooling fan running time - NO 259 I
counter.
1 = NO No reset
2 = MOTOR TIME Motor cooling fan running time counter reset (01.38 MOTOR
RUN-TIME)
3 = FAN ON TIME Drive cooling fan running time counter reset (01.31 FAN-ON-
TIME)
16.10 INT CONFIG USER Defines the number of parallel connected R8i inverter modules I
in the drive. Activates the reduced run function. See section
Reduced run function on page 83.
1...12 Number of parallel connected inverters
16.14 RUN INTERLOCK Activates the run interlock function. - OFF 264 B
1 = ON Active (Main Status Word 08.01 bit 13 value is 1). Motor start is
prevented or motor stops if it was already running.
Note: Run interlock does not activate any alarm or fault.
0 = OFF Inactive
17 DC HOLD DC hold function settings
17.01 DC HOLD Activates the DC hold function. DC hold is not possible if 1=1 NO 276 B
parameter 99.08 MOTOR CTRL MODE is set to SCALAR.
When both the reference and the speed drop below the value
defined by parameter 17.02 DC HOLD SPEED, the drive will
stop generating sinusoidal current and start to inject DC into the
motor. The current is set by parameter 17.03 DC HOLD
CURRENT. When the reference speed exceeds parameter
17.02 value, normal drive operation continues.
SPEEDmotor
DC hold
Ref.
DC HOLD SPEED t
(par. 17.02)
Note: DC hold has no effect if the start signal is switched off.
Note: Injecting DC current into the motor causes the motor to
heat up. In applications where long DC hold times are required,
externally ventilated motors should be used. If the DC hold
period is long, the DC hold cannot prevent the motor shaft from
rotating if a constant load is applied to the motor.
1 = YES Active
0 = NO Inactive
17.02 DC HOLD SPEED Defines the DC hold speed. 1=1 5 277 R
0...3600 rpm Speed
17.03 DC HOLD Defines the DC hold current. 1=1 30 278 R
CURRENT
0...100% Value in percent of motor nominal current
Actual signals and parameters
186
Index Name/Selection Description FbEq Def. PB T
18 LED PANEL CTRL The NLMD-01 Monitoring Display has a LED bar to show
an absolute real type value.
0 50 100 150%
The source and the scale of the display signal are defined by
this parameter group.
Note: If NLMD -01 and CDP 312R control panel are used
together, actual signal 01.26 LED PANEL OUTPUT must be the
first signal in CDP 312R Actual Signal Display Mode. Otherwise
the NLMD-01 LED bar display will show an incorrect value.
18.01 LED PANEL Selects the signal source for the NLMD-01 Monitoring Display. 107 301 I
OUTPUT
0…9999 For example parameter index 109 denotes parameter 01.09
POWER.
Note: The unit of the selected signal must be percent (%).
18.02 SCALE PANEL Defines the value of the signal selected by parameter 18.01 1=1 100 302 R
LED PANEL OUTPUT which corresponds to 100% on the LED
bar display.
Example: Signal 01.05 FREQUENCY is shown on the LED
display:
At 50 Hz the LED display indicates full value (100%) when:
Parameter 18.01 is set to 105.
Parameter 18.02 is set to 5000 (= 100 · 50 = 5000, where 100 is
the integer scale (FbEq) for signal 01.05.
0...65536 Scaling factor
Actual signals and parameters
187
Index Name/Selection Description FbEq Def. PB T
19 DATA STORAGE Parameters for receiving information from or sending to an
external control system. The parameters are unconnected and
they can be used for linking, testing and commissioning
purposes. See chapter Fieldbus control.
AC 800M / AC 80 RMIO
Dataset table
Address For
Data
Data set Index assignment of DriveWindow
set
14 dataset PC tool
A Index 1 Group Index
1
Index 2 90 08 19.01
14 2
Index 3
3
A = value assigned from an external control system
AC 800M / AC 80 RMIO
Dataset table
Address From
Data
Data set Index assignment of DriveWindow
set
15 dataset PC tool
Index 1 Group Index
1
Index 2 92 08 19.02
B 15 2
Index 3
3
B = value assigned from an external control system
19.01 DATA 1 Stores data written from a user-defined source. 1=1 326 R
Example: Monitor a signal written by an external control
system to data set 18 word 3 using the DriveWindow PC tool as
follows:
Define the data set 18 word 3 destination address in the
converter application program by setting parameter 90.15 DATA
SET 18 VAL 3 to 1901 (points to 19.01 DATA 1.)
Set DriveWindow monitoring channel to read parameter 19.01.
-32768...32767 Data value
19.02 DATA 2 See parameter 19.01 DATA 1. 1=1 327 R
-32768...32767 Data value ...
... ... ... ...
19.08 DATA 8 1=1 333 R
-32768...32767 Data value
20 LIMITS Drive operation limits
Note: The absolute nominal torque is calculated in the
application program from the motor parameters. See parameter
group 99 START-UP DATA.
20.01 MINIMUM SPEED Defines the allowed minimum speed. See par. See 351 R
Note: The limit is linked to the motor nominal speed 50.01. par.
setting, parameter 99.05 MOTOR NOM SPEED. If 99.05.
Par. 99.05 value is changed, the default speed limit is
also changed.
Actual signals and parameters
188
Index Name/Selection Description FbEq Def. PB T
-9000...1500 rpm Minimum speed limit
Note: If the value is positive, the motor cannot be run in the
reverse direction.
20.02 MAXIMUM SPEED Defines the allowed maximum speed. See par. See 352 R
Note: The limit is linked to the motor nominal speed 50.01. par.
setting, parameter 99.05 MOTOR NOM SPEED. If 99.05.
Par. 99.05 value is changed, the default speed limit is
also changed.
-1500...9000 rpm Maximum speed limit
20.03 ZERO SPEED Defines the zero speed limit. The motor is stopped along See par. 4% of 353 R
LIMIT a speed ramp until ZERO SPEED LIMIT is reached. After the 50.01. nom.
limit, the motor coasts to stop. motor
speed
0...15000 rpm Zero speed limit
20.04 MAXIMUM Defines the allowed maximum motor current Ihd. The maximum 100 = 170 354 R
CURRENT values are limited according to the duty cycle tables. See the 1%
appropriate technical catalogue.
0...200% Current limit in percent of the allowed maximum motor current
20.05 MAXIMUM Defines the maximum torque limit for the drive. 100 = 300 355 R
TORQUE 1%
0...600% Torque limit in percent of the motor nominal torque
20.06 MINIMUM Defines the minimum torque limit for the drive. 100 = -300 356 R
TORQUE 1%
-600...0% Torque limit in percent of the motor nominal torque
20.07 SPC TORQMAX Defines the maximum speed controller output limit. 100 = 300 357 R
1%
0...600% Limit in percent of the motor nominal torque
20.08 SPC TORQMIN Defines the minimum speed controller limit. 100 = -300 358 R
1%
-600...0% Limit in percent of the motor nominal torque
20.09 TREF TORQMAX Defines the maximum torque reference limit. 100 = 300 359 R
1%
0...600% Limit in percent of the motor nominal torque
20.10 TREF TORQMIN Defines the minimum torque reference limit. 100 = -300 360 R
1%
-600...0% Limit in percent of the motor nominal torque
20.11 FREQ TRIP Defines together with parameters 20.01 MINIMUM SPEED and 100 = 50 361 R
MARGIN 20.02 MAXIMUM SPEED the maximum allowed frequency 1 Hz
(overspeed protection). If this frequency is reached,
OVERSPEED fault is activated.
Example: If the maximum speed is 1420 rpm = 50 Hz and
frequency trip margin is 10 Hz, the drive trips at 60 Hz.
0...500 Hz Frequency trip margin
20.12 PULLOUT TCOEF Limits the maximum motoring torque to prevent motor pull-out. 1=1 70 362 R
MAX See parameter 20.13 PULLOUT TCOEF MIN.
40...100% Maximum torque limit in percent of the calculated pull-out
torque
Actual signals and parameters
189
Index Name/Selection Description FbEq Def. PB T
20.13 PULLOUT TCOEF Limits the minimum motor torque to prevent pull-out (when 1=1 50 363 R
MIN pulse encoder speed feedback is not used, i.e. 50.03 SPEED
FB SEL = INTERNAL).
|T|
PULLOUT TCOEF MAX
(par. 20.12)
PULLOUT TCOEF MIN
(par. 20.13)
f / Hz
20 Hz
0...100% Minimum torque limit in percent of the calculated pull-out torque
20.14 ADAPTIVE UDC Selects the adaptive DC voltage measurement function. 1=1 1 364 B
MEAS With several inverters connected to the same DC link, the DC
voltage measurement function should be OFF to ensure that
the inverters operate similarly during undervoltage control
(parameter 30.22 UNDERVOLTAGE CTL).
0 = OFF No adaptive DC voltage measurement function: Full DC voltage
(100%) equals to 1.35 · U1max, where U1max is the maximum
value of the input voltage range.
During undervoltage control, torque is controlled as defined by
parameters 20.15 UNDERVOLT TORQ UP and 20.16
UNDERVOLT TORQ DN.
1 = ON Adaptive DC voltage measurement function: DC voltage floats
according to the network conditions.
20.15 UNDERVOLT Limits the maximum torque during undervoltage control (30.22 10 =1% 500 365 R
TORQ UP UNDERVOLTAGE CTL). See parameters 20.16 UNDERVOLT
TORQ DN and 20.14 ADAPTIVE UDC MEAS.
T
UNDERVOLT TORQ UP
(par. 20.15)
UDC / V
UDC nominal
DC UNDERVOLT LIM
UNDERVOLT TORQ DN
(par. 20.16) UDC undervoltage trip limit
-T
0...600% Value in percent of the maximum motor torque
20.16 UNDERVOLT Limits the minimum torque at undervoltage trip limit. This -10 = -500 366 R
TORQ DN parameter is used together with the undervoltage controller -1%
(30.22 UNDERVOLTAGE CTL) to tune the generating torque
level of the drive during a supply power failure. See parameters
20.15 UNDERVOLT TORQ UP and 20.14 ADAPTIVE UDC
MEAS.
DC undervoltage trip limit is 0.6 × 1.35 × U1min, where U1min is
the minimum value of the input voltage range.
-500...0% Value in percent of the minimum motor torque
Actual signals and parameters
190
Index Name/Selection Description FbEq Def. PB T
20.17 P MOTORING LIM Defines the allowed maximum power fed by the inverter to the 100 = 300 367 R
motor. 1%
0...600% Power limit in percent of the motor nominal power
20.18 P GENERATING Defines the allowed maximum power fed by the motor to the 100 = -300 368 R
LIM inverter. 1%
-600...0% Power limit in percent of the motor nominal power
21 START/STOP Start and stop modes of the motor
FUNC Note: Coast stop is always the stop mode in a fault situation.
21.01 START FUNCTION Selects the motor starting method. 1 376 I
1 = AUTO Automatic start guarantees optimal motor start in most cases.
It includes the flying start function (starting to a rotating
machine) and the automatic restart function. The drive motor
control program identifies the flux as well as the mechanical
state of the motor and starts the motor instantly under all
conditions.
2 = DC MAGN DC magnetising should be selected if a high break-away torque
is required. The drive pre-magnetises the motor before the
start. The pre-magnetising time is determined automatically,
being typically 200 ms to 2 s depending on the motor size. DC
magnetising guarantees the highest possible break-away
torque.
Note: Starting to a rotating machine is not possible when DC
magnetising is selected.
Note: DC magnetising cannot be selected if parameter 99.08
MOTOR CTRL MODE = SCALAR.
3 = CNST DC Constant DC magnetising should be selected instead of DC
MAGN magnetising if constant pre-magnetising time is required (for
example if the motor start must be simultaneous with a
mechanical brake release). This selection also guarantees the
highest possible break-away torque when the pre-magnetising
time is set long enough.The pre-magnetising time is defined by
parameter 21.02 CONST MAGN TIME.
This mode remembers the last position of the motor shaft. This
minimises possible shaft movement during the next start. See
parameter 21.11 START JERK COMP.
Note: Starting to a rotating machine is not possible when DC
magnetising is selected.
Note: DC magnetising cannot be selected if parameter 99.08
MOTOR CTRL MODE = SCALAR.
WARNING! The drive will start after the set
magnetising time has passed although the motor
magnetisation is not completed. Ensure always in
applications where a full break-away torque is essential that the
constant magnetising time is long enough to allow generation of
full magnetisation and torque.
21.02 CONST MAGN Defines the magnetising time in the constant magnetising mode 1 = 1 ms 300 377 R
TIME (21.01 START FUNCTION = CNST DC MAGN). After the start
command, the drive automatically pre-magnetises the motor
the set time.
Actual signals and parameters
191
Index Name/Selection Description FbEq Def. PB T
30...10000 ms Magnetising time. To ensure full magnetising, set this value to
the same value as or higher than the rotor time constant. If not
known, use the rule-of-thumb value given in the table below:
Rated motor power Constant magnetising time
<10 kW > 100 to 200 ms
10 to 200 kW > 200 to 1000 ms
200 to 1000 kW > 1000 to 2000 ms
21.03 STOP FUNCTION Selects the motor stop function in local and I/O control modes. 1 378 I
1 = STOP Stop along a ramp. See parameter group 22 ACCEL/DECEL.
RAMPING
2 = STOP TORQ Stop according to the set torque limit (par. 20.05...20.08).
3 = COAST STOP Stop by cutting off the motor power supply. The motor coasts to
stop.
21.04 EME STOP MODE Selects the motor emergency stop function. See section 1 379 I
Emergency stop on page 67.
1 = STOP Stop along the emergency stop ramp. See parameter 22.04
RAMPING EME STOP RAMP.
2 = STOP TORQ Stop according to the set torque limit (par. 20.05...20.08).
3 = COAST STOP Stop by cutting off the motor power supply. The motor coasts to
stop.
4 = FOLLOW STOP Follower drive is decelerated to a stop with the Master drive
torque reference. 07.01 Main Control Word bit 6 (RAMP IN
ZERO) value is set to zero and emergency stop ramp is
activated.
5 = EXT DEC REF Stop according to the external speed reference using
deceleration ramp time (Par. 22.02 DECELER TIME).
6 = EXT DEC REF2 Stop according to the external speed reference using
emergency stop deceleration reference received from fieldbus.
Deceleration of speed reference follows Emergency stop ramp
time in follower drive.
21.05 EMSTOP DER Defines the maximum deceleration rate for emergency stop. If 1 = 1 1800 380 R
MAX L the drive is not able to decelerate within the window defined by
parameters 21.06 EMSTOP DER MAX L and 21.05 EMSTOP
DER MIN L, it is stopped by coasting and 08.02 AUX STATUS
WORD bit 2 value is set to 1.
Setting this parameter to 1800 rpm/s (= default value) disables
the supervision of the minimum deceleration.
See also parameter 21.07 EM STOP DEC MON DEL and
section Emergency stop on page 67.
0...18000 rpm/s Maximum deceleration rate
21.06 EMSTOP DER MIN Defines the minimum deceleration rate for emergency stop. If 1=1 0 381 R
L the drive is not able to decelerate within the window defined by
parameters 21.06 EMSTOP DER MIN L and 21.05 EMSTOP
DER MAX L, it is stopped by coasting and 08.02 AUX STATUS
WORD bit 2 value is set to 1.
Setting this parameter to 0 rpm/s (= default value) disables the
supervision of the maximum deceleration.
Actual deceleration can be monitored with signal 02.16 dv/dt.
See also parameter 21.07 EM STOP DEC MON DEL and
section Emergency stop on page 67.
Actual signals and parameters
192
Index Name/Selection Description FbEq Def. PB T
0...18000 rpm/s Minimum deceleration time
21.07 EM STOP DEC Defines the time delay between the emergency stop signal and 10 = 1 s 20 382 R
MON DEL the start of the deceleration monitoring. See parameters 21.06
EMSTOP DER MAX L and 21.05 EMSTOP DER MIN L.
0...100 s Time delay
21.09 AUTO RESTART Activates automatic restart using flying start after a short supply 1 = 1 OFF 384 B
power failure. See parameter 21.10 AUTO RESTART TIME.
0 = OFF Inactive
1 = ON Active
21.10 AUTO RESTART Defines the maximum time for a power failure for the auto 10 = 1 s 5 385 R
TIME restart function (21.09 AUTO RESTART). This time also
includes the charging delay of the inverters.
0.3...5 s Maximum time
21.11 START JERK Enables internal position control during the magnetising of the 1 = 1% 0 386 R
COMP motor to minimise shaft movement when the start mode
selected by parameter 21.01 START FUNCTION is CONST DC
MAGN. Find the setting that gives the smallest shaft movement.
Setting this parameter to 0 (= default value), disables the
function.
0...100% Value in percent
21.12 LOCAL EMSTOP Selects the source for the emergency stop activation signal in 1=1 1 387 I
MODE local control mode. See section Emergency stop on page 67.
0 = DI Digital input
1 = DI+FIELDBUS Digital input or fieldbus
22 ACCEL/DECEL Speed reference ramp functions. See section Acceleration and
deceleration ramps on page 72.
22.01 ACCELER TIME Defines the acceleration time i.e. the time required for the 100 = 20 401 R
speed to change from zero to the speed defined by parameter 1s
50.01 SPEED SCALING.
The maximum acceleration time is 1800 s (acceleration time
can be expanded by parameter 22.03 ACC/DEC TIME SCLE).
0...1000 s Acceleration time
22.02 DECELER TIME Defines the deceleration time i.e. the time required for the 100 = 20 402 R
speed to change from the value defined by parameter 50.01 1s
SPEED SCALING to zero.
The maximum deceleration time is 1800 s (deceleration time
can be expanded by parameter 22.03 ACC/DEC TIME SCLE).
If the deceleration time is set too short, the drive will
automatically prolong the deceleration in order not to exceed
drive operating limits. If there is any doubt about the
deceleration time being too short, ensure that the DC
overvoltage control is on (parameter 30.23 OVERVOLTAGE
CTL).
Note: If a short deceleration time is needed for a high inertia
application, the drive should be equipped with an electric
braking option for example with a brake chopper and a brake
resistor.
0...1000 s Deceleration time
Actual signals and parameters
193
Index Name/Selection Description FbEq Def. PB T
22.03 ACC/DEC TIME Multiplies the acceleration/deceleration defined by parameter 100 = 1 1 403 R
SCLE 22.01/22.02 ACCELER/DECELER TIME.
0.1...100 Multiplication factor
22.04 EME STOP RAMP Defines the time inside which the drive is stopped if 10 = 1 s 20 404 R
an emergency stop is activated and parameter 21.04 EME
STOP MODE is set to STOP RAMPING. (i.e. the time required
for the speed to change from the value defined by parameter
50.01 SPEED SCALING to zero).
0...3000 s Deceleration time
22.05 SHAPE TIME Selects the shape of the acceleration/deceleration ramp. 100 = 0 405 R
This function is deactivated during emergency stop. 1s
0...1000 s 0.00 s: Linear ramp. Suitable for steady acceleration or
deceleration and for slow ramps.
0.01 … 1000.00 s: S-curve ramp. S-curve ramps are ideal for
conveyors carrying fragile loads, or other applications where a
smooth transition is required when changing from one speed to
another. The S-curve consists of symmetrical curves at both
ends of the ramp and a linear part in between.
Motor
speed
Linear
S-curve
t (s)
acceleration ramp shape
time time
(par. 22.01) (par. 22.05)
22.06 VARIABLE SLOPE Controls the slope of the speed ramp during a speed reference 1 = 1 OFF 406 B
change. See parameter 22.07 VAR SLOPE RATE and section
Variable slope on page 73.
1 = ON Control is active with the exception of LOCAL control mode.
0 = OFF Control inactive
22.07 VAR SLOPE RATE Defines the rate of the speed reference change, when 1 = 1 ms 4.05 407 R
parameter 22.06 VARIABLE SLOPE is ON.
Set this parameter to the same value as the updating time
interval of the external control system.
4.1...30000 ms Rate of the speed reference change
22.08 BAL RAMP REF Forces the output of the speed ramp to a selected value. The See par. 0 408 R
function is activated by setting 07.02 AUX CTRL WORD 1 bit 3 50.01.
value to 1.
See par. Speed ramp output
20.01...20.02 (rpm)
Actual signals and parameters
194
Index Name/Selection Description FbEq Def. PB T
23 SPEED REF Speed reference functions. See control block diagram in
section Speed reference on page 313.
23.01 SPEED REF Defines the main speed reference for the speed controller input. See par. 0 426 R
50.01.
See par. Speed reference.
20.01...20.02 (rpm) Note: The value of this parameter value is not saved to the
flash memory.
23.02 CONST SPEED 1 Defines constant speed 1. Constant speed reference is 1=1 0 427 I
activated by 07.01 MAIN CONTROL WORD bit 8. See also
Main Control Word bits 4...6.
-18000...18000 rpm Constant speed 1
23.03 CONST SPEED 2 Defines constant speed 2. Constant speed reference is 1=1 0 428 I
activated by 07.01 MAIN CONTROL WORD bit 9. See also
Main Control Word bits 4...6.
-18000...18000 rpm Constant speed 2
23.04 SPEED Defines a value to be added to filtered speed reference 02.02 See par. 0 429 R
CORRECTION SPEED REF 3. 50.01.
Note: Parameter value is cleared at the beginning of an
emergency stop.
Note: Parameter value is not saved to the flash memory.
Note: If an external control system or RMIO software writes
a value into this parameter, the value must be set to zero before
a stop command is issued for the drive.
See par. 99.05 Speed correction
(rpm)
23.05 SPEED SHARE Speed reference share coefficient. 10 = 1% 100 430 R
Note: Parameter value is not effective during emergency stop.
-400...400% Value in percent
23.06 SPEED ERROR Defines the speed error filter time constant. (Speed error = 1 = 1 ms 0 431 R
FILT 02.18 SPEED REF4 - Motor speed)
0...999999 ms Speed error filter time
Actual signals and parameters
195
Index Name/Selection Description FbEq Def. PB T
23.07 WINDOW INTG ON The window control, together with selection ADD of parameter 1=1 OFF 432 B
26.01 TORQUE SELECTOR, forms a speed supervision
function for a torque controlled drive.
07.02 AUX CTRL WORD 1 bit 7 WINDOW CTRL must be set to
1 to enable the window control.
See also window control status bit, 08.02 AUX STATUS WORD
bit 1.
1 = ON Active. When window control is on, the integration part of the
speed controller is active. This selection is used only when
parameter 26.01 TORQUE SELECTOR value is set to ADD.
Window control supervises the speed error value (speed
reference - actual speed). In normal operation, the drive is
torque controlled according to 02.08 TORQ REF1.
The speed controller is evoked only if
- the speed error exceeds the value of parameter 23.08
WINDOW WIDTH POS
or
- the absolute value of the negative speed error exceeds the
value of parameter 23.09 WINDOW WIDTH NEG.
When the speed error moves outside the window, the
exceeding part of the error value is connected to the speed
controller. The speed controller produces a reference term,
relative to the speed controller input and gain, which the torque
selector adds to the torque reference. The result is used as the
internal torque reference for the drive.
When window control is used, the speed control (P-control)
brings the speed to the sum of SPEED REF4 + WINDOW
WIDTH. (Note the permanent error of the P-control.)
Example: In a load loss condition the motor speed rises until a
speed limit of the drive is reached. If window control is used, the
internal torque reference of the drive is decreased to prevent
an excessive rise of the motor speed.
0 = OFF Inactive. When window control is on, the integrator part of the
speed control is inactive.
23.08 WINDOW WIDTH Defines the speed limit for the window control, when the See par. Motor 433 R
POS calculated speed error (speed reference - actual speed) is 50.01. nom.
positive. Parameter 07.02 AUX CTRL WORD 1 bit 7 WINDOW speed
CTRL must be set to 1 to enable the window control.
Note: Window control speed limits (defined by par. 23.08 and
23.09) are forced to zero if the sum of 02.18 SPEED REF 4 and
23.09 WINDOW WIDTH NEG / 23.08 WINDOW WIDTH POS is
> 20.02 MAXIMUM SPEED or
< 20.01 MINIMUM SPEED.
See also parameter 23.11 SYMMETRIC WINDOW.
This parameter is also used with speed controlled follower with
load share function as maximum output limiting. See chapter
Control block diagrams in section Speed reference ramp.
0... 15000 (rpm) Speed limit
Actual signals and parameters
196
Index Name/Selection Description FbEq Def. PB T
23.09 WINDOW WIDTH Defines the speed limit for the window control, when the See par. Motor 434 R
NEG calculated speed error (speed reference - actual speed) is 50.01. nom.
negative. Parameter 07.02 AUX CTRL WORD 1 bit 7 WINDOW speed
CTRL must be set to 1 to enable the window control.
Note: Window control speed limits (defined by par. 23.08 and
23.09) are forced to zero if the sum of 02.18 SPEED REF 4 and
23.09 WINDOW WIDTH NEG / 23.08 WINDOW WIDTH POS is
> 20.02 MAXIMUM SPEED or
< 20.01 MINIMUM SPEED.
See also parameter 23.11 SYMMETRIC WINDOW.
This parameter is also used with speed controlled follower with
load share function as minimum output limiting. See chapter
Control block diagrams in section Speed reference ramp.
0... 15000 (rpm) Speed limit. The maximum is the absolute value of the setting
defined by parameter 23.08 WINDOW WIDTH POS.
23.10 SPEED STEP Defines an additional speed step given to the input of the speed See par. 0 435 R
controller (added to the speed error value). See control block 50.01.
diagram in section Speed control on page 315.
Note: If an external control system writes a value into this
parameter, the value must be set to zero (from the external
control system) before a stop command is issued for the drive.
Note: Parameter value is not saved to the flash memory.
See par. Additional speed step
20.01...20.02 (rpm)
23.11 SYMMETRIC Activates the symmetric window control function. Values for 1=1 0 436 B
WINDOW 23.08 WINDOW WIDTH POS and 23.09 WINDOW WIDTH
NEG are calculated from the absolute value of the speed
instead of the signed value of the speed. Thus window width
functions are symmetric for both directions of rotation.
Parameter 23.09 WINDOW WIDTH NEG functions as
overspeed supervision and 23.08 WINDOW WIDTH POS as
underspeed supervision.
0 = OFF Inactive
1 = ON Active
23.12 RFE SPEED Activates the resonance frequency elimination function. The 1=1 0= B
FILTER actual speed of the speed controller is filtered by a common OFF
2nd order band-elimination filter to eliminate amplification of
mechanical resonance frequencies. The filter is configured by
parameters 23.13...23.16.
Note: When tuning the filter, the user should have basic
understanding of frequency filters. Incorrect tuning of the
parameters may amplify mechanical oscillations and cause
damage to the drive hardware. When the filter configuration
parameters are changed, it is recommended that the inverter is
either stopped or that the filter is switched off to ensure stability
of the speed controller.
1 = ON Active
0 = OFF Inactive
Actual signals and parameters
197
Index Name/Selection Description FbEq Def. PB T
23.13 FREQUENCY OF Defines the zero frequency of the band-elimination filter. The 10 = 45 R
ZERO frequency must be set near the resonance frequency, which is 1 Hz
filtered out before the speed controller.
Frequency response
20
0
20log10|H(ω)|
-20
-40
-60
0 50 100 150
f / Hz
0.5...500 Hz Zero frequency
23.14 DAMPING OF Defines the damping coefficient for the 23.13 FREQUENCY OF 100 = 0 R
ZERO ZERO. Value 0 corresponds to the maximum elimination of the 1.0
resonance frequency FREQUENCY OF ZERO.
20
fzero = 45 Hz
ξzero = 0.25
0 ξpole = 1
20log10|H(ω)|
-20 fzero = 45 Hz
ξzero = 0
ξpole = 1
-40
-60
0 50 100 150
f / Hz
Note: To ensure that the resonance frequency band is filtered,
not amplified, DAMPING OF ZERO must be smaller than
DAMPING OF POLE (parameter 23.16).
-1...1 Damping coefficient
Actual signals and parameters
198
Index Name/Selection Description FbEq Def. PB T
23.15 FREQUENCY OF Defines the frequency of pole of the band-elimination filter. 10 = 40 R
POLE 1 Hz
40
fzero = 45 Hz
fpole = 50 Hz
20 ξzero = 0
ξpole = 0.25
0
20log10|H(ω)|
fzero = 45 Hz
-20 fzero = 45 Hz
fpole = 30 Hz
fpole = 40 Hz
-40 ξzero = 0
ξzero = 0
ξpole = 0.25
ξpole = 0.25
-60
50 100
0
f / Hz
Note: If this parameter value is very different from parameter
23.13 FREQUENCY OF ZERO value, the frequencies near the
FREQUENCY OF POLE are amplified, which may cause
damage to the driven machine.
0.5...500 Hz Frequency of pole
23.16 DAMPING OF Defines the damping coefficient for the 23.15 FREQUENCY OF 100 = 0.25 R
POLE POLE. 1.0
Shapes the frequency response of the band-elimination filter:
Narrower bandwidth results in better dynamic properties. By
setting this parameter value to 1 the effect of the pole is
eliminated.
40
fzero = 45 Hz
fpole = 40 Hz
20
ξzero = 0
ξpole = 0.05
0
20log10|H(ω)|
-20 fzero = 45 Hz fzero = 45 Hz
fpole = 40 Hz fpole = 40 Hz
-40 ξzero = 0 ξzero = 0
ξpole = 0.75 ξpole = 0.25
-60
50 100
0
f / Hz
Note: To ensure that the resonance frequency band is filtered,
not amplified, DAMPING OF POLE must be higher than
DAMPING OF ZERO (parameter 23.14).
-1...1 Damping coefficient
23.17 RAMPED INCH Speed reference. 07.02 Auxiliary Control Word 1 bit 12 selects See par. 0 442 R
REF the used speed reference: 23.17 RAMPED INCH REF or 02.27 50.01.
USED SPEED REF.
See control block diagram in section Speed reference on page
313.
-18000...18000 rpm Speed
Actual signals and parameters
199
Index Name/Selection Description FbEq Def. PB T
23.18 FOLL SPD CTRL Defines the correction term for the load share function used 10 = 1% 0% 443 R
COR with speed controlled Follower drives. I.e. defines how
accurately the Follower drive follows the Master torque.
A greater value results in a more accurate performance.
See parameter 23.19 FOLL SPD COR MODE and section Load
share function with speed controlled Follower on page 114.
Note: Parameter 24.02 DROOP RATE setting must be 0.
0...100% Value in percent
23.19 FOLL SPD COR Selects the torque correction mode for the load share function 1 = 1 1 444 I
MODE used with speed controlled Follower drives. Used together with
parameter 23.18 FOLL SPD CTRL COR.
1 = FAST Fast torque correction mode. Follower torque is corrected as
fast as possible after the Master drive torque change.
2 = SLOW Slow torque correction mode. Follower torque is corrected
slowly after the Master drive torque change.
24 SPEED CONTROL Speed controller variables. See section Speed controller tuning
on page 24.
The speed controller is based on PID algorithm.
1
sTIS
Yr + u
+ + +
- + KPS
+
Tds
τfs+1
+
b
-
y
u(s) = KPS[(bYr(s)-Y(s))+(1/(sTIS) + Tds/(τfs+1))e(s)]
u = actual output of the controller
e = speed error (difference between actual and
reference speed)
Yr = setpoint value
TIS = integration time
KPS = gain
Td = derivation time
24.01 PI TUNE Activates automatic tuning of the speed controller. Tuning is 1=1 OFF 451 B
based on the estimation of the mechanical time constant.
Parameters 24.03 KPS, 24.09 TIS and 24.15 ACC COMP DER
TIME are updated after the PI tuning.
Instructions:
- Run the motor at a constant speed of 20 to 40% of the rated
speed.
- Activate the PI tune by setting this parameter to 1 = ON.
Note: The motor load must be connected to the motor.
0 = OFF Inactive
1 = ON Active
Actual signals and parameters
200
Index Name/Selection Description FbEq Def. PB T
24.02 DROOP RATE Defines the droop rate. The correct droop rate for a process 10 = 1% 0 452 R
must be found out case by case in practice.
The drooping slightly decreases the drive speed as the drive
load increases. The actual speed decrease at a certain
operating point depends on the droop rate setting and the drive
load (= torque reference / speed controller output). At 100%
speed controller output, drooping is at its nominal level, i.e.
equal to the value of the DROOP RATE. The drooping effect
decreases linearly to zero along with the decreasing load.
This parameter value is also valid during emergency stop.
Speed decrease = Speed controller output · Drooping ·
Max.speed
Example: Speed controller output is 50%, DROOP
RATE is 1%, maximum speed of the drive is 1500 rpm.
Speed decrease = 0.50 · 0.01 · 1500 rpm = 7.5 rpm
Motor speed
% of
nominal
No drooping
100% } Par. 24.02
Drooping DROOP RATE
100%
Speed Controller Drive load
Output / %
Note: Parameter setting must be 0 when load share is used
with speed controlled Follower drives. See section Load share
function with speed controlled Follower on page 114.
0...100% Droop rate in percent of the motor nominal speed
24.03 KPS Defines the relative gain of the speed controller. Great gain may 100 = 1 10 453 R
cause speed oscillation.
The figure below shows the speed controller output after an
error step when the error remains constant.
% Gain = KPS = 1
TIS = Integration time = 0
Td= Derivation time = 0
Error value
Controller output
Controller
output = KPS · e e = Error value
t
0...250 Gain. If KPS is set to 1, a 10% change in error value (reference
- actual value) causes the speed controller output to change by
10%.
Actual signals and parameters
201
Index Name/Selection Description FbEq Def. PB T
24.04 KPS MIN Defines the gain when speed controller output is zero. 100 = 1 10 454 R
Speed error filtering with parameter 23.04 SPEED
CORRECTION is typically not enough to tune the drive. The
adaptive gain of the speed controller can be used to smooth out
disturbances caused by small load and backlashes.
See parameter 24.05 KPS WEAKPOINT.
KPS
KPS
KPS MIN
(par. 25.04)
TORQUE REF 5
(par. 02.12)
KPS WEAKPOINT (par. 24.05)
0...150 Minimum KPS (gain)
24.05 KPS WEAKPOINT Defines the speed controller output when gain is KPS. See 100 = 0 455 R
parameter 24.04 KPS MIN. 1%
0...see par. 20.05 KPS (gain) weakpoint
(%)
24.06 KPS WP FILT TIME Softens the rate of the change of the gain. 1 = 1 ms 100 456 R
0...999999 ms KPS (gain) weakpoint filter time
24.07 SET P WEIGHTING Enables the setpoint weighting. In setpoint weighting the OFF 457 B
setpoint is weighted by factor b < 1. Decreasing b toward zero
reduces the overshoot on setpoint changes. Weighting is
applied only to the P-part of the PID controller.
When response to the ramp changes without delays is required,
see acceleration compensation parameters 24.14 ACC COMP
DER TIME and 24.15 ACC COMPFILT TIME.
This parameter can be changed on-line.
See parameter 24.08 SET POINT WEIGHT and PID algorithm
of the speed controller above.
0 = OFF Disabled
1 = ON Enabled
24.08 SET POINT Defines the setpoint weighting, i.e. the speed controller output 1 = 1% 100 458 R
WEIGHT when gain is KPS.
30...100% Setpoint weighting
Actual signals and parameters
202
Index Name/Selection Description FbEq Def. PB T
24.09 TIS Defines the integration time of the speed controller. The 1000 = 2.5 459 R
integration time defines the rate at which the controller output 1s
changes when the error value is constant and the relative gain
of the speed controller is 1. The shorter the integration time, the
faster the continuous error value is corrected. Too short
an integration time makes the control unstable.
The figure below shows the speed controller output after an
error step when the error remains constant.
% Controller output
Gain = KPS = 1
TIS = Integration time > 0
KPS · e Td= Derivation time = 0
KPS · e e = Error value
t
TI
0.01...1000 s Integration time
24.10 TIS INIT VALUE Defines the initial value of the integrator. 100 = 0 460 R
1%
See par. Value in percent of motor nominal torque
20.06...20.05 (%)
24.11 BAL REF Defines the external value to be forced to the output of the 100 = 0 461 R
speed controller. Signal 07.02 Auxiliary Control Word 1 bit 8 1%
value must be 1.
See control block diagram in section Speed control on page
315.
See par. Value in percent of the nominal motor torque
20.06...20.05 (%)
Actual signals and parameters
203
Index Name/Selection Description FbEq Def. PB T
24.12 DERIVATION TIME Defines the derivation time of the speed controller. Derivative 1 = 1 ms 0 462 R
action boosts the controller output if the error value changes.
The longer the derivation time, the more the speed controller
output is boosted during the change. If the derivation time is set
to zero, the controller works as a PI controller, otherwise as
a PID controller. The derivation makes the control more
responsive for disturbances.
Note: Changing this parameter is recommended only if a pulse
encoder is used.
The figure below shows the speed controller output after an
error step when the error remains constant.
Gain = KPS = 1
TIS = Integration time > 0
Td= Derivation time > 0
Ts= Sample time period = 2 ms
Δe = Error value change between two samples
Effect of derivation filter time
%
Controller Output
Δe
KPS · Td · KPS · e
Ts
Error Value
e = Error value
KPS · e
TIS t
0...10000 ms Derivation time
24.13 DERIV FILT TIME Defines the derivation filter time constant. 1 = 1 ms 8 463 R
0...100000 ms Derivation filter time constant
Actual signals and parameters
204
Index Name/Selection Description FbEq Def. PB T
24.14 ACC COMP DER Defines the ramp time for acceleration (deceleration) 10 = 1 s 0 464 R
TIME compensation i.e. the time within the drive accelerates to
nominal motor speed (99.05 MOTOR NOM SPEED) with
nominal torque when the load consists only of inertia mass.
(Friction compensation is not taken into account.)
In order to compensate inertia during acceleration a derivative
of the reference is added to the output of the speed controller.
The principle of a derivative action is described for parameter
24.12 DERIVATION TIME.
Note: As a general rule, set this parameter to the value
between 50 and 100% of the sum of the mechanical time
constants of the motor and the driven machine. (The speed
controller PI tune does this automatically, see parameter 24.01
PI TUNE.)
The figure below shows the speed responses when a high
inertia load is accelerated along a ramp.
Actual speed without acceleration compensation
Actual speed with acceleration compensation
Speed reference
Acceleration compensation
See parameter 24.15 ACC COMPFILT TIME.
0...1000 s Derivation time. The function is deactivated by setting the value
to 0 s.
24.15 ACC COMPFILT Defines the filter time for the acceleration compensation. 1 = 1 ms 8 465 R
TIME
0...999999 ms Time
24.16 SLIP GAIN Defines the slip gain for the motor slip compensation control. 1 = 1% 100 466 R
100% means full slip compensation; 0% means no slip
compensation. The default value is 100%. Other values can be
used if a static speed error is detected despite of the full slip
compensation.
Example: 1000 rpm constant speed reference is given to the
drive. Despite of the full slip compensation (SLIP GAIN =
100%), a manual tachometer measurement from the motor axis
gives a speed value of 998 rpm. The static speed error is
1000 rpm - 998 rpm = 2 rpm. To compensate the error, the slip
gain should be increased until no static speed error exist.
Parameter is effective only when the calculated internal speed
is used as actual speed feedback.
0...400% Slip gain value
Actual signals and parameters
205
Index Name/Selection Description FbEq Def. PB T
24.17 KPS TIS MIN FREQ Defines the minimum motor frequency limit above which the 100 = 5 467 R
relative gain and integration time are defined by parameters 1 Hz
24.19 KPS VAL MIN FREQ and 24.20 TIS VAL MIN FREQ.
At low speed, speed control can be improved by increasing the
relative gain and decreasing the integration time.
KPS
TIS
KPS VAL MIN FREQ (par. 24.19)
KPS
TIS
TIS VAL MIN FREQ (par. 24.20)
Motor frequency
KPS TIS MIN FREQ KPS TIS MAX FREQ
(par. 24.17) (par. 24.18)
0...200 Hz Frequency
24.18 KPS TIS MAX Defines the frequency at which KPS (gain) and TIS (integration 100 = 11.7 468 R
FREQ time) become constant. See parameter 24.17 KPS TIS MIN 1 Hz
FREQ.
0...200 Hz Frequency
24.19 KPS VAL MIN Defines the relative gain at speed defined by parameter 24.17 1 = 1% 100 469 R
FREQ KPS TIS MIN FREQ.
100...500% Value in percent of KPS (gain)
24.20 TIS VAL MIN FREQ Defines the integral time at speed defined by 24.17 KPS TIS 1 = 1% 100 470 R
MIN FREQ.
100...500% Value in percent of TIS (integration time)
25 TORQUE REF Torque reference functions. See control block diagram in
section Torque reference on page 316.
25.01 TORQUE REF A Defines torque reference A. Reference can be scaled by 100 = 0 476 R
parameter 25.03 LOAD SHARE. 1%
Note: This signal is reset when the control is switched to I/O
control. See parameter 10.07 AUTO/HAND.
-327…327% Torque reference A
25.02 TORQ REF A FTC Defines the low pass filter time constant for TORQUE REF A 1 = 1 ms 0 477 R
(25.01).
0...60000 ms Low pass filter time constant
25.03 LOAD SHARE Scales the external torque reference defined by parameter 10 = 1% 100 478 R
25.01 TORQUE REF A to a required level.
Note: Drooping (24.02 DROOP RATE) must be disabled when
load share is used with speed controlled Follower drives.See
section Load share function with speed controlled Follower on
page 114.
-400...400% Value in percent of TORQUE REF A
Actual signals and parameters
206
Index Name/Selection Description FbEq Def. PB T
25.04 TORQUE REF B Defines torque reference B. Torque reference B is ramped by 100 = 0 479 R
parameters 25.05 TORQ RAMP UP TIME and 25.06 TORQ 1%
RAMP DN TIME.
Note: This signal is reset when the control is switched to
external control (par. 98.02 = FIELDBUS or ADVANT/N-FB).
See parameter 10.07 AUTO/HAND.
Note: This parameter value is not saved to the flash memory.
-327…327% Torque reference B
25.05 TORQ RAMP UP Defines the torque reference ramp up time. 100 = 0 480 R
1s
0...120 s Time for the reference to increase from zero to the nominal
motor torque.
25.06 TORQ RAMP Defines the torque reference ramp down time. 100 = 0 481 R
DOWN 1s
0...120 s Time for the reference to decrease from the nominal motor
torque to zero.
25.07 TORQ ACT FILT Defines the filter time constant for signal 01.07 MOTOR TORQ 1 = 1 ms 100 482 R
TIM FILT2.
2...20000 ms Filter time constant
26 TORQUE REF Torque reference handling. See control block diagram in
HANDLING section Torque reference on page 316.
26.01 TORQUE Selects the reference used in motor torque control. 2 501 I
SELECTOR
1 = ZERO This selection forces the output of the torque selector to zero.
2 = SPEED Speed control
3 = TORQUE Torque control
Note: If TORQUE is selected, the drive does not restrict the
speed variation as long as the speed is within the limits defined
by parameters 20.01 MINIMUM SPEED and 20.02 MAXIMUM
SPEED. More definite speed supervision is often needed.
In those cases, the selection ADD should be used instead of
TORQUE.
Note: To prevent torque limitation in the generating mode, keep
the minimum torque limits < 0.
4 = MINIMUM The torque selector compares the torque reference (02.08
TORQ REF1) and the speed controller output (02.09 TORQ
REF2), and the smaller of them is used as the reference for the
motor torque control. If the speed error becomes negative, the
drive follows TORQ REF2 until the speed error becomes
positive again (latch function). Thus the drive never accelerates
uncontrolled if the load is lost in torque control.
5 = MAXIMUM The torque selector compares the torque reference (02.08
TORQ REF1) and the speed controller output (02.09 TORQ
REF 2) and the greater of them is used as the reference for the
motor torque control. If the speed error becomes positive, the
drive follows TORQ REF2 until the speed error becomes
negative again (latch function). Thus the drive never
accelerates uncontrolled if the load is lost in torque control.
Actual signals and parameters
207
Index Name/Selection Description FbEq Def. PB T
6 = ADD The torque selector adds speed controller output 02.09
TORQUE REF 2 to torque reference 02.08 TORQUE REF 1.
This selection together with the window control forms a speed
supervision function for a torque controlled Follower drive. See
parameter 23.07 WINDOW INTG ON and signal 07.02 AUX
CTRL WORD 1.
In normal generating mode the drive is speed controlled.
Torque reference TORQUE REF 1 is typically used for
acceleration and deceleration compensation (24.14 ACC
COMP DER TIME).
26.02 LOAD Adds load compensation to 02.10 TORQ REF3. 100 = 0 502 R
COMPENSATION Note: If an external control system writes a value into this 1%
parameter, the value must be set to zero (from the external
control system) before a stop command is issued for the drive.
Note: Value of this parameter is not saved to the flash memory.
See par. Load compensation
20.06...20.05 (%)
26.03 TORQUE STEP Adds an additional torque step to 02.11 TORQ REF4. 100 = 0 503 R
Note: If an external control system writes a value into this 1%
parameter, the value must be set to zero (from the external
control system) before a stop command is issued for the drive.
Note: Value of this parameter is not saved to the flash memory.
See par. Torque step
20.06...20.05 (%)
26.04 OSC Activates the damping of torsional vibration or DC voltage 1=1 OFF 504 B
COMPENSATION oscillation. The bandpass filter uses speed error or DC voltage
as an input selected by parameter 26.08 OSC COMP INPUT.
The amplified output of the filter is added to the torque
reference after phase shift defined by parameter 26.06
OSCILLATION PHASE. See parameters 26.05…26.08 and
section Oscillation damping on page 74.
0 = ON Active
1 = OFF Inactive
26.05 OSCILLATION Defines the center frequency of the filter. Oscillation frequency 100 = 31 505 R
FREQ is determined from the speed difference signal and the 1 Hz
following equation:
f = Npeaks / T
Npeaks is the number of peaks within time T (seconds).
0...60 Hz Oscillation frequency
26.06 OSCILLATION Defines the phase shift for the output of the filter. 1 = 1.41° 0 506 R
PHASE
0...360° Oscillation phase
26.07 OSCILLATION Defines how much the output of the filter is amplified before it is 100 = 0 507 R
GAIN added to torque reference. Oscillation gain is scaled according 1%
to the speed controller gain so that changing the gain will not
disturb oscillation damping. This scaling is not effective when
DC VOLTAGE is selected to input.
0...100% Oscillation gain
26.08 OSC COMP INPUT Determines the input signal for oscillation damping function. 1 =1 0 508 B
0 = SPEED ERROR Speed error is selected to input of oscillation damping function. 0
Actual signals and parameters
208
Index Name/Selection Description FbEq Def. PB T
1 = DC VOLTAGE DC voltage is selected to input of oscillation damping function. 1
27 FLUX CONTROL Flux control settings
27.01 FLUX Activates the flux optimisation function. Optimises the motor 1=1 NO 526 B
OPTIMIZATION flux by minimising the motor losses and reducing motor noise.
Flux optimisation is used in drives that usually operate below
nominal load. See section Flux optimisation on page 71.
1 = YES Active
0 = NO Inactive
27.02 FLUX BRAKING Activates the flux braking function. 1=1 OFF 527 B
The braking ability of the drive can be highly improved by
utilising flux braking. During braking, mechanical energy of the
driven equipment has to be dissipated by the motor and the
inverter. By modifying the magnetising level of the motor,
thermal losses can be increased and the motor can be stopped
more effectively. This function can be used with the
non-regenerative incoming sections. See section Flux braking
on page 71.
1 = YES Active
0 = NO Inactive
27.03 FLUX REF Defines the flux reference value. 10 = 1% 100 528 R
See par. Flux reference
27.05...27.04 (%)
27.04 FLUX MAX Defines the maximum limit of the flux. 10 = 1% 140 529 R
100...140% Maximum flux
27.05 FLUX MIN Defines the minimum limit of the flux. 10 = 1% 25 530 R
0...100% Minimum flux
27.06 FLUX RAMP GAIN This parameter can be used to speed up the slope of the flux 1=1 1 531 I
reference and it is needed only, when very fast (e.g. 2…4 s)
acceleration or deceleration is required in the process. The
value increment effects to faster flux reference changes. If very
fast acceleration or deceleration is required the value 10 is
suitable for most applications.
0...128 Flux ramp gain
27.08 HEX FIELD Selects whether motor flux is controlled along a circular or 1=1 OFF 533 B
WEAKEN a hexagonal pattern in the field weakening area of the
frequency range (above 50 or 60 Hz). See section Hexagonal
motor flux on page 82.
1 = ON Motor flux follows a circular pattern below the field weakening
point (typically 50 or 60 Hz) and a hexagonal pattern in the field
weakening range. Optimal selection in the applications that
require maximal instantaneous torque in the field weakening
range of the speed. The losses at constant operation are higher
than with selection OFF.
0 = OFF The rotating flux vector follows a circular pattern. Optimal
selection in most applications: Minimal losses at constant load.
Maximal instantaneous torque is not available in the field
weakening range of the speed.
Actual signals and parameters
209
Index Name/Selection Description FbEq Def. PB T
28 MOTOR MODEL Motor model fine tuning.
Note: If pulse encoder is used, parameters 28.01...28.05 are
not effective.
28.01 ZER_COEF1 Affects to the sensitivity of the motor pull-out prevention within 1 = 1% 6 551 R
the generator quadrant, when speed is 20% below nominal
speed and torque is 30%. This parameter is automatically set
during motor ID run or first start and normally requires no
alteration. If the motor is prone to pull-out at low speeds within
the generator quadrant, decrease the coefficient. If the motor is
unstable at zero speed, increase the coefficient.
Note: Parameter is not active, when parameter
28.14 FS METHOD setting is ON.
0...100% Zero coefficient 1
28.02 ZER_GAIN Affects the sensitivity of the motor pull-out prevention within the 1 = 1% 7 552 R
generator quadrant. The impact is inverse compared to
parameter 28.01 ZER_COEF1: If the motor is prone to pull-out
at low speeds within the generator quadrant, increase the
coefficient. If the motor is unstable at zero speed, decrease the
coefficient.
Note: Parameter is not active, when parameter
28.14 FS METHOD setting is ON.
0...100% Zero gain
28.03 MOT_COEF Affects the accuracy and linearity of torque control at low 1 = 1% 40 553 R
frequencies (<10% of the nominal frequency) within the motor
quadrant, when torque is 30%. This parameter is essential in
maximising the breakaway torque and affects the stability of the
torque, when the torque is above 100%. Decreasing the value
improves the ability to reach the maximum allowed torque. Too
small value makes the motor prone to pull-out at low
frequencies within the motor quadrant.
Note: Parameter is not active, when parameter
28.14 FS METHOD setting is ON.
0...100% Motor coefficient in percent
28.04 GEN_COEF Affects the stability of the torque at low frequencies (<30% of 1 = 1% 0 554 R
the nominal frequency) within the generator quadrant. A greater
value results in a more stable torque, however increasing the
susceptibility to pull-out if the torque is above 40%.
Vibration can be damped by increasing this value.
0...100% Coefficient
28.05 MG_COEF Affects the accuracy and linearity of torque control at low 1 = 1% 0 555 R
frequencies and torque within all quadrants. Parameter has no
effect when frequency exceeds 30% the of nominal frequency
or torque exceeds 80% of the nominal torque.
0...100% Coefficient
28.06 CABLE LENGTH Defines the motor cable length. This parameter affects the 1=1m 10 556 R
switching frequency at low frequencies (<20% of the nominal
motor frequency). With longer cables, the switching frequency
decreases.
Parameter value should be adjusted only, if motor power is
below 10 kW and the motor cable is longer than 80 metres.
0...1000 m Motor cable length
Actual signals and parameters
210
Index Name/Selection Description FbEq Def. PB T
28.07 LONG DISTANCE Activates the long distance mode. The mode limits voltage 1=1 ON 557 B
MOD peaks in the motor circuit and reduces the switching frequency
of the inverter. Long distance mode can be used with long
motor cables.
1 = ON Active (used only with ACS 600)
0 = OFF Inactive
28.08 TR TUNE Affects the calculated rotor time constant. Parameter should be 1 = 1 0 558 R
adjusted if the nominal speed of the motor rating plate does not
correspond the real speed.
Example: If the real slip speed is 10% higher than the
calculated slip speed stated on the motor rating plate: TR TUNE
is set to 10%.
Note: This parameter is effective only when a pulse encoder is
used.
-60...200% Time constant tuning
28.09 RS INC1 Defines the stator resistance coefficient at 0 Hz. By increasing 10 = 1% 25 559 R
the stator resistance value at low frequencies, the pull-out limit
is increased.
RS INC1
RS INC1 RS INC2
(par. 28.09)
RS INC2
(par. 28.10) f / Hz
0 1,25 · fN
-60...100% Stator resistant coefficient 1
28.10 RS INC2 Defines the stator resistance coefficient at 1.25 · Motor nominal 10 = 1% 0 560 R
frequency. See parameter 28.09 RS INC1.
-60...100% Stator resistant coefficient 2
28.11 CALC CURRENT Determines the relative gain which is used to correct the 10 = 1% 100 561 R
CORR calculated current Icalc based on the measured current lmeas:
Icalc = lcalc(-1) + (calc_current_corr/100) · (lmeas - lcalc(-1))
(lcalc(-1) is the previous value of Icalc.)
Default value, 100%, forces the calculated current to follow the
measured current. There is no need to adjust this value if no
interferences are observed in the current measurement.
If instantaneous current readings are disturbed by current
oscillations caused by long motor cables (or LC filter), the noise
immunity can be improved by decreasing the parameter value.
Normally 10% is a suitable value for Direct Torque Control with
long cables (when no long distance mode has been selected by
Par. 28.07 LONG DISTANCE MODE).
5...100% Calculated current correction
Actual signals and parameters
211
Index Name/Selection Description FbEq Def. PB T
28.12 FLYSTART CUR Defines the current reference used with flying start (start to 1 = 1% 50% 562 I
REF [%] a rotating motor) when no pulse encoder is used.
If flying start fails (i.e. drive is unable to detect motor speed
01.02 SPEED ESTIMATED): Monitor signals 01.02 SPEED
ESTIMATED and 01.06 MOTOR CURRENT with DriveWindow
PC tool and increase the reference in steps of 5% until the
flying start function is successfully performed (i.e. drive is able
to detect 01.02 SPEED ESTIMATED).
See also parameter 28.13 FLYSTART INIT DLY.
0...100% Value in percent
28.13 FLYSTART INIT Defines together with the motor characteristics the delay before 1 = 1 25 563 I
DLY the speed value estimated at the beginning of flying start is
connected to the speed reference ramp output. Increase the
delay, if the motor starts to rotate in the wrong direction or if the
motor starts to rotate with the wrong speed reference.
See also parameter 28.12 FLYSTART CUR REF [%].
0...59 Delay
28.14 FS METHOD Activates the flux stabilisation function at low frequencies, < 3 1=1 ON 564 B
Hz, when the torque exceeds 30%. Effective in the motoring
and generating modes.
Note: When flux stabilation is active, parameters 28.01...28.03
are not effective.
1 = ON Active
0 = OFF Inactive
28.15 RS20 [mOhm] Defines the stator resistance of the motor model at 20°C. 28676 = Set 565 I
By increasing the default value defined during ID run (does not 1 Ω during
include the temperature dependence of the resistance), the ID run.
motor model can be fine tuned especially in applications where
the motor or ambient temperature is not measured.
Note: If stator resistance value is too high, the desired starting
torque cannot be achieved.
0...x mΩ Resistance. The maximum value depends on the defined motor
parameters (99 START-UP DATA).
Actual signals and parameters
212
Index Name/Selection Description FbEq Def. PB T
29 SCALAR Scalar control is activated by setting parameter 99.08 MOTOR
CONTROL CTRL MODE to SCALAR. This parameter group is not visible
when DTC control mode is selected.
Note: The following start-up parameters have no effect in scalar
control:
99.03 MOTOR NOM CURRENT
99.05 MOTOR NOM SPEED
99.06 MOTOR NOM POWER
Note: In the scalar mode parameter 50.01 SPEED SCALING
affects the actual speed signals.
Scalar control is suitable in special cases where DTC cannot be
applied. Scalar control mode is recommended:
- for multimotor drives with variable number of motors
- when the nominal current of the motor is less than 1/6 of the
nominal output current of the drive (inverter)
- the drive is used for test purposes with no motor connected.
The motor identification run, flying start, torque control, DC
hold, motor phase loss check, and stall functions are disabled in
the scalar control mode.
See section Scalar control on page 81.
29.01 FREQUENCY REF Defines the frequency reference. 100 = 0 576 R
1 Hz
See Par. Frequency reference
29.03…29.02 (Hz)
29.02 FREQUENCY MAX Defines the maximum frequency. If parameter 20.02 MAXIMUM 100 = See 577 R
SPEED is changed, this parameter value is also changed. 1 Hz par.
20.01.
-300...300 Hz Maximum frequency
29.03 FREQUENCY MIN Defines the minimum frequency. If parameter 20.01 MINIMUM 100 = See 578 R
SPEED is changed, this parameter value is also changed. 1 Hz par.
20.02.
-300...300 Hz Minimum frequency
Actual signals and parameters
213
Index Name/Selection Description FbEq Def. PB T
29.04 IR Defines the relative output voltage boost at zero speed (IR 100 = 1 0 579 R
COMPENSATION compensation). The function is useful in applications which
require high break-away torque, but no DTC motor control can
be applied. The figure below illustrates the IR compensation.
Note: The function can be used only if parameter 99.08
MOTOR CTRL MODE is set to SCALAR.
U / UN
(%)
Relative output voltage. IR compensation
is set to 15%.
100%
Relative output voltage. No IR
15%
compensation.
f (Hz)
Field weakening point
0...30% Value in percent of the motor nominal voltage. Select a value at
which the motor is able to start and run at constant speed over
the whole speed range.
29.05 ADD FREQ REF Additional frequency reference, when AI+FBA SPEED REF 100 = 0 580 R
function has been activated by parameter 11.02 REFERENCE 1 Hz
SELECT. This additional frequency reference can also be
updated by Application program, if AI+FBA SPEED REF is not
selected.
-500…+500 Hz Additional frequency reference in Hz.
Actual signals and parameters
214
Index Name/Selection Description FbEq Def. PB T
29.06 IR STEP-UP FREQ Defines the frequency at which the step-up IR compensation 100 = 0 581 R
reaches the IR compensation used in scalar control (29.04 IR 1 Hz
COMPENSATION).
A voltage boost is used in step-up applications to achieve
higher break-away torque. Since voltage cannot be fed to the
transformer at 0 Hz, special IR compensation is used in step-up
applications. Full IR compensation starts around slip frequency.
The figure below illustrates the step-up IR compensation.
U / UN
(%)
100%
26.03 IR
COMPENSATION
f (Hz)
26.04 IR STEP-UP Field weakening
FREQ point (FWP)
For more information, see the Sine Filters User’s Manual for
ACS800 Drives [3AFE68389178 (English)].
0…50 Hz Value in Hz 0
29.07 ENA INC SW FREQ Activates the minimum switching frequency limitation with sine 0 582 B
filter application.
0 = NO Inactive 0
1 = YES Active. Minimum switching frequency limit is set according to 1
inverter type.
30 FAULT Programmable protection functions
FUNCTIONS
30.01 MOT THERM P Selects the thermal protection mode of the motor. When 1=1 1 601 I
MODE overtemperature is detected the drive reacts as defined by
parameter 30.02 MOTOR THERM PROT.
Note: The motor thermal model can be used when only one
motor is connected to the inverter.
See section Motor thermal mode on page 86.
Actual signals and parameters
215
Index Name/Selection Description FbEq Def. PB T
1 = DTC The protection is based on the calculated motor thermal model.
The following assumptions are used in the calculation:
- The motor is at the estimated temperature (value of 01.18
MOTOR TEMP EST saved at power switch off) when the power
is switched on. With the first power switch on, the motor is at
the ambient temperature (30°C).
- The motor temperature increases if it operates in the region
above the load curve.
- The motor temperature decreases if it operates in the region
below the curve. This applies only if the motor is overheated.
- The motor thermal time constant is an approximate value for
a standard self-ventilated squirrel-cage motor.
It is possible to finetune the model by parameter 30.10 MOTOR
LOAD CURVE.
Note: The model cannot be used with high power motors (i.e.
when parameter 99.03 MOTOR NOM CURRENT value is
higher than 800 A).
WARNING! The model does not protect the motor if it
does not cool properly due to dust and dirt.
2 = USER MODE The protection is based on the user-defined motor thermal
model and the following basic assumptions:
- The motor is at the estimated temperature (value of 01.18
MOTOR TEMP EST saved at power switch off) when the power
is switched on. With the first power switch on, the motor is at
the ambient temperature (30°C).
- The motor temperature increases if it operates in the region
above the load curve.
- The motor temperature decreases if it operates in the region
below the curve. This applies only if the motor is overheated.
The user-defined thermal model uses the motor thermal time
constant (parameter 30.09 MOTOR THERM TIME) and the
motor load curve (parameters 30.10...30.12). User tuning is
typically needed only if the ambient temperature differs from the
normal operating temperature specified for the motor.
WARNING! The model does not protect the motor if it
does not cool properly due to dust and dirt.
30.02 MOTOR THERM Selects how the drive reacts when the motor overtemperature 1 602 I
PROT is detected by the function defined by parameter 30.01 MOT
THERM MODE.
The fault and alarm limits are defined by parameters 30.28
THERM MOD ALM LIM and 30.29 THERM MOD FLT LIM.
Note: An external temperature measurement is activated by
parameter 30.03 MOT1 TEMP AI1 SEL or 30.06 MOT2 TEMP
AI2 SEL. External temperature measurement alarm and fault
limits are defined by parameters 30.04, 30.05, 30.07 and 30.08.
1 = FAULT The drive generates alarm MOTOR TEMP when the
temperature exceeds the alarm level. The drive trips on fault
MOTOR TEMP when the temperature exceeds the fault level.
2 = WARNING The drive generates alarm MOTOR TEMP when the
temperature exceeds the alarm level.
Actual signals and parameters
216
Index Name/Selection Description FbEq Def. PB T
3 = NO Inactive
30.03 MOT1 TEMP AI1 Activates the motor 1 temperature measurement function and 1 603 I
SEL selects the sensor type. See section Temperature sensors on
page 87.
1 = NOT IN USE Inactive
2 = 1xPT100 The function is active. The temperature is measured with one
Pt100 sensor. Analogue output AO1 feeds constant current
through the sensor. The sensor resistance increases as the
motor temperature rises, as does the voltage over the sensor.
The temperature measurement function reads the voltage
through analogue input AI1 and converts it to degrees
centigrade.
Constant current: 9.1 mA (0...10 V range with RMIO or 0...2 V
range with RAIO).
3 = 2xPT100 The function is active. Temperature is measured using two
Pt100 sensors. See selection 1xPT100.
Constant current: 9.1 mA (0...10 V range with RAIO)
4 = 3xPT100 The function is active. Temperature is measured using three
Pt100 sensors. See selection 1xPT100.
Constant current: 9.1 mA (0...10 V range with RAIO)
5 = 1...3 PTC The function is active. The temperature is supervised using one
to three PTC sensors or one to three KTY84-1xx silicon
temperature sensors. Analogue output AO1 feeds constant
current through the sensor(s).
The resistance of the sensor increases sharply as the motor
temperature rises over the sensor reference temperature Tref,
as does the voltage over the resistor. The temperature
measurement function reads the voltage through analogue
input AI1 and converts it into ohms. The figure below shows
typical PTC sensor resistance values as a function of the motor
operating temperature.
Ohm
4000
1330
Temperature PTC resistance
Normal 0…1.5 kohm 550
Excessive > 4 kohm
100
T
Constant current: 1.6 mA (0...10 V range with RAIO).
6 = EXT TEMP Externally measured motor temperature for motor
overtemperature protection and motor model. Measured
temperature is written either from fieldbus or adaptive program
application to signal 01.16 MOTOR 1 TEMP.
30.04 MOT 1 TEMP ALM Defines the alarm limit for motor 1 temperature measurement 1 = 1°C 110°C 604 R
L activated by parameter 30.03 MOT1 TEMP AI1 SEL Alarm or 1 Ω or 0 Ω
MOTOR TEMP M is generated when the limit is exceeded.
Actual signals and parameters
217
Index Name/Selection Description FbEq Def. PB T
-10...180°C (Pt100) Limit in °C or Ω
/ 0...5000 ohm
(PTC / KTY84-1xx)
30.05 MOT 1 TEMP FLT L Defines the fault trip limit for motor 1 temperature measurement 1 = 1°C 130°C 605 R
activated by parameter 30.03 MOT1 TEMP AI1 SEL. Fault or 1 Ω or 0 Ω
MOTOR TEMP M is generated when the limit is exceeded.
-10...180°C (Pt100) Limit in °C or Ω
/ 0...5000 ohm
(PTC / KTY84-1xx)
30.06 MOT2 TEMP AI2 Activates the motor 2 temperature measurement function and 1 606 I
SEL selects the sensor type. Two motors can be protected only by
using an RAIO I/O Extension module (parameter 98.06 AI/O
EXT MODULE 1 setting must be TEMP MEAS).
Note: If parameter 98.06 selection is not TEMP MEAS, the
analogue I/O extension is used for motor 1 temperature
measurement (the standard I/O terminals are not in use).
See section Temperature sensors on page 87.
1 = NOT IN USE Inactive
2 = 1xPT100 See 30.03 MOT1 TEMP AI1 SEL.
Constant current: 9.1 mA (0...2 V range with RAIO)
3 = 2xPT100 See 30.03 MOT1 TEMP AI1 SEL.
Constant current: 9.1 mA (0...10 V range with RAIO)
4 = 3xPT100 See 30.03 MOT1 TEMP AI1 SEL.
Constant current: 9.1 mA (0...10 V range with RAIO)
5 = 1...3 PTC See 30.03 MOT1 TEMP AI1 SEL.
Constant current: 1.6 mA (0...10 V range with RAIO)
30.07 MOT 2 TEMP Defines the alarm limit for the motor 2 temperature 1 = 1°C 110°C 607 R
ALM L measurement function activated by parameter 30.06 MOT2 or 1 Ω or 0 Ω
TEMP AI2 SEL. Alarm MOTOR TEMP M is generated when the
limit is exceeded.
-10...180°C (Pt100) Limit in °C or Ω
/ 0...5000 Ω (PTC /
KTY84-1xx)
30.08 MOT 2 TEMP FLT L Defines the fault trip limit for the motor 2 temperature 1 = 1°C 130°C 608 R
measurement function activated by parameter 30.06 MOT2 or 1 Ω or 0 Ω
TEMP AI2 SEL. Fault MOTOR TEMP M is generated when the
limit is exceeded.
-10...180°C (Pt100) Limit in °C or Ω
/ 0...5000 Ω (PTC /
KTY84-1xx)
Actual signals and parameters
218
Index Name/Selection Description FbEq Def. PB T
30.09 MOTOR THERM Defines the thermal time constant for the user-defined thermal 1 = 1 s 609 R
TIME model (i.e. time inside which the temperature has reached 63%
of the nominal temperature). See selection USER MODE of
parameter 30.01 MOT THERM P MODE.
Motor
Load
100%
Temperature
t
100%
63%
Motor thermal time constant t
To monitor the calculated temperature, see signal 01.18
MOTOR TEMP EST.
256...10000 s Time constant. If thermal protection according to UL
requirements for NEMA class motors is needed, the thermal
time for Class 10 trip curve is 350 s, for Class 20 trip curve
700 s and for Class 30 trip curve 1050 s.
Motor Thermal Times for ABB HXR and AMA Motors:
HXR motor type Temp. rise time
400S 2700 s
400L 3600 s
450L 4200 s
500L 4800 s
560L 6000 s
AMA motor type Temp. rise time
all types 1500 s
Actual signals and parameters
219
Index Name/Selection Description FbEq Def. PB T
30.10 MOTOR LOAD Defines the maximum allowed operating load of the motor. 1 = 1% 100 610 R
CURVE When parameter is set to 100%, the maximum allowed load is
equal to the value of parameter 99.03 MOTOR NOM
CURRENT. The load curve level should be adjusted if the
ambient temperature differs from the nominal value.
This parameter is used when USER MODE is selected by
parameter 30.01 MOT THERM P MODE.
I / IN I = Motor current
(%) IN = Nominal motor current
150
Par. 30.10
100
50
Par. 30.11
Par. 30.12 Drive output frequency
50...150% Allowed continuous motor load in percent of the nominal motor
current
30.11 ZERO SPEED Defines the maximum motor load at zero speed of the load 1 = 1% 74 611 R
LOAD curve. A higher value can be used if the motor has an external
motor fan to boost the cooling. See the motor manufacturer's
recommendations. This parameter is used when USER MODE
is selected by parameter 30.01 MOT THERM P MODE.
See parameter 30.10 MOTOR LOAD CURVE.
25...150% Allowed continuous motor load at zero speed in percent of the
nominal motor current
30.12 BREAK POINT Defines the break point frequency of the load curve i.e. the 100 = 45 612 R
point at which the motor load curve begins to decrease from the 1 Hz
value of parameter 30.10 MOTOR LOAD CURVE to the value
of parameter 30.11 ZERO SPEED LOAD. This parameter is
used when USER MODE is selected by parameter 30.01 MOT
THERM P MODE.
1...300 Hz Drive output frequency at 100% load
30.13 STALL FUNCTION Selects how the drive reacts to a motor stall condition. The 1 613 I
protection is activated if the following conditions have been
valid longer than the time set by parameter 30.15 STALL TIME:
- output frequency of the drive is below the level set by
parameter 30.14 STALL FREQ HI.
- the application is at a stall limit set by the user (defined by
parameters 20.04...20.10).
Note: Stall limit is restricted by internal current limit
TORQ_INV_CUR_LIM.
See section Stall protection on page 93.
1 = NO Inactive
2 = WARNING The drive generates alarm MOTOR STALL. The indication
disappears in half of the time set by parameter 30.15 STALL
TIME.
3 = FAULT The drive trips on fault MOTOR STALL.
Actual signals and parameters
220
Index Name/Selection Description FbEq Def. PB T
30.14 STALL FREQ HI Defines the frequency limit for the stall protection. See 100 = 20 614 R
parameter 30.13 STALL FUNCTION. 1 Hz
0.1…50 Hz Stall frequency
30.15 STALL TIME Defines the time delay for the stall protection. See parameter 1=1s 20 615 R
30.13 STALL FUNCTION.
10...400 s Stall time
30.16 UNDERLOAD Selects how the drive reacts to underload. The protection 1 616 I
FUNC wakes up if
- the motor torque falls below the curve selected by parameter
30.18 UNDERLOAD CURVE
- output frequency is higher than 10% of the nominal motor
frequency
- the above conditions have been valid longer than the time set
by parameter 30.17 UNDERLOAD TIME.
TM TM = Motor torque
ƒN = Nominal motor frequency
Underload curve
Underload region
f
0.1 · fN
1 = NO Protection is inactive.
2 = WARNING The drive generates alarm UNDERLOAD.
3 = FAULT The drive trips on fault UNDERLOAD.
30.17 UNDERLOAD TIME Time limit for the underload function. See parameter 30.16 1=1 600 617 R
UNDERLOAD FUNC.
0...600 s Underload time
30.18 UNDERLOAD Selects the load curve for the underload function. See 1 618 I
CURVE parameter 30.16 UNDERLOAD FUNC.
TM / TN
TM = Motor torque
(%) TN= Nominal motor torque
100 ƒN = Nominal motor frequency
80 3
70%
60 2
50%
40 1 5
30%
20
4
0
ƒN 2.4 · ƒN
1...5 Number of the load curve
Actual signals and parameters
221
Index Name/Selection Description FbEq Def. PB T
30.19 MOTOR PHASE Activates the motor phase loss supervision function. 1=1 NO 619 B
LOSS
1 = FAULT Active. The drive trips on fault MOTOR PHASE.
2 = NO Inactive
30.20 EARTH FAULT Selects how the drive reacts when an earth fault or current 1=1 FAULT 620 B
unbalance is detected in the motor or the motor cable. See
section Earth fault and current unbalance protection on page
95.
Note: With parallel connected inverter modules (2...12 × R8i)
only selection FAULT is valid.
1 = FAULT The drive trips on fault EARTH FAULT / CUR UNBAL x.
Note: With parallel connected inverters modules, the earth fault
function monitors the inverter output current unbalance
(e.g. short circuit) and the fault text is CUR UNBAL x instead of
EARTH FAULT.
0 = WARNING The drive generates alarm EARTH FAULT.
30.21 PANEL LOSS Selects how the drive reacts to a control panel or DriveWindow 1 = 1 FAULT 621 B
communication break.
1 = FAULT Drive trips on fault PANEL LOSS and the motor stops as
defined by parameter 21.03 STOP FUNCTION.
0 = LAST SPEED The drive generates alarm PANEL LOSS 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.
WARNING! Make sure that it is safe to continue
operation in case of a communication break.
30.22 UNDERVOLTAGE Activates the undervoltage control of the intermediate DC link. 1=1 OFF 622 B
CTL If the DC voltage drops due to input power cut off, the
undervoltage controller will automatically decrease the motor
torque in order to keep the voltage above the lower limit. By
decreasing the motor torque, the inertia of the load will cause
regeneration back to the drive, keeping the DC link charged
and preventing an undervoltage trip until the motor coasts to
stop. This will act as a power-loss ride-through functionality in
systems with high inertia, such as a centrifuge or a fan.
Note: The undervoltage controller is able to adjust the torque
within all operating quadrants without limitations, if the following
parameter values are set high enough:
- power limits: 20.17, 20.18,
- torque limits: 20.05, 20.06 and
- maximum current: 20.04.
See section Undervoltage control on page 63.
1 = ON Active
0 = OFF Inactive
Actual signals and parameters
222
Index Name/Selection Description FbEq Def. PB T
30.23 OVERVOLTAGE Activates the overvoltage control of the intermediate DC link. 1=1 ON 623 B
CTL Fast braking of a high inertia load causes the voltage to rise to
the overvoltage control limit. To prevent the DC voltage from
exceeding the limit, the overvoltage controller automatically
decreases the braking torque.
Note: If a brake chopper and resistor or a regenerative supply
section are included in the drive, the controller must be OFF.
See section Overvoltage control on page 65.
1 = ON Active
0 = OFF Inactive
30.24 PPCC FAULT Activates the fault mask. Unwanted AINT board current 1=1 NO 624 B
MASK measurement or communication faults can be masked in
situations where the DC voltage has been disconnected but the
RMIO board has an external power supply and fault indication
is not needed. A fault is produced only when the motor is
started. See also parameter 31.02 START INHIBIT ALM.
0 = NO Inactive
1 = YES Active
30.25 EARTH FAULT Selects the earth fault level for non-parallel connected R8i 1=1 Inverter 625 R
LEVEL inverters. type
Note: DO NOT change earth fault level with parallel connected depen-
inverter modules. With parallel connected inverters, the fault is dent
CUR UNBAL x instead of EARTH FAULT.
The earth fault level is given in percent of the current
measurement range.
0 Disabled
1 1% unbalance in the sum current
2 3% unbalance in the sum current
3 8% unbalance in the sum current
4 13% unbalance in the sum current
5 18% unbalance in the sum current
6 28% unbalance in the sum current
7 39% unbalance in the sum current
8 62% unbalance in the sum current
30.26 COMM LOSS RO Selects the operation of the fieldbus controlled digital output 1=1 ZERO B
(07.02 AUX CTRL WORD bits 13...15) in a communication
break. See parameter group 14 DIGITAL OUTPUTS and
chapter Fieldbus control.
The action taken by the drive on a communication break is
defined by parameter 70.05 CH0 COM LOSS CTRL.
0 = ZERO Digital output is de-energised.
1 = LAST VALUE Digital output keeps the last state before the communication
loss.
WARNING! After the communication recovers, the
update of the digital outputs starts immediately
without fault message resetting.
Actual signals and parameters
223
Index Name/Selection Description FbEq Def. PB T
30.27 AI<MIN FUNC Selects how the drive reacts when an analogue input (RMIO 1 I
analogue input AI2, AI3 or RAIO analogue input AI2) signal falls
below the minimum limit set by parameter 13.06 MINIMUM AI2
or 13.10 MINIMUM AI3.
1 = FAULT The drive trips on fault AI<MIN FUNC and the motor coasts to
stop.
2 = NO Inactive
3 = LAST SPEED The drive generates alarm AI<MIN FUNC 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.
WARNING! Make sure that it is safe to continue
operation in case the analogue input signal is lost.
30.28 THERM MOD ALM Defines the thermal model alarm limit. See parameter 30.02 90 I
LIM MOTOR THERM PROT. The calculated temperature of the
thermal model is shown by signal 01.18 MOTOR TEMP EST.
0...300°C Thermal model alarm limit
30.29 THERM MOD FLT Defines the thermal model fault trip limit. See parameter 30.02 110 I
LIM MOTOR THERM PROT. The calculated temperature of the
thermal model is shown by signal 01.18 MOTOR TEMP EST.
0...300°C Thermal model fault limit
30.30 MOT NOM TEMP Defines the temperature rise of the motor when the motor is 1 = 1°C 80 R
RISE loaded with nominal current.
Temperature
Motor
nominal
temperature
rise
Ambient temperature t
Note: If the ABB motor rating plate has coefficient MNTRC,
multiply it by 80°C to get the motor nominal temperature rise.
With non-ABB motors, contact the motor manufacturer.
0...300°C Nominal temperature rise of the motor
30.31 AMBIENT TEMP Defines the typical ambient temperature for the thermal 1 = 1°C 30 R
protection mode (parameter 30.01 MOT THERM P MODE).
-40...100°C Ambient temperature
30.32 RS TEMP SCALE Defines the tuning coefficient for stator resistance Rs 1 = 1% 40 R
temperature dependence, which is based on the temperature
measured with Pt100 sensors or on the internal motor thermal
protection model. The measured total resistance includes motor
cable and stator resistances. With pulse encoder feedback,
100% compensation can usually be used. Undercompensation
decreases the starting torque at high motor temperatures.
0...200% Coefficient in percent
Actual signals and parameters
224
Index Name/Selection Description FbEq Def. PB T
31 FAULT Programmable protection functions
FUNCTIONS
31.01 KLIXON MOT Selects how the drive reacts when a thermistor relay or 1=1 0 626 B
OVER T a thermistor switch connected to digital input opens. See
parameter 10.05 KLIXON and section Alternative thermal
connection for PTC thermistor on page 91.
0 = FAULT The drive trips on fault KLIXON.
1 = ALARM The drive generates alarm KLIXON.
31.02 START INHIBIT Activates/deactivates the logging of Safe Torque Off alarm 1=1 0 627 B
ALM START INHIBI into the fault/alarm logger. This function has no
effect on status or alarm words.
0 = OFF Inactive
1 = ON Active
31.03 TEMP MEAS FLT Selects how the drive reacts when the motor temperature 1=1 0 628 B
SEL measurement circuit has a fault. See section Temperature
sensors on page 87.
0 = ALARM The drive generates alarm T MEAS CIRC.
1 = FAULT The drive trips on fault T MEAS CIRC.
31.04 MOT PROT FLT Selects how the drive reacts when motor overload protection is 1 = 1 0 B
SEL activated, i.e. motor protection switch opens. See parameter
10.11 MOT PROT SWITCH.
0 = FAULT The drive trips on fault MPROT SWITCH.
1 = ALARM The drive generates alarm MPROT SWITCH.
34 BRAKE CHOPPER Control of the internal brake chopper with frames R2…R6 and
R2i…R5i.
34.01 BRAKE CHOPPER Activates the internal brake chopper control. OFF 701 B
CTL
0 = OFF Inactive
1 = ON Active.
Note: Ensure the brake chopper and resistor(s) are installed
and the overvoltage control is switched off by parameter 30.23
OVERVOLTAGE CTL.
34.02 BR OVERLOAD Activates the overload protection of the brake resistor. 1=1 NO 702
FUNC See parameters 34.04 BR THERM T CONST and 34.06 MAX
CONT BR POWER.
0 = NO Inactive
1 = WARNING Active. If the drive detects an overload, it generates alarm BR
OVERHEAT.
2 = FAULT Active. If the drive detects an overload, it trips on fault BR
OVERHEAT.
34.03 BR RESISTANCE Defines the resistance value of the brake resistor. The value is 1=1 100.00 703 R
used for brake chopper protection.
0… 100 ohm Resistance value
Actual signals and parameters
225
Index Name/Selection Description FbEq Def. PB T
34.04 BR THERM T Defines the thermal time constant of the brake resistor. The 1=1 0.000 704 R
CONST value is used in the overload protection (parameter 34.02 BR
OVERLOAD FUNC).
With type SACE brake resistors, the parameter setting must be
200 s.
With type SAFUR brake resistors, the parameter setting must
be 555 s.
0...10000 s Time constant
34.05 MAX CONT BR Defines the maximum continuous braking power which will 1=1 0 705 R
POWER raise the resistor temperature to the maximum allowed value.
The value is used in the overload protection (parameter 34.02
BR OVERLOAD FUNC).
0.01...10000 kW Power
34.06 BC CONTROL Selects the control mode of braking chopper. 1=1 0 706 B
MODE
0 = AS Chopper operation is allowed when the DC voltage exceeds the 0
GENERATOR braking limit, the inverter bridge modulates and the motor
generates power to the drive.
The selection prevents the operation in case the intermediate
circuit DC voltage rises because of an abnormally high supply
voltage. A long time supply voltage rise would damage the
chopper.
1 = COMMON DC Chopper operation is allowed always when the DC voltage 1
exceeds the braking limit. The selection is to be used in
applications where several inverters are connected to the same
intermediate circuit (DC bus).
WARNING! Excessive supply voltage will raise the
intermediate circuit voltage above the operation limit
of the chopper. If the voltage remains abnormally
high for a long period, the braking chopper will be
overloaded and damaged.
35 MOTOR FAN CTRL Control logic and diagnostics of the motor fan.
The fan starter is controlled via a digital output. See parameter
group 14 DIGITAL OUTPUTS. Signal 08.06 AUX STATUS
WORD 2 bit 0 (FAN ON CMD) must be used as a control bit.
An acknowledgement signal can be selected by parameter
10.06 MOTOR FAN ACK.
35.01 MOTOR FAN CTRL Activates the motor fan diagnostics and the timer functions. See 1 726 I
08.06 AUX STATUS WORD 2 bit 0.
1 = OFF Motor fan control and diagnostics disabled
2 = ALARM If the fan acknowledgement signal is lost, alarm MOTOR FAN is
generated.
3 = ALARM/FAULT If the fan acknowledgement signal is lost, alarm MOTOR FAN is
generated. If the acknowledgement signal is still lost after the
delay time defined by parameter 35.02 FAN ACK DELAY, the
drive trips on fault MOTOR FAN.
35.02 FAN ACK DELAY Defines the delay time between fan acknowledgement signal 1=1s 5 727 R
loss and MOTOR FAN fault activation (see parameter 35.01
MOTOR FAN CTRL). Delay time count starts when the FAN ON
CMD activates (08.06 AUX STATUS WORD 2 bit 0).
2...300 s Delay time
Actual signals and parameters
226
Index Name/Selection Description FbEq Def. PB T
35.03 FAN OFF DELAY Defines the fan off delay time. 1= 20 728 R
1 min
0...100 min Delay time
35.04 FAN ON DELAY Defines the fan on delay time. 1=1s 0 729 R
0...100 s Delay time
36 MOTOR CABLE The motor cable can be protected against overload by using the
PROTECTION thermal model. To activate this function, the cable parameters
must be set.
The thermal model of the motor cable is based on the current
measurement and known loading data of the cable.
36.01 CABLE NOM Defines the continuous current of the motor cable, including 1=1 9999.9 751 R
CURRENT possible limitation factors due to environment conditions
(ambient temperature, distances to other cables, etc.). See the
cable manufacturer's data book.
0...10000 A Cable current
Note: The new value becomes valid only after the next RMIO
board power-up.
36.02 CABLE TEMP Defines the loading time of the motor cable, i.e. time inside 10 = 1 s 85 752 R
CONST which the cable current has reached 63% of the nominal cable
current defined by 36.01 CABLE NOM CURRENT.
This parameter enables the calculation of the motor cable
temperature, 01.27 CABLE TEMPERATURE. If the value
exceeds 102%, alarm CABLE TEMP is activated, and if the
value reaches 106%, fault and alarm CABLE TEMP are
activated.
0…50000 s Time. The function is disabled by setting the value to 0 s.
50 SPEED Speed scaling and encoder connection.
MEASUREMENT See also encoder activation parameter 98.01 ENCODER
MODULE.
50.01 SPEED SCALING Defines the speed reference which corresponds to integer 15000 = 1500 1001 R
value 20000 used in fieldbus control or I/O control. In the scalar 1500
mode this parameter effects the actual speed signals. rpm
0...100000 rpm Speed reference
50.02 SPEED MEAS Defines how the encoder pulses are calculated. 1=1 3 1002 I
MODE
0 = A_-B DIR Channel A: positive edges calculated for speed. Channel B:
direction.
1 = A_-_ Channel A: positive and negative edges calculated for speed.
Channel B: not used.
2 = A_-_B DIR Channel A: positive and negative edges are calculated for
speed. Channel B: direction.
3 = A_-_B_-_ All edges of the signals are calculated.
50.03 SPEED FB SEL Selects the speed feedback value used in speed control. 1=1 1 1003 I
1 = INTERNAL Calculated speed estimate
2 = ENCODER Actual speed measured with pulse encoder
50.04 ENCODER PULSE States the number of pulse encoder pulses per one revolution. 1=1 2048 1004 R
NR
1...30000 ppr Pulse number in ppr (= pulses per round)
Actual signals and parameters
227
Index Name/Selection Description FbEq Def. PB T
50.05 ENCODER ALM/ Defines the operation of the drive if a failure is detected in 1=1 ALAR 1005 B
FLT communication between the pulse encoder and the pulse M
encoder interface module, or between the module and the
drive. Encoder supervision function activates if any of the
following conditions is fulfilled:
- No pulses are received from the encoder within the time
defined by parameter 50.11 ENCODER DELAY and the drive is
simultaneously at current or torque limit.
-There is a 20% difference between the estimated speed and
the measured speed received from the pulse encoder.
- There is no communication between the pulse encoder
module and the RMIO board.
- During fast acceleration measured speed drops to zero.
1 = FAULT The drive trips on fault ENCODER ERR.
0 = ALARM The drive generates alarm ENCODER ERR.
50.06 SP ACT FILT TIME Defines the time constant of the first order actual speed filter. 1 = 1 ms 4 1006 R
0...999999 ms Time constant
50.07 POS COUNT Selects the position count mode. The position counter is 1=1 ROUN 1007 I
MODE controlled by 07.02 AUX CTRL WORD 1 bits 9...11. The status D
can be monitored by 08.02 AUX STATUS WORD bit 5. See
section Position counter on page 120.
0 = PULSE EDGES Both edges of the pulses are counted. Actual values can be
read from signals 03.07 POS COUNT LO and 03.08 POS
COUNT HI.
1 = ROUND&DEG The application software counts the number of motor shaft
rounds and the shaft angle in degrees. Actual values can be
read from signals 03.09 POS COUNT DEGREES and 03.10
POS COUNT ROUNDS.
50.08 POS COUNT INIT Position counter value (16 least significant bits) when par. 50.07 1 = 1 0 1008
LO setting is PULSE EDGES. See section Position counter on
page 120.
0...65536 Value
50.09 POS COUNT INIT Position counter value (16 most significant bits) when par 50.07 1 = 1 0 1009
HI setting is PULSE EDGES. See section Position counter on
page 120.
0...65536 Value
50.10 ABOVE SPEED Defines the supervision limit for the actual speed. When actual See par. 0 1010 R
LIMIT speed has reached the limit, 08.01 MAIN STATUS WORD bit 50.01.
10 value is set to 1.
See par. Actual speed limit
20.01...20.02 rpm
50.11 ENCODER DELAY Defines the time delay for the encoder supervision function. 1 = 1 ms 1000 1011 R
Supervision selected by parameter 50.05 ENCODER ALM/FLT
is activated if no pulses are received from the encoder within
the defined time when the drive is simultaneously at current or
torque limit.
0...50000 ms Time delay. The function is disabled by setting this value to 0.
50.12 MOTOR SP FILT Defines the filter time constant for signal 01.01 MOTOR SPEED 1 = 1 ms 500 1012 R
TIME FILT.
2...20000 ms Filter time constant
Actual signals and parameters
228
Index Name/Selection Description FbEq Def. PB T
50.13 ZERO DETECT Defines the time the speed controller uses the last actual speed 4 1013 I
DELAY value. This parameter can be adjusted to optimise the speed
regulator for the best possible performance at low speeds when
a pulse encoder is used and pulses are not received from the
pulse encoder during a 1 ms time period.
The definition of low speed depends on the type of the used
encoder. If the encoder pulse number is 2048 and both edges
of both of the channels (A and B) are counted, the number of
pulses per revolution is 8192. This means that at least one
pulse per millisecond is received at 7.3 rpm (1 pulse/ms =>
1000 pulses/s => 1000/8192 rev/s = 7.3 rpm). Thus 4 ms
between pulses corresponds to 1.8 rpm and 80 ms to 0.09 rpm.
Example:
Pulse 1: After receiving a pulse, speed is calculated and
proportional part of the speed controller (P-part) is set to
a value related to the speed error. When no new pulses are
received within 1 ms, the measured speed and P-part due to
the constant speed reference remain unchanged. After the
50.14 SPEED HOLD TIME, the P-part is forced to zero so that
speed control will not be based on absolute speed
measurement value. After ZERO DETECT DELAY, it is
assumed that speed is zero: Measured speed is cleared and
the use of P-part is allowed.
Pulse 2: After the next pulse, speed is calculated again and the
P-part is set accordingly. P-part is forced to zero after SPEED
HOLD TIME. Speed is not set to zero any more, because a new
pulse comes before the time defined by ZERO DETECT
DELAY has elapsed.
Pulse 3: The time between pulses 3 and 4 is longer than
SPEED HOLD TIME and P-part is forced to zero.
Pulse 4: The time between pulses 4 and 5 is so short that
neither P-part nor the measured speed is forced to zero.
1 2 3 4 5
encoder pulse
edges
speed 0
t1 t1
speed
control 0
P-part t2 t2 t2 t2
t1 = ZERO DETECT DELAY = 250 ms
t2 = SPEED HOLD TIME = 4 ms
A long ZERO DETECT DELAY time gives accurate speed
measurement. Short SPEED HOLD TIME keeps the speed
control stable, because speed control output is not influenced
by the earlier speed measurement sample.
If the value of the P-part is very large, forcing it to zero causes
undesirable torque steps.
The tuning values depend on the mechanics. Therefore after
increasing these parameter values, check that the actual torque
value is still smooth.
1...2000 ms Zero detect delay
Actual signals and parameters
229
Index Name/Selection Description FbEq Def. PB T
50.14 SPEED HOLD Defines the time delay for the proportional part (P-part) of the 4 1014 I
TIME speed controller. After the time has elapsed and no pulses have
been received, the P-part is forced to zero.
When time is increased, the effect of the P-part at low
frequencies is amplified due to the longer effect time of the
P-part. Oscillation can occur, if the time set is too long.
See par. 50.13 ZERO DETECT DELAY.
Note: The value of SPEED HOLD TIME < ZERO DETECT
DELAY.
See par. Speed hold time
50.13...2000 (ms)
51 MASTER Fieldbus adapter communication settings.
ADAPTER (fieldbus The parameters are visible and need to be adjusted, only when
adapter) a fieldbus adapter module (optional) is installed and activated
by parameter 98.02 COMM. MODULE. For details on the
parameters, refer to the manual of the fieldbus module and
chapter Fieldbus control.
These parameter settings will remain the same even though the
macro is changed.
Note: Any changes in these parameters take effect only after
the next power-up of the drive, or when auxiliary power supply
is connected to RMIO board for the next time, or when fieldbus
adapter parameter 51.27 is activated.
Note: With NMBA-0x module, set parameter 70.19 CH0 HW
CONNECTION value to RING and 71.01 to NO to enable
forwarding of the received messages in the DDCS link.
51.01 FIELDBUS PAR1 (Module type and software version) 1026 R
51.02 FIELDBUS PAR2 (According to module type) 1027 R
... ... ... ...
51.33 FIELDBUS PAR33 R
52 STANDARD Standard Modbus Link settings. See chapter Fieldbus control
MODBUS and RMBA-01 Modbus Adapter User’s Manual [3AFE64498851
(English)].
These settings are visible only when the STANDARD MODBUS
has been selected by parameter 98.02 COMM. MODULE.
52.01 STATION NUMBER Defines the address of the device. Two units with the same 1 I
address are not allowed on-line.
1...247 Address
52.02 BAUDRATE Defines the transfer rate of the link. 5 I
1 = 600 600 bits/s
2 = 1200 1200 bits/s
3 = 2400 2400 bits/s
4 = 4800 4800 bits/s
5 = 9600 9600 bits/s
6 = 19200 19200 bits/s
Actual signals and parameters
230
Index Name/Selection Description FbEq Def. PB T
52.03 PARITY Defines the use of parity and stop bit(s). The same setting must 3 I
be used in all on-line stations.
1= No parity bit, one stop bit
NONE1STOPBIT
2= No parity, 2 stop bits
NONE2STOPBIT
3 = ODD Odd parity indication bit, one stop bit
4 = EVEN Even parity indication bit, one stop bit
53 USER Adaptive programming settings. See ACS600/ACS800
PARAMETERS Application Guide Adaptive Program for System Application
Program 7.x [3AFE68420075 (English)].
53.01 NUMERIC 1 User-defined numeric parameter for adaptive programming I
-8388608...8388607 Numeric value
53.02 NUMERIC 2 User-defined numeric parameter for adaptive programming I
-8388608...8388607 Numeric value
... ... ... I
53.10 NUMERIC 10 User-defined numeric parameter for adaptive programming
-8388608...8388607 Numeric value
53.11 STRING 1 User-defined alarm or fault text indication of the EVENT block. C
0...9 characters ASCII string type
53.12 STRING 2 User-defined alarm or fault text indication of the EVENT block. C
0...9 characters ASCII string type
... ... ...
53.17 STRING 7 User-defined alarm or fault text indication of the EVENT block. C
0...9 characters ASCII string type
55 ADAPTIVE PROG1 Adaptive programming task 1 settings:
- selections of the function blocks and their input connections
- diagnostics.
See ACS600/ACS800 Application Guide Adaptive Program for
System Application Program 7.x [3AFE68420075 (English)].
This parameter group is mainly used with the DriveAP 2.x PC
tool.
55.01 STATUS Shows the value of the adaptive program task 1status word. Pb
1…128 The table below shows the alternative bit states and the
corresponding values on the panel display.
Bit Display Meaning
0 1 Stopped
1 2 Running
2 4 Faulted
3 8 Editing
4 10 Checking
5 20 Pushing
6 40 Popping
8 80 Initialising
55.02 FAULTED PAR Points out the faulted parameter in adaptive program task 1. I
Actual signals and parameters
231
Index Name/Selection Description FbEq Def. PB T
0...32768 Value
55.05 BLOCK1 Selects the function block type for Block 1 in the adaptive I
program task 1.
0...32768 Function block type
55.06 INPUT1 Selects the source for input I1 of Block 1. P
-255.255.31 … Parameter index or a constant value: P
+255.255.31 / C - Parameter pointer: Inversion, group, index and bit fields. The
-32768 … C 32767 bit number is effective only for blocks handling boolean inputs.
- Constant value: Inversion and constant fields. Inversion field
must have value C to enable the constant setting.
Example: The state of digital input DI2 is connected to Input 1
as follows:
- Set the source selection parameter (55.06) to +.01.15.01.
(The application program stores the state of digital input DI2 to
bit 1 of actual signal 01.15.)
- If you need an inverted value, switch the sign of the pointer
value (-01.15.01.).
55.07 INPUT2 Selects the source for input I2 of Block 1. P
See parameter 55.06 INPUT1.
55.08 INPUT3 Selects the source for input I3 of Block 1. P
See parameter 55.06 INPUT1.
55.09 OUTPUT Stores and displays the output of Block 1. I
0...32768 No user-setting possible
55.10 BLOCK2 Selects the function block type for Block 2 in the adaptive I
program task 1.
0...32768 Function block type
55.11 INPUT1 Selects the source for input I1 of Block 2. P
-255.255.31 C See parameter 55.06 INPUT1.
-32768 ...
255.255.31 C
32767
55.12 INPUT2 Selects the source for input I2 of Block 2.
See parameter 55.06 INPUT1.
55.13 INPUT3 Selects the source for input I3 of Block 2.
See parameter 55.06 INPUT1.
55.14 OUTPUT Stores and displays the output of Block 2. I
0...32768 No user-setting possible
55.15 BLOCK3 Selects the function block type for Block 3 in the adaptive I
program task 1.
0...32768 Function block type
... ... ...
55.34 OUTPUT Stores and displays the output of Block 6. I
0...32768 No user-setting possible
Actual signals and parameters
232
Index Name/Selection Description FbEq Def. PB T
56 ADAPT PROG1 Adaptive program task 1 control. The update time of task 1
CNTRL control is 10 ms.
See parameter group 55 ADAPTIVE PROG1.
56.01 ADAPT PROG Selects the operation mode for the adaptive program task 1. 1 I
CMD
1 = STOP Stop. The program can be edited.
2 = START Run. The program cannot be edited.
3 = EDIT Stop to edit mode (i.e. the execution of the task is stopped for
editing) The program can be edited.
56.02 EDIT CMD Selects the command for the block placed in the location 1 I
defined by parameter 56.03 EDIT BLOCK.
1 = NO Home value. The value automatically restores to NO after an
editing command has been executed.
The program must be in the editing mode (see parameter 56.01
ADAPT PROG CMD).
2 = PUSH Shifts the block in the location defined by parameter 56.03 EDIT
BLOCK and the subsequent blocks one location up. A new
block can be placed in the emptied location.
The program must be in the editing mode (see parameter 56.01
ADAPT PROG CMD).
3 = DELETED Selects the block in the location defined by parameter 56.03
EDIT BLOCK and shifts the subsequent blocks one step down.
The program must be in the editing mode (see parameter 56.01
ADAPT PROG CMD).
4 = PROTECT Activation of the task protection: Read protects the input
connections of the blocks. Activate as follows:
- Ensure the task operation mode is START or STOP
(parameter 56.01 ADAPT PROG CMD).
- Set the passcode by parameter 56.05 PASS CODE.
- Set parameter 56.02 to PROTECT.
When protection is activated:
- All parameters in group 55 ADAPTIVE PROG1 excluding the
block output parameters are hidden (read protected).
- It is not possible to switch the task operating mode (parameter
56.01 ADAPT PROG CMD) to the editing mode.
- Parameter 56.05 PASS CODE value is set to 0.
5 = UNPROTECT Deactivation of the task protection: no read protection of the
inputs of the blocks. Deactivate as follows:
- Ensure the task operation mode is START or STOP
(parameter 56.01 ADAPT PROG CMD).
- Set the passcode by parameter 56.05 PASS CODE.
- Set parameter 56.02 to UNPROTECT.
56.03 EDIT BLOCK Defines the block location number for the command selected by 0 I
parameter 56.02 EDIT CMD.
1...15 Block location number
Actual signals and parameters
233
Index Name/Selection Description FbEq Def. PB T
56.04 TIMELEVEL_SEL Indicates the fixed execution cycle time of 10 ms for the 1 I
adaptive program task 1.
56.05 PASS CODE Defines the passcode, which activates/deactivates the 0 I
protection of the input connections of the blocks. See
parameter 56.02 EDIT CMD.
0 h...FFFFFF h Passcode. The setting restores to 0 after the protection is
activated/deactivated.
Note: When you activate the protection, write down the
passcode and store it for later use.
57 ADAPTIVE PROG2 Adaptive programming task 2 settings:
- selections of the function blocks and their input connections
- diagnostics.
See ACS600/ACS800 Application Guide Adaptive Program for
System Application Program 7.x [3AFE68420075 (English)].
This parameter group is mainly used with the DriveAP 2.x PC
tool.
57.01 STATUS Shows the value of the adaptive program task 2 status word. Pb
1…128 The table below shows the alternative bit states and the
corresponding values on the panel display.
Bit Display Meaning
0 1 Stopped
1 2 Running
2 4 Faulted
3 8 Editing
4 10 Checking
5 20 Pushing
6 40 Popping
8 80 Initialising
57.02 FAULTED PAR Points out the faulted parameter in adaptive program task 2. I
0...32768 Value
57.05 BLOCK 1 Selects the function block type for Block 1 in the adaptive I
program task 2.
0...32768 Function block type
57.06 INPUT 1 Selects the source for input I1 of Block 1. P
-255.255.31 … Parameter index or a constant value:
+255.255.31 / C - Parameter pointer: Inversion, group, index and bit fields. The
-32768 … C 32767 bit number is effective only for blocks handling boolean inputs.
- Constant value: Inversion and constant fields. Inversion field
must have value C to enable the constant setting.
Example: The state of digital input DI2 is connected to Input 1
as follows:
- Set the source selection parameter (55.06) to +.01.15.01.
(The application program stores the state of digital input DI2 to
bit 1 of actual signal 01.15.)
- If you need an inverted value, switch the sign of the pointer
value (-01.15.01.).
57.07 INPUT 2 Selects the source for input I2 of Block 1.
See parameter 57.06 INPUT 1.
Actual signals and parameters
234
Index Name/Selection Description FbEq Def. PB T
57.08 INPUT 3 Selects the source for input I3 of Block 1.
See parameter 57.06 INPUT 1.
57.09 OUTPUT Stores and displays the output of Block 1. I
0...32768 No user-setting possible
57.10 BLOCK 2 Selects the function block type for Block 2 in the adaptive I
program task 2.
0...32768 Function block type
57.11 INPUT 1 Selects the source for input I1 of Block 2. P
See parameter 57.06 INPUT 1.
57.12 INPUT 2 Selects the source for input I2 of Block 2.
See parameter 57.06 INPUT 1.
57.13 INPUT 3 Selects the source for input I3 of Block 2.
See parameter 57.06 INPUT 1.
57.14 OUTPUT Stores and displays the output of Block 2. I
0...32768 No user-setting possible
57.15 BLOCK 3 Selects the function block type for Block 3 in the adaptive I
program task 2.
0...32768 Function block type
... ... I
57.104 OUTPUT Stores and displays the output of Block 20.
0...32768 No user-setting possible
58 ADAPT PROG2 Adaptive program task 2 control. The update time of task 2
CNTRL control is 100 ms.
See parameter group 57 ADAPTIVE PROG2.
See ACS600/ACS800 Application Guide Adaptive Program for
System Application Program 7.x [3AFE68420075 (English)].
58.01 ADAPT PROG Selects the operation mode for the adaptive program task 2. 1 I
CMD
1 = STOP Stop. The program can be edited.
2 = START Run. The program cannot be edited.
3 = EDIT Stop to edit mode. The program can be edited.
58.02 EDIT CMD Selects the command for the block placed in the location 1 I
defined by parameter 58.03 EDIT BLOCK. The program must
be in editing mode (see parameter 58.01ADAPT PROG CMD).
1 = NO Home value. The value automatically restores to NO after an
editing command has been executed.
2 = PUSH Shifts the block in the location defined by parameter 58.03 EDIT
BLOCK and the subsequent blocks one location up. A new
block can be placed in the emptied location.
3 = DELETED Selects the block in the location defined by parameter 58.03
EDIT BLOCK and shifts the subsequent blocks one step down.
Actual signals and parameters
235
Index Name/Selection Description FbEq Def. PB T
4 = PROTECT Activation of the task protection: Read protects the input
connections of the blocks. Activate as follows:
- Ensure the task operation mode is START or STOP
(parameter 58.01 ADAPT PROG CMD).
- Set the passcode by parameter 58.05 PASS CODE.
- Set parameter 56.02 to PROTECT.
When protection is activated:
- All parameters in group 55 ADAPTIVE PROG1 excluding the
block output parameters are hidden (read protected).
- It is not possible to switch the task operating mode (parameter
58.01 ADAPT PROG CMD) to the editing mode.
- Parameter 58.05 PASS CODE value is set to 0.
5 = UNPROTECT Deactivation of the task protection: no read protection of the
input connection of the blocks. Deactivate as follows:
- Ensure the Application task operation mode is START or
STOP (parameter 58.01 ADAPT PROG CMD).
- Set the passcode by parameter 58.05 PASS CODE.
- Set parameter 56.02 to UNPROTECT.
58.03 EDIT BLOCK Defines the block location number for the command selected by 0 I
parameter 58.02 EDIT CMD.
1...15 Block location number
58.04 TIMELEVEL_SEL Indicates the fixed execution cycle time of 100 ms for the 1 I
adaptive program task 2.
58.05 PASS CODE Defines the passcode, which activates/deactivates the 0 I
protection of the input connections of the blocks. See
parameter 58.02 EDIT CMD.
0 h...FFFFFF h Passcode. The setting restores to 0 after the protection is
activated/deactivated.
Note: When you activate the protection, write down the
passcode and store it for later use.
66 AP CONNECT Parameters through which the adaptive program can control
the start command and the optional analogue outputs of the
drive.
For more information, see ACS600/ACS800 Application Guide
Adaptive Program for System Application Program 7.x
[3AFE68420075 (English)].
Note: It is recommended that these parameter values are set
with the DriveAP 2.x graphic tool.
66.01 START Selects the source for the drive start in I/O control. (Connected P
parallel with I/O start signals. See START/STOP function in
parameter group 10 DIGITAL INPUTS.)
-255.255.31: C Parameter pointer or constant value:
-32768 … - Parameter pointer: Inversion, group, index and bit fields. The
-255.255.31: C bit number is effective only for blocks handling boolean inputs.
32767
- Constant value: Inversion and constant fields. The inversion
field must have value C to enable the setting of the constant.
Actual signals and parameters
236
Index Name/Selection Description FbEq Def. PB T
66.02 EXT2 AO1 Selects the source for extension AI/O module 2 analogue P
output 1 control.
-255.255.31: C Parameter pointer or constant value:
-32768 ... - Parameter pointer: Inversion, group, index and bit fields. The
-255.255.31: C bit number is effective only for blocks handling boolean inputs.
32767
- Constant value: Inversion and constant fields. The inversion
field must have value C to enable the setting of the constant.
66.03 EXT2 AO2 Selects the source for extension AI/O module 2 analogue P
output 2 control.
-255.255.31: C Parameter pointer or constant value:
-32768 ... - Parameter pointer: Inversion, group, index and bit fields. The
-255.255.31: C bit number is effective only for blocks handling boolean inputs.
32767
- Constant value: Inversion and constant fields. The inversion
field must have value C to enable the setting of the constant.
66.04 ALM WORD3 BIT9 Selects the source for 09.11 ALARM WORD3 bit 9 P
-255.255.31: C Parameter pointer or constant value:
-32768 ... - Parameter pointer: Inversion, group, index and bit fields. The
-255.255.31: C bit number is effective only for blocks handling boolean inputs.
32767
- Constant value: Inversion and constant fields. The inversion
field must have value C to enable the setting of the constant.
66.05 FLT WORD2 BIT8 Selects the sourse for 09.02 FAULT WORD2 bit 8 P
8-255.255.31: C Parameter pointer or constant value:
-32768 ... - Parameter pointer: Inversion, group, index and bit fields. The
-255.255.31: C bit number is effective only for blocks handling boolean inputs.
32767
- Constant value: Inversion and constant fields. The inversion
field must have value C to enable the setting of the constant.
66.06 MSW BIT11 Selects the source for 08.01 MAIN STATUS WORD bit 11 P
8-255.255.31: C Parameter pointer or constant value:
-32768 ... - Parameter pointer: Inversion, group, index and bit fields. The
-255.255.31: C bit number is effective only for blocks handling boolean inputs.
32767
- Constant value: Inversion and constant fields. The inversion
field must have value C to enable the setting of the constant.
70 DDCS CONTROL Settings for fibre optic channels CH0, CH1, CH2 and CH3
CH2 is used for Master/Follower application. See section
Master/Follower on page 104.
70.01 CH0 NODE ADDR Defines the node address for DDCS channel CH0. No two 1=1 1 1375 R
nodes on-line may have the same address.
With AC 800M (CI858) DriveBus connection the drives are
addressed from 1 to 24. With AC 80 DriveBus connection, the
drives are addressed from 1 to 12.
With Nxxx-type adapter modules the node address is 1.
With optical ModuleBus connection CH0 node address is
calculated with the following steps:
1. Multiply the hundreds of the position value by 16.
2. Add the tens and ones of the position value to the result.
For example, if the position value is 101, parameter 70.01 must
be set to value 16 × 1 + 1 = 17.
0...254 Node address
Actual signals and parameters
237
Index Name/Selection Description FbEq Def. PB T
70.02 CH0 LINK Defines the light intensity of the transmission LEDs. LEDs act 1=1 10 1376 R
CONTROL as light sources for optic fibres which are connected to DDCS
channel CH0.
With the maximum length of optic fiber cable, use value 15.
1...15 Light intensity
70.03 CH0 BAUD RATE Defines the communication speed of DDCS channel CH0. 1=1 3 1377 I
If FCI (Fieldbus Communication Interface) and fieldbus
communication modules are used, parameter has to be set to
4 Mbits/s. Otherwise, the external control system sets the
communication speed automatically.
0 8 Mbit/s
1 4 Mbit/s
2 2 Mbit/s
3 1 Mbit/s
70.04 CH0 TIMEOUT Defines the time delay before channel CH0 or R-type fieldbus 1 = 1 ms 100 1378 R
adapter interface communication break alarm/fault (COMM
MODULE) is activated. Time count starts when the link fails to
update the communication message. The action taken by the
drive on a communication break is defined by parameter 70.05
CH0 COM LOSS CTRL.
0...60000 ms Time. The function is disabled by setting this value to 0.
70.05 CH0 COM LOSS Selects how the drive reacts when communication error on 1 1379 I
CTRL DDCS channel CH0 or on R-type fieldbus adapter interface has
been detected. Time delay for the communication break alarm/
fault activation is defined by parameter 70.04 CH0 TIMEOUT.
See also parameter 30.26 COM LOSS RO.
1 = STOP Fault COMM MODULE is generated. Drive ramps to stop. The
RAMPNG deceleration time is defined by parameter 22.02 DECELER
TIME.
2 = STOP TORQ Fault COMM MODULE is generated. Drive is stopped
according to the torque limit.
3 = COAST STOP Fault COMM MODULE is generated. Drive coasts to stop.
4 = LAST SPEED Alarm COMM MODULE is generated. The drive continues
running according to the last defined reference value.
5 = CNST SPEED1 Alarm COMM MODULE is generated. The drive continues
running with the speed reference defined by parameter 23.02
CONST SPEED 1.
70.06 CH1 LINK Defines the light intensity of the transmission LEDs. LEDs act 1=1 10 1380 R
CONTROL as light sources for optic fibres which are connected to DDCS
channel CH1.
With the maximum length of optic fiber cable, use value 15.
1...15 Light intensity
70.07 CH2 NODE ADDR Defines the node address for DDCS channel CH2. This 1=1 1 1381 R
parameter is used with Master/Follower applications where
feedback signals are read to master drive. In master drive this
parameter must be 1 or 0. In follower drive the value > 1
activates the data sending from follower to master.
1...125 Node address
70.08 CH2 M/F MODE Defines the role of the drive in the Master/Follower link. 1 1382 I
Actual signals and parameters
238
Index Name/Selection Description FbEq Def. PB T
1 = NOT IN USE The Master/Follower link is not active.
2 = MASTER Master drive
3 = FOLLOWER Follower drive
70.09 MASTER SIGNAL 1 In case of master drive this parameter selects the data which is 1 = 1 0 1383 P
sent by the Master to the Follower drive(s) (to data set 41 index B
1). In case of follower drive this parameter selects the data
which is sent from follower to master.
0...20000 Parameter index 231 denotes signal 02.31 FOLLOWER MCW.
70.10 MASTER SIGNAL 2 In case of master drive this parameter selects the data which is 1 = 1 0 1384 R
sent by the Master to the Follower drive(s) (to data set 41 index
2). In case of follower drive this parameter selects the data
which is sent from follower to master.
0...20000 Parameter index 2301 denotes parameter 23.01 SPEED REF.
70.11 MASTER SIGNAL 3 In case of master drive this parameter selects the data which is 1 = 1 0 1385 R
sent by the Master to the Follower drive(s) (to data set 41 index
2). The selected data can be scaled by parameter 70.30
MASTER SGN3 SCALE before it is sent to the Follower drive.
In case of follower drive this parameter selects the data which is
sent from follower to master.
0...20000 Parameter index 210 denotes signal 02.10 TORQUE REF 3.
70.12 CH2 LINK Defines the light intensity of the transmission LEDs. LEDs act 1=1 10 1386 R
CONTROL as light sources for optic fibres which are connected to DDCS
channel CH2.
With the maximum length of optic fiber cable, use value 15.
1...15 Light intensity
70.13 CH2 TIMEOUT Defines the time delay before a channel CH2 communication 1=1 100 1387 R
break fault is activated. Time count starts when the link fails to
update the communication message. The action taken by the
drive on a CH2 communication break is defined by parameter
70.14 CH2 COM LOSS CTRL.
0...60000 ms Time
70.14 CH2 COM LOSS Selects how the drive reacts when communication fault on 1 1388 I
CTRL DDCS channel CH2 has been detected (Master/Follower link
communication error). Time delay for the communication break
alarm/fault activation is defined by parameter 70.13 CH2
TIMEOUT.
1 = FAULT Drive is trips on fault CH2 COMM LOSS.
2 = ALARM Drive generates alarm CH2 COMM LOSS.
70.15 CH3 NODE ADDR Defines the node address for DDCS channel 3. No two nodes 1=1 1 1389 R
on-line may have the same address. Typically this setting
needs to be changed when the drive is connected in a ring or
star which consists of several drives and a PC with a
DriveWindow PC tool.
The new node address becomes valid only after the next
power-up of the drive, or when auxiliary power supply is
connected to RMIO board for the next time.
Note: Address 1 is reserved for sparepart restore function.
1...254 Address. Addresses 76…125 are reserved for branching units.
Actual signals and parameters
239
Index Name/Selection Description FbEq Def. PB T
70.16 CH3 LINK Defines the light intensity of the transmission LEDs. LEDs act 1=1 15 1390 R
CONTROL as light sources for optic fibres which are connected to DDCS
channel CH3.
With the maximum length of optic fiber cable, use value 15.
1...15 Light intensity
70.17 FOLL SPEED REF Defines the source for the speed reference of the Follower 1=1 FOLLO 1391 B
drive. See control block diagram in section Speed reference on WER
page 313.
0 = FOLLOWER Speed reference is read from data set 1 or 10....24 or from I/O.
1 = MASTER Follower drive follows the Master drive speed reference. Speed
reference is read from data set 41.
70.18 FOLL TORQ REF Defines the source for the torque reference of the Follower 1=1 MAST 1392 B
drive. See control block diagram in section Torque reference on ER
page 316.
0 = FOLLOWER Torque reference is read from data set 1 or 10...24 or from I/O.
1 = MASTER Follower follows the Master drive torque reference. Torque
reference is read from data set 41.
70.19 CH0 HW Selects the topology of the DDCS channel CH0 link. 1=1 STAR B
CONNECTION Note: This parameter has no effect in the DriveBus mode.
Note: With NMBA-0x module, set parameter value to RING to
enable forwarding of received messages in the DDCS link.
0 = RING Devices are connected in a ring. Forwarding of messages is
enabled.
1 = STAR Devices are connected in a star. Forwarding of messages is
disabled. This selection is used with NDBU branching units.
70.20 CH3 HW Selects the topology of the DDCS channel CH3 link. 1=1 STAR B
CONNECTION
0 = RING Devices are connected in a ring. Forwarding of messages is
enabled.
1 = STAR Devices are connected in a star. Forwarding of messages is
disabled. This selection is used with NDBU branching units.
70.29 FOLL DS SEL This parameter is used to activate selected data set package to 1 = 1 1 I
be used in the follower drive. Each data set package contains 3
data words. This function is needed in customer application,
where the process master is changed on-line using CACP M/F
application as communication master in M/F link. See Firmware
Manual Configuration and Control Program for ABB Industrial
Drive [3AUA0000021158 (English)].
1 = MASTER Content of data set 41 (broadcast message) is read to speed
and torque reference chain in follower drive.
2 = FOLL NODE 2 Content of data set 45 is read to speed and torque reference
chain in follower drive, if parameter 70.07 CH2 NODE ADDR =
2.
3 = FOLL NODE 3 Content of data set 47 is read to speed and torque reference
chain in follower drive, if parameter 70.07 CH2 NODE ADDR =
3.
4 = FOLL NODE 4 Content of data set 49 is read to speed and torque reference
chain in follower drive, if parameter 70.07 CH2 NODE ADDR =
4.
Actual signals and parameters
240
Index Name/Selection Description FbEq Def. PB T
5 = FOLL NODE 5 Content of data set 51 is read to speed and torque reference
chain in follower drive, if parameter 70.07 CH2 NODE ADDR =
5.
6 = FOLL NODE 6 Content of data set 53 is read to speed and torque reference
chain in follower drive, if parameter 70.07 CH2 NODE ADDR =
6.
7 = FOLL NODE 7 Content of data set 55 is read to speed and torque reference
chain in follower drive, if parameter 70.07 CH2 NODE ADDR =
7.
70.30 MASTER SGN3 Scales the signal selected by parameter 70.11 MASTER 10 = 1% 100% R
SCALE SIGNAL 3 before it is sent to the Follower drive. With scaling it
is possible to send higher signal values.
Rescaling is defined by parameter 70.31 FOLLOW SGN3
SCALE.
0...1000% Value in percent
70.31 FOLLOW SGN3 Rescales the signal selected by parameter 70.11 MASTER 10 = 1% 100% R
SCALE SIGNAL 3 when it is received by the Follower drive. See
parameter 70.30 MASTER SGN3 SCALE.
0...1000% Value in percent
70.32 CH2 HW Selects the topology of the DDCS channel CH2 link. 1=1 RING B
CONNECTION
0 = RING Devices are connected in a ring. Forwarding of messages is
enabled.
1 = STAR Devices are connected in a star. Forwarding of messages is
disabled. This selection is used with NDBU branching units.
70.33 MAILBOX DS SEL Selects the data set pair for mailbox use when parameter 98.02
COMM. MODULE setting is ADVANT/N-FB. See section Data
sets 10...33 on page 300.
0 = 32/33 Data sets 32 and 33 are used for setting and inquiring
parameter values.
1 = 24/25 Data sets 24 and 25 are used for setting and inquiring
parameter values.
70.34 FOLLOWER MCW Mask word in follower drive for Main Control Word. Only the 1=1 0 Pb
MASK selected bits are used in follower command word; the
unselected bits are read from parameter 07.01 MCW. The value
FFFF means that all command word bits in the follower drive
are read from the follower command word (defined by 70.09
MASTER SIGNAL 1 in master drive).
0...65535
70.35 FOLLOWER SEL This parameter selects in master from which followers the data 1 = 1 7 I
is read.
1 = FOLLOWER 2 Data is read from follower drive in which CH2 NODE ADDRESS
= 2.
2 = FOLLOWER 3 Data is read from follower drive in which CH2 NODE ADDRESS
= 3.
3 = FOLLOWER Data is read from follower drives in which CH2 NODE
2+3 ADDRESS = 2 or 3.
4 = FOLLOWER 4 Data is read from follower drive in which CH2 NODE ADDRESS
= 4.
Actual signals and parameters
241
Index Name/Selection Description FbEq Def. PB T
5 = FOLLOWER2+4 Data is read from follower drives in which CH2 NODE
ADDRESS = 2 or 4.
6 = FOLLOWER3+4 Data is read from follower drives in which CH2 NODE
ADDRESS = 3 or 4.
7 = FOLL 2+3+4 Data is read from follower drives in which CH2 NODE
ADDRESS = 2, 3 or 4.
8 = NOT USED No data is read from followers.
70.36 FOLL FAULT SEL Master drive has a supervision of follower drives status. 1=1 3 I
Masters reaction to followers interlockings can be selected with
this parameter.
1 = NO REACTION Other drives in Master/Follower link continues running, if one or
more of the followers is faulted.
2 = ALARM An alarm FOLLOWER TRIP is activated in master drive.
3 = FAULT A fault FOLLOWER TRIP is activated in master drive. All drives
are stopped.
70.37 FOLL ENABLE SEL Starting of master drive can be interlocked to status of 1=1 3 R
followers.
1 = MSW BIT 0 If follower selected by parameter 70.35 FOLLOWER SEL is not
RDY ON, starting of master drive is disabled.
2 = MSW BIT 1 If follower selected by parameter 70.35 FOLLOWER SEL is not
RDY RUN, starting of master drive is disabled.
3 = MSW BIT0+1 If follower selected by parameter 70.35 FOLLOWER SEL is not
RDY ON and RDY RUN, starting of master drive is disabled.
4 = ALLWAYS Starting of master drive is not interlocked to status of
follower(s).
71 DRIVEBUS COMM DDCS channel CH0 DriveBus settings
71.01 CH0 DRIVEBUS Selects the communication mode for the DDCS channel CH0. 1 = 1 NO B
MODE The new mode becomes valid only after the next power-up of
the drive, or when auxiliary power supply is connected to RMIO
board for the next time.
Data is exchanged 4 times faster in the DriveBus mode than in
the DDCS mode.
0 = NO DDCS mode
1 =YES DriveBus mode
Actual signals and parameters
242
Index Name/Selection Description FbEq Def. PB T
90 D SET REC ADDR Addresses into which the received fieldbus data sets are
written.
The parameters are visible only when a fieldbus communication
is activated by setting parameter 98.02 COMM. MODULE to
FIELDBUS or ADVANT/N-FB. For more information, see
chapter Fieldbus control.
RMIO/NAMC-xx
Address
assignment
DDCS link Data set table of data sets AMC table
External
control 10 Group
system 12 90.01...90.18
CH0 14 91.01...91.09
32
90.01 D SET 10 VAL 1 Selects the address into which data word 1 of data set 10 is 701 1735 I
written. Update time is 2 ms.
0...9999 Parameter index
90.02 D SET 10 VAL 2 Selects the address into which data word 2 of data set 10 is 1736 I
written. Update time is 2 ms.
0...9999 Parameter index
90.03 D SET 10 VAL 3 Selects the address into which data word 3 of data set 10 is 1737 I
written. Update time is 2 ms.
0...9999 Parameter index
90.04 D SET 12 VAL 1 Selects the address into which data word 1 of data set 12 is 1738 I
written. Update time is 4 ms.
0...9999 Parameter index
90.05 D SET 12 VAL 2 Selects the address into which data word 2 of data set 12 is 1739 I
written. Update time is 4 ms.
0...9999 Parameter index
90.06 D SET 12 VAL 3 Selects the address into which data word 3 of data set 12 is 1740 I
written. Update time is 4 ms.
0...9999 Parameter index
90.07 D SET 14 VAL 1 Selects the address into which data word 1 of data set 14 is 1741 I
written. Update time is 10 ms.
0...9999 Parameter index
90.08 D SET 14 VAL 2 Selects the address into which data word 2 of data set 14 is 1742 I
written. Update time is 10 ms.
0...9999 Parameter index
90.09 D SET 14 VAL 3 Selects the address into which data word 3 of data set 14 is 1743 I
written. Update time is 10 ms.
0...9999 Parameter index
Actual signals and parameters
243
Index Name/Selection Description FbEq Def. PB T
90.10 D SET 16 VAL 1 Selects the address into which data word 1 of data set 16 is 1744 I
written. Update time is 10 ms.
0...9999 Parameter index
90.11 D SET 16 VAL 2 Selects the address into which data word 2 of data set 16 is 1745 I
written. Update time is 10 ms.
0...9999 Parameter index
90.12 D SET 16 VAL 3 Selects the address into which data word 3 of data set 16 is 1746 I
written. Update time is 10 ms.
0...9999 Parameter index
90.13 D SET 18 VAL 1 Selects the address into which data word 1 of data set 18 is 1747 I
written. Update time is 100 ms.
0...9999 Parameter index
90.14 D SET 18 VAL 2 Selects the address into which data word 2 of data set 18 is 1748 I
written. Update time is 100 ms.
0...9999 Parameter index
90.15 D SET 18 VAL 3 Selects the address into which data word 3 of data set 18 is 1749 I
written. Update time is 100 ms.
0...9999 Parameter index
90.16 D SET 20 VAL 1 Selects the address into which data word 1 of data set 20 is 1750 I
written. Update time is 100 ms.
0...9999 Parameter index
90.17 D SET 20 VAL 2 Selects the address into which data word 2 of data set 20 is 1751 I
written. Update time is 100 ms.
0...9999 Parameter index
90.18 D SET 20 VAL 3 Selects the address into which data word 3 of data set 20 is 1752 I
written. Update time is 100 ms.
0...9999 Parameter index
91 D SET REC ADDR See parameter group 90 D SET REC ADDR.
91.01 D SET 22 VAL 1 Selects the address into which data word 1 of data set 22 is 1753 I
written. Update time is 100 ms.
0...9999 Parameter index
91.02 D SET 22 VAL 2 Selects the address into which data word 2 of data set 22 is 1754 I
written. Update time is 100 ms.
0...9999 Parameter index
91.03 D SET 22 VAL 3 Selects the address into which data word 3 of data set 22 is 1755 I
written. Update time is 100 ms.
0...9999 Parameter index
91.04 D SET 24 VAL 1 Selects the address into which data word 1 of data set 24 is 1756 I
written. Update time is 100 ms.
0...9999 Parameter index
91.05 D SET 24 VAL 2 Selects the address into which data word 2 of data set 24 is 1757 I
written. Update time is 100 ms.
0...9999 Parameter index
91.06 D SET 24 VAL 3 Selects the address into which data word 3 of data set 24 is 1758 I
written. Update time is 100 ms.
0...9999 Parameter index
Actual signals and parameters
244
Index Name/Selection Description FbEq Def. PB T
92 D SET TR ADDR Data sets which the drive sends to the fieldbus master station.
The parameters in groups 92 and 93 are visible only when a
fieldbus communication is activated by setting parameter 98.02
COMM. MODULE to FIELDBUS or ADVANT/N-FB. For more
information, see chapter Fieldbus control.
RMIO
Address
assignment
DDCS link Data set table of data sets AMC table
External Group
11
control
CH0 13 92.01...92.18
system
15 93.01...93.09
33
92.01 D SET 11 VAL 1 Selects the address from which data word 1 of data set 11 is 1771 I
read. Update time is 2 ms.
0...9999 Parameter index
92.02 D SET 11 VAL 2 Selects the address from which data word 2 of data set 11 is 1772 I
read. Update time is 2 ms.
0...9999 Parameter index
92.03 D SET 11 VAL 3 Selects the address from which data word 3 of data set 11 is 1773 I
read. Update time is 2 ms.
0...9999 Parameter index
92.04 D SET 13 VAL 1 Selects the address from which data word 1 of data set 13 is 1774 I
read. Update time is 4 ms.
0...9999 Parameter index
92.05 D SET 13 VAL 2 Selects the address from which data word 2 of data set 13 is 1775 I
read. Update time is 4 ms.
0...9999 Parameter index
92.06 D SET 13 VAL 3 Selects the address from which data word 3 of data set 13 is 1776 I
read. Update time is 4 ms.
0...9999 Parameter index
92.07 D SET 15 VAL 1 Selects the address from which data word 1 of data set 15 is 1777 I
read. Update time is 10 ms.
0...9999 Parameter index
92.08 D SET 15 VAL 2 Selects the address from which data word 2 of data set 15 is 1778 I
read. Update time is 10 ms.
0...9999 Parameter index
92.09 D SET 15 VAL 3 Selects the address from which data word 3 of data set 15 is 1779 I
read. Update time is 10 ms.
0...9999 Parameter index
92.10 D SET 17 VAL 1 Selects the address from which data word 1 of data set 17 is 1780 I
read. Update time is 10 ms.
0...9999 Parameter index
Actual signals and parameters
245
Index Name/Selection Description FbEq Def. PB T
92.11 D SET 17 VAL 2 Selects the address from which data word 2 of data set 17 is 1781 I
read. Update time is 10 ms.
0...9999 Parameter index
92.12 D SET 17 VAL 3 Selects the address from which data word 3 of data set 17 is 1782 I
read. Update time is 10 ms.
0...9999 Parameter index
92.13 D SET 19 VAL 1 Selects the address from which data word 1 of data set 19 is 1783 I
read. Update time is 100 ms.
0...9999 Parameter index
92.14 D SET 19 VAL 2 Selects the address from which data word 2 of data set 19 is 1784 I
read. Update time is 100 ms.
0...9999 Parameter index
92.15 D SET 19 VAL 3 Selects the address from which data word 3 of data set 19 is 1785 I
read. Update time is 100 ms.
0...9999 Parameter index
92.16 D SET 21 VAL 1 Selects the address from which data word 1 of data set 21 is 1786 I
read. Update time is 100 ms.
0...9999 Parameter index
92.17 D SET 21 VAL 2 Selects the address from which data word 2 of data set 21 is 1787 I
read. Update time is 100 ms.
0...9999 Parameter index
92.18 D SET 21 VAL 3 Selects the address from which data word 3 of data set 21 is 1788 I
read. Update time is 100 ms.
93 D SET TR ADDR See parameter group 92 D SET TR ADDR.
93.01 D SET 23 VAL 1 Selects the address from which data word 1 of data set 23 is 1789 I
read. Update time is 100 ms.
0...9999 Parameter index
93.02 D SET 23 VAL 2 Selects the address from which data word 2 of data set 23 is 1790 I
read. Update time is 100 ms.
0...9999 Parameter index
93.03 D SET 23 VAL 3 Selects the address from which data word 3 of data set 23 is 1791 I
read. Update time is 100 ms.
0...9999 Parameter index
93.04 D SET 25 VAL 1 Selects the address from which data word 1 of data set 25 is 1792 I
read. Update time is 100 ms.
0...9999 Parameter index
93.05 D SET 25 VAL 2 Selects the address from which data word 2 of data set 25 is 1793 I
read. Update time is 100 ms.
0...9999 Parameter index
93.06 D SET 25 VAL 3 Selects the address from which data word 3 of data set 25 is 1794 I
read. Update time is 100 ms.
0...9999 Parameter index
Actual signals and parameters
246
Index Name/Selection Description FbEq Def. PB T
95 LSU Line-side converter reference and actual signal selection. This
parameter group is used with single drives.
Note: Parameters are effective only when a fibre optic
communication link is connected between the inverter RMIO
control board channel CH1 and the line-side converter control
board channel CH0.
95.01 LSU Q POW REF Defines the reference value for the line-side converter reactive See par. 0 I
power generation. Line-side converter can generate reactive descrip-
power to the supply network. This reference is written into tion.
line-side converter unit parameter 24.02 Q POWER REF2. For
more information, see IGBT Supply Control Program 7.x
Firmware manual [3AFE68315735 (English)].
Example 1: When parameter 24.03 Q POWER REF2 SEL is
set to PERCENT, value 10000 of parameter 24.02 Q POWER
REF2 equals to value 100% of parameter 24.01 Q POWER
REF (i.e. 100% of the converter nominal power given in signal
04.06 CONV NOM POWER).
Example 2: When parameter 24.03 Q POWER REF2 SEL is
set to kVAr, value 1000 of parameter 24.02 Q POWER REF2
equals to parameter 24.01 Q POWER REF value calculated
with the following equation: 100 ×(1000 kVAr divided by
converter nominal power in kVAr)%.
Example 3: When parameter 24.02 Q POWER REF2 SEL is
set to PHI, value 3000 of parameter 24.02 POWER REF2
equals approximately to parameter 24.01 Q POWER REF value
calculated with the following equation:
S
P P Q
cos ( 30 ) = ---- = ------------------------
S 2 2 30°
P +Q
P
Positive reference 30° denotes capacitive load.
Negative reference 30° denotes inductive load.
P = signal 01.09 POWER value
Parameter 24.02 values are converter to degrees by the
line-side converter application program: -3000...3000 =
-30°...30°. Values above 3000 or below -3000 equal to -30°/30°,
since the range is limited to -3000/3000.
-10000...10000 Reference value
95.02 LSU DC REF [V] Defines the intermediate circuit DC voltage reference for the 1=1V 0 I
line-side converter. This reference is written into line-side
converter parameter 23.01 DC VOLT REF.
Note: The IGBT Supply Unit DC voltage is limited by its
minimum value. With 400 V supply, the minimum DC voltage is
approximately 560 V.
For more information, see IGBT Supply Control Program 7.x
Firmware manual [3AFE68315735 (English)].
0...1100 V Voltage
95.03 LSU PAR1 SEL Selects the line-side converter address from which the actual 106 I
signal 03.31 LSU ACT SIGNAL1 is read from.
Actual signals and parameters
247
Index Name/Selection Description FbEq Def. PB T
0...10000 Line-side converter parameter index. Default value 106 =
line-side converter parameter 01.06 LINE CURRENT.
For more information, see IGBT Supply Control Program 7.x
Firmware manual [3AFE68315735 (English)].
95.04 LSU PAR2 SEL Selects the line-side converter address from which the actual 110 I
signal 03.32 LSU ACT SIGNAL2 is read from.
0...10000 Line-side converter parameter index. Default value 110 =
line-side converter parameter 01.10 DC VOLTAGE.
For more information, see IGBT Supply Control Program 7.x
Firmware manual [3AFE68315735 (English)].
95.05 LSU COMM SEL The control and data transfer of line-side converter by inverter Acc. to I
unit is selected according to application. The parameter 98.02 HW
COMM. MODULE in LSU must have the equal value with this type
parameter.
1 = NO COMM No control for line-side converter via optic fibre from inverter
RMIO channel CH1.
2 = LIMITED Limited control. This is used normally with ACS800-11,
ACS800-17, ACS800-31 and ACS800-37 drives.
F IE L D B U S
F IE L D B U S A C T IV E
A D A P T E R S U P P L Y
U N IT
IN V E R T E R
U N IT
M A IN C O N T R O L W O R D
B it 0
L S U Q P O W R E F
L S U Q P O W R E F 9 5 .0 1
L S U D C R E F
L S U D C R E F 9 5 .0 2
L IN E C O N V E R T E R IN T E R N A L
D R IV E T Y P E M C W L S U S T A T U S W O R D
C O N T R O L
0 8 .2 5 L S U S T A T U S W O R D
0 3 .3 2 L S U A C T S IG N A L S 2 A D D R E S S
A S S IG N M E N T
0 3 .3 1 L S U A C T S IG N A L S 1 O F D A T A
L S U P A R 1 S E L 9 5 .0 3
L S U P A R 2 S E L 9 5 .0 4
3 = WIDE Wide communication. More actual values can be read from the
line-side converter. See signal group 05 LSU SIGNALS on
page 141.
4 = WTA Wide communication with wind turbine application
95.06 LSU RUN MCW Selection of run command for LSU. LSU charging and 1=1 0 I
BIT modulation is normally started with 07.01 MCW bit 0, but
starting of modulation can be separated to free bits of MCW
(bits 11…15).
97 DRIVE Drive name or application
97.01 DEVICE NAME Defines the name for the drive or application. The name is 0 1861 C
visible on the control panel display in the Drive Selection Mode
or on the DriveWindow main menu.
Note: The name can be typed only by using a drive PC tool.
0...32 characters E.g. Unwinder 1 -
Actual signals and parameters
248
Index Name/Selection Description FbEq Def. PB T
98 OPTION MODULES Activation of option modules.
ACS800 fieldbus adapter modules are connected to Slot 1 or 2
of the drive or to RDCO board DDCS channel CH0.
Other optional modules are connected to Slot 1 or 2 of the drive
or to RDCO board DDCS channel CH1 via optional AIMA-01
I/O Module Adapter. Multiple AIMA-01 adapters are connected
in a ring.
If the adapter is connected to channel CH0 or to AIMA-01, each
adapter module node number must be set with a switch (DIP
switch or switch S1).
The parameter settings in this group will remain the same even
though the application macro is changed by parameter 99.11
APPLICATION MACRO.
See chapter Fieldbus control.
98.01 ENCODER Activates the communication to the optional pulse encoder 1 1901 I
MODULE module. See also parameter group 50 SPEED
MEASUREMENT.
For more information, see RTAC-01 Pulse Encoder Interface
User's Manual [3AFE64486853 (English)] or NTAC/NDIO/NAIO
I/O Modules Installation and Start-up Guide [3AFY58919730
(English)].
0 = NTAC Communication active. Module type: NTAC module.
Connection interface: Fibre optic DDCS link (RMIO channel
CH1).
Note: Module node number must be set to 16 with DIP switch.
1 = NO Communication inactive
2 = RTAC-SLOT1 Communication active. Module type: RTAC.
Connection interface: Option Slot 1 of the drive.
3 = RTAC-SLOT2 Communication active. Module type: RTAC.
Connection interface: Option Slot 2 of the drive.
4 = RTAC-DDCS Communication active. Module type: RTAC. Switch S1
Connection interface: Optional I/O Module
DE F
Adapter (AIMA-01 connected to RMIO C
01
9AB
channel CH1) that communicates with the
2
drive through a fibre optic DDCS link.
3
4 5 78
6
Note: Module node number must be 0
(default setting of switch S1).
98.02 COMM. MODULE Selects the external serial communication and its interface in 3 1902 I
remote control mode. See chapter Fieldbus control.
1 = NO No external communication. The drive is controlled through the
I/O. See parameter group 10 DIGITAL INPUTS.
2 = FIELDBUS The drive communicates through an Rxxx type fieldbus adapter
connected to Slot 1 or trough an Nxxx type fieldbus adapter
connected to RMIO board DDCS channel CH0 using data sets
1 and 2.
Data set 1 and 2 are typically used with type Rxxx or Nxxx
fieldbus adapter modules. See also parameter group 51
MASTER ADAPTER (fieldbus adapter) and parameter 11.02
AI+FBA SPEED REF.
Actual signals and parameters
249
Index Name/Selection Description FbEq Def. PB T
3 = ADVANT/N-FB The drive communicates via RMIO board DDCS channel CH0
using data sets 10 to 33. This selection is used with e.g.
AC 800M, AC 80, APC2 and Nxxx type fieldbus adapters. See
also parameter groups 70 DDCS CONTROL and
71 DRIVEBUS COMM.
4 = STD MODBUS The drive communicates through RMBA-0x Modbus adapter
module connected to option Slot 1/2 of the drive.
Note: With NMBA, use selection FIELDBUS or ADVANT/N-FB.
See parameter group 52 STANDARD MODBUS and RMBA-01
Modbus Adapter User's Manual [3AFE64498851 (English)].
98.03 DI/O EXT Activates RDIO/NDIO Digital I/O Extension module 1. RDIO/ 1 1903 I
MODULE 1 NDIO can be used to replace or extend the I/O.
Note: The communication to the I/O extension module must be
activated by parameter 98.09 DI/O EXT1 LOCATION.
For more information, see RDIO-01 Digital I/O Extension User's
Manual [3AFE64485733 (English)] or NTAC/NDIO/NAIO I/O
Modules Installation and Start-up Guide [3AFY58919730
(English)].
1 = NO Inactive
2 = REPLACE RDIO/NDIO Extension module 1 replaces DI1, DI2, DI3, DO1
and DO2 of the RMIO board. (DO1 and DO2 of the RMIO board
and DO1 and DO2 of the RDIO module work parallel.)
3 = EXTEND RDIO/NDIO is used to extend the I/O with digital inputs and
outputs EXT1_DI1, EXT1_DI2, EXT1_DI3, EXT1_DO1 and
EXT1_DO2.
98.04 DI/O EXT Activates RDIO/NDIO Digital I/O Extension module 2. RDIO/ 1 1904 I
MODULE 2 NDIO can be used to replace or extend the I/O.
Note: The communication to the I/O extension module must be
activated by parameter 98.10 DI/O EXT2 LOCATION.
For more information, see RDIO-01 Digital I/O Extension User's
Manual [3AFE64485733 (English)] or NTAC/NDIO/NAIO I/O
Modules Installation and Start-up Guide [3AFY58919730
(English)].
1 = NO Inactive
2 = REPLACE RDIO/NDIO replaces DI4, DI5, DI6 and DO3 of the RMIO
board. EXT2_DO2 is activated. (DO3 of the RMIO board and
DO3 of the RDIO Extension module work parallel.)
3 = EXTENDED RDIO/NDIO is used to extend the I/O with digital inputs and
outputs EXT2_DI1, EXT2_DI2, EXT2_DI3, EXT2_DO1 and
EXT2_DO2.
4 = STEP UP DI/O EXT MODULE 2 is used for protection of sine filter.
DI1 = choke overtemperature fault CHOKE OTEMP
(FF82) = 0, no choke overtemperature fault = 1.
DI2 = fan overtemp alarm of sine filter FAN OVERTEMP
(FF83) = 0, no fan overtemp alarm = 1.
DI3 = not in use for sinus filter protection.
Actual signals and parameters
250
Index Name/Selection Description FbEq Def. PB T
98.06 AI/O EXT Defines the signal type for the inputs and outputs of the RAIO/ 1 1906 I
MODULE 1 NAIO Analogue I/O Extension module 1 or reserves the RAIO/
NAIO module for the motor temperature measurement function.
The input signal setting must match the signal connected to the
module. The input signal type can be selected with the
configuration DIP switch on the circuit board of the module.
For more information, see RAIO-01 Analogue I/O Extension
User's Manual [3AFE64484567 (English)] or NTAC/NDIO/NAIO
I/O Modules Installation and Start-up Guide [3AFY58919730
(English)].
Switch S2 (Operating mode) for RAIO-01
Analogue input AI1 Analogue input AI2 Input signal
ON ON ± 0(4)…20 mA
± 0(2)…10 V
1 2
± 0…2 V
1 2 3 4 5 6 3 4 5 6
ON ON 0(4)…20 mA
0(2)…10 V
1 2
0…2 V
1 2 3 4 5 6 3 4 5 6
(Default)
Switch S2 (Current or voltage signal)
ON ON Current signal
± 0(4)…20 mA
1 2
(Default)
3 4 5 6 1 2 3 4 5 6
ON ON Voltage signal
± 0(2)…10 V
1 2 3 4 5 6 1 2 3 4 5 6
ON ON Voltage signal
± 0…2 V
1 2 3 4 5 6 1 2 3 4 5 6
The analogue I/O extension module replaces AI1 and AI2 of the
RMIO board, and extends the outputs with AO3 and AO4.
Note: The communication must be activated by parameter
98.11 AI/O EXT1 LOCATION.
1 = NO Inactive
2 = UNIPOLAR AI Unipolar
3 = BIBOLAR AI Bipolar
4 = TEMP MEAS Motor temperature measurement (Pt100, PTC or KTY84-1xx)
with RAIO/NAIO module. See parameter 30.06 MOT2 TEMP
AI2 SEL.
98.08 COMM PROFILE Defines the profile on which the communication with the
fieldbus or another drive is based. Visible only when fieldbus
communication is activated by parameter 98.02 COMM.
MODULE.
1 = ABB DRIVES ABB Drives profile
2 = ABB DRIVES C When no DC Voltage, 08.01 MAIN STATUS WORD
B0 = FALSE
Actual signals and parameters
251
Index Name/Selection Description FbEq Def. PB T
98.09 DI/O EXT1 Activates the communication to the optional digital I/O 2 1909 I
LOCATION extension module 1 and defines the type and connection
interface of the module. Parameter 98.03 DI/O EXT MODULE 1
activates digital I/O extension module 1.
Faster DC input signal detection can be achieved by disabling
the hardware filter of the digital input with the configuration DIP
switch on the circuit board of the module.
DIP switch S2 (RDIO)
DI3 DI2 DI1
ON
Enabled
Hardware filtering
Disabled
1 2 3 4
Note: Always enable the hardware filtering with an AC input
signal.
1 = NDIO Communication active. Module type: NDIO module. Connection
interface: Fibre optic DDCS link (RDCO board channel CH1)
Note: Module node number must be set to 2 with DIP switch.
2 = NOT IN USE Inactive
3 = RDIO-SLOT1 Communication active. Module type: RDIO. Connection
interface: Option Slot 1 of the drive.
4 = RDIO-SLOT2 Communication active. Module type: RDIO. Connection
interface: Option Slot 2 of the drive.
5 = RDIO-DDCS Communication active. Module type: RDIO. Switch S1
Connection interface: Optional I/O module
DE F
adapter (AIMA) that communicates with the C
01
9AB
drive through a fibre optic DDCS link. 2
3
Note: Module node number must be set to 2 8
67
45
with switch S1.
98.10 DI/O EXT2 Activates the communication to the optional digital I/O 2 1910 I
LOCATION extension module 2 and defines the type and connection
interface of the module. Parameter 98.04 DI/O EXT MODULE 2
activates digital I/O extension module 2.
Faster DC input signal detection can be achieved by disabling
the hardware filter of the digital input with the configuration DIP
switch on the circuit board of the module.
DIP switch S2 (RDIO)
DI3 DI2 DI1
ON
Enabled
Hardware filtering
Disabled
1 2 3 4
Note: Always enable the hardware filtering with an AC input
signal.
1 = NDIO Communication active. Module type: NDIO module. Connection
interface: Fibre optic DDCS link (RDCO board channel CH1)
Note: Module node number must be set to 3 with DIP switch.
2 = NOT IN USE Inactive
3 = RDIO-SLOT1 Communication active. Module type: RDIO. Connection
interface: Option Slot 1 of the drive.
4 = RDIO-SLOT2 Communication active. Module type: RDIO. Connection
interface: Option Slot 2 of the drive.
Actual signals and parameters
252
Index Name/Selection Description FbEq Def. PB T
5 = RDIO-DDCS Communication active. Module type: RDIO. Switch S1
Connection interface: Optional I/O module
DE F
adapter (AIMA) that communicates with the C
01
9AB
drive through a fibre optic DDCS link.
2
3
Note: Module node number must be set to 3 4 5 78
6
with switch S1.
98.11 AI/O EXT1 Activates the communication to the optional analogue I/O 2 1911 I
LOCATION extension module 1, and defines the type and connection
interface of the module.
Parameter 98.06 AI/O EXT MODULE 1 selects how analogue
I/O extension module 1 will be used.
1 = NAIO Communication active. Module type: NAIO. Connection
interface: Fibre optic DDCS link (RDCO board channel CH1).
Note: Module node number must be set to 5 with DIP switch.
2 = NOT IN USE Communication inactive
3 = RAIO-SLOT1 Communication active. Module type: RAIO. Connection
interface: Option Slot 1 of the drive.
4 = RAIO-SLOT2 Communication active. Module type: RAIO. Connection
interface: Option Slot 2 of the drive.
5 = RAIO-DDCS Communication active. Module type: RAIO. Switch S1
Connection interface: Optional I/O module
DE F
adapter (AIMA) that communicates with the C 01
9AB
drive through a fibre optic DDCS link.
2
3
Note: Module node number must be set to 5 4 5 78
6
with switch S1.
98.12 FUSE SWITCH Activates the inverter DC switch (switch fuse) monitoring 1=1 Type B
CTRL function. The monitoring must be active when the Switch Fuse depend
Control Board (ASFC) is in use and connected to the inverter ent
AINT board, i.e. in all frame R8i inverters equipped with
optional DC switch.
For frame R8i inverter, the DC switch position status is sent by
the ASFC board through a fibre optic link. The data is written to
actual signal 08.20 INV ENABLED WORD together with the
inverter DC capacitor charging status.
Drive IGBT pulses are always blocked when the program
detects that the DC switch is opened or inverter charging is
ongoing (at power switch on). The application program
generates alarm INV DISABLED if the DC switch is opened
when the inverter is stopped. The inverter trips on fault INV
DISABLED if the DC switch is opened when the inverter is
running.
The default setting (ON or OFF) for each unit is set accordingly
at the factory.
0 = OFF Inactive. DC switch is not used.
1 = ON Active. DC switch is used. See multidrive hardware drawings.
Actual signals and parameters
253
Index Name/Selection Description FbEq Def. PB T
98.13 AI1 EXT2 MODE Defines the signal type for input AI1 of the RAIO/NAIO 1 I
Analogue I/O Extension module 2.
The input signal setting must match the signal connected to the
module. The input signal type can be selected by using the
configuration DIP switch on the circuit board of the module:
Switch S2 (Operating mode) for RAIO-01
Analogue input AI1 Analogue input AI2 Input signal
ON ON ± 0(4)…20 mA
± 0(2)…10 V
1 2
± 0…2 V
1 2 3 4 5 6 3 4 5 6
ON ON 0(4)…20 mA
0(2)…10 V
0…2 V
1 2 3 4 5 6 1 2 3 4 5 6
(Default)
Switch S2 (Current or voltage signal)
ON ON Current signal
± 0(4)…20 mA
(Default)
1 2 3 4 5 6 1 2 3 4 5 6
ON ON Voltage signal
± 0(2)…10 V
1 2 3 4 5 6 1 2 3 4 5 6
ON ON Voltage signal
± 0…2 V
1 2 3 4 5 6 1 2 3 4 5 6
Note: The communication must be activated by parameter
98.15 AI/O EXT2 LOCATION.
For more information, see RAIO-01 Analogue I/O Extension
User's Manual [3AFE64484567 (English)] or NTAC/NDIO/NAIO
I/O Modules Installation and Start-up Guide [3AFY58919730
(English)].
1 = UNIPOLAR AI1 Unipolar
2 = BIBOLAR AI1 Bipolar
98.14 AI2 EXT2 MODE Defines the signal type for input AI2 of the RAIO Analogue I/O
Extension module 2. See parameter 98.13 AI1 EXT2 MODE.
See parameter 98.13.
98.15 AI/O EXT2 Activates the communication to the optional analogue I/O 2 I
LOCATION extension module 2, and defines the type and connection
interface of the module.
Parameters 98.13 AI/O EXT2 MODE and 98.14 AI2 EXT2
MODE select how analogue I/O extension module 2 will be
used.
1 = NAIO Communication active. Module type: NAIO. Connection
interface: Fibre optic DDCS link (RDCO board CH1).
Note: Module node number must be set to 6 with DIP switch.
2 = NOT IN USE Communication inactive
3 = RAIO-SLOT1 Communication active. Module type: RAIO. Connection
interface: Option Slot 1 of the drive.
Actual signals and parameters
254
Index Name/Selection Description FbEq Def. PB T
4 = RAIO-SLOT2 Communication active. Module type: RAIO. Connection
interface: Option Slot 2 of the drive.
5 = RAIO-DDCS Communication active. Module type: RAIO. Switch S1
Connection interface: Optional I/O module
DE F
adapter (AIMA) that communicates with the C
01
9AB
drive through a fibre optic DDCS link.
2
3
Note: Module node number must be set to 6 4 5 78
6
with switch S1.
99 START-UP DATA Language selection. Definition of motor set-up data.
Note: The drive will not start if the start-up data parameters
have not been changed from the factory settings, or the
nominal current of the motor is too small compared to the
nominal current of the inverter.
WARNING! Running the motor and the driven
equipment with incorrect start-up data can result in
improper operation, reduction in control accuracy
and damage to equipment.
If several motors are connected to the drive, follow the
instruction given in chapter Start-up.
Note: Changing any of the motor parameters in group 99,
causes the cancellation of all existing Motor ID run results!
99.01 LANGUAGE Selects the display language. 0 1926 I
0 = ENGLISH British English
1 = ENGLISH AM Not available
2 = DEUTSCH German
3 = ITALIANO Not available
4 = ESPANOL Not available
5 = PORTUGUES Not available
6 = NEDERLANDS Not available
7 = FRANCAIS Not available
8 = DANSK Not available
9 = SUOMI Not available
10 = SVENSKA Not available
11 = CESKY Not available
12 = POLSKI Not available
13 = PO-RUSSKI Not available
99.02 MOTOR NOM Defines the nominal motor voltage. Must be equal to the value 1=1V 0 1927 R
VOLTAGE on the motor rating plate.
1/2...2 × UN V Voltage. Allowed range is 1/2...2 × UN of the drive.
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.
Actual signals and parameters
255
Index Name/Selection Description FbEq Def. PB T
99.03 MOTOR NOM Defines the nominal motor current. Must be equal to the value 10 = 1 A 0 1928 R
CURRENT on the motor rating plate. If several motors are connected to the
inverter, enter the total current of the motors.
Note: Correct motor run requires that the magnetizing current
of the motor does not exceed 90% of the nominal current of the
inverter.
0...2 · Ihd A Allowed range: Approximately 1/6...2 × Ihd of the drive when
parameter 99.08 MOTOR CTRL MODE is set to DTC.
Allowed range: Approximately 0...2 × Ihd of the drive when
parameter 99.08 MOTOR CTRL MODE is set to SCALAR.
99.04 MOTOR NOM Defines the nominal motor frequency. 100 = 50 1929 R
FREQ Note: If the nominal frequency of the motor is higher than 1 Hz
50 Hz, speed limits must be set before ID run. See parameter
group 20 LIMITS (DTC mode) or 29 SCALAR CONTROL
(scalar mode).
8...300 Hz Nominal frequency (50 or 60 Hz typically)
99.05 MOTOR NOM Defines the nominal motor speed. Must be equal to the value 1= 1 1930 R
SPEED on the motor rating plate. The motor synchronous speed or 1 rpm
another approximate value must not be given instead!
Note: If the value of parameter 99.05 is changed, the speed
limits in parameter group 20 LIMITS change automatically as
well.
1...18000 rpm Nominal motor speed
99.06 MOTOR NOM Defines the nominal motor power. Set exactly as on the motor 10 = 0 1931 R
POWER rating plate. 1 kW
If several motors are connected to the inverter, enter the total
power of the motors. Set also parameter 99.12 MOTOR NOM
COS FII.
0...9000 kW Nominal motor power
99.07 MOTOR ID RUN Selects the type of the motor identification. During the 1 1932 I
identification, the drive will identify the characteristics of the
motor for optimum motor control. The ID run procedure is
described in section ID RUN (motor identification run) on
page 22.
Note: The ID run (STANDARD or REDUCED) should be
selected if:
- the operation point is near zero speed, and/or
- operation at torque range above the motor nominal torque
within a wide speed range and without any measured speed
feedback is required.
Note: The ID run (STANDARD or REDUCED) cannot be
performed if parameter 99.08 MOTOR CTRL MODE is set to
SCALAR.
1 = NO Motor ID run is not performed. If ID run has not been already
performed or if the motor parameters (par. group 99 START-UP
DATA) have been changed: The motor model is calculated at
first start by magnetising the motor at zero speed. The model is
stored to the FPROM memory. The first start lasts longer than
normal start.
Alarm ID MAGN is indicated during the first start.
This mode can be selected in most applications.
Actual signals and parameters
256
Index Name/Selection Description FbEq Def. PB T
2 = STANDARD Standard ID run. Guarantees the best possible control
accuracy. The ID run takes about one minute.
Note: The motor must be de-coupled from the driven
equipment.
Note: Check the direction of rotation of the motor before
starting the ID run. During the run, the motor will rotate in the
forward direction.
WARNING! The motor will run at up to approximately
50...80% of the nominal speed during the ID run.
ENSURE THAT IT IS SAFE TO RUN THE MOTOR
BEFORE PERFORMING THE ID RUN!
3 = REDUCED Reduced ID run. Should be selected instead of the Standard ID
run if mechanical losses are higher than 20% (i.e. the motor
cannot be de-coupled from the driven equipment).
Note: Check the direction of rotation of the motor before
starting the ID run. During the run, the motor will rotate in the
forward direction.
WARNING! The motor will run at up to approximately
50...80% of the nominal speed during the ID Run.
ENSURE THAT IT IS SAFE TO RUN THE MOTOR
BEFORE PERFORMING THE ID RUN!
4 = CURRENT CAL Current offset and gain measurement calibration. Calibration is
performed on the next start.
99.08 MOTOR CTRL Selects the motor control mode. 1=1 DTC 1933 B
MODE If several motors are connected to the inverter, there are certain
restrictions on the usage of DTC.
1 = SCALAR Scalar control is suitable in special cases where DTC cannot be
applied.
The scalar control mode is recommended:
- for multimotor drives:
1) when the load is not equally shared between the motors,
2) when the motors are of different sizes, or
3) when the motors are going to be changed after the motor
identification.
- when the nominal current of the motor is less than 1/6 of the
nominal output current of the inverter
- when the drive is used without a motor connected (for
example for test purposes)
- when the drive runs a medium voltage motor via a step-up
transformer.
Note: The outstanding motor control accuracy of the DTC
cannot be achieved in scalar control. There are some standard
features that are disabled in the scalar control mode, for
example motor identification run (group 99 START-UP DATA),
speed limits and torque limits (group 20 LIMITS), DC hold
(group 17 DC HOLD) and DC magnetizing (group 21 START/
STOP FUNC).
See also parameter group 98.04 DI/O EXT MODULE 2
selection STEP UP and 29 SCALAR CONTROL.
0 = DTC Direct Torque Control mode is suitable for most applications.
See section Motor control, DTC on page 78.
Actual signals and parameters
257
Index Name/Selection Description FbEq Def. PB T
99.09 APPLIC RESTORE Restores the original settings of the active application macro, 1=1 0 1934 B
99.11 APPLICATION MACRO.
- If a Factory macro is active, the parameter values are restored
to the default settings (factory settings). Exceptions: parameter
settings in parameter group 99 remain unchanged. The motor
model remains unchanged.
- If user macro 1 or 2 is active, the parameter values are
restored to the last saved values. In addition, the last saved
motor model is restored. Exceptions: Settings of parameters
16.05 USER MACRO CHG and 99.11 APPLICATION MACRO
remain unchanged. (User macro can be changed via digital
input by setting parameter 10.10 I/O MACRO CHANGE.)
Note: The parameter settings and the motor model are restored
according to the same principles when a macro is changed to
another.
0 = NO No restoring
1 = YES Restoring
99.10 DRIVE ID NUMBER Defines the ID number of the drive. This parameter requires 0 1935 I
support from an external control system.
0...32767 ID number
Actual signals and parameters
258
Index Name/Selection Description FbEq Def. PB T
99.11 APPLICATION Selects the application macro. 1 1936 I
MACRO
DriveWindow parameter
or CDP 312R change
RAM memory
Par. 16.06
POWER-UP
USER 1
USER 1 Parameter file SAVE
LOAD
USER MACRO 1 file USER 2
USER 2
SAVE
LOAD
USER MACRO 2 file
FACTORY
FACTORY FILE
FPROM memory
In addition to the Factory setting there is a selection for saving
the current settings as a user macro (USER 1 SAVE or USER 2
SAVE), and recalling these settings (USER 1 LOAD or USER 2
LOAD).
Backup of the default parameter settings (factory settings) can
be restored by parameter 99.09 APPLIC RESTORE.
The macro can be changed from an external control system
using 07.03 AUX CTRL WORD 2 bit 12. See also parameter
16.05 USER MACRO CHG. The status of the active macro is
indicated by 08.02 AUX STATUS WORD bits 14 and 15.
Note: When user macros are saved to the PC with
DriveWindow, both macros must be saved separately. See
section User macro save with DriveWindow on page 126.
Note: Restoring of the DriveWindow backup file (.BPG)
restores both macros. See section Backup and restore function
with DriveWindow on page 125.
For more information, see chapter Application macros.
1 = FACTORY Loads factory parameters (default values) into the parameter
file.
2 = USER 1 LOAD Loads User 1 macro into use. Before loading, check that the
saved parameter settings and the motor model are suitable for
the application.
3 = USER 1 SAVE Saves User 1 macro. Stores the current parameter settings and
the motor model.
Note: There are parameters that are not included in the
macros. See parameter 99.09 APPLIC RESTORE.
4 = USER 2 LOAD Loads User 2 macro into use. Before loading, check that the
saved parameter settings and the motor model are suitable for
the application.
5 = USER 2 SAVE Saves User 2 macro. Stores the current parameter settings and
the motor model.
Note: There are parameters that are not included in the
macros. See parameter 99.09 APPLIC RESTORE.
99.12 MOTOR NOM COS Defines the cosϕ. Must be equal to the value on the motor 100 = 0.7 1937 R
FII rating plate. Cosfii1
0.3...1 Cosϕ
Actual signals and parameters
259
Index Name/Selection Description FbEq Def. PB T
99.13 POWER IS GIVEN Selects whether the first start or ID run is be performed by using 1 = 1 0 1938 B
power or cosϕ of the motor. Cosϕ is recommended. Use power
selection if cosϕ is unknown.
0 = COSFII Cosϕ (defined by parameter 99.12 MOTOR NOM COS FII)
1 = POWER Power
Actual signals and parameters
260
Actual signals and parameters
261
Fault tracing
What this chapter contains
This chapter lists all alarm and fault messages including the possible causes and
corrective actions.
Safety
WARNING! Only qualified electricians are allowed to maintain the drive. Read the
Safety Instructions on the first pages of the appropriate hardware manual or the
safety manual before you work on the drive.
Alarm and fault indications
An alarm or a fault message on the panel display indicates abnormal drive status.
Most alarm and fault causes can be identified and corrected using this information.
If not, an ABB representative should be contacted.
If the drive is operated with the control panel detached, the red LED in the panel
mounting platform indicates the fault condition. (Note: Some drive types are not
fitted with the LEDs as standard).
The four-digit code number in brackets after the message is for the fieldbus
communication (see chapter Fieldbus control).
How to reset
The drive can be reset either by pressing the keypad RESET key, by digital input or
fieldbus, or 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 detected, it is stored in the fault history. The latest faults and alarms
are stored together with the time stamp at which the event was detected. See
section Fault and event loggers on page 124 and chapter Control panel for more
information.
Fault tracing
262
Abbreviations
AW Alarm Word
LW Limit Word
MSW Main Status Word
FW Fault Word
SFW System Fault Word
AP AFW Application Alarm and Fault Word
Fault tracing
263
Alarm messages generated by the drive
Alarm Cause What to do
ACS800 TEMP Drive IGBT temperature is excessive. Check ambient conditions.
(4210) Check air flow and fan operation.
09.04 AW 1 bit 4
Check heatsink fins for dust pick-up.
Check motor power against unit power.
ANALOG IO Analogue I/O error on RMIO board If AIMA-01 I/O Module Adapter is used, check
(5441) RMIO board channel CH1 fibre optic cables.
09.04 AW 1 bit 8 Replace RMIO board.
AI<MIN FUNC Analogue control signal is below minimum Check for proper analogue control signal
(8110) allowed value. This can be caused by incorrect levels.
09.05 AW 2 bit 10 signal level or failure in control wiring. Check control wiring.
(programmable Check Fault Function parameter.
Fault Function, see Check analogue input AI minimum value
Par. 30.27) settings (parameter group 13 ANALOGUE
INPUTS).
ALM (xx) Drive internal alarm Check for loose connections in drive cabinet.
08.01 MSW bit 7 Write down alarm code (in brackets). Contact
your local ABB representative.
AP [message] Message generated by an EVENT block in the Consult the documentation or author of the
Adaptive Program. Adaptive Program.
AP PRG ERR An adaptive program error Download application by DriveAP 2 or set
(FFD6) block parameters by panel or DriveWindow.
Replace RMIO board.
BATT FAILURE APBU branching unit memory backup battery With parallel-connected inverter modules,
(5581) error caused by enable backup battery by setting actuator 6 of
09.05 AW 2 bit 12 - incorrect APBU switch S3 setting switch S3 to ON.
- too low battery voltage. Replace backup battery.
Note: Actuator 6 of switch S3 is normally
activated (ON) during commissioning.
Note: Set actuator 6 of switch S3 to OFF when
APBU is stored as spare part.
BR OVERHEAT Brake resistor overload Stop drive. Let resistor cool down.
(7112) Check parameter settings of resistor overload
protection function (parameter group 34
BRAKE CHOPPER).
Check that braking cycle meets allowed limits.
Check that supply AC voltage of drive is not
excessive.
CABLE TEMP Motor cable temperature is too high (i.e. Check motor load.
(4080) relative cable temperature 01.27 CABLE Check motor cable and its type.
09.05 AW 2 bit 3 TEMPERATURE is 102%).
Check cable thermal model settings
(parameter group 36 MOTOR CABLE
PROTECTION).
Fault tracing
264
Alarm Cause What to do
CALIBRA DONE Current transducer calibration completed.
(FF37)
CALIBRA REQ Current transducer calibration requested by Start drive.
(FF36) parameter 99.07MOTOR ID RUN.
CH2 COMM LOSS RMIO channel CH2 (Master/Follower link) Check fibre optic cables on DDCS channels
(7520) communication error CH2s.
09.04 AW 1 bit 11 Check that fibre optic cable loop is closed.
(programmable Replace fibre optic cables.
Fault Function, see Check that there is one master drive and
Par. 70.14) remainder are followers in M/F link (70.08 CH2
M/F MODE).
Check if Master can communicate.
Replace optional RDCO module.
COMM MODULE Cyclical communication between drive and Check fieldbus communication status. See
(7510) type Rxxx fieldbus module or between drive chapter Fieldbus control, or appropriate
09.05 AW 2 bit 11 and external control system connected to fieldbus adapter manual.
DDCS channel CH0 is lost. Check group 51 MASTER ADAPTER (fieldbus
(programmable
Fault Function, see adapter) parameter settings.
Par. 70.04 and Check group 52 STANDARD MODBUS
70.05) (Standard Modbus link) parameter settings.
Check drive node address.
Check that bus master is communicating and
correctly configured.
Check cable connections and earthings.
Check fieldbus adapter connection.
Check optic fibres between Advant controller
(or type Nxxx fieldbus adapter) and RMIO
board DDCS channel CH0.
Replace fibre optic cables.
DC UNDERVOLT Undervoltage trip limit has been reached Only indication
(3220) during Auto Restart.
09.05 AW 2 bit 14
DIGITAL IO Digital input error on RMIO board Replace RMIO board.
(5442)
09.04 AW 1 bit 7
Fault tracing
265
Alarm Cause What to do
EARTH FAULT Drive has detected load unbalance typically Check that there are no power factor correction
(2330) due to external fault (earth fault in motor or capacitors or surge absorbers in motor cable.
09.04 AW 1 bit 14 motor cable) or internal fault (damaged Check that there is no earth fault in motor or
component). motor cables:
(programmable
Fault Function, see - measure insulation resistances of motor and
Par. 30.20) motor cable.
If no earth fault can be detected, contact your
local ABB representative.
Earth fault level can be sensitive with If no earth fault is detected, increase
non-parallel-connected R8i inverter modules parameter setting 30.25 EARTH FAULT
with long motor cables. LEVEL by one.
EM STOP Emergency Stop has been activated either by Return emergency stop push button to normal
(F081) digital input DI1 (if programmed with adaptive position.
09.04 AW 1 bit 1 programming blocks) or by 07.01 MAIN Check that Control Word is sent by external
CONTROL WORD bit 1 or 2 (= 0). control system to drive. See 07.01 MAIN
CONTROL WORD bits 1 and 2 or CW block
(see ACS600/ACS800 Application Guide
Adaptive Program for System Application
Program 7.x [3AFE68420075 (English)]).
Change drive status to READY: Main Control
Word bit 0 is first set to 0 and then back to 1.
With local and I/O control: Restart drive.
ENCODER A<>B Pulse encoder phasing is wrong: Phase A is Interchange connection of pulse encoder
(7302) connected to terminal of phase B and vice phases A and B.
09.05 AW 2 bit 4 versa.
ENCODER ERR Communication fault between pulse encoder Check parameter group 50 SPEED
(7301) and pulse encoder interface module or MEASUREMENT settings.
09.04 AW 1 bit 5 between pulse encoder interface module and Check encoder pulse number.
drive.
(programmable Check pulse encoder and its wiring and
Fault Function, see This can be caused by loose cable connection, module and its wiring including Ch A and Ch B
Par. 50.05) communication time-out, faulty pulse encoder, phasing. Sign of 01.03 SPEED MEASURED
faulty pulse encoder module, or too great must be same as sign of internal actual speed
difference between estimated and measured 01.02 MOTOR SPEED. If not, exchange
actual speeds. channels A and B.
Check connection between RMIO board and
RTAC pulse encoder module.
Check fibre optic connection between RMIO
board and NTAC pulse encoder module.
Check earthing of pulse encoder cable.
Check for highly emissive components nearby.
EXT AIO Analogue I/O error on RAIO I/O Extension Check cabinet temperature.
(7081) module Replace RAIO module if alarm is continuously
09.04 AW 1 bit 10 active.
EXT DIO Digital input error on RDIO I/O Extension Check cabinet temperature.
(7082) module Replace RDIO module if alarm is continuously
09.04 AW 1 bit 9 active.
Fault tracing
266
Alarm Cause What to do
FAN OVERTEMP Fan fault of sine filter. Check the fan and replace if faulted.
(FF83) Check DI2 circuit of DI/O EXT MODULE 2.
FOLLOWER FLT There is an active alarm in follower drive. Check the fault loggers of follower drives to
(FF7E) Note, this message is indicated in master locate drive and its alarm message.
drive. Information is received via M/F link to
master.
ID DONE Drive has performed motor identification Continue drive operation.
(FF32) magnetisation and is ready for operation. This
alarm belongs to normal start-up procedure.
ID MAGN Motor identification magnetisation is on. This Wait until drive indicates that motor
(FF31) alarm belongs to normal start-up procedure. identification is completed.
ID MAGN REQ Motor identification is required. This alarm Start Identification Magnetisation by pressing
(FF30) belongs to normal start-up procedure. Drive Start key, or select ID run and start. See
expects user to select how motor identification parameter 99.07 MOTOR ID RUN.
should be performed: by Identification
Magnetisation or by ID run.
ID N CHANGED Drive ID (i.e. Modbus ID) number has been Change ID number back to 1. See section How
(FF68) changed from 1. to select a drive and change its panel link ID
number on page 46.
INV DISABLED Drive DC switch has been opened while drive Close DC switch.
(3200) was stopped. DC switch status of each parallel-connected
09.02 FW 2 bit 4 This diagnostics is valid only for R8i inverter inverter module can be monitored by signal
08.20 INV modules equipped with ASFC Switch Fuse 08.20 INV ENABLED WORD.
ENABLED WORD Controller unit. If DC switch is not included in drive system,
deactivate this function by Par. 98.12 FUSE
SWITCH CTRL. Note: With R7i inverter units
equipped with charging option +F272
monitoring must be active.
INV OVERLOAD Inverter overload (ACS 600 only). 200% cycle Check load.
(5481) load has lasted 10 seconds. Check drive dimensioning.
I/O SP REF Analogue input AI1 of RMIO board has been Use analogue input AI2 for speed reference by
(7281) selected for speed reference and motor setting parameter 11.01 EXT REF1 SELECT to
temperature measurement when I/O control STD AI2
(98.02 = NO) or HAND/AUTO (10.07 HAND/ or
AUTO) function has been selected. use RAIO Analogue I/O Extension module.
See 98.06 AI/O EXT MODULE 1.
Fault tracing
267
Alarm Cause What to do
KLIXON Motor 1 or motor 2 overtemperature: Thermal Check motor ratings and load.
(4311) switch or thermistor relay connected to digital Check cable.
(programmable input has opened or overtemperature is
Check PTC thermistor and thermal switch /
Fault Function, see detected by PTC thermistor connected digital
thermistor relay connections.
Par. 31.01) input DI6.
If thermistor resistance is over 4 kohm, motor
temperature is too high. Wait for motor to cool
down. State of DI6 returns back to 1 when
thermistor resistance is between 0...1.5 kohm.
Replace I/O board if voltage of selected digital
input for thermal switch / thermistor relay is
correct, but state of DI6 is 0 (01.15 DI6-1
STATUS or 08.05 DI STATUS WORD).
Check parameter 10.05 KLIXON setting.
Check Fault Function parameter.
LSU DI2 OPEN LSU start is prevented. Check the interlockings in DI2 circuit in LSU.
(FF96)
LSU TEMP Converter IGBT temperature is excessive. Check ambient conditions.
(4292) Warning is activated if temperature exceeds Check air flow and fan operation.
05.12 LSU ALARM 135 °C.
Check heatsink fins for dust pick-up.
WORD bit 4
Check line current against converter current.
MACRO CHANGE Macro is restoring or user macro is being Wait until drive has finished task.
(FF69) saved.
M/F CONNECT Incompatible data type has been selected to be Change 70.09...70.11 parameter values.
(7582) sent by Master drive to Follower drive(s).
MOD BOARD T Overtemperature in AINT board of inverter Check inverter fan.
(FF88) module. Check ambient temperature.
09.11 AW 3 bit 14
MOD CHOKE T Overtemperature in choke of liquid cooled R8i Check inverter fan.
(FF89) inverter module Check ambient temperature.
09.11 AW 3 bit 13 Check liquid cooling system.
MOTOR FAN Acknowledgement signal is missing from Check acknowledgement circuit (35.02 FAN
(7083) external motor fan control circuit. ACK DELAY).
09.05 AW 2 bit 0 Check overload protection device of motor fan.
If protection has tripped, reset it.
Check condition of fan bearings by rotating fan
manually.
Replace fan.
MOTOR STALL Motor is operating in stall region due to e.g. Check motor load and drive ratings.
(7121) excessive load or insufficient motor power. Check Fault Function parameters.
09.05 AW 2 bit 9
(programmable
Fault Function, see
Par. 30.13...30.15)
Fault tracing
268
Alarm Cause What to do
MOTOR STARTS Motor identification run starts (drive is in Local Wait until drive indicates that motor
(FF34) control mode). This alarm belongs to ID run identification is completed.
procedure.
MOTOR TEMP Motor overtemperature based on motor Check motor ratings, load and cooling.
(4310) thermal model. This can be caused by Check start-up data.
09.04 AW 1 bit 3 excessive load, insufficient motor power,
Check Fault Function parameter.
inadequate cooling or incorrect start-up data.
(programmable Check parameter 30.28 THERM MOD ALM L
Fault Function, see setting. If USER MODE is selected, check
Par. 30.02) parameter 30.09...30.12, 30.30 and 30.31
settings.
MOTOR TEMP M Measured motor 1 or 2 temperature has Check alarm limit value.
(4312) exceeded alarm limit set by parameters 30.04 Check that actual number of sensors
09.04 AW 1 bit 2 MOT 1 TEMP ALM L or 30.07 MOT 2 TEMP corresponds to set parameter value (30.03
ALM L. MOT1 TEMP AI1 SEL or 30.06 MOT2 TEMP
(programmable
Fault Function, see AI2 SEL).
Par. 30.04 or 30.07) Let motor cool down. Ensure proper motor
cooling: Check cooling fan, clean cooling
surfaces, etc.
Check motor ratings and load.
Check start-up data.
Check Fault Function parameter.
Check Pt100, KTY84-1xx or PTC connections
of AI and AO of RMIO board or RAIO
Extension module.
If RAIO Extension module is used for
temperature measurement, check DIP switch
and parameter 98.06 AIO EXT MODULE 1
settings.
MPROT SWITCH Motor overload, i.e. motor protection switch Check motor ratings and load.
(4315) has opened. Check cable connections.
09.04 AW 1 bit 12 Check Fault Function parameter.
(programmable Check parameter 10.11 MOT PROT SWITCH
Fault Function, see setting.
Par. 31.04)
Check digital input status. See 01.15 DI6-1
STATUS or 08.05 DI STATUS WORD.
PANEL LOSS Control panel or DriveWindow selected as Check control panel connection. Check control
(5300) active control location for drive has ceased panel connector. See appropriate hardware
09.05 AW 2 bit 13 communicating. manual.
(programmable Press RESET key (on control panel or
Fault Function, see DriveWindow).
Par. 30.21) Replace control panel in mounting platform.
Check Fault Function parameter.
Check DriveWindow connections.
POWDOWN FILE Error in restoring powerdown.ddf file Replace RMIO board if alarm is continuously
(FFA5) active.
09.05 AW 2 bit 8
Fault tracing
269
Alarm Cause What to do
POWFAIL FILE Error in restoring powerfail.ddf file during RMIO Replace RMIO board if alarm is continuously
(FFA0) board power switch-off. active.
09.05 AW 2 bit 7
PP OVERLOAD Excessive IGBT junction to case temperature. Check cooling.
(5482) This can be caused by excessive load at low Check inverter dimensioning.
08.07 LW 1 bit 5 frequencies (e.g. fast direction change with Increase speed reference ramp time.
excessive load and inertia).
Reduce load.
REPLACE FAN Running time of inverter cooling fan has Change fan.
(4280) exceeded its estimated life time. Reset fan run time counter (01.31 FAN-ON-
TIME).
RESTARTED Motor has been restarted with AUTO Only indication
(1086) RESTART after short power failure. See
09.05 AW 2 bit 15 parameter 21.09 AUTO RESTART.
SAFETY SWITCH Safety switch was opened while drive was Close safety switch.
(7084) stopped (parameter 10.09 SAFETY SWITCH).
09.04 AW 1 bit 15
START INHIBI Safe Torque Off function has been activated Close Safe Torque Off function switch.
(FF7A) while drive was stopped. If switch is closed and fault is still active, check
09.04 AW 1 bit 0 power supply at AGPS board input terminals.
Replace AGPS board.
SWC ON INHIB Drive is in ON INHIB state. Set 07.01 MAIN CONTROL WORD bit 0 first to
(FF7F) 0, then back to 1.
08.01 MSW bit 6
SYNCRO SPEED Motor nominal speed setting is incorrect: Value Check nominal speed from motor rating plate
(FF87) is too near synchronous speed of motor. and set parameter 99.05 MOTOR NOM
Tolerance is 0.1%. SPEED exactly accordingly.
This alarm is active only in DTC mode.
SYSTEM START Inverter software has been started, i.e. If this alarm appears during normal operation
(1087) auxiliary voltage +24 V DC is connected. of drive, check RMIO board power supply.
Check +24 V DC supply circuit connections.
Check for possible short cuts in +24 V DC
circuit.
TEMP DIF x y Excessive temperature difference between Check cooling fan.
(4380) several parallel-connected inverter modules or Replace fan.
09.11 AW 3 bit 15 cooling fan failure.
Check air filters.
09.18 TEMP DIF Excessive temperature can be caused e.g. by
ALM WORD unequal current sharing between parallel-
connected inverter modules.
x (1...12) refers to inverter module number and
y (U, V, W) refers to faulty phase.
Fault tracing
270
Alarm Cause What to do
T MEAS CIRC Error in motor temperature measurement Check connections of motor temperature
(FF91) circuit. This can be caused by broken measurement circuit. See section Temperature
09.04 AW 1 bit 6 temperature sensor or cable. sensors on page 87 for connection diagrams.
(programmable
Fault Function, see
Par. 31.03)
UNDERLOAD Motor load is too low due to e.g. release Check for problem in driven equipment.
(FF6A) mechanism in driven equipment. Check Fault Function parameters.
09.05 AW 2 bit 1
(programmable
Fault Function, see
Par. 30.16...30.18)
Fault tracing
271
Alarm messages generated by the control panel
Alarm Cause What to do
DOWNLOADING Download function of panel has failed. No data Make sure panel is in local mode.
FAILED has been copied from panel to drive. Retry (there might be interference on link).
Contact your local ABB representative.
DRIVE Program versions in panel and drive do not Check program versions. See signal group 04
INCOMPATIBLE match. It is not possible to copy data from INFORMATION.
DOWNLOADING panel to drive.
NOT POSSIBLE
DRIVE IS Downloading is not possible while motor is Stop motor. Perform download.
RUNNING running.
DOWNLOADING
NOT POSSIBLE
NO Cabling problem or hardware malfunction on Press RESET key. Panel reset may take up to
COMMUNICATION panel link. half a minute, please wait.
Check panel link connections.
Panel type is not compatible with drive Check panel type and version of drive
application program version. application program. Panel type is printed on
panel cover. Application program version is
stored in signal 04.03 APPLIC SW VERSION.
NO FREE ID Panel link already includes 31 stations. Disconnect another station from link to free ID
NUMBERS number.
ID NUMBER
SETTING NOT
POSSIBLE
NOT UPLOADED No upload function has been performed. Perform upload function before downloading.
DOWNLOADING See section Function mode on page 43.
NOT POSSIBLE
UPLOADING Upload function of panel has failed. No data Retry (there might be interference on link).
FAILED has been copied from drive to panel. Contact your local ABB representative.
WRITE ACCESS Certain parameters do not allow changes while Stop motor and change parameter value.
DENIED motor is running. If tried, no change is
PARAMETER accepted, and alarm is displayed.
SETTING NOT
POSSIBLE Parameter lock is on. Open parameter lock by parameter 16.02
PARAMETER LOCK.
Fault tracing
272
Alarms by number
Alarm Alarm name Alarm Alarm name Alarm Alarm name
number number number
1086 RESTARTED 7121 MOTOR STALL FFA0 POWFAIL FILE
1087 SYSTEM START 7281 I/O SP REF FFA3 BACKUP USED
2212 INV CUR LIM 7301 ENCODER ERR FFA5 POWDOWN FILE
2300 MOT CUR LIM 7302 ENCODER A<>B FFD6 AP PRG ERR
2330 EARTH FAULT 7510 COMM MODULE
3200 INV DISABLED 7520 CH2 COMM LOSS
3211 DC BUS LIM 7582 M/F CONNECT
3220 DC UNDERVOLT 8110 AI<MIN FUNC
3381 POWER FAIL F081 EM STOP
4080 CABLE TEMP FF30 ID MAGN REQ
4210 ACS TEMP x y FF31 ID MAGN
4210 ACS800 TEMP FF32 ID DONE
4280 REPLACE FAN FF33 ID RUN SEL
4292 LSU TEMP FF34 MOTOR STARTS
4310 MOTOR TEMP FF35 ID RUN
4311 KLIXON FF36 CALIBRA REQ
4312 MOTOR TEMP M FF37 CALIBRA DONE
4315 MPROT SWITCH FF38 HW RECONF RQ
4380 TEMP DIF x y FF39 '--> POWEROFF
5300 PANEL LOSS FF68 ID N CHANGED
5441 ANALOG IO FF69 MACRO CHANGE
5442 DIGITAL IO FF6A UNDERLOAD
5481 INV OVERLOAD FF7A START INHIB
5482 PP OVERLOAD FF7F SWC ON INHIB
5581 BATT FAILURE FF83 FAN OVERTEMP
7081 EXT AIO FF85 MOT TORQ LIM
7082 EXT DIO FF86 MOT POW LIM
7083 MOTOR FAN FF87 SYNCRO SPEED
7084 SAFETY SWITCH FF88 MOD BOARD T
7112 BR OVERHEAT FF89 MOD CHOKE T
7114 BC OVERHEAT FF91 T MEAS CIRC
Fault tracing
273
Fault messages generated by the drive
Fault Cause What to do
ACS800 TEMP Drive IGBT temperature is excessive. Check ambient conditions.
(4210) Check air flow and fan operation.
09.01 FW 1 bit 3 Check heatsink fins for dust pick-up.
Check motor power against unit power.
ACS TEMP x y Excessive internal temperature in inverter Check ambient conditions.
(4210) module of several parallel-connected inverter Check air flow and fan operation.
09.01 FW 1 bit 3 modules. x (1...12) refers to faulty inverter
Check heatsink fins for dust pick-up.
module number and y (U, V, W) refers to faulty
09.16 OVERTEMP Check motor power against unit power.
phase.
WORD
AI<MIN FUNC Analogue control signal is below minimum Check for proper analogue control signal
(8110) allowed value. This can be caused by incorrect levels.
09.02 FW 2 bit 10 signal level or failure in control wiring. Check control wiring.
(programmable Check Fault Function parameter.
Fault Function, see Check analogue input AI minimum value
Par. 30.27) settings (parameter group 13 ANALOGUE
INPUTS).
AP [message] Message generated by an EVENT block in the Consult the documentation or author of the
Adaptive Program. Adaptive Program.
BACKUP ERROR Failure when restoring PC-stored backup of Retry.
(FFA2) drive parameters. Check connections.
Check that parameters are compatible with
drive.
BC OVERHEAT Brake chopper overload Stop drive. Let chopper cool down.
(7114) Check parameter settings of resistor overload
protection function (parameter group 34
BRAKE CHOPPER).
Check that braking cycle meets allowed limits.
Check that supply AC voltage of drive is not
excessive.
BC SHORT CIR Short circuit in brake chopper IGBT(s) Replace brake chopper.
(7113) Ensure brake resistor is connected and not
damaged.
BR BROKEN Brake resistor is not connected or it is Check resistor and resistor connection.
(7110) damaged. Check that resistance rating meets
Resistance rating of brake resistor is too high. specifications. See drive hardware manual.
BR OVERHEAT Brake resistor overload Stop drive. Let resistor cool down.
(7112) Check parameter settings of resistor overload
protection function (parameter group 34
BRAKE CHOPPER).
Check that braking cycle meets allowed limits.
Check that supply AC voltage of drive is not
excessive.
Fault tracing
274
Fault Cause What to do
BR WIRING Wrong connection of brake resistor(s) Check resistor connection.
(7111) Ensure brake resistor is not damaged.
CABLE TEMP Motor cable temperature is too high (i.e. Check motor load.
(4080) relative cable temperature 01.27 CABLE Check motor cable and its type.
09.02 FW 2 bit 3 TEMPERATURE is 106%).
Check cable thermal model settings
(parameter group 36 MOTOR CABLE
PROTECTION).
CHOKE OTEMP Excessive temperature of drive output filter. Let drive cool down.
(FF82) Supervision is in use in sine filter and step-up Check ambient temperature-
09.06 FAULT applications.
Check filter fan rotates in correct direction and
WORD3 bit 8 air flows freely.
Check the DI1 circuit of DI/O EXT MODULE 2.
CH2 COMM LOSS RMIO channel CH2 (Master/Follower link) Check fibre optic cables on DDCS channels
(7520) communication error CH2s.
09.01 FW 1 bit 11 Check that fibre optic cable loop is closed.
(programmable Replace fibre optic cables.
Fault function, see Check that there is one Master drive and
Par. 70.14) remainder are Followers in M/F link (70.08
CH2 M/F MODE).
Check if Master can communicate.
Replace optional RDCO module.
COMM MODULE Cyclical communication between drive and Check fieldbus communication status. See
(7510) type Rxxx fieldbus module or between drive chapter Fieldbus control, or appropriate
09.02 FW 2 bit 12 and external control system connected to fieldbus adapter manual.
DDCS channel CH0 is lost. Check group 51 MASTER ADAPTER (fieldbus
(programmable
Fault function, see adapter) parameter settings.
Par. 70.04 and Note: When COMM MODULE fault is Check group 52 STANDARD MODBUS
70.05) activated, torque selector (26.01 TORQUE (Standard Modbus link) parameter settings.
SELECTOR) is set to speed control. Check drive node address.
Check that bus master is communicating and
correctly configured.
Check cable connections and earthings.
Check fieldbus adapter connections.
Check optic fibres between Advant controller
(or type Nxxx fieldbus adapter) and RMIO
board DDCS channel CH0.
Replace fibre optic cables.
CTRL B TEMP RMIO control board temperature is out of Check cabinet air flow and fan operation.
(4110) acceptable range. Environment temperature is
09.02 FW 2 bit 7 too high (> 80°C).
CURR MEAS Current transformer failure in output current Check current transducer connections to Main
(2211) measurement circuit Circuit Interface Board, AINT.
Fault tracing
275
Fault Cause What to do
CUR UNBAL x Drive has detected excessive output current Check motor and motor cable circuit.
(2330) unbalance in inverter unit of several parallel- Check that there are no power factor correction
09.13 CURRENT connected inverter modules. This can be capacitors or surge absorbers in motor cable.
UNBALANCE caused by external fault (earth fault, motor
DO NOT change parameter 30.25 EARTH
fault, motor cabling fault, etc.) or internal fault
09.01 FW 1 bit 4 FAULT LEVEL.setting.
(damaged inverter component). x (1...12)
refers to faulty inverter module number. Check contents of APBU branching unit data
logger.
Contact your local ABB representative.
DC HIGH RUSH Drive supply voltage is excessive. DC voltage Check supply voltage level, rated voltage of
(FF80) rises too fast for overvoltage controller (if used) drive and allowed voltage range of drive.
09.06 FW 3 bit 11 to react.
When supply voltage is over 124% of unit
voltage rating (415, 500 or 690 V), motor
speed rushes to trip level (40% of nominal
speed).
DC OVERVOLT Excessive intermediate circuit DC voltage. This Check that overvoltage controller is on
(3210) can be caused by (parameter 30.23 OVERVOLTAGE CTL).
09.01 FW 1 bit 2 1. Static or transient overvoltages in mains. Check mains for static or transient overvoltage.
2. Faulty brake chopper or resistor(s) (if used). Check brake chopper and resistor(s) (if used).
3. Too short deceleration time (if there is no
Check deceleration time.
brake chopper or regenerative incoming
section). If regenerative incoming section is used, check
4. Internal fault in inverter unit. that diode mode is not forced during
deceleration: Check that TSU 07.01 Main
DC overvoltage trip limit is 1.3 × 1.35 × U1max,
Control Word bit 9 status is FALSE.
where U1max is maximum value of input
voltage range. Use coast to stop function (if applicable).
Check DC voltage level and inverter nominal
Unom of UDC overvoltage
U1max voltage.
inverter unit trip limit
Retrofit frequency converter with brake
400 V 415 V 728 V DC
chopper and brake resistor(s).
500 V 500 V 877 V DC
690 V 690 V 1210 V DC
DC UNDERVOLT Intermediate circuit DC voltage is not sufficient Check mains supply and fuses.
(3220) due to missing mains phase in diode rectifier With standard drive hardware:
09.02 FW 2 bit 2 bridge.
Check that RUN ENABLE signal connected to
DC undervoltage trip limit is 0.6 × 1.35 × U1min, digital input DI2 is active (1 = active) when
where U1min is minimum value of input voltage inverter is powered.
range.
Unom of UDC undervoltage
U1min
inverter unit trip limit
400 V 380 V 308 V DC
500 V 380 V 308 V DC
690 V 525 V 425 V DC
DDF FORMAT File error in flash memory Replace RMIO board.
(FFA6)
09.03 SFW bit 3
Fault tracing
276
Fault Cause What to do
EARTH FAULT Drive has detected load unbalance typically Check that there are no power factor correction
(2330) due to external fault (earth fault in motor or capacitors or surge absorbers in motor cable.
09.01 FW 1 bit 4 motor cable) or internal fault (damaged Check that there is no earth fault in motor or
component). motor cables:
(programmable
Fault Function, see - measure insulation resistances of motor and
Par. 30.20) motor cable.
If no earth fault can be detected, contact your
local ABB representative.
Earth fault level can be sensitive with non- If no earth fault is detected, increase
parallel-connected R8i inverter modules with parameter setting 30.25 EARTH FAULT
long motor cables. LEVEL by one.
EM STOP DEC Motor speed is not within defined limits during Check parameter 21.05 EM STOP DER MAX L
(F082) emergency stop deceleration. and 21.07 EM STOP DEC MON DEL settings.
09.04 AW 1 bit 13 Check load.
ENCODER A<>B Pulse encoder phasing is wrong: Phase A is Interchange connection of pulse encoder
(7302) connected to terminal of phase B and vice phases A and B.
09.07 FW 4 bit 0 versa.
ENCODER ERR Communication fault between pulse encoder Check parameter group 50 SPEED
(7301) and pulse encoder interface module or MEASUREMENT settings.
09.02 FW 2 bit 5 between pulse encoder interface module and Check encoder pulse number.
drive.
(programmable Check pulse encoder and its wiring and
Fault Function, see This can be caused by loose cable connection, module and its wiring including Ch A and Ch B
Par. 50.05) communication time-out, faulty pulse encoder, phasing. Sign of signal 01.03 SPEED
faulty pulse encoder module, or too great MEASURED must be same as sign of internal
difference between estimated and measured actual speed 01.02 MOTOR SPEED. If not,
actual speeds. exchange channels A and B.
Check connection between RMIO and optional
RDCO module.
Check fibre optic connection between RMIO
board and NTAC pulse encoder module.
Check earthing of pulse encoder cable.
Check for highly emissive components nearby.
FACTORY FILE Factory macro parameter file error Replace RMIO board.
(FFA7)
09.03 SFW bit 0
FLT (xx) Drive internal fault Check for loose connections in drive cabinet.
08.01 MSW bit 3 Write down Fault code (in brackets). Contact
your local ABB representative.
FOLLOWER FLT A fault active in follower drive. Check the fault loggers of follower drives to
(FF7E) Note, this message is indicated in master locate faulty drive and its fault message.
drive. Information is received via M/F link to
master.
GD DISABLED X AGPS power supply of parallel-connected R8i Check Safe Torque Off function circuit.
(FF53) inverter module has been switched off during Replace AGPS board of R8i inverter module.
run. X (1...12) refers to inverter module
09.06 FW 3 bit 6
number.
Fault tracing
277
Fault Cause What to do
ID RUN FAIL Motor ID run is not completed successfully. Check nominal motor values from parameter
(FF84) group 99 START-UP DATA.
08.01 MSW bit 3 Check that no external control system is
connected to drive.
Switch off auxiliary voltage supply from RMIO
board and power-up drive again.
Check group 20 LIMITS parameter settings.
20.02 MAXIMUM SPEED should be at least
80% of 99.05 NOMINAL SPEED.
Check that no limits prevent ID run. Restore
factory settings and try again.
Check that motor shaft is not locked.
ILLEGAL INST Operating system error Change RMIO board of RDCU control unit.
(FF5F)
09.03 SFW bit 11
INT CONFIG Number of R8i inverter modules recognized by Check status of inverters. See signal 08.22 INT
(5410) application program during PPCC link CONFIG WORD.
09.06 FW 3 bit 7 configuration is not equal to original number of Check fibre optic cables between APBU and
inverters. inverter modules.
Check inverter modules which are not
recognized by application program.
If reduced run function is used, isolate faulted
inverter module from main circuit and write
number of remaining inverter modules to
parameter 16.10 INT CONFIG USER. Reset
drive. See section Reduced run function on
page 83.
INV DISABLED DC switch has opened while drive was running Close DC switch.
(3200) or start command was given. DC switch status of each parallel-connected
09.02 FW 2 bit 4 This diagnostics is valid only for R8i inverter inverter module can be monitored by signal
modules equipped with AFSC-0x Fuse Switch 08.20 INV ENABLED WORD.
Controller unit. If DC switch is not included in drive system,
deactivate this function by Par. 98.12 FUSE
SWITCH CTRL. Note: With R7i inverter units
equipped with charging option +F272
monitoring must be active.
INV OVERLOAD Forced cooling cycle for inverter is active after Load is too high.
(5481) the overloading cycle 10 / 60 s. Check the dimensioning and process.
09.05 AW 2 bit 2
Fault tracing
278
Fault Cause What to do
IO COMM ERR I/O communication fault. This can be caused Option slot installation (RAIO, RDIO, RTAC):
(7000) by faulty I/O unit, defective fibre optic cable - Check option module status LED (WD/INIT,
09.02 FW 2 bit 6 connection or incorrect module identification yellow). LED is lit when drive is configuring
number (if I/O extension modules are present module during power-up. If LED does not go
via optic link). out after one second, configuration has failed.
- Check option module connections.
- Check connection between option module
and RMIO board.
- Change option module.
- Switch drive supply power off and on again.
I/O Module Adapter installation (AIMA-01):
- Replace fibre optic cables.
- Check node ID of extension I/O module.
- Check light intensity of fibre optic channels on
AIMA-01 adapter. See I/O Module Adapter
AIMA-01User’s Manual [3AFE 64661442
(English)].
- Replace I/O module adapter / extension
unit(s) if fault is still active.
LSU CHARGING DC link voltage is not high enough after In LSU:
(3284) charging. Check charging circuit fuses.
05.11 LSU FAULT DC link voltage has not exceeded minimum Check charging circuit.
WORD bit 0 limit or current is not below preset limit.
Check possible short circuit in DC link.
Faulty PPCC link (DC voltage measurement is
Check undervoltage trip limit (parameter 30.12
zero).
DC UNDERVOLT TRIP).
Check PPCC link. See fault message PPCC
LINK.
LSU COMM Cyclical communication between INU and LSU Check optic fibres in RDCU units between INU
(7581) is lost. - LSU.
05.11 LSU FAULT Replace fibre optic cables.
WORD bit 10 Check that following parameters have similar
selection (e.g. WIDE - INU COM WIDE or
LIMITED - INU COM LIM)
95.05 LSU COMM SEL in INU
98.02 COMM MODULE in LSU.
LSU DC OVOLT Excessive intermediate circuit DC voltage. This Check level of supply voltage, DC voltage and
(3283) can be caused by converter nominal voltage.
05.11 LSU FAULT - static or transient overvoltages in mains, or Check DC overvoltage trip limit (parameter
WORD bit 15 - excessive supply voltage during 30.11) in LSU.
synchronisation.
Default trip limit is 427 V DC for 240 V units,
740 V DC for 415 V units, 891 V DC for 500 V
units and 1230 V DC for 690 V units.
Fault tracing
279
Fault Cause What to do
LSU DC UVOLT Intermediate circuit DC voltage is not sufficient Check supply and converter fuses.
(3282) because of due to missing mains phase, blown Check supply voltage.
05.11 LSU FAULT fuse or converter internal fault.
Check DC undervoltage trip limit (parameter
WORD bit 14 Default trip limit is 170 V DC for 240 V units, 30.12 BREAK POINT ) in LSU.
293 V DC for 415 V units, 354 V DC for 500 V
units and 488 V DC for 690 V units.
LSU EARTH F Earth fault in earthed/grounded network. Check converter and LCL filter for earth
(2383) Sum of line currents measured with internal leakages.
05.11 LSU FAULT current transducers is too high. Check motor.
WORD bit 12 Earth (ground) fault in LCL filter, converter, DC Check motor cables.
link, inverter(s), motor cables or motor, or Check inverter(s).
current imbalance in parallel connected
Earth (ground) fault detection can be too
converters.
sensitive. Check parameter 30.03 EARTH
FAULT LEVEL settings in LSU.
Check converter fuses (parallel connected
converter modules).
LSU EXT DI1 Overtemperature monitoring with thermal Check all acknowledge circuit connections to
(1082) switches (KLIXON) in DI1 circuit. This digital input DI1 in LSU.
05.11 LSU FAULT supervision is active only when converter is in
WORD bit 5 RDY_RUN state (i.e. 08.01 MAIN STATUS
WORD bit 1 = 1).
LSU EXT DI4 LSU digital input DI4 fault. Check digital input DI4.
(1080) Check parameter 30.04 DI4 EXT EVENT
05.11 LSU FAULT setting.
WORD bit 4
LSU EXT DI5 LSU digital input DI5 fault. Check digital input DI5 circuit.
(1081) Check parameter 30.05 DI5 EXT EVENT and
05.11 LSU FAULT 30.10 DI5 TRIP DELAY settings.
WORD bit 2
LSU INTERNAL Internal fault Write down the fault message from LSU fault
(1083) log and contact your local ABB representative.
05.11 LSU FAULT
WORD bit 8
LSU MAIN BR LSU main contactor / main breaker is not Check main contactor / main breaker control
(2384) functioning properly, or there is a loose/bad interlocking circuit.
05.11 LSU FAULT connection. Check main contactor operating voltage level
WORD bit 6 (should be 230 V).
Check digital input DI3 connections.
LSU NET VOLT Main supply voltage is out of acceptable range Check main supply voltage.
(3285) during synchronisation or Line-side Restart unit.
05.11 LSU FAULT Identification. Trip limits is 115 V for 230 V
WORD bit 9 units, 208 V for 415 V units, 250 V for 500 V
units and 345 V for 690 V units.
Fault tracing
280
Fault Cause What to do
LSU OVERCURR Excessive input current at LSU. There are two Check motor load.
(2380) overcurrent trip limits: Check supply voltage.
05.11 LSU FAULT - 0.98 converter maximum current (parameter Check that there are no power factor
WORD bit 1 04.08 ) compensation capacitors in supply.
- approximately 190% of converter nominal Check converter power semiconductors
current (parameter 04.05). (IGBTs) and current transducers.
LSU OVERTEMP LSU converter IGBT temperature is excessive. Check ambient conditions.
(4291) Trip level is 140 °C. Check air flow and fan operation.
05.11 LSU FAULT Check heatsink fins for dust pick-up.
WORD bit 3
Check line current against converter current.
LSU SC Short circuit fault Measure resistances of converter power
(2381) semiconductors (IGBTs).
05.11 LSU FAULT If faulty IGBTs are found, replace IGBTs and/or
WORD bit 7 INT and/or NGDR boards or converter module.
Check main circuit.
LSU START Syncronisation failed. Not synchronised within Check grid distortion situation.
(FF97) 7 seconds.
LSU SYNCHRO Synchronisation to supply network has failed. Perform Line-side Identification routine again.
(8180) Supply frequency has changed remarkably See parameter 99.07 LINE SIDE ID RUN in
05.11 LSU FAULT since sine-sidei identification routine. LSU.
WORD bit 13 Check 3 phase supply to LSU.
KLIXON Motor 1 or motor 2 overtemperature: Thermal Check motor ratings and load.
(4311) switch or thermistor relay connected to digital Check cable.
09.01 FW 1 bit 5 input has opened or overtemperature detected
Check PTC thermistor and thermal switch /
by PTC thermistor connected digital input DI6.
(programmable thermistor relay connections.
Fault Function, see If PTC thermistor resistance is over 4 kohm,
Par. 31.01) motor temperature is too high. Wait for motor
to cool down. State of DI6 returns back to 1
when thermistor resistance is between 0…1.5
kohm.
Replace I/O board if voltage of selected digital
input for thermal switch / thermistor relay is
correct, but state of DI6 is 0 (01.15 DI6-1
STATUS or 08.05 DI STATUS WORD).
Check parameter 10.05 KLIXON setting.
Check FAULT FUNCTIONS parameters.
LINE CONV Line-side converter fault Shift panel from motor-side converter control
(FF51) board to line-side converter control board.
09.06 FW 3 bit 3 See line-side converter firmware manual for
fault description.
MOD BOARD T Overtemperature in AINT board of inverter Check inverter fan.
(FF88) module. Check ambient temperature.
09.06 FW 3 bit 14
Fault tracing
281
Fault Cause What to do
MOD CHOKE T Overtemperature in choke of liquid cooled R8i Check inverter fan.
(FF89) inverter module Check ambient temperature.
09.06 FW 3 bit 13 Check liquid cooling system.
MOTOR FAN Acknowledgement signal is missing from Check acknowledgement circuit (35.02 FAN
(7083) external motor fan control circuit. ACK DELAY).
09.06 FW 3 bit 0 Check overload protection device of motor fan.
If protection has tripped, reset it.
Check condition of fan bearings by rotating fan
manually.
Replace fan.
MOTOR PHASE One of motor phases is lost due to fault in Check motor and motor cable.
(FF56) motor, motor cable, thermal relay (if used) or Check thermal relay (if used).
09.02 FW 2 bit 15 internal fault.
Check Fault Function parameter. Deactivate
(programmable protection.
Fault Function, see Fault can also appear with small motors
Par. 30.19). (< 30 kW) at low speed. Deactivate protection
in this case.
MOTOR STALL Motor is operating in stall region due to e.g. Check motor load and drive ratings.
(7121) excessive load or insufficient motor power. Check Fault Function parameters.
09.02 FW 2 bit 14
(programmable
Fault Function, see
Par. 30.13...30.15)
MOTOR TEMP Motor overtemperature based on motor Check motor ratings, load and cooling.
(4310) thermal model. This can be caused by Check start-up data.
09.01 FW 1 bit 6 excessive load, insufficient motor power,
Check Fault Function parameter.
inadequate cooling or incorrect start-up data.
(programmable Check parameter 30.29 THERM MOD FLT LIM
Fault Function, see setting. If USER MODE is selected, check
Par. 30.02) parameter 30.09...30.12, 30.30 and 30.31
settings.
Fault tracing
282
Fault Cause What to do
MOTOR TEMP M Measured motor 1 or 2 temperature has Check fault limit value.
(4312) exceeded fault limit set by parameter 30.05 Check that actual number of sensors
09.01 FW 1 bit 5 MOT 1 TEMP FLT L or 30.08 MOT 2 TEMP corresponds to set parameter value (30.03
FLT L. MOT1 TEMP AI1 SEL or 30.06 MOT2 TEMP
(programmable
Fault Function, see AI2 SEL).
Par. 30.05 or 30.08) Let motor cool down. Ensure proper motor
cooling: Check cooling fan, clean cooling
surfaces, etc.
Check motor ratings and load.
Check start-up data.
Check Fault Function parameter.
Check Pt100, KTY84-1xx or PTC connections
of AI and AO of RMIO board or RAIO
Extension module.
If RAIO Extension module is used for
temperature measurement, check DIP switch
and parameter 98.06 AIO EXT MODULE 1
settings.
MPROT SWITCH Motor overload, i.e. motor protection switch Check motor ratings and load.
(4315) has opened. Check cable connections.
09.01 FW 1 bit 10 Check Fault Function parameter.
(programmable Check parameter 10.11 MOT PROT SWITCH
Fault Function, see setting.
Par. 31.04)
Check digital input status. See 01.15 DI6-1
STATUS or 08.05 DI STATUS WORD.
NO MOTOR DATA Motor data is not given or motor data does not Check motor data (parameters 99.02...99.06).
(FF52) match with inverter data.
09.02 FW 2 bit 1
NVOS ERROR Non-volatile operating system error Replace RMIO board.
(FFA8)
09.03 SFW bit 2
OVERFREQ Motor is turning faster than highest allowed Check minimum/maximum speed settings.
(7123) speed due to incorrectly set minimum/ Check adequacy of motor braking torque.
09.01 FW1 bit 9 maximum speed, insufficient braking torque or
Check applicability of torque control.
changes in load when torque reference is
used. If drive has Diode Supply Unit (DSU), check
need for brake chopper and resistor(s).
Check parameter 20.11 FREQ TRIP MARGIN
setting.
OVER SWFREQ Switching frequency is too high. This can be Replace RMIO board.
(FF55) caused by electronic board hardware fault. Replace AINT board.
09.02 FW 2 bit 8 With parallel-connected inverter modules,
replace branching unit.
Fault tracing
283
Fault Cause What to do
OVERCURRENT Output current exceeds trip limit. Check motor load.
(2310) Check acceleration time.
09.01 FW 1 bit 1 Check motor and motor cable (including
phasing).
Check encoder cable (including phasing).
Check that there are no power factor correction
capacitors or surge absorbers in motor cable.
If drive tripped during flying start, check that
parameter 21.01 START FUNCTION is set to
AUTO. (Other modes do not support flying
start.)
Check nominal motor values from parameter
group 99 START-UP DATA to confirm motor
model is correct.
OVERCURR x Overcurrent fault in inverter unit of several Check motor load.
(2310) parallel-connected inverter modules. x (1...12) Check acceleration time.
09.01 FW 1 bit 1 refers to faulty inverter module number.
Check motor and motor cable (including
09.14 phasing).
OVERCURRENT Check encoder cable (including phasing).
WORD
Check that there are no power factor correction
capacitors or surge absorbers in motor cable.
If drive tripped during flying start, check that
parameter 21.01 START FUNCTION is set to
AUTO. (Other modes do not support flying
start.)
Check motor nominal values from parameter
group 99 START-UP DATA to confirm that
motor model is correct.
PANEL LOSS Control panel or DriveWindow selected as Check control panel connection. Check control
(5300) active control location for drive has ceased panel connector. See appropriate hardware
09.02 FW 2 bit 13 communicating. manual.
(programmable Press RESET key (on control panel or
Fault Function, see DriveWindow).
Par. 30.21) Replace control panel in mounting platform.
Check Fault Function parameter.
Check DriveWindow connection.
PARAM CRC CRC (Cyclic Redundancy Check) error Switch control board power off and on again.
(6320) Reload firmware to control board.
Replace control board.
POWERFAIL INT board powerfail. Check that AINT board power cable is
(3381) connected.
Check that POW board is working correctly.
Replace AINT board.
Fault tracing
284
Fault Cause What to do
POWF INV x AINT board powerfail in R8i inverter unit of Check that AINT board power cable is
(3381) several parallel-connected inverter modules. connected.
x refers to inverter module number (x = 1…12). Check that POW board is working correctly.
Replace AINT board.
PPCC LINK AINT board current measurement or Check fibre optic cables between RMIO and
(5210) communication fault between RMIO and AINT. AINT boards.
09.02 FW 2 bit 11 Fault can be masked with 30.24 PPCC FAULT If fault is still active, replace RMIO and/or AINT
MASK. board.
Check IGBT(s).
Replace fibre optic cables.
If RMIO is powered from external supply,
ensure that supply is on. See parameter 16.07
CTRL BOARD SUPPLY.
Check that there is no short circuit in power
stage. Short circuit or overcurrent caused by
faulty IGBTs can activate PPCC LINK fault.
PPCC LINK xx AINT board current measurement or Check fibre optic cable connection between
(5210) communication fault between RMIO and AINT RMIO and AINT boards.
09.02 FW 2 bit 11 in inverter unit of several parallel-connected Check cabling of branching unit.
inverter modules. xx (1...12) refers to faulty
If fault is still active, replace branching unit,
inverter module number.
RMIO and/or AINT board.
Fault can be masked with 30.24 PPCC FAULT
Check IGBT(s).
MASK.
Replace fibre optic cables.
Check that there is no short circuit in power
stage. Short circuit or overcurrent caused by
faulty IGBTs can activate PPCC LINK fault.
If fault is still active, replace inverter module.
PP OVERLOAD Excessive IGBT junction to case temperature. Check cooling.
(5482) This can be caused by excessive load at low Check inverter dimensioning.
08.07 LIMIT WORD frequencies (e.g. fast direction change with Increase speed reference ramp time.
INV bit 5 excessive load and inertia).
Reduce load.
RUN DISABLE No Run enable signal received, because: Check that RUN ENABLE signal connected to
(FF54) - circuit connected to digital input DI2 is open digital input DI2 is active (1 = active, i.e. circuit
09.02 FW2 bit 4 (0 = open) is closed) when inverter is powered.
- of external device fault.
Note: If DC switch is opened, fault RUN
DISABLE is activated.
SAFETY SWITCH Safety switch was opened during run Close safety switch.
(7084) (parameter 10.09 SAFETY SWITCH)
09.06 FW3 bit 2
SC INV x y Short circuit (i.e. excessive output current) in Check motor and motor cable.
(2340) inverter unit of several parallel-connected Check inverter module IGBTs.
09.01 FW 1 bit 0 inverter modules. x (1...12) refers to faulty
If faulty IGBT module is detected, replace
inverter module number and y (U, V, W) refers
09.15 SHORT IGBT module or inverter module.
to faulty phase.
CIRC FAULT
Fault tracing
285
Fault Cause What to do
SHORT CIRC Short circuit fault (i.e. excessive output current) Check motor and motor cable.
(2340) 09.15 SHORT CIRC FAULT x (=1) refers to Check inverter module IGBTs.
09.01 FW 1 bit 0 faulty inverter module number and y (U, V, W) If faulty IGBT module is detected, replace
09.15 SHORT refers to faulty phase. IGBT module or inverter module.
CIRC FAULT
START INHIBI Safe Torque Off has been activated during Close Safe Torque Off switch.
(FF7A) motor run or motor start command has been If switch is closed and fault is still active, check
08.21 START given when Safe Torque Off is active. power supply at AGPS board input terminals.
INHIBI WORD for Replace AGPS board.
ACS800
09.06 FW 3 bit 5
SUPPLY PHASE DC voltage ripple in intermediate circuit is too Check mains fuses.
(3130) high. This can be caused by missing mains Check if mains supply is unbalanced.
09.02 FW 2 bit 0 phase in diode bridge rectifier, or DC voltage
oscillation due to thyristor rectifying (if used).
TEMP DIF x y Excessive temperature difference between Check cooling fan.
(4380) several parallel-connected inverter modules or Replace fan.
09.06 FW 3 bit 15 cooling fan failure. Excessive temperature can
Check air filters.
be caused e.g. by unequal current sharing
09.17 TEMP DIF
between parallel-connected inverter modules.
FLT WORD
x (1...12) refers to inverter module number and
y (U, V, W) refers to faulty phase.
T MEAS CIRC Error in motor temperature measurement Check connections of motor temperature
(FF91) circuit. This can be caused by broken measurement circuit. See section Temperature
09.06 FW 3 bit 4 temperature sensor or cable. sensors on page 87 for connection diagrams.
(programmable
Fault Function, see
Par. 31.03)
UNDERLOAD Motor load is too low due to e.g. release Check for problem in driven equipment.
(FF6A) mechanism in driven equipment. Check Fault Function parameters.
09.01 FW 1 bit 8
(programmable
Fault Function, see
Par. 30.16...30.18)
USER MACRO No user macro saved or file is defective. Create user macro.
(FFA1)
09.03 SFW bit 1
Fault tracing
286
Faults by number
Fault Fault name Fault Fault name Fault Fault name
number number number
1080 LSU EXT DI4 4080 CABLE TEMP 7112 BR OVERHEAT
1081 LSU EXT DI5 4110 CTRL B TEMP 7113 BC SHORT CIR
1082 LSU EXT DI1 4210 ACS800 TEMP 7114 BC OVERHEAT
1083 LSU INTERNAL 4210 ACS TEMP x y 7121 MOTOR STALL
1086 RESTARTED 4280 REPLACE FAN 7123 OVERFREQ
1087 SYSTEM START 4290 INV OVERTEMP 7281 I/O SP REF
2211 CURR MEAS 4291 LSU OVERTEMP 7301 ENCODER ERR
2212 INV CUR LIM 4292 LSU TEMP 7302 ENCODER A<>B
2300 MOT CUR LIM 4310 MOTOR TEMP 7510 COMM MODULE
2310 OVERCURR x 4311 KLIXON 7520 CH2 COMM LOSS
2310 OVERCURRENT 4312 MOTOR TEMP M 7581 LSU COMM
3211 DC BUS LIM 4315 MPROT SWITCH 7582 M/F CONNECT
2330 CUR UNBAL 4380 TEMP DIF 8110 AI<MIN FUNC
2330 CUR UNBAL x 4380 TEMP DIF x y 8180 LSU SYNCHRO
2330 EARTH FAULT 5210 PPCC LINK F081 EM STOP
2340 SC INV x y 5210 PPCC LINK xx F082 EM STOP DEC
2340 SHORT CIRC 5300 PANEL LOSS FF30 ID MAGN REQ
2380 LSU OVERCURR 5410 INT CONFIG FF31 ID MAGN
2381 LSU SC 5441 ANALOG IO FF32 ID DONE
2383 LSU EARTH F 5442 DIGITAL IO FF33 ID RUN SEL
2384 LSU MAIN BR 5481 INV OVERLOAD FF34 MOTOR STARTS
3130 SUPPLY PHASE 5482 PP OVERLOAD FF35 ID RUN
3200 INV DISABLED 5581 BATT FAILURE FF36 CALIBRA REQ
3210 DC OVERVOLT 6320 PARAM CRC FF37 CALIBRA DONE
3220 DC UNDERVOLT 7000 IO COMM ERR FF38 HW RECONF RQ
3282 LSU DC UVOLT 7081 EXT AIO FF39 '--> POWEROFF
3283 LSU DC OVOLT 7082 EXT DIO FF51 LINE CONV
3284 LSU CHARGING 7083 MOTOR FAN FF52 NO MOTOR DATA
3285 LSU NET VOLT 7084 SAFETY SWITCH FF53 GD DISABLED X
3381 POWER FAIL 7110 BR BROKEN FF54 RUN DISABL
3381 POWF INV x 7111 BR WIRING FF55 OVER SWFREQ
Fault tracing
287
Fault Fault name Fault Fault name Fault Fault name
number number number
FF56 MOTOR PHASE
FF5F ILLEGAL
INSTRUCTION
FF68 ID N CHANGED
FF69 MACRO CHANGE
FF6A UNDERLOAD
FF7A START INHIBI
FF7E FOLLOWER FLT
FF7F SWC ON INHIB
FF80 DC HIGH RUSH
FF81 IN CHOKE TEMP
FF82 CHOKE OTEMP
FF83 FAN OVERTEMP
FF84 ID RUN FAIL
FF85 MOT TORQ LIM
FF86 MOT POW LIM
FF87 SYNCRO SPEED
FF88 MOD BOARD T
FF89 MOD CHOKE
FF91 T MEAS CIRC
FF96 LSU DI2 OPEN
FF97 LSU START
FFA0 POWFAIL FILE
FFA1 USER MACRO
FFA2 BACKUP ERROR
FFA3 BACKUP USED
FFA5 POWDOWN FILE
FFA6 DDF FORMAT
FFA7 FACTORY FILE
FFA8 NVOS ERROR
FFD6 AP PRG ERR
Fault tracing
288
Fault tracing
289
Application macros
What this chapter contains
This chapter describes the intended use and operation of the system application
macros. It also describes how to save a user macro, and how to recall it.
Overview of macros
Application macros are preprogrammed parameter sets. While starting the drive, the
user selects the FACTORY macro by parameter 99.11 APPLICATION MACRO,
makes the essential changes and saves the result as a user macro (USER 1 or 2
SAVE). User macro settings can be recalled (USER 1 or 2 LOAD). The table below
contains a summary of the macros.
Macro Suitable applications
Factory Ordinary speed control applications where no, one, two or three constant speeds are
used:
- conveyors
- speed controlled pumps and fans
- test benches with predefined constant speeds.
User The user can save the customised standard macro i.e. the parameter settings and the
results of the motor identification to permanent memory, and recall the data at a later
time.
USER 1/2 SAVE User macro 1 or 2 is saved to the FPROM memory.
USER 1/2 LOAD User macro 1 or 2 is loaded to the RAM memory.
There are three parameter files available in the FPROM memory: PARAMETER.ddf,
USER_MACRO1.ddf and USER_MACRO2.ddf.
With Factory macro all parameter changes are saved automatically to file
PARAMETER.ddf. When user macros are in use, all parameter changes must be
saved to the corresponding user macro file by parameter 99.11 APPLICATION
MACRO. See section User macros on page 290.
Application macros
290
User macros
It is possible to create two user macros. They can be saved and restored by
parameters 99.09 APPLIC RESTORE and 99.11 APPLICATION MACRO. The user
macro allows the user to save parameter settings including parameter group 99
START-UP DATA and the results of the motor identification to permanent memory,
and to recall the data at a later time.
Two user macros are essential when switching between two motors is required.
How to create user macro 1
• Adjust parameters.
• Perform the motor identification.
• Save the parameter settings and the results of the motor identification by setting
parameter 99.11 to USER 1 SAVE (and press ENTER). The storing takes 20 s to
1 min.
Note: If user macro save function is executed several times, drive memory fills up
and file compression starts. File compression can last up to 10 minutes. Macro
saving will be completed after the file compression. (Operation is indicated on the
last row of the control panel display by blinking dots).
How to recall user macro 1
• Change parameter 99.11 to USER 1 LOAD.
• Press ENTER to load.
User macros can also be activated by 07.03 AUX CTRL WORD 2 bit 12 or via digital
input, if the function is enabled by parameter 16.05 USER MACRO CHG. See also
parameter 10.10 I/O MACRO CHANGE. The status of the active macro can be
monitored with 08.02 AUX STATUS WORD bits 14 and 15.
Note: User macro load restores also the motor settings in group 99 START-UP
DATA and the results of the motor identification. Check that the settings correspond
to the used motor.
See also section User macro save with DriveWindow on page 126.
Example: The user can switch the drive between two motors without having to adjust
the motor parameters and to repeat the motor identification every time the motor is
changed. The user needs only to adjust the settings and perform the motor
identification once for both motors and then to save the data as two user macros.
When the motor is changed, only the corresponding user macro needs to be loaded,
and the drive is ready to operate.
Application macros
291
Fieldbus control
What this chapter contains
This chapter describes how the drive can be controlled by external devices over
a communication network.
System overview
The drive can be connected to an external control system – usually a fieldbus
controller – via an adapter module. The drive can be set to receive all of its control
information through the external control interface, or the control can be distributed
between the external control interface and other available sources, for example
digital and analogue inputs.
The following diagram shows the control interfaces and I/O connections of the drive.
Fieldbus
controller
Fieldbus
(* (*
ACS800 Other
devices
Advant
Fieldbus adapter Controller controller
Rxxx (e.g. AC 800M,
Modbus AC 80)
Slot 1
RMIO board
(*
RMBA-01 adapter
std. Modbus link
Slot 1 or 2 I/O adapter
RTAC/RDIO/RAIO
CH1
RDCO comm. AIMA-01 I/O
module (DDCS) adapter module
CH0 Fieldbus adapter
(DDCS) Nxxx
or
Data Flow
Control Word (CW)
References
Process I/O (cyclic)
Status Word (SW)
Actual values
Parameter R/W requests/responses Service messages (acyclic)
(* Either an Rxxx or Nxxx, and an RMBA-01 adapter can be connected to the drive simultaneously.
Fieldbus control
292
Redundant fieldbus control
It is possible to connect two fieldbuses to the drive with the following adapter
configuration:
• Type Rxxx fieldbus adapter module (not RMBA-01) is installed in drive Slot 1.
• RMBA-01 Modbus Adapter module is installed in drive Slot 2.
E.g. PROFIBUS Modbus
ACS800
RMIO board
RPBA-01 adapter
PROFIBUS-DP link
Slot 1
RMBA-01 adapter
std. Modbus link
Slot 2
The control (i.e. the Main Reference data set, see section Data sets 1 and 2 on
page 299) is activated by setting parameter 98.02 COMM. MODULE to FIELDBUS
or STD MODBUS.
In case there is a communication problem with one fieldbus, the control can be
switched to the other fieldbus. Switching between the buses can be controlled
e.g. with adaptive programming. Parameters and signals can be read by both
fieldbuses, but simultaneous cyclical writing to the same parameter is forbidden.
RDCO channels CH0...3
The following table gives information on the DDCS (Distributed Drives
Communication System) channels CH0...CH3 of the RDCO module (DDCS
Communication Option).
Channel Interfaces RDCO-01* RDCO-02*
CH0 Advant controller 10 MBd 5 MBd
Fieldbus Interface DDCS/DriveBus
CH1 Basic I/O / Optional I/O 5 MBd 5 MBd
CH2 Master/Follower 10 MBd 10 MBd
CH3 DriveWindow (PC, 1 Mbit/s) 10 MBd 10 MBd
*RDCO-01/02 is connected to the RMIO board.
The RMIO board CH0 supports either DriveBus or DDCS protocol. DriveBus
protocol is faster than the DDCS protocol.
Fieldbus control
293
Commissioning and supporting tools
DriveWindow and other tools can be connected to RMIO DDCS channel CH3, either
in a ring, or a star configuration using branching units. Before starting the
communication, node addresses must be set for each drive. See parameter 70.15
CH3 NODE ADDR. The new node address becomes valid on the next power-up of
the RMIO-board. DDCS channel CH3 is the slave in the communication link.
Setting up communication through fieldbus
Fieldbus adapters for several communication protocols are available (e.g.
PROFIBUS and Modbus). Rxxx type fieldbus adapter modules are mounted in
expansion Slot 1 of the drive. Nxxx type fieldbus adapter modules are connected to
channel CH0 of the RDCO.
Note: For instructions on setting up an RMBA-01 module, see section Setting up
communication through the standard Modbus link on page 295.
Before configuring the drive for fieldbus control, the adapter module must be
mechanically and electrically installed according to the instructions given in the
hardware manual of the drive, and the module manual. The communication between
the drive and the adapter module is then activated by setting parameter 98.02
COMM. MODULE.
The following table lists the parameters, which need to be defined when setting up
communication through a fieldbus adapter.
Parameter Alternative Setting for fieldbus control Function/Information
settings
COMMUNICATION INITIALISATION
98.02 NO FIELDBUS (with Rxxx or Initialises communication between drive and
COMM. FIELDBUS Nxxx) fieldbus adapter module. Activates module set-up
MODULE ADVANT/N-FB ADVANT/N-FB (with Nxxx) parameters for type Nxxx and Rxxx fieldbus
STD MODBUS modules (group 51 MASTER ADAPTER (fieldbus
adapter)).
70.01 CH0 0-254 1 Defines the node address for DDCS channel CH0
NODE ADDR
71.01 CH0 YES = NO Selects the communication mode for DDCS channel
DRIVEBUS DriveBus mode CH0
MODE* NO = DDCS
mode
70.04 CH0 0...60000 ms Defines the delay time before channel CH0 (type
TIMEOUT Nxxx adapter) or type Rxxx fieldbus adapter
interface communication break alarm/fault is
indicated.
70.05 CH0 STOP Defines the action taken after CH0 or type Rxxx
COM LOSS RAMPNG fieldbus adapter interface communication fault
CTRL STOP TORQ
COAST STOP
LAST SPEED
CNST SPEED1
Fieldbus control
294
70.19 CH0 RING Default value is STAR which Selects the topology of the channel CH0 link.
HW STAR is typically used with
CONNECTI branching units (NDBU).
ON This parameter has no effect
in DriveBus mode.
ADAPTER MODULE CONFIGURATION
51.01 - - Displays the type of the fieldbus adapter
MODULE module.
TYPE
51.02 These parameters are adapter module-specific. For more information, see the module manual.
(FIELDBUS Note that not all of these parameters are necessarily visible.
PARAMETE
R 2)
...
51.26
(FIELDBUS
PARAMETE
R 26)
51.27 FBA (0) DONE; - Validates any changed adapter module
PAR (1) REFRESH configuration parameter settings. After refreshing,
REFRESH** the value reverts automatically to DONE.
51.28 FILE xyz (binary - Displays the required CPI firmware revision of the
CPI FW coded fieldbus adapter as defined in the configuration file
REV** decimal) stored in the memory of the drive. The CPI firmware
version of the fieldbus adapter (refer to par. 51.32)
must contain the same or a later CPI version to be
compatible. x = major revision number; y = minor
revision number; z = correction number. Example:
107 = revision 1.07.
51.29 FILE xyz (binary - Displays the fieldbus adapter module configuration
CONFIG ID** coded file identification stored in the memory of the drive.
decimal) This information is drive application program-
dependent.
51.30 FILE xyz (binary - Displays the fieldbus adapter module configuration
CONFIG coded file revision stored in the memory of the drive.
REV** decimal) x = major revision number; y = minor revision
number; z = correction number. Example:
1 = revision 0.01.
51.31 FBA (0) IDLE; - Displays the status of the adapter module.
STATUS** (1) EXEC. INIT; IDLE = Adapter not configured.
(2) TIME OUT; EXEC. INIT = Adapter initialising.
(3) CONFIG TIME OUT = A timeout has occurred in the
ERROR; communication between the adapter and the drive.
(4) OFF-LINE; CONFIG ERROR = Adapter configuration error. The
(5) ON-LINE; major or minor revision code of the CPI firmware
(6) RESET revision stored in the adapter differs from that stated
in the configuration file in the memory of the drive.
OFF-LINE = Adapter is off-line.
ON-LINE = Adapter is on-line.
RESET = Adapter performing a hardware reset.
Fieldbus control
295
51.32 FBA - - Displays the CPI program revision of the module
CPI FW inserted in Slot 1. x = major revision number;
REV** y = minor revision number; z = correction number.
Example: 107 = revision 1.07.
51.33 FBA - - Displays the application program revision of the
APPL FW module inserted in Slot 1. x = major revision
REV** number; y = minor revision number; z = correction
number. Example: 107 = revision 1.07.
RECEIVE AND TRANSMIT DATA DEFINITIONS
Groups Addresses for receive and transmit data. See
90 D SET section External control interface on page 299.
REC
ADDR...93 D
SET TR
ADDR
* Parameter is valid after the next power-up of the drive.
** Parameters 51.27...51.33 are only visible when type Rxxx fieldbus adapter is installed.
Setting up communication through the standard Modbus link
An RMBA-01 Modbus Adapter installed in Slot 1 or 2 of the drive forms an interface
called the standard Modbus link. The standard Modbus link can be used for external
control of the drive by a Modbus controller (RTU protocol only).
Before configuring the drive for Modbus control, the adapter module must be
mechanically and electrically installed according to the instructions given in the
hardware manual of the drive, and the module manual. The communication between
the drive and the adapter module is then activated by setting parameter 98.02
COMM. MODULE.
The following table lists the parameters, which need to be defined when setting up
communication through the standard Modbus link.
Note: With NMBA-01 Modbus Adapter, parameter 98.02 COMM. MODULE must be
set to FIELDBUS or ADVANT/N-FB. See parameter setting instructions in section
Setting up communication through fieldbus on page 293.
Parameter Alternative settings Setting for fieldbus control Function/Information
98.02 COMM. NO STD MODBUS Initialises communication between drive
MODULE FIELDBUS and Modbus adapter module. Activates
ADVANT/N-FB communication parameters in group 52
STD MODBUS STANDARD MODBUS.
52.01STATION 1...247 Specifies the station number of the drive on
NUMBER the standard Modbus link.
52.02 600; 1200; 2400; Defines the communication speed of the
BAUDRATE 4800; 9600; 19200 standard Modbus link.
52.03 PARITY NONE1STOPBIT Defines the parity setting for the standard
NONE2STOPBIT Modbus link.
ODD
EVEN
Fieldbus control
296
The drive parameters, data words, references and actual values are mapped into the
4xxyy register area:
Signal Address Modbus address
Control Word (MCW) 07.01 MAIN CTRL WORD 40001
Reference 1 (REF1) 23.01 SPEED REF in DTC or 40002
29.01 FREQ REF in scalar control
Reference 2 (REF2) 25.04 TORQUE REF B 40003
Status Word (MSW) 08.01 MAIN STATUS WORD 40004
Actual 1 (ACT1) 01.01 MOTOR SPEED FILT 40005
Actual 2 (ACT2) 01.07 MOTOR TORQ FILT2 40006
For the mapping of other signals and parameters see section Modbus and Modbus
Plus address on page 132.
More information on Modbus communication is available from the Modicon website
http://www.modicon.com.
Modbus link
The CDP 312R control panel, NLMD-01 Led Monitoring Display panel or
DriveWindow can be connected to the drive through a Modbus link. The
communication speed of the link is 9600 bit/s (8 data bits, 1 stop bit, odd parity).
The connected device is the master of the communication link. NBCI-01 Bus
Connection Modules must be used if the distance between the panel and the drive is
over three metres.
Modbus is designed for integration with Modicon PLCs (PLC = Programmable Logic
Controller) or other automation devices, and its services correspond mainly to the
PLC architecture. The drive looks like a Modicon PLC from the network.
Fieldbus control
297
Setting up communication through Advant controller
The Advant controller is connected via DDCS link to channel CH0 of the RDCO. The
communication between the drive and controller is activated by setting parameter
98.02 COMM. MODULE.
• AC 800M Advant Controller
DriveBus connection: CI858 DriveBus Communication Interface required. See CI858
DriveBus Communication Interface User’s Manual, [3AFE 68237432 (English)].
For more information, see AC 800M Controller Hardware Manual [3BSE 027 941
(English)], AC 800M/C Communication, Protocols and Design Manual
[3BSE 028 811 (English),] ABB Industrial Systems, Västerås, Sweden.
Optical ModuleBus connection: TB811 (5 MBd) or TB810 (10 MBd) Optical
ModuleBus Port Interface required. See section Optical ModuleBus connection
below.
• AC 80 Advant Controller
DriveBus connection: Connectable to RMIO-01/02 board with RDCO-01
Optical ModuleBus connection: TB811 (5 MBd) or TB810 (10 MBd) Optical
ModuleBus Port Interface required. See section Optical ModuleBus connection
below.
• CI810A Fieldbus Communication Interface (FCI)
Optical ModuleBus connection
TB811 (5 MBd) or TB810 (10 MBd) Optical ModuleBus Port Interface required.
The TB811 Optical ModuleBus Port Interface is equipped with 5 MBd optical
components, while the TB810 with 10 MBd components. All optical components on
a fibre optic link must be of the same type since 5 MBd components do not match
with 10 MBd components. The choice between TB810 and TB811 depends on the
equipment it is connected to. With RDCO Communication Option Module, the
Interface is selected as follows:
Optional ModuleBus Port DDCS Communication Option Module
Interface
RDCO-01 RDCO-02 RDCO-03
TB811 × ×
TB810 ×
If branching unit NDBU-85/95 is used with CI810A, TB810 Optical ModuleBus Port
Interface must be used.
Fieldbus control
298
The following table lists the parameters, which need to be defined when setting up
communication between the drive and Advant controller.
Parameter Alternative Setting for Function/Information
settings fieldbus control
98.02 COMM. NO ADVANT/N-FB Initialises communication between drive
MODULE FIELDBUS (fibre optic channel CH0) and Advant
ADVANT/N-FB controller. The transmission speed is
STD MODBUS 4 Mbit/s.
70.01 CH0 0-254 AC 800M DriveBus (CI858) 1...24 Defines the node address for DDCS
NODE ADDR AC 800M ModuleBus 1...125 channel CH0.
AC 80 DriveBus 1-12
AC 80 ModuleBus 17-125
FCI (CI810A) 17-125
APC2 1
71.01 CH0 YES = DriveBus AC 800M DriveBus (CI858) YES Defines the communication mode for
DRIVEBUS mode AC 800M ModuleBus NO DDCS channel CH0.
MODE.* NO = DDCS mode AC 80 DriveBus YES
APC2/AC80 ModuleBus/FCI
(CI810A) NO
70.04 CH0 0-60000 ms Defines the delay time before channel
TIMEOUT CH0 (Advant controller) communication
break fault is indicated.
70.05 CH0 STOP RAMPNG Defines the action taken after CH0
COM LOSS STOP TORQ (Advant controller) communication fault.
CTRL COAST STOP
LAST SPEED
CNST SPEED1
70.19 CH0 HW RING Default value is STAR which is Selects the topology of the channel CH0
CONNECTION STAR typically used with branching units link.
(NDBU).
This parameter has no effect in the
DriveBus mode.
Groups Defines the addresses for receive and
90 D SET REC transmit data. See section External
ADDR...93 D control interface on page 299.
SET TR ADDR
* Parameter is valid after the next power-up of the drive.
Fieldbus control
299
External control interface
The communication between an external system and drive consists of data sets.
The link sends the data set into the data set table in the drive program and returns
the content of the next data set to the external control system as a return message.
If DriveBus protocol is used, the DriveBus master can send one message which
contains 1 data set for 10 drives during a 1 ms time period.
The System Application program supports the use of data sets 1, 2 or data sets
10...33. One data set (DS) consists of three 16-bit words called data words (DW).
The data received from an external control system affects only the RAM (not the
FPROM) memory of the RMIO board.
Data sets 1 and 2
Data set 1 for controlling the drive is referred to as the Main Reference data set.
Data set 2 containing actual information is referred to as the Main Actual Signal data
set. Fieldbus communication uses mainly data sets 1 and 2 (i.e. when parameter
98.02 COMM. MODULE setting is FIELDBUS).
The contents of the Main Reference and Main Actual Signal data sets are fixed as
follows:
For type Nxxx fieldbus adapters and RMBA-01
DS DW Signal Address Update time
1 1 Control Word 07.01 MAIN CTRL WORD 10 ms
2 Reference 1 23.01 SPEED REF in DTC or 10 ms
29.01 FREQ REF in scalar control
3 Reference 2 25.04 TORQUE REF B 10 ms
2 1 Status Word 08.01 MAIN STATUS WORD 10 ms
2 Actual 1 01.01MOTOR SPEED FILT 10 ms
3 Actual 2 01.07 MOTOR TORQ FILT2E 10 ms
For type Rxxx fieldbus adapters
For RMBA-01, see section For type Nxxx fieldbus adapters and RMBA-01 above.
DS DW Signal Address Update time
1 1 Control Word 07.01 MAIN CTRL WORD 10 ms
2 Reference 1 23.01 SPEED REF in DTC or 10 ms
29.01 FREQ REF in scalar control
Reference 2 is defined in group 51 MASTER ADAPTER (fieldbus adapter).
2 1 Status Word 08.01MAIN STATUS WORD 10 ms
2 Actual 1 01.01 MOTOR SPEED FILT 10 ms
Fieldbus control
300
Data sets 10...33
Data sets 10...33 are used when there is a need to transfer several control signals
and actual values. Advant controller communication uses data sets 10...33 (i.e.
when parameter 98.02 COMM. MODULE setting is ADVANT/N-FB).
The contents of data sets can be selected by parameter groups 90 D SET REC
ADDR...93 D SET TR ADDR or by means of transmit data sets 32...33. Data sets 32
and 33 are dedicated for mail box use. These data sets can be used for setting or
inquiring parameter values. Transmit and receive addresses and data for data sets
32 and 33 are defined in the external control system application. Data sets 24 and 25
can also be selected for mail box use instead of data sets 32 and 33 by parameter
70.33 MAILBOX DS SEL.
Fieldbus control
301
Data sets received from an external control system
Data set Data word Time (1 Default address Parameter (2
10 (3 1 2 ms 07.01 MAIN CTRL WORD 90.01
2 2 ms 23.01 SPEED REF 90.02
3 2 ms 25.01 TORQ REF A 90.03
(3
12 1 4 ms 07.02 AUX CTRL WORD 90.04
2 4 ms 90.05
3 4 ms 90.06
14 1 10 ms 90.07
2 10 ms 90.08
3 10 ms 90.09
16 1 10 ms 90.10
2 10 ms 90.11
3 10 ms 90.12
18 1 100 ms 90.13
2 100 ms 90.14
3 100 ms 90.15
20 1 100 ms 90.16
2 100 ms 90.17
3 100 ms 90.18
22 1 100 ms 91.01
2 100 ms 91.02
3 100 ms 91.03
24 4) 1 100 ms 91.04
2 100 ms 91.05
3 100 ms 91.06
26, 28, 30 1 Not in use
2 Not in use
3 Not in use
32 1 100 ms Transmit address Write
2 100 ms Transmit data Write
3 100 ms Inquire address Read
1)
Time inside which the drive reads data from the data sets to the parameter table or writes data from
the parameter table to the data sets. Since the drive is a follower of the communication master,
the actual communication cycle time depends on the communication speed of the master.
2)
Selects the addresses into which the received fieldbus data sets are written.
3)
Boolean data type parameters are not supported. If boolean data type parameters need to be set
from external control system, use data sets 14...24.
4)
Data set 24 can also be selected for mailbox use. See parameter 70.33 MAILBOX DS SEL.
Fieldbus control
302
Data set transmitted to an external control system
Data set Data word Time (1 Default address Parameter (2
11 3) 1 2 ms 08.01 MAIN STATUS WORD 92.01
2 2 ms 01.02 SPEED MEASURED 92.02
3 2 ms 02.09 TORQUE REF 2 92.03
13 3) 1 4 ms 08.02 AUX STATUS WORD 92.04
2 4 ms 01.01 MOTOR SPEED FILT 92.05
3 4 ms 01.08 MOTOR TORQUE 92.06
15 1 10 ms 09.01 FAULT WORD 1 92.07
2 10 ms 09.02 FAULT WORD 2 92.08
3 10 ms 09.06 FAULT WORD 3 92.09
17 1 10 ms 09.04 ALARM WORD 1 92.10
2 10 ms 09.05 ALARM WORD 2 92.11
3 10 ms 92.12
19 1 100 ms 08.03 LIMIT WORD 1 92.13
2 100 ms 08.04 LIMIT WORD 2 92.14
3 100 ms 92.15
21 1 100 ms 01.12 TEMPERATURE (of the heat 92.16
sink)
2 100 ms 01.15 MOTOR MEAS TEMP 92.17
3 100 ms 92.18
23 1 100 ms 93.01
2 100 ms 93.02
3 100 ms 93.03
4) 1 100 ms 93.04
25
2 100 ms 93.05
3 100 ms 93.06
27, 29, 31 Not in use
33 1 100 ms Transmit address feedback Write
2 100 ms Inquired data Read
3 100 ms Inquire address feedback Read
1)
Time inside which the drive reads data from the data sets to the parameter table or writes data from
the parameter table to the data sets. Since the drive is a follower of the communication master,
the actual communication cycle time depends on the communication speed of the master.
2)
Selects the data sets which the drive sends to the fieldbus master station.
3)
Boolean data type parameters are not supported. If boolean data type parameters need to be set to
the external control system, use data sets 15…25.
4)
Data set 25 can also be selected for mailbox use. See parameter 70.33 MAILBOX DS SEL.
Fieldbus control
303
Use of mailbox
A B B P L C A C S 8 0 0
P a r a m e te r w r ite to d r iv e
T r a n s m it a d d r e s s D a ta s e t
V a lu e = 1 9 0 1 3 2 .1 P a ra m e te r V a lu e
T r a n s m it d a t a D a ta s e t 1 9 .0 1 1 2 3 4
V a lu e = 1 2 3 4 1
3 2 .2 .
.
T r a n s m it a d d r e s s f e e d b a c k D a ta s e t
.
.
.
.
V a lu e = 1 9 0 1
3 3 .1
P a ra m e te r re a d fro m d r iv e
I n q u ir e a d d r e s s D a ta s e t
V a lu e = 2 4 0 3 2 4 .0 3 4 3 0 0
3 2 .3 .
.
.
.
I n q u ir e d d a t a
. .
D a ta s e t
V a lu e = 4 3 0 0
3 3 .2
I n q u ir e a d d r e s s fe e d b a c k D a ta s e t
V a lu e = 2 4 0 3
3 3 .3
ABB Drives communication profile
The ABB Drives profile is a PROFIBUS-based model, which describes the drive
interface between the state transitions under an external control system.
The Control Word (CW) is the principal means of controlling the drive from
an external control system. The Control Word is sent by the external control system
to the drive. The drive switches between its states according to the bit-coded
instructions of the Control Word.
The Status Word (SW) is a word containing status information, sent by the drive to
the external control system.
For Status and Control Word bits, see signal groups 07 CONTROL WORDS...
08 STATUS WORDS.
The following figure presents the state diagram for the ABB Drives communication
profile.
The OFF commands are active except for Fault trips.
• OFF3 makes OFF1 inactive
• OFF2 makes OFF1 and OFF3 inactive.
Fieldbus control
304
Fieldbus control
305
Control examples
Control example: START by AUTO- or DC MAGN-mode, STOP by ramp generator control
State
1 100%
DC Voltage ON
30% FLUX ACTUAL
FLUX 0%
23.01 SPEED REF
Par. 50.10 ABOVE SPEED LIMIT
MOTOR SPEED
Par. 20.03 ZERO SPEED LIMIT 0 rpm
2 1
0 ON, OFF1
1
1 OFF2
1
2 OFF3
MCW 7.01 bits
3 6
3 RUN 0
4 RAMP OUT ZERO 1
5 RAMP HOLD 1
6 RAMP IN ZERO 1
4
7 RESET 7
0
8 INCHING1 0
9 INCHING2 0
10 REMOTE CMD 1
1
0 RDY ON
1
1 RDY RUN
2 RDY REF
MSW 8.01 bits
0
3 TRIPPED 0
4 OFF 2 STA 1
5 OFF 3 STA 1
6 SWC ON INHIB 0
7 ALARM 0
8 AT SETPOINT 0
9 REMOTE 1
10 ABOVE LIMIT
0
0
1
ACW 7.02 bits
2 RAMP BYPASS
0
3 BAL RAMP OUT
0
4 FLUX ON DC 0
5 FLUX ON 0
6
7
0
ASW 8.02 bits
...
3 MAGNETIZED 0
...
4 ZERO SPEED 5 1
t
Fieldbus control
306
Control example: START by FLUX ON DC command, STOP by torque limit
State
DC Voltage ON 1
100%
FLUX 0%
23.01 SPEED REF
Par. 50.10 ABOVE SPEED LIMIT
MOTOR SPEED
Par. 20.03 ZERO SPEED LIMIT 0 rpm
2 1
0 ON, OFF1
1
1 OFF2
1
2 OFF3
MCW 7.01 bits
3 RUN
9
4 0
4 RAMP OUT ZERO 1
6 1
5 RAMP HOLD 10
6 RAMP IN ZERO 1
7 RESET 0
8 INCHING1 0
9 INCHING2 0
10 REMOTE CMD 1
1
0 RDY ON
1
1 RDY RUN
2 RDY REF
MSW 8.01 bits
0
3 TRIPPED 0
4 OFF 2 STA 1
5 OFF 3 STA 1
6 ON INHIBITED 0
7 ALARM 0
8 AT SETPOINT 0
9 REMOTE 1
10 ABOVE LIMIT
0
0
1
ACW 7.02 bits
2 RAMP BYPASS 0
3 BAL RAMP OUT 0
5 8 1
4 FLUX ON DC 3
5 FLUX ON
0
6
7
0
ASW 8.02 bits
...
3 MAGNETIZED 0
...
4 ZERO SPEED 7 1
Fieldbus control
307
Control example: FAULT RESET, RUN by CONST SPEED 1 (INCHING 1), CONST
SPEED 2, (INCHING 2) and SPEED REF State
DC Voltage ON
FLUX 100%
0%
23.01 SPEED REF
MOTOR SPEED
Par. 50.10 ABOVE SPEED LIMIT
Par. 23.02 CONST SPEED 1
Par. 20.03 ZERO SPEED LIMIT 0 rpm
Par. 23.03 CONST SPEED2
1
0 ON, OFF1
4 1
1 OFF2
1
2 OFF3
MCW 7.01 bits
2 1
3 RUN 6 1
4 RAMP OUT ZERO
5 RAMP HOLD 5 9 1
6 RAMP IN ZERO 1
3
7 RESET 0
8 INCHING1 0
7
9 INCHING2 0
10 REMOTE CMD 8 1
1
0 RDY ON
1
1 RDY RUN
1
2 RDY REF
MSW 8.01 bits
3 TRIPPED 1 0
4 OFF 2 STA 1
5 OFF 3 STA 1
6 ON INHIBITED
0
7 ALARM 0
8 AT SETPOINT 1
9 REMOTE 1
10 ABOVE LIMIT 1
0
1
ACW 7.02 bits
2 RAMP BYPASS 0
3 BAL RAMP OUT 0
4 FLUX ON DC 0
5 FLUX ON 0
6
7
0
ASW 8.02 bits
...
3 MAGNETIZED 1
...
1
4 ZERO SPEED
Fieldbus control
308
Control example: Emergency Stop (OFF3) with ramp and AUTO RESTART after
a short supply power failure
State
DC Voltage 100%
UDC 75% 0%
Undervoltage trip limit
100%
FLUX
0%
23.01 SPEED REF
Par. 50.10 ABOVE SPEED LIMIT
MOTOR SPEED
Par. 20.03 ZERO SPEED LIMIT 0 rpm
0 ON, OFF1 1
1 OFF2 1
1
2 OFF3
MCW 7.01 bits
1
3 RUN
1
4 RAMP OUT ZERO
5 RAMP HOLD 1
1
6 RAMP IN ZERO
7 RESET
0
8 INCHING1 0
9 INCHING2 0
10 REMOTE CMD *) 1
1
0 RDY ON
1
1 RDY RUN
1
2 RDY REF
MSW 8.01 bits
3 TRIPPED 0
4 OFF 2 STA 1
5 OFF 3 STA 1
6 ON INHIBITED 0
7 ALARM 1) 2)
0
8 AT SETPOINT 1
9 REMOTE 1
10 ABOVE LIMIT 1
0 ON, OFF1
Internal Control MCW
Internal commands with AUTO RESTART function.
7 RESET .
*) MSW and DC UNDERVOLTAGE
fault frozen when AUTO RESTART is enabled.
1) DC UNDERVOLTAGE alarm
2) AUTO RESTARTED alarm
0
ASW 8.02 bits
...
1
3 MAGNETIZED
...
4 ZERO SPEED
0
t
Fieldbus control
309
Control block diagrams
What this chapter contains
This chapter contains the control block diagrams. Speed control is executed every
1 ms. Speed ramp is executed every 2 ms.
Control block diagrams
310
R e la y o u tp u t
D ig ita l in p u ts R O 1 E M E R G E N C Y
E M E S T O P M O D E 2 1 .0 4 E M S T O P
S T O P IN T E R N A L M C W
N O D I1 E M S T O P D E R M A X L 2 1 .0 5
Control block diagrams
F U N C T IO N C O N T R O L
E M E R G E N C Y
S T O P
E M S T O P D E R M IN L 2 1 .0 6
O F F 3 8 .0 1 b 4 O F F 2 S T A
C H A R G IN G F e e d b a c k o f D C s w itc h E M S T O P D E C M O N D E L 2 1 .0 7
L O G IC w ith M u ltid r iv e s y s te m s &
L O C A L E M S T O P M O D E 2 1 .1 2 8 .0 2 b 5 O F F 3 S T A
R 2 i...R 5 i, R 7 i
Z E R O S P E E D L IM IT 2 0 .0 3 O F F 2
8 .0 1 b 1 4 M O D U L A T IN G
&
E V E N T L O C A L C O N T R O L 8 .0 1 b 1 3 R U N IN T E R L O C K
R U N E N A B L E D I2 8 .0 2 b 4 R U N D IS A B L E D
1 6 .0 1
Main control word control
H A N D /A U T O D I O F F 3
1 0 .0 7 M C W O F F 2
L O C A L M C W F o llo w e r
7 .0 1 M C W
F ie ld b u s D S M C W s e le c to r
A d a p te r D S 8 1 .1 fro m
R M B A -0 1 M /F lin k
P a r. C O M M M O D U L E
A B B D S 1 0 g ro u p 9 8 .0 2 R U N 2 .3 1
A u t o m a t io n , 9 0 , 9 2 R U N
.... R E A D / S T D M O D B U S 4 S U P P L Y U N IT C O N T R O L A C T IV A T E D 7 0 .3 4
N -ty p e o f > 1
D S 2 4 W R IT E & F O L L O W E R
F ie ld b u s A D V A N T /N -F B 3 S U P P L Y U N IT M S W b it 0 R D Y _ O N
F U N C & M C W M A S K
F ie ld b u s F IE L D B U S 2
D S 1 .1 *) R U N IN T E R L O C K 1 6 .1 4 2 .2 6
A d a p te rs
I/O C O N T R O L N O 1 U S E D M C W
A U T O R E S T A R T 2 1 .0 9 A U T O R E S T A R T
F U N C T IO N A B B
A U T O R E S T A R T T IM E 2 1 .1 0 D R IV E
S T A R T / S T O P
P R O F IL E
D I R A M P O U T Z E R O
S T A R T /S T O P C H 0 T IM E O U T 7 0 .0 4 C H 0 / F IE L D B U S S T A T E
C O M M L O S S M A C H IN E
1 0 .0 1 I/O R A M P IN Z E R O
C H 0 C O M L O S S C T R L 7 0 .0 5 C O N T R O L
M C W
Z E R O S P E E D 8 .0 2 b 1 1
I/O O F F
S T A R T b it 0
S T O P F U N C T IO N 2 1 .0 3
/ S T O P R U N
Z E R O S P E E D L IM IT 2 0 .0 3 b it 3 I/O C O N T R O L S U P P L Y U N IT O N b it0 * * )
L O G IC D D C S
C O N T R O L
R E S E T R A M P C H 1
M A IN S T A T U S W O R D 8 .0 1 b 0 ( w ith s in g le d r iv e s ) R E S E T B it 7
IN Z E R O c o m m u n ic a t io n
b it 6
R E S E T D I
R E S E T
1 0 .0 3 b it 7 * ) N o t e ! R U N I N T E R L O C K c a n b e c o n n e c t e d to e .g . d ig ita l in p u t b y A d a p t iv e P r o g r a m m in g .
* * ) N o te ! S ta r tin g o f m o d u la tio n c a n b e s e p a r a te d to fr e e b it o f M C W w ith p a r a m e te r 9 5 .0 6 L S U R U N M C W B IT
M A IN C O N T R O L W O R D C O N T R O L - S Y S T E M A P P L IC A T IO N p a g e 1 (1 0 )
0 = F O R W A R D D IR E C T IO N
D I 1 = R E V E R S E D IR E C T IO N (2 0 0 0 0 = = P a r. 5 0 .0 1 S P E E D S C A L IN G )
D IR E C T IO N 1 0 .0 2 -1
I/O S P E E D
1 X R E F E R E N C E
R M IO
A N A L O G U E
A I2 H IG H V A L U E 1 3 .0 4 IN P U T
E X T R E F 1 S E L E C T = S T D A I2 1 1 .0 1
A I2 L O W V A L U E 1 3 .0 5 A I2
= P T 1 0 0 o r P T C
M IN IM U M A I2 1 3 .0 6
3 0 .0 3
F IL T E R A I2 1 3 .0 7 &
= N O 9 8 .0 6
C O M M M O D U L E = N O 9 8 .0 2
&
R M IO A I/O E X T M O D U L E 1 9 8 .0 6
A N A L O G U E = U N IP O L A R o r B IP O L A R 1 1 .0 3
A I1 H IG H V A L U E 1 3 .0 1 IN P U T
E X T R E F E R E N C E
A I1
A I1 L O W V A L U E 1 3 .0 2 M O T O R 1
M IN IM U M A I1 1 3 .1 2 M O T 1 T E M P A L M L 3 0 .0 4 T E M P E R A T U R E
P R O T E C T IO N
F IL T E R A I1 1 3 .0 3 M O T 1 T E M P F L T L 3 0 .0 5
P T 1 0 0
A I/O E X T M O D U L E 1 S C A L IN G P T C
1 .1 6
A I/O 9 8 .0 6 M O T O R 1 T E M P
E X T E N S IO N M O T O R
= T E M P M E A S 3 0 .0 3 = 1 ...3 x P T 1 0 0 o r P T C
M O D U L E 1 M O D E L
E X T 1 :A I1 3 0 .0 3 = 1 ...3 x P T 1 0 0 o r E X T T E M P
A I/O E X T 1 L O C A T IO N 9 8 .1 1 M O T 2 T E M P A L M L 3 0 .0 7 M O T O R 2
T E M P E R A T U R E
M O T 2 T E M P F L T L 3 0 .0 8
S C A L IN G P R O T E C T IO N
1 .1 7 P T 1 0 0
E X T 1 :A I2
M O T O R 2 T E M P P T C
A I/O E X T M O D U L E 1 = U N IP O L A R o r B IP O L A R A I 9 8 .0 6
R M IO &
A N A L O G U E A I/O E X T 1 L O C A T IO N = N O T IN U S E 9 8 .1 1
( u n s c a le d )
A I3 H IG H V A L U E 1 3 .0 8 IN P U T
1 .2 1 A I3 [m A ] E X T 1 A I/O A I1 u n s c a le d
1 .1 9 A I1 [V ]
A I3 L O W V A L U E 1 3 .0 9 I/O T O R Q U E R E F E R E N C E B
R M IO A I1 u n s c a le d
M IN IM U M A I3 1 3 .1 0 A I3
(1 0 0 0 0 = = M O T O R N O M IN A L T O R Q U E )
F IL T E R A I3 1 3 .1 1 E X T 1 A I/O A I2 u n s c a le d
1 .2 0 A I2 [m A ]
I/O speed and torque references and motor temperature protection
R M IO A I2 u n s c a le d
A I/O
E X T E N S IO N
A I1 E X T 2 M O D E 9 8 .1 3 M O D U L E 2
A I2 E X T 2 M O D E 9 8 .1 4 E X T 2 :A I1 1 .4 1 E X T 2 A I1
A I/O E X T 2 L O C A T IO N 9 8 .1 5
I/O S P E E D A N D T O R Q U E R E F E R E N C E S A N D
E X T 2 :A I2 1 .4 2 E X T 2 A I2
M O T O R T E M P E R A T U R E P R O T E C T IO N - S Y S T E M A P P L IC A T IO N p a g e 2 (1 0 )
311
Control block diagrams
312
S P E E D
Control block diagrams
M O N IT O R A B O V E L IM IT
E N C O D E R A L M /F L T = F A U L T 5 0 .0 5 A B O V E S P E E D L IM IT 5 0 .1 0
&
S P E E D F B S E L = E N C O D E R 5 0 .0 3 8 .0 1 b 1 0
> 1
&
E N C O D E R A L M /F L T = A L A R M 5 0 .0 5
S P A C T F IL T T IM E
E N C O D E R E R R O R F IL T E R
5 0 .0 6
Speed measurement
S P E E D M E A S U R E D M O T O R S P E E D
P u ls e E n c o d e r E N C O D E R 1 .0 3
R T A C -0 1 1 .0 4
S P E E D
P u ls e C A L C T o s p e e d c o n tro l
E n c o d e r M O T O R
M o d u le M O D E L 1 .0 2
E N C O D E R M O D U L E 9 8 .0 1
S P E E D E S T IM A T E D
S P E E D S C A L IN G 5 0 .0 1
S P E E D M E A S M O D E 5 0 .0 2
E N C O D E R P U L S E N R 5 0 .0 4 F IL T E R
N T A C -0 2 E N C O D E R A L M /F L T 5 0 .0 5
M O T O R S P E E D F IL T
E N C O D E R D E L A Y 5 0 .1 1
P u ls e 1 .0 1
E n c o d e r Z E R O D E T E C T D E L A Y 5 0 .1 3
P u ls e E n c o d e r M o d u le M O T O R S P F IL T T IM 5 0 .1 2
S P E E D H O L D T IM E 5 0 .1 4
a lte r n a tiv e
P O S IT IO N
C O U N T E R
F U N C T IO N
P O S C O U N T M O D E 5 0 .0 7 3 .0 7 P O S C O U N T L O W
P O S C O U N T IN IT L O W 5 0 .1 4 3 .0 8 P O S C O U N T H IG H
P O S C O U N T IN IT H IG H 5 0 .1 4
S Y N C C M D D I S Y N C C O M M A N D 3 .0 9 P O S C O U N T D E G R E E S x x .x x In p u t fo r re fe re n c e o r c o m m a n d
1 0 .0 4 3 .1 0 P O S C O U N T R O U N D S x x .x x P a ra m e te r (s a v e d to F L A S H m e m o ry )
S Y N C C O M M A N D 7 .0 2 b 9
S Y N C D IS A B L E 7 .0 2 b 1 0 8 .0 2 b 5 S Y N C R D Y x .x x R e a d o n ly s ig n a l
R E S E T S Y N C R D Y 7 .0 2 b 1 1 x .x x > x B it o f p a c k e d b o o le a n w o r d
S P E E D M E A S U R E M E N T C H A IN - S Y S T E M A P P L IC A T IO N p a g e 3 (1 0 )
L IM IT E R
M IN IM U M S P E E D 2 0 .0 1
M A X IM U M S P E E D 2 0 .0 2
F O L L R E F S E L A C W 2 = O N 7 .0 3 b 6
S P E E D R E F 2
F O L L S P E E D R E F = O N 7 .0 3 b 7 S P E E D S H A R E 2 3 .0 5
2 .0 1
F O L L S P E E D R E F = M A S T E R 7 0 .1 7
X
D A T A S E T E N A B L E R A M P E D IN C H R E F 7 .0 2 b 1 2
C H 2 M /F M O D E = F O L L O W E R 7 0 .0 8 &
Speed reference
D S 4 1 .2
L O C A L C O N T R O L
M a s te r / R A M P E D IN C H R E F 2 3 .1 7
F o llo w e r D S S P E E D R E F
M A S T E R F O L L O W E R S P E E D R E F U S E D S P E E D R E F
a p p lic a tio n
2 .1 9
in te r fa c e 2 .2 7
L O C A L C O N T R O L +
F ie ld b u s L O C A L R E F
A d a p te r D S 8 1 .2 S P E E D R E F 2 3 .0 1
R M B A -0 1 C O M M M O D U L E
A B B P a r. 9 8 .0 2 L O C A L C O N T R O L
A u t o m a t io n ,
D S 1 0 g ro u p
C O M M M O D U L E = N O 9 8 .0 2 &
N -ty p e o f .... 9 0 , 9 2
R E A D / S T D M O D B U S 4 A I+ F B A S P E E D R E F = O N 1 1 .0 2 A D D IT IV E
F ie ld b u s
A d a p te rs
D S 2 4 W R IT E A D V A N T /N -F B 3 S P E E D R E F
F U N C I/O S P E E D R E F E R E N C E
F ie ld b u s F IE L D B U S 2 2 .2 5
A d a p te rs
D S 1 .2
N O 1 F R E Q U E N C Y R E F E R E N C E
I/O S P E E D R E F E R E N C E ( s e e fig u r e o n p a g e 1 0 ) x x .x x In p u t fo r re fe re n c e o r c o m m a n d
x x .x x P a ra m e te r (s a v e d to F L A S H m e m o ry )
x .x x R e a d o n ly s ig n a l
M O T O R C T R L M O D E = S C A L A R 9 9 .0 8
x .x x b x B it o f p a c k e d b o o le a n w o r d
S P E E D R E F E R E N C E C H A IN - S Y S T E M A P P L IC A T IO N p a g e 4 (1 0 )
313
Control block diagrams
314
R A M P _ O U T _ Z E R O 7 .0 1 b 4
x x .x x In p u t fo r re fe re n c e o r c o m m a n d
R A M P H O L D 7 .0 1 b 5 &
x x .x x P a ra m e te r (s a v e d to F L A S H m e m o ry )
R A M P _ IN _ Z E R O 7 .0 1 b 6
x .x x R e a d o n ly s ig n a l
Control block diagrams
&
x .x x b x B it o f p a c k e d b o o le a n w o r d IN C H IN G 1 7 .0 1 b 8
M IN IM U M S P E E D 2 0 .0 1 L IM IT E R
IN C H IN G 2 7 .0 1 b 9 & M A X IM U M S P E E D 2 0 .0 2
C O N S T S P E E D 1 2 3 .0 2 S P E E D R E F 3 S P E E D R E F 4
C O N S T S P E E D 2 2 3 .0 3 2 .0 2 2 .1 8
Speed reference ramp
R A M P O U T Z E R O 7 .0 1 b 4 +
0
R A M P B Y P A S S 7 .0 2 b 2
F A S T D I5 S E L = S P E E D C O R R 1 2 .0 3
B A L R A M P O U T 7 .0 2 b 3
E M E R G E N C Y
S T O P O F F 3 D I5
B A L R A M P R E F 2 2 .0 8
7 .0 1 b 2
> 1 A C C /D E C 0
7 .0 1 b 6
0
R A M P IN S P E E D R E F 2 S P E E D C O R R E C T IO N 2 3 .0 4
Z E R O 2 .0 1
A C C E L E R T IM E 2 2 .0 1 F O L L S P D C O R R E N A 7 .0 3 b 9
A C C E L .
A C C /D E C T IM E S C L E 2 2 .0 3 S P E E D C O N T R O L L IM IT E R
d V /d t
D S T O R Q R E F A 2 .2 0 L O A D S H A R E F O L L S P D
2 .1 6
D E C E L E R T IM E 2 2 .0 2 F U N C T IO N O F C O R R O U T
D E C E L .
( d n re f / d t ) L O A D S H A R E 2 5 .0 3 S P E E D
2 .3 0
E M E S T O P R A M P 2 2 .0 4 C O N T R O L L E D
F O L L S P D C T R L C O R 2 3 .1 8 F O L L O W E R 0
S H A P E T IM E 2 2 .0 5
F O L L S P D C O R M O D E 2 3 .1 9
R A M P H O L D 7 .0 1 b 5
V A R IA B L E S L O P E 2 2 .0 6 F O L L _ S P D _ C O R _ M A X _ L IM
&
W IN D O W W ID T H P O S 2 3 .0 8 M A X L IM 8 .0 4 b 3
L O C A L C O N T R O L
V A R IA B L E F O L L _ S P D _ C O R _ M IN _ L IM
S L O P E
V A R S L O P E R A T E 2 2 .0 7 F U N C T IO N W IN D O W W ID T H N E G 2 3 .0 9
M IN L IM 8 .0 4 b 2
-1
S P E E D R E F E R E N C E R A M P C H A IN -S Y S T E M A P P L IC A T IO N p a g e 5 (1 0 )
A C C E L E R
A C C C O M P D E R T IM E 2 4 .1 4 C O M P
A C C C O M P F IL T T IM E 2 4 .1 5 T O R Q A C C C O M P R E F
2 .0 7
Speed control
S P E E D R E F 3 2 .0 2
L IM IT E R
S P C T O R Q M A X 2 0 .0 7
K P S 2 4 .0 3
S P E E D S P C T O R Q M IN 2 0 .0 8
-1 E R R O R N E G K P S M IN 2 4 .0 4
K P S
X 2 .0 3 K P S W E A K P O IN T 2 4 .0 5
K P S B A L _ N C O N T 7 .0 2 b 8
K P S W P F IL T T IM E 2 4 .0 6 K P S T O R Q U E R E F 2
X M IN B A L R E F 2 4 .1 1
- T O R Q
2 .0 9
S P E E D R E F 4 D R O O P R A T E 2 4 .0 2 S E T P W E IG H T IN G R E F 2
K P S
W E A K P O IN T
2 .1 8 + S P E E D S T E P 2 3 .1 0 + 2 4 .0 7 S P C T O R Q M IN L IM
S U B T O R Q U E P R O P R E F 8 .0 3 b 1
M O T O R S P E E D S E T P O IN T W E IG H T P
F IL T E R W IN D O W 2 .0 4 S P C T O R Q M A X L IM
1 .0 4 - + 2 4 .0 8 8 .0 3 b 2
0
S P E E D E R R O R F IL T 2 3 .0 6 T IS 2 4 .0 9 2 .0 5 +
T IS IN IT V A L U E 2 4 .1 0
I T O R Q U E
R F E S P E E D F IL T E R 2 3 .1 2
IN T E G
F R E Q U E N C Y O F Z E R O 2 3 .1 3 R F E R E F
D A M P IN G O F Z E R O 2 3 .1 4 D E R IV A T IO N T IM E 2 4 .1 2 2 .0 6
F R E Q U E N C Y O F P O L E 2 3 .1 5 D E R IV F IL T T IM E 2 4 .1 3 D T O R Q U E D E R R E F
D A M P IN G O F P O L E 2 3 .1 6
K P S ,
T IS K P S V A L
K P S T IS M IN F R E Q 2 4 .1 7 M IN F R E Q
W IN D O W W ID T H P O S 2 3 .0 8 K P S
K P S T IS M A X F R E Q 2 4 .1 8 T IS
W IN D O W W ID T H N E G 2 3 .0 9 K P S V A L
E N A B L E K P S V A L M IN F R E Q 2 4 .1 9 M IN F R E Q x x .x x In p u t fo r re fe re n c e o r c o m m a n d
W IN D O W F R E Q
K P S T IS
C O N T R O L M A X F R E Q
T IS V A L M IN F R E Q 2 4 .2 0 x x .x x P a ra m e te r (s a v e d to F L A S H m e m o ry )
K P S T IS
M IN F R E Q
W IN D O W C T R L 7 .0 2 b 7 x .x x R e a d o n ly s ig n a l
&
W IN D O W IN T G O N 2 3 .0 7 x .x x b x B it o f p a c k e d b o o le a n w o r d
S P E E D C O N T R O L - S Y S T E M A P P L IC A T IO N p a g e 6 (1 0 )
315
Control block diagrams
316
F O L L R E F S E L A C W 2 = O N 7 .0 3 b 6
F O L L T O R Q U E R E F = O N 7 .0 3 b 8
T R E F T O R Q
Control block diagrams
F O L L T O R Q R E F = M A S T E R 7 0 .1 8 L IM IT E R M IN L IM
T R E F T O R Q M A X 2 0 .0 9 8 .0 3 b 7
C H 2 M /F M O D E = F O L L O W E R 7 0 .0 8 & T R E F T O R Q M IN 2 0 .1 0 T R E F T O R Q
L O C A L C O N T R O L M A X L IM
8 .0 3 b 8
L O A D S H A R E 2 5 .0 3
Torque reference
D A T A S E T X T O R Q R E F 1
D S 4 1 .3 + 2 .0 8
M a s te r / M A S T E R F O L L O W E R T O R Q U E R E F D S T O R Q R E F A U S E D T O R Q R E F A F IL T E R
F o llo w e r 2 .2 0
a p p lic a tio n 2 .2 8
in te r fa c e
T O R Q R E F A F T C 2 5 .0 2
S T D M O D B U S D S 8 1 .3
R M B A -0 1 C O M M M O D U L E 9 8 .0 2
A B B P a r. S T D M O D B U S 4
D S 1 0 g ro u p
A u t o m a t io n D S 1 0 .3 A D V A N T /N -F B 3
.... 9 0 , 9 2
N -ty p e o f R E A D / F IE L D B U S 2
F ie ld b u s D S 2 4 W R IT E D S 1 .3 2 5 .0 1
A d a p te rs F U N C . 1
N O T O R Q U E R E F A
N -ty p e o f D S 1 .3
F ie ld b u s
A d a p te rs R - t y p e o f F ie ld b u s A d a p t e r L O C A L C O N T R O L
&
W ith R - ty p e o f F ie ld b u s a d a p te r s , d e f in e to r q u e r e fe r e n c e T O R Q U E C O N T R O L R A M P
T O R Q U E R E F A o r B in p a r a m e te r g r o u p 5 1 .
Torque reference chain continues on the following page.
T O R Q U E R E F B
L O C A L R E F
2 5 .0 4
C O M M M O D U L E = F IE L D B U S 9 8 .0 2
> 1
C O M M M O D U L E = N O 9 8 .0 2 T O R Q R A M P U P 2 5 .0 5
T O R Q R A M P D O W N 2 5 .0 6
I/O T O R Q U E R E F E R E N C E B
F IE L D B U S T O R Q U E R E F B
(N -ty p e o r R M B A -0 1 )
N o te ! W ith o th e r R - ty p e o f F ie ld b u s m o d u le s ,
to r q u e r e fe r e n c e is a s s ig n e d b y P a r . g r o u p 5 1 . T O R Q U E R E F E R E N C E C H A IN - S Y S T E M A P P L IC A T IO N p a g e 7 (1 0 )
F R E Q
T O R Q U E S T E P 2 6 .0 3 L IM IT E R
S P E E D R E F 4 T O R Q U E R E F 5 T O R Q F R E Q L IM R E F
2 .1 8 + 2 .1 2 2 .2 2
L O A D C O M P E N S A T IO N 2 6 .0 2 T O R Q U E R E F 4
+
M O T O R S P E E D S U B
O S C IL L A T IO N 2 .1 1
1 .0 4 - T O R Q U E R E F 3 + F R E Q M A X L IM IT
D A M P IN G
F R E Q U E N C Y 1 .0 5
2 .1 0 8 .0 3 b 1 1
O S C C O M P E N S A T IO N 2 6 .0 4
F R E Q M IN L IM IT
O S C IL L A T IO N F R E Q 2 6 .0 5 M IN IM U M S P E E D 2 0 .0 1 8 .0 3 b 1 0
O S C IL L A T IO N P H A S E 2 6 .0 6 M A X IM U M S P E E D 2 0 .0 2 F R E Q L IM IT
O S C IL L A T IO N G A IN 2 6 .0 7 F R E Q T R IP M A R G IN 2 0 .1 1 8 .0 3 b 1 5
T O R Q U E S E L E C T O R T O R Q U E S E L E C T O R
2 6 .0 1
0
D C
S P E E D V O L T A G E
L IM IT E R
T O R Q U E R E F 1 T O R Q F R E Q L IM R E F T O R Q D C L IM R E F
T O R Q U E 2 .2 2 2 .2 3
2 .0 8
F ro m to r q u e r e fe r e n c e c h a in D C V O L T A G E 1 .1 0
M IN
U N D E R V O L T A G E C T L 3 0 .2 2
U N D E R D C U N D E R V O L T L IM
V O L T A G E
M A X U N D E R V O L T T O R Q U P 2 0 .1 5 C O N T R O L 8 .0 3 b 1 2
U N D E R V O L T T O R Q D N 2 0 .1 6
T O R Q U E R E F 2
A D D D C O V E R V O L T L IM
O V E R
2 .0 9 O V E R V O L T A G E C T L 3 0 .2 3 V O L T A G E
C O N T R O L
8 .0 3 b 1 3
F ro m s p e e d c o n tr o lle r
P O W E R T O R Q U E T O R Q U E
L IM IT L IM IT E R L IM IT
C A L C . C A L C
T O R Q D C L IM R E F T O R Q P O W L IM R E F T O R Q U S E D R E F
2 .2 3 2 .2 4 2 .1 3
F R E Q U E N C Y 1 .0 5 F L U X U S E D R E F 2 .1 4 M O T O R C U R R E N T 1 .0 6
T O R Q M A X L IM T O R Q U S E R C U R L IM
P M O T O R IN G L IM P M O T O R IN G L IM M IN IM U M T O R Q U E 2 0 .0 6 8 .0 3 b 6 8 .0 3 b 3
2 0 .1 7 8 .0 4 b 0 T O R Q M IN L IM M A X IM U M C U R R E N T 2 0 .0 4 T O R Q IN V C U R L IM
M A X IM U M T O R Q U E 2 0 .0 5
8 .0 3 b 5 8 .0 3 b 4
P G E N E R A T IN G L IM P G E N E R A T IN G L IM P U L L O U T T C O E F M A X 2 0 .1 2 T O R Q M O T O R L IM
2 0 .1 8 8 .0 4 b 1 P U L L O U T T C O F M IN 2 0 .1 3 8 .0 3 b 0 IN V E R T E R M A X IM U M C U R R E N T
T O R Q U E R E F E R E N C E C H A IN - S Y S T E M A P P L IC A T IO N p a g e 8 (1 0 )
317
Control block diagrams
318
S T A R T
S T A R T F U N C T IO N 2 1 .0 1 C O N T R O L
A U T O
S T A R T
D C M A G N
C O N S T M A G N T IM E 2 1 .0 2 C N S T D C M A G N
S T A R T F L U X
R E F E R E N C E
U S E D M C W 2 .2 6
Control block diagrams
F IE L D
F L U X M IN 2 7 .0 5
F L U X F L U X W E A K E N IN G
B R A K IN G F L U X U S E D R E F
O P T IM IS A T IO N
M O T O R T O R Q U E 1 .0 8 2 .1 4
F L U X R E F 2 7 .0 3
Flux and DTC control
F L U X B R A K IN G
M O T O R N O M F R E Q
2 7 .0 2 IN T E R N A L
F R E Q U E N C Y 1 .0 5 F L U X R E F 8 .0 3 b 9 F L U X M IN L IM IT
F L U X O P T IM IS A T IO N 2 7 .0 1
C A L C U L A T IO N
D C V O L T A G E 1 .1 0 2 .2 1 F IE L D W K P O IN T A C T
F L U X M A X 2 7 .0 4
F L U X M IN 2 7 .0 5
F L U X R A M P G A IN 2 7 .0 6
D IR E C T T O R Q U E A S IC A C S 8 0 0
a n d F L U X
H Y S T E R E S IS T o r q b its
C O N T R O L
O p tim a l
F lu x b its S w itc h in g
C o n tro l
C o n tr o l b its
T O R Q U E U S E D R E F 2 .1 3
F L U X A C T 2 .1 5 1 .0 8 M O T O R T O R Q U E
x x .x x In p u t fo r re fe re n c e o r c o m m a n d
M O T O R M O D E L D C V O L T A G E A C T U A L
x x .x x P a ra m e te r (s a v e d to F L A S H m e m o ry )
C U R R E N T A C T U A L
x .x x R e a d o n ly s ig n a l C A L C U L A T E M
A C T U A L V A L U E S
x .x x b x B it o f p a c k e d b o o le a n w o r d
E S T IM A T E a n d
C A L C U L A T E
F L U X A N D D T C C O N T R O L - S Y S T E M A P P L IC A T IO N p a g e 9 (1 0 )
A C C E L E R T IM E 2 2 .0 1 R A M P
D E C E L E R T IM E 2 2 .0 2
E M E S T O P R A M P 2 2 .0 4
D C
S H A P E T IM E 2 2 .0 5 V O L T A G E
L IM IT E R L IM IT E R
S P E E D S H A R E L IM IT E R
F R E Q U E N C Y M A X 2 9 .0 2 L O C A L C O N T R O L T O R Q F R E Q L IM R E F T O R Q D C L IM R E F
2 3 .0 5
Scalar control
F R E Q U E N C Y M IN 2 9 .0 3 2 .2 2 2 .2 3
F R E Q . R E F X
L O C A L R E F D C V O L T A G E
2 9 .0 1
1 .1 0
F R E Q U E N C Y R E F E R E N C E +
U N D E R V O L T A G E C T L
U N D E R D C U N D E R V O L T L IM
V O L T A G E
2 9 .0 2 3 0 .2 2 C O N T R O L 8 .0 3 b 1 2
L O C A L C O N T R O L
F R E Q U E N C Y M A X
C O M M M O D U L E = N O 9 8 .0 2 &
2 9 .0 3 O V E R V O L T A G E C T L D C O V E R V O L T L IM
O V E R
A I+ F B A S P E E D R E F = O N 1 1 .0 2 V O L T A G E
F R E Q U E N C Y M IN 3 0 .2 3 C O N T R O L
8 .0 3 b 1 3
I/O S P E E D R E F E R E N C E 2 9 .0 5
A D D F R E Q R E F
F L U X U S E D R E F 2 .1 4 S C A L A R C O N T R O L A S IC A C S 8 0 0
T O R Q U E
L IM IT S W IT C H IN G F R E Q R E F T o r q b its
C A L C O p tim a l
T O R Q U S E D R E F F R E Q U E N C Y 1 .0 5 F lu x b its S w itc h in g
2 .1 3 C o n tro l
C o n tr o l b its
M O T O R C U R R E N T 1 .0 6
T O R Q U S E R C U R L IM
8 .0 3 b 3 IR
D C V O L T A G E A C T U A L
C O M P E N S A T IO N
M A X IM U M C U R R E N T 2 0 .0 4 T O R Q IN V C U R L IM M O T O R N O M F R E Q
8 .0 3 b 4 M O T O R N O M V O L T A G E C U R R E N T A C T U A L
IR C O M P E N S A T IO N 2 9 .0 4 2 .1 5 F L U X A C T
IN V E R T E R M A X IM U M C U R R E N T
M A IN C O N T R O L W O R D 1 .0 8 M O T O R T O R Q U E
M
S C A L A R C O N T R O L - S Y S T E M A P P L IC A T IO N p a g e 1 0 (1 0 )
319
Control block diagrams
320
Control block diagrams
321
Terms
Term Full name Description
ACS800/ACS600 AC drive
ACU Auxiliary Control Unit
AGPS Gate Driver Power supply board
AI Analogue input Interface for analogue input signals
AIMA I/O Module Adapter Extension unit for mounting of I/O extension modules
AINT Main Circuit Interface Board Interface for RMIO/NAMC and main circuit
AO Analogue output Interface for analogue output signals
APBU PPCS Branching Unit Optical PPCS branching unit used with parallel
inverter modules.
APC2 Application Program Controller 2
AC 80 Advant Controller 80
AC 800M Advant Controller 800 M
ASIC Application Specific Integrated Circuit
CDP 311 Common Drives Panel 311
CDP 312R Common Drives Panel 312 Control panel is used for setting drive parameters and
monitoring the drive. Control panel uses the Modbus-
protocol.
CE Marking Communauté Européenne Marking CE marking is the manufacturer's claim that the
product meets the essential requirements of all
relevant European Directives.
CI858 DriveBus Communication Interface Used with AC 800M.
DDCC Distributed Drives Communication Communication ASIC
Circuit
DDCS Distributed Drives Communication Communication protocol used with drive products
System
DI Digital input Interface for digital input signals
DO Digital output Interface for digital output signals
DriveSize Windows based PC tool for dimensioning of the drive
and motor
DriveWindow DriveWindow is an easy to use Windows application
for commissioning and maintaining ABB drives
equipped with fibre optic communication.
DSP Digital Signal Processor Processor type used in RMIO and NAMC board
Terms
322
Term Full name Description
DSU Diode Supply Unit Diode input bridge
DTC Direct Torque Control See section Motor control, DTC on page 78.
EEPROM Electrically Erasable Programmable Non-volatile memory
ROM
EMC Electromagnetic Compatibility EMC is the ability of electrical/electronic equipment to
operate without problems within an electromagnetic
environment. Likewise, the equipment must not
disturb or interfere with any other product or system
within its locality.
EMI Electromagnetic interference
ESD Electrostatic discharge
FCB Function Chart Builder Software tool for ACS800 Template Application
programming
FCE Function Chart Editor FCB editor for application block drawing
FCI Fieldbus Communication Interface E.g. CI810A Fieldbus Communication Interface
Flash EEPROM Electrically Erasable EEPROM memory Non-volatile memory
FSR Full Scale Range
HW Hardware Physical device or equipment
I/O Input/Output Input/Output interface (e.g. DI, DO, AI, AO)
IC International Cooling International cooling standard
ICMC Integrated Control Motor Circuit Motor and inverter control ASIC used in ACS600
ICU Incoming Unit Section through which the drive connects to the main
supply
ID run Identification run During the identification run, the drive will identify the
characteristics of the motor for optimum motor control.
IEC International Electrotechnical Organisation for Electrical and Electronic Engineering
Commission Standards
IEEE Institute of Electrical and Electronic US professional society which takes part in
Engineers standardisation. For example IEEE Conference
Reviews.
IGBT Insulated Gate Bipolar Transistor Power semiconductor
IM International Mounting International mounting standard
IOCC Input Output Control Circuit I/O ASIC used in ACS600
IP International Protection Degree of protection provided by enclosures
ISO International Organisation for E.g. ISO 9000 series of quality standards
Standardisation
KLIXON Thermal switch
Terms
323
Term Full name Description
KTY-84-1xx Silicon temperature sensor Temperature dependent silicon sensor. Used e.g. in
AC motors to indicate motor temperature.
LCD Liquid Crystal Display Electronic display type used in the CDP 312R control
panel
LED Light Emitting Diode Semiconductor
Modbus Fieldbus communication protocol
Multidrive Drive consisting of several inverter modules
connected to same DC link
NAFA AF100 Adapter AF 100 Adapter kit includes a Fieldbus
Communication Interface (FCI).
NAIO Analogue I/O Extension Module Optional module to replace or extend analogue I/O
channels
NBCI Bus Connection Module
NBRA Brake chopper. Option device for efficient braking for
drives with no regenerative input bridge.
NBRC Brake Chopper Controller Board Controls the operation of the brake chopper (NBRA).
NCPC Control Panel Cable Optional cable for remote connection of the CDP
312R control panel
NCSA CS 31 Adapter Module Optional module which enables connection of a drive
to a CS 31 system.
NDBU DDCS Branching Unit
NDIO Digital I/O Extension Module Optional module to replace or extend digital I/O
channels
NDNA DeviceNet Adapter Module Optional module which enables the connection of the
drive to a DeviceNet system.
NDPA PCMCIA interface card to PC
NDPC Cable adapter between DDCS link and Cable adapter between CH3 optic fibre cable and
PC NDPA card. Used with DriveWare products.
NETA Ethernet Adapter Module Optional module for browser-based remote
monitoring of drives via Ethernet
NIBA Interbus-S Adapter Module Optional module which enables connection of a drive
to an InterBus-S system
NLMD Led Monitoring Display The NLMD-01 Monitoring Display has a LED bar to
show an absolute real type value. Used for signal
monitoring.
NMBA Modbus Adapter Module Optional module which enables the connection of the
drive to a Modbus system.
NOCR Optical Converter/Repeater board
NPBA PROFIBUS Adapter Module Optional module which enables the connection of the
drive to a PROFIBUS system.
Terms
324
Term Full name Description
NTAC Pulse Encoder Interface Module Optional pulse encoder interface
NTC Negative Temperature Coefficient
resistor
PCB Printed Circuit Board
PCMCIA Personal Computer Memory Card DDCS/PCMCIA interface used with DriveWindow as
International Association an interface between the PC and the drive.
PE Protective Earth Earthing (grounding) terminal
PFC Pump and Fan Control Drive macro for controlling pump and fan sections
PID Proportional, Integral and Derivate Drive speed control is based on PID algorithm.
PLC Programmable Logic Controller
PPCS Power Plate Communication System Optical serial link for inverter control
ppr Pulses per revolution E.g. number of encoder pulses per one revolution
PROM Programmable ROM
Pt100 Platinum Wire Resistance Element 100 Temperature dependent resistor
PTC Positive Temperature Coefficient resistor PTC thermistor
PWM Pulse Width Modulation Inverter control method
RAM Random Access Memory Volatile memory
RAIO Analogue I/O Extension Module Optional I/O module for ACS800 to replace or extend
analogue I/O channels.
RDCO DDCS Communication Option Module Optional I/O module for DDCS communication for
ACS800. Includes channels CH0…CH3.
RDCU Drive Control Unit DIN rail installable drive controller unit which consists
of an RMIO board, a bottom plate and a plastic cover.
RDIO Digital I/O Extension Module Optional module for ACS800 to replace or extend
digital I/O channels.
RDNA DeviceNet Adapter Module Optional module which enables the connection of the
drive to a DeviceNet system.
RMBA Modbus Adapter Module Optional module through which a drive is connected
to a Modbus serial communication bus.
RMIO Motor Control and I/O Board Motor, I/O and inverter control board
RFI Radio Frequency Interference
RFE Resonance Frequency Eliminator Software filter used in the drive to eliminate
oscillations.
RMS Root Mean Square For sine wave the RMS value is obtained by dividing
the maximum value by the square root of 2.
RPBA PROFIBUS-DP Adapter Module
Terms
325
Term Full name Description
RO Relay output Interface for a digital output signal. Implemented with
a relay.
ROM Read Only Memory Non-volatile memory
RS 232, RS 485 Standards for data transmission interfaces
RTAC Pulse Encoder Interface Module Optional pulse encoder interface for ACS800
SDCS UCM-1 UC resistor board Used in thyristor supply unit
SDCS -COM-1 Communication board Used in thyristor supply unit
SDCS-CON-1 Control board Used in thyristor supply unit
SDCS-IOB-22 Digital connection card (115 V) Used in thyristor supply unit
SDCS-IOB-23 Digital connection card (230 V) Used in thyristor supply unit
SDCS-IOE-2 UC measurement board Used in thyristor supply unit
SDCS-PIN-41 Pulse transformer board Used in thyristor supply unit
SDCS-PIN-51 Measurement board Used in thyristor supply unit
SDCS-POW-1 Power supply board Used in thyristor supply unit
SW Software
TSU Thyristor Supply Unit Full controlled thyristor input bridge
UART Universal Asynchronous Receiver Communication controlled circuit used in
Transmitter asynchronous communication protocols.
UPS Uninterrupted Power Supply Power supply equipment with battery to maintain
output voltage during power failure
UR fuse Ultra Rapid fuse Fuse type used to protect semiconductors
VSD Variable Speed Drives
WIDE Wide communication. More actual values (group 5)
can be read from the line-side converter to the
inverter side.
WTA Wide communication. Used with wind turbine
application.
Terms
326
Terms
3AFE64670646 REV E / EN
EFFECTIVE: 05.12.2008
ABB Oy ABB Inc. ABB Beijing Drive Systems Co. Ltd.
AC Drives Automation Technologies No. 1, Block D, A-10 Jiuxianqiao Beilu
P.O. Box 184 Drives & Motors Chaoyang District
FI-00381 HELSINKI 16250 West Glendale Drive Beijing, P.R. China, 100015
FINLAND New Berlin, WI 53151 Telephone +86 10 5821 7788
Telephone +358 10 22 11 USA Fax +86 10 5821 7618
Fax +358 10 22 22681 Telephone 262 785-3200 Internet www.abb.com
Internet www.abb.com 800-HELP-365
Fax 262 780-5135
ABB Drives
Application Guide
Adaptive Program
Adaptive Program
Application Guide
3AFE64527274 Rev C
EN
EFFECTIVE: 08.04.2005
© 2005 ABB Oy. All Rights Reserved.
5
Table of Contents
Table of Contents
Introduction to the guide
Chapter overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Reader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Related publications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Adaptive Program
Chapter overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
What is the Adaptive Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
How to build the program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
How to connect the program to the drive application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
How to control the execution of the program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Function blocks
Chapter overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
General rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Block inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Parameter value as an integer input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
How the block handles the input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
How to select the input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Constant as an integer input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
How to set and connect the input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Parameter value as a boolean input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
How the block handles the input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
How to select the input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Constant as a boolean input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
How to set and connect the input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
String input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
How to select the input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Function blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
ABS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
ADD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
AND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
BITWISE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
COMPARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
COUNT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
DPOT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Table of Contents
6
EVENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
MASK-SET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
MAX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
MIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
MULDIV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
NO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
OR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
PI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
PI-BAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
PI-BIPOLAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
RAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
SR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
SWITCH-B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
SWITCH-I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
TOFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
TON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
TRIGG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
XOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Actual signals and parameters in ACS800 Standard Application Program
Chapter overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Actual signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Customer diagrams
Chapter overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Table of Contents
7
Introduction to the guide
Chapter overview
The chapter gives general information on the guide.
Compatibility
The guide complies with the drive application programs in which the Adaptive
Programming features are included.
Safety instructions
Follow all safety instructions delivered with the drive.
• Read the complete safety instructions before you install, commission or use
the drive. The complete safety instructions are given at the beginning of the
Hardware Manual.
• Read the software function specific warnings and notes before changing the
default settings of the function. For each function, the warnings and notes are
given in the Firmware Manual in the subsection describing the related user-
adjustable parameters.
Reader
The reader of the manual is expected to:
• know the standard electrical wiring practices, electronic components and
electrical schematic symbols.
• have no experience or training in installing, operating or servicing of ABB drives.
Use
The guide is to be used together with the firmware manual of the drive application
program. The firmware manual contains the basic information on the drive
parameters including the parameters of the Adaptive Program. The guide gives
more detailed information on the Adaptive Program:
• what the Adaptive Program is
• how to build a program
• how the function blocks operate
• how to document the program
• the parameters and actual signals of ACS800 Standard Application Program
essential for the Adaptive Program.
Introduction to the guide
8
Related publications
The user documentation of the drive also includes:
• Firmware manual (the appropriate manual is delivered with the unit)
• Hardware manual (the appropriate manual is delivered with the unit)
• Guides/supplements for the optional equipment and programs (appropriate
manuals are included in the delivery).
Introduction to the guide
9
Adaptive Program
Chapter overview
The chapter describes the basics of the Adaptive Program and instructs in building a
program.
What is the Adaptive Program
Conventionally, the user can control the operation of the drive by parameters. Each
parameter has a fixed set of choices or a setting range. The parameters make the
programming easy, but the choices are limited: you cannot customise the operation
any further. The Adaptive Program makes freer customising possible without the
need of a special programming tool or language:
• The program is built of function blocks.
• The control panel is the programming tool.
• The user can document the program by drawing it on block diagram template
sheets.
The maximum size of the Adaptive Program is 15 function blocks. The program may
consist of several separate functions.
Adaptive Program
10
How to build the program
The programmer connects a function block to other blocks through a Block
Parameter Set. The sets are also used for reading values from the drive application
program and transferring data to the drive application program. Each Block
Parameter Set consists of five parameters.
The figure shows the use of Block Block Parameter Set 1
Parameter Set 1 in the ACS800
Standard Application Program
(parameters 84.05 to 84.09): Select
ADD
- Parameter 84.05 selects the …
function block type.
XOR
- Parameter 84.06 selects the source
84.05
that input I1 of the function block is
connected to. ACT. SIGNAL/ Select
- Parameter 84.07 selects the source PARAMETER
that input I2 of the function block is TABLE
connected to.
- Parameter 84.08 selects the source 1.01 84.06
that input I3 of the function block is Select ADD
connected to. 1.02 I1 +
- Parameter 84.09 stores the value of I2 O
the function block output. The user
••• I3
cannot edit the parameter value.
84.07
99.99 Select
84.08
Store
84.09
Adaptive Program
11
How to connect the program to the drive application
The output of the Adaptive Program needs to be connected to the drive application
program. For that purpose the user needs two parameters:
• a connection parameter and
• a source selection parameter (pointer).
The figure below shows the connection principle.
Example: Source selection Connection
ACT. SIGNAL/ parameter (pointer) parameter
The Adaptive Program PARAMETER
output is stored in parameter TABLE
84.09. The diagram shows
how to use the value as Select
1.01 AI1
speed reference REF1 in AI2
the ACS800 Standard Select … Speed
Application Program. 1.02 EXT1REF Reference
8409 PTR
11.03
•••
11.10
84.09
•••
99.99
How to control the execution of the program
The Adaptive Program executes the function blocks in numerical order, all blocks on
the same time level. This cannot be changed by the user. The user can:
• select the operation mode of the program (stop, start, editing)
• adjust the execution time level of the program
• delete or add blocks.
Adaptive Program
12
Adaptive Program
13
Function blocks
Chapter overview
The chapter describes the function blocks.
General rules
The use of input I1 is compulsory (it must not be left unconnected). Use of input
I2, I3, etc. is voluntary for the most blocks. As a rule of thumb, a unconnected input
does not affect the output of the block.
Block inputs
The blocks use three input formats:
• integer
• boolean
• text string
The used format varies depending on the block. For example, the ADD block uses
integer inputs and the OR block boolean inputs. Text string format is used only by the
EVENT block.
Note: The inputs of the block are read when the execution of the block starts, not
simultaneously for all blocks!
Function blocks
14
Parameter value as an integer input
How the block handles the input
The block reads the selected value in as an integer.
Note: The parameter selected as an input should be a real or integer value. If the
value is not in integer format by default, the block converts it. The integer (fieldbus)
scaling for each parameter is given in the Firmware Manual.
How to select the input
• Scroll to the input selection parameter of the block and switch to edit mode
(Enter).
• Set the values of the inversion, group, index and bit fields according to the
address from which the input value is to be read (double arrow and arrow keys).
The figure below shows the panel display when the input I1 selection parameter is in
edit mode. The value is inverted if there is a minus ( - ) sign in the inversion field.
The bit selection field is not effective for an integer or string type input.
Display of the panel 1 L -> 0 rpm 0
84 ADAPTIVE PROGRAM
06 INPUT1
[±001.018.00]
Inversion field
Group field
Index field
Bit field
Example: Analogue input AI1 is 5.8 V in a drive equipped with the ACS800 Standard
Application Program. How is the signal connected to the MAX block in the Adaptive
Program? What is the value at the block input?
AI1 is connected to the block as follows:
• Scroll to the input I1 selection parameter and shift to edit mode (Enter).
• Set the value in the group field to 1 and the value in the index field to 18. (Value of
AI1 is internally stored as actual signal 1.18.)
The value at the input of the block is 5800, since the integer scaling of actual signal
1.18 is: 0.001 V = 1 (given in the Firmware Manual).
Function blocks
15
Constant as an integer input
How to set and connect the input
Option 1
• Scroll to the input selection parameter of the block and switch to edit mode
(Enter).
• Select C in the inversion field (double arrow and arrow keys). The appearance of
the row changes. The rest of the line is now a constant field.
• Give the constant value to the constant field (double arrow and arrow keys).
• Accept by Enter.
The figure below shows the panel display when the input I1 selection parameter is in
edit mode and the constant field is visible. The constant may have a value from
-32768 to 32767. The constant cannot be changed while the adaptive program is
running.
Display of the panel 1 L -> 0 rpm 0
84 ADAPTIVE PROGRAM
06 INPUT1
[C.-10000]
Inversion (constant) field
Constant setting field
Option 2
• Set the constant to one of the parameters reserved for the constants.
• Connect the constant value to a block as usual by the input selection parameter.
The constants can be changed while the adaptive program is running. They may
have values from –8388608…8388607.
Function blocks
16
Parameter value as a boolean input
How the block handles the input
• The block reads the selected value as an integer.
• The block uses the bit defined by the bit field as the boolean input.
Bit value 1 is boolean value true and 0 is boolean value false.
Example: The figure below shows the value of input I1 selection parameter when
the input is connected to a bit indicating the status of digital input DI2. (In ACS800
Standard Application Program, the digital input states are internally stored as actual
signal 1.17 DI6-1 STATUS. Bit 1 corresponds to DI2, bit 0 to DI1.)
Display of the panel 1 L -> 0 rpm 0
84 ADAPTIVE PROGRAM
06 INPUT1
[±001.017.01]
Inversion field
Group field
Index field
Bit field
How to select the input
See the section Parameter value as an integer input above.
Note: The parameter selected as an input should have a packed boolean value
(binary data word). See the Firmware Manual.
Function blocks
17
Constant as a boolean input
How to set and connect the input
• Scroll to the input selection parameter of the block and switch to edit mode
(Enter).
• Select C in the inversion field (double arrow and arrow keys). The rest of the line
changes to a constant setting field.
• Give the constant. If boolean value true is needed, set the constant to -1. If
boolean value false is needed, set to 0.
• Accept by Enter.
String input
How to select the input
String input is needed only with the EVENT block.
For the input selection procedure, see the section Parameter value as an integer
input above. The bit selection field is not effective.
Note: The parameter selected as an input must have a string value. In the ACS800
Standard Application Program, there are parameters in group 85 USER
CONSTANTS which can be used for string inputs.
Function blocks
18
Function blocks
ABS Type Arithmetic function
Illustration
ABS
I1
I2 O
I3
Operation The output is the absolute value of input I1 multiplied by I2 and divided by I3.
O = I1 · I2 / I3
Connections Input I1, I2 and I3: 24 bit integer values (23 bits + sign)
Output (O): 24 bit integer (23 bits + sign)
ADD Type Arithmetic function
Illustration
ADD
I1 +
I2 O
I3
Operation The output is the sum of the inputs.
O = I1 + I2 + I3
Connections Input I1, I2 and I3: 24 bit integer values (23 bits + sign)
Output (O): 24 bit integer (23 bits + sign)
AND Type Logical function
Illustration
AND
I1 &
I2 O
I3
Operation The output is true if all connected inputs are true. Otherwise the output is false.
Truth table:
I1 I2 I3 O (binary) O (value on display)
0 0 0 False (All bits 0) 0
0 0 1 False (All bits 0) 0
0 1 0 False (All bits 0) 0
0 1 1 False (All bits 0) 0
1 0 0 False (All bits 0) 0
1 0 1 False (All bits 0) 0
1 1 0 False (All bits 0) 0
1 1 1 True (All bits 1) -1
Function blocks
19
Connections Input I1, I2 and I3: Boolean values
Output (O): 24 bit integer value (packed boolean)
BITWISE Type Arithmetic function
Illustration
BITWISE
I1
I2 O
I3
Operation The block compares bits of three 24 bit word inputs and forms the output bits as
follows:
O = (I1 OR I2) AND I3
Example
I1 I2 I3 O
0 0 0 0
0 1 0 0
1 0 0 0
1 1 0 0
0 0 1 0
0 1 1 1
1 0 1 1
1 1 1 1
Connections Input I1: 24 bit integer value (packed boolean)
Input I2: 24 bit integer value (packed boolean)
Input I3: 24 bit integer value (packed boolean)
Output (O): 24 bit integer value (packed boolean)
COMPARE Type Comparative function
Illustration
COMPARE
I1
I2 O
I3
Function blocks
20
Operation Output bits 0, 1 and 2:
- If I1 > I2, O = … 001 (Output bit 0 is set.)
- If I1 = I2, O = … 010 (Output bit 1 is set.)
- If I1 < I2, O = … 100 (Output bit 2 is set.)
Output bit 3:
- If I1 > I2, O = … 1xxx (Output bit 3 is set and remains set until I1 < I2 - I3, after
which bit 3 is reset.)
Output value on display:
bit 0 bit 1 bit 2 bit 3 O (value on display)
0 0 0 0 0
1 0 0 0 1
0 1 0 0 2
0 0 1 0 4
0 0 0 1 8
1 0 0 1 9
0 1 0 1 10
0 0 1 1 12
Connections Input I1, I2 and I3: 24 bit integer values (23 bits + sign)
Output (O): 24 bit integer (packed boolean)
COUNT Type Counter function
Illustration
COUNT
I1
I2 O
I3
Operation The counter function counts rising edges of the input I1.
The counter is reset by the rising edge of input I2 and limited to the value set with
the input I3.
I1: Trigger input
I2: Reset
I3: Max limit for the counter (B0…B19 -> 0…1048575)
O: Value of the counter (B0…B19 -> 0…1048575), and status of the counter (B20).
B20 = 1: Counter is at max limit or input I3 is negative.
Connections Input I1 and I2: Boolean values
Input I3: 24 bit integer value (20 bits used by the counter)
Output (O): 24 bit integer value (20 bits for counter value and 4 indication bits)
Function blocks
21
DPOT Type Counter function
Illustration
DPOT
I1
I2 O
I3
Operation The digitally controlled ramp function increments or decrements the output O
according to control inputs I1 and I2. The input I1 ramps the output to positive
direction and I2 to negative direction. If both inputs are active, nothing happens. The
step is defined by the input I3.
Input I1: Count up
Input I2: Count down
Input I3: Ramp step to positive/negative direction (step/sec).
Note: The internal calculation uses 48 bits accuracy to avoid offset errors.
Connections Input I1 and I2: Boolean values
Input I3: 24 bit integer value (23 bits + sign)
Output (O): 24 bit integer value (23 bits + sign)
EVENT Type Event function
Illustration
EVENT
I1
I2
I3
Operation Input I1 triggers the event. I2 selects the parameter index from which the event
message (text string) is read. I3 selects the type of the event (warning or fault).
I1 I2 I3 Cause
0->1 block activates the event
0 block deactivates the event
I2 contents of the event message
0 type of event: warning
1 type of event: fault
2 type of event: event
Connections Input I1, I3: 24 bit integer values (23 bits + sign)
Input I2: String (compulsory)
FILTER Type Filtering function
Illustration
FILTER
I1
O
I2
Function blocks
22
Operation The output is the filtered value of input I1. Input I2 is the filtering time.
O = I1 · (1 - e-t/I2)
Note: The internal calculation uses 48 bits accuracy to avoid offset errors.
Connections Input I1: 24 bit integer value (23 bits + sign)
Input I2: 24 bit integer value (23 bits + sign). One corresponds to 1 ms.
Output (O): 24 bit integer (23 bits + sign)
MASK-SET Type Logical function
Illustration
MASK SET
I1
I2 O
I3
Operation The block function sets or resets the bits defined in I2 in I1.
Input I1: Word input
Input I2: Set word input
Input I3: Set/reset I2 in I1.
Example with SET Example with RESET
I1 I2 I3 O I1 I2 I3 O
0 0 True 0 0 0 False 0
1 0 True 1 1 0 False 1
1 1 True 1 1 1 False 0
0 1 True 1 0 1 False 0
Connections Input I1: 24 bit integer value (packed boolean)
Input I2: 24 bit integer value (packed boolean)
Input I3: Boolean
Output (O): 24 bit integer value (packed boolean)
MAX Type Comparative function
Illustration
MAX
I1
I2 O
I3
Operation The output is the highest input value.
O = MAX (I1, I2, I3)
Connections Input I1, I2 and I3: 24 bit integer values (23 bits + sign)
Output (O): 24 bit integer (23 bits + sign)
Function blocks
23
MIN Type Comparative function
Illustration
MIN
I1
I2 O
I3
Operation The output is the lowest input value.
O = MIN (I1, I2, I3)
Connections Input I1, I2 and I3: 24 bit integer values (23 bits + sign)
Output (O): 24 bit integer (23 bits + sign)
MULDIV Type Arithmetic function
Illustration
MULDIV
I1
I2 O
I3
Operation The output is the product of input I1 and input I2 divided by input I3.
O = (I1 · I2) / I3
Connections Input I1, I2 and I3: 24 bit integer values (23 bits + sign)
Output (O): 24 bit integer (23 bits + sign)
NO Type -
Illustration
NO
I1
I2 O
I3
Operation The block does not do anything.
Connections -
OR Type Logical function
Illustration
OR
I1 >1
I2 O
I3
Function blocks
24
Operation The output is true if any of the inputs is true. Truth table:
I1 I2 I3 O (binary) O (value on display)
0 0 0 False (All bits 0) 0
0 0 1 True (All bits 1) -1
0 1 0 True (All bits 1) -1
0 1 1 True (All bits 1) -1
1 0 0 True (All bits 1) -1
1 1 0 True (All bits 1) -1
1 1 1 True (All bits 1) -1
Connections Input I1, I2 and I3: Boolean values
Output (O): 24 bit integer value (packed boolean)
PI Type PI controller
Illustration
PI
I1
I2 O
I3
Operation The output is input I1 multiplied by I2/100 plus integrated I1 multiplied by I3/100.
O = I1· I2/100+(I3/100) · I1
Note: The internal calculation uses 48 bits accuracy to avoid offset errors.
Connections Inputs I1: 24 bit integer value (23 bit + sign)
Input I2:
- 24 bit integer value (23 bit + sign)
- Gain factor. 100 corresponds to 1. 10 000 corresponds to 100.
Input I3:
- Integrator coefficient. 100 corresponds to 1. 10 000 corresponds to 100.
Output (O): 24 bit integer (23 bits + sign). The range is limited to 0…10000.
PI-BAL Type Initialisation block for the PI controller
Illustration
PI-BAL
I1
I2
Operation The block initialises the PI block first. When input I1 becomes true, the block writes
the value of I2 to the output of the PI block. When I1 becomes false, the block
releases the output of the PI controller block which continues normal operation from
the set output.
Note: The block may be used only with the PI block. The block must follow the
PI block.
Connections Input I1: Boolean value
Input I2: 24 bit integer value (23 bits + sign)
Function blocks
25
PI- Type PI controller
BIPOLAR
Illustration
PI BIPOLAR
I1
I2 O
I3
Operation See the PI block.
Except
Output (O) range: -10000…10000.
RAMP Type Ramp function
Illustration
RAMP
I1
I2 O
I3
Function blocks
26
Operation The block uses input I1 as a reference value. The step values (inputs I2 and I3)
increase or decrease the output O as long as the output differs from limit I1. When O
= I1, the output remains steady.
Input I1: Reference value
Input I2: Step to positive direction (step/sec). Increase the output, when O < I1.
Input I3: Step to negative direction (step/sec). Decrease the output, when O > I1.
On = On-1 + I2 when I1 > O
On = On-1 - I3 when I1 < O
On = I1 when I1 = O
Example:
Input I1: 0 -> 150 -> -100 ->0
Input I2: 100 step/sec
Input I3: 10 step/sec
Output:
Going up: Ramp step from Input I2
Going down: Ramp step from Input I3
Input I1
150
time
0
-100
Output
150
100 step/sec 10 step/sec
time
0
100 step/sec
-100
Connections Input I1, I2 and I3: 24 bit integer values (23 bits + sign)
Output (O): 24 bit integer (23 bits + sign)
Note: The internal calculation uses 48 bits accuracy to avoid offset errors.
Function blocks
27
SR Type Logical function
Illustration
SR
I1
I2 O
I3
Operation Set/reset block. Input I1 sets and I2 and I3 reset the output.
- If I1, I2 and I3 are false, the current value remains at the output.
- If I1 is true and I2 and I3 are false, the output is true.
- If I2 or I3 is true, the output is false.
I1 I2 I3 O (binary) O (value on display)
0 0 0 Output Output
0 0 1 False (All bits 0) 0
0 1 0 False (All bits 0) 0
0 1 1 False (All bits 0) 0
1 0 0 True (All bits 1) -1
1 0 1 False (All bits 0) 0
1 1 0 False (All bits 0) 0
1 1 1 False (All bits 0) 0
Connections Input I1, I2 and I3: Boolean values
Output (O): 24 bit integer value (23 bits + sign)
SWITCH-B Type Logical function
Illustration
SWITCH-B
I1
I2 O
I3
Operation The output is equal to input I2 if input I1 is true and equal to input I3 if input I1 is
false.
I1 I2 I3 O O (value on display)
0 I2 I3 I3 True = -1
1 I2 I3 I2 False = 0
Connections Input I1, I2 and I3: Boolean values
Output (O): 24 bit integer value (packed boolean)
Function blocks
28
SWITCH-I Type Logical function
Illustration
SWITCH-I
I1
I2 O
I3
Operation The output is equal to input I2 if input I1 is true and equal to input I3 if input I1 is
false.
I1 I2 I3 O
0 I2 I3 I3
1 I2 I3 I2
Connections Input I1: Boolean value
Input I2 and I3: 24 bit integer values (23 bits + sign)
Output (O): 24 bit integer value (23 bits + sign)
TOFF Type Timing function
Illustration
TOFF
I1
O
I2
Operation The output is true when input I1 is true. The output is false when input I1 has been
false for a time equal or longer than input I2.
Input I1
0
Input I2 Input I2 t
Output
All bits 1
All bits 0
t
Values on display: True = -1, false = 0.
Connections Input I1: Boolean value
Input I2: 24 bit integer value (23 bits + sign). One corresponds to 1 ms.
Output (O):
- 24 bit integer value (packed boolean)
Function blocks
29
TON Type Timing function
Illustration
TON
I1
O
I2
Operation The output is true when input I1 has been true for a time equal or longer than input
I2. The output is false when the input is false.
Input I1
0
time
Input I2 Input I2
Output
All bits 1
All bits 0
time
Values on display: True = -1, false = 0.
Connections Input I1: Boolean value
Input I2: 24 bit integer value (23 bits + sign). 1 corresponds to 1 ms.
Output (O): 24 bit integer value (packed boolean)
TRIGG Type Timing function
Illustration
TRIGG
I1
I2 O
I3
Operation The rising edge of input I1 sets the output bit 0 for one program cycle.
The rising edge of input I2 sets the output bit 1 for one program cycle.
The rising edge of input I3 sets the output bit 2 for one program cycle.
Example
Tc = Program
Input I1 cycle time
0
Output, Bit 0 t
0
Tc Tc t
Function blocks
30
Connections Input I1, I2 and I3: Boolean values
Output (O):
- 24 bit integer value (23 bits + sign)
XOR Type Logical function
Illustration
XOR
I1 = 1
I2 O
I3
Operation The output is true if one input is true, otherwise the output is false. Truth table:
I1 I2 I3 O (binary) O (value on display)
0 0 0 False (All bits 0) 0
0 0 1 True (All bits 1) -1
0 1 0 True (All bits 1) -1
0 1 1 False (All bits 0) 0
1 0 0 True (All bits 1) -1
1 0 1 False (All bits 0) 0
1 1 0 False (All bits 0) 0
1 1 1 True (All bits 1) -1
Connections Input I1, I2 and I3: Boolean values
Output (O):
- 24 bit integer value (23 bits + sign)
Function blocks
31
Actual signals and parameters in ACS800 Standard
Application Program
Chapter overview
The chapter lists the actual signals, parameters and parameter values of ACS800
Application Program that are essential for the Adaptive Programming.
Actual signals
The table below lists the actual signals that are essential for the Adaptive Program.
The abbreviation FbEq stands the fieldbus equivalent.
Index Signal Name/Value Description FbEq.
09 ACTUAL SIGNALS Signals for the Adaptive Program
09.01 AI1 SCALED Value of analogue input AI1 scaled to an integer value. 20000 =
10 V
09.02 AI2 SCALED Value of analogue input AI2 scaled to an integer value. 20000 =
20 mA
09.03 AI3 SCALED Value of analogue input AI3 scaled to an integer value. 20000 =
20 mA
09.04 AI5 SCALED Value of analogue input AI5 scaled to an integer value. 20000 =
20 mA
09.05 AI6 SCALED Value of analogue input AI6 scaled to an integer value. 20000 =
20 mA
09.06 MASTER CW Control Word (CW) of the Main Reference Dataset received from the master -32768
station through the fieldbus interface. …32767
09.07 MASTER REF1 Reference 1 (REF1) of the Main Reference Dataset received from the master -32768
station through the fieldbus interface … 32767
09.08 MASTER REF2 Reference 2 (REF2) of the Main Reference Dataset received from the master -32768
station through the fieldbus interface. … 32767
09.09 AUX DS VAL1 Reference 3 (REF3) of the Auxiliary Reference Dataset received from the -32768
master station through the fieldbus interface. … 32767
09.10 AUX DS VAL2 Reference 4 (REF4) of the Auxiliary Reference Dataset received from the -32768
master station through the fieldbus interface. … 32767
09.11 AUX DS VAL3 Reference 5 (REF5) of the Auxiliary Reference Dataset received from the -32768
master station through the fieldbus interface. … 32767
Actual signals and parameters in ACS800 Standard Application Program
32
Parameters
The table below lists the parameters and parameters values that are essential for the
Adaptive Program. The abbreviation FbEq stands for fieldbus equivalent.
Index Parameter name / Description FbEq
value
10 START/STOP/DIR Parameters through which the Adaptive Program can control the start, stop
and direction of the drive.
10.01 EXT1 STRT/STP/DIR
PARAM 10.04 Source selected by 10.04 17
10.02 EXT2 STRT/STP/DIR
PARAM 10.05 Source selected by 10.05. 17
10.04 EXT 1 STRT PTR Selects the source for parameter 10.01.
-255.255.31 … Parameter pointer or constant value:
+255.255.31 / C.-32768 - Parameter pointer: Inversion, group, index and bit fields. The bit number is
… C.32767 effective only for blocks handling boolean inputs.
- Constant value: Inversion and constant fields. The inversion field must have
value C to enable the setting of the constant.
10.05 EXT 2 STRT PTR Selects the source for 10.02.
-255.255.31 … Parameter pointer or constant value. See Parameter 10.04.
+255.255.31 / C.-32768
… C.32767
11 REFERENCE SELECT Parameters through which the Adaptive Program can control the reference of
the drive.
11.02 EXT1/EXT2 SELECT
PARAM 11.09 Source selected by 11.09. 16
11.03 EXT REF1 SELECT
PARAM 11.10 Source selected by 11.10. 37
11.06 EXT REF2 SELECT
PARAM 11.11 Source selected by 11.11. 38
11.09 EXT 1/2 SEL PTR Selects the source for 11.02.
-255.255.31 … Parameter pointer or constant value. See Parameter 10.04.
+255.255.31 / C.-32768
… C.32767
11.10 EXT 1 REF PTR Selects the source for 11.03.
-255.255.31 … Parameter pointer or constant value. See Parameter 10.04.
+255.255.31 / C.-32768
… C.32767
11.11 EXT 2 REF PTR Selects the source for 11.06.
-255.255.31 … Parameter pointer or constant value. See Parameter 10.04.
+255.255.31 / C.-32768
… C.32767
14 RELAY OUTPUTS Parameters through which the Adaptive Program can control the relay
outputs of the drive.
14.01 RELAY RO1 OUTPUT
PARAM 14.16 Source selected by parameter 14.16. 36
14.02 RELAY RO2 OUTPUT
Actual signals and parameters in ACS800 Standard Application Program
33
Index Parameter name / Description FbEq
value
PARAM 14.17 Source selected by parameter 14.17. 36
14.03 RELAY RO3 OUTPUT
PARAM 14.18 Source selected by parameter 14.18. 36
14.10 DIO MOD1 RO1
PARAM 14.19 Source selected by parameter 14.19. 7
14.11 DIO MOD1 RO2
PARAM 14.20 Source selected by parameter 14.20. 7
14.12 DIO MOD2 RO1
PARAM 14.21 Source selected by parameter 14.21. 7
14.13 DIO MOD2 RO2
PARAM 14.22 Source selected by parameter 14.22. 7
14.14 DIO MOD3 RO1
PARAM 14.23 Source selected by parameter 14.23. 7
14.15 DIO MOD3 RO2
PARAM 14.24 Source selected by parameter 14.24. 7
14.16 RO PTR1 Selects the source for parameter 14.01.
-255.255.31 … Parameter pointer or constant value. See Parameter 10.04.
+255.255.31 / C.-32768
… C.32767
14.17 RO PTR2 Selects the source for parameter 14.02.
-255.255.31 … Parameter pointer or constant value. See Parameter 10.04.
+255.255.31 / C.-32768
… C.32767
14.18 RO PTR3 Selects the source for parameter 14.03.
-255.255.31 … Parameter pointer or constant value. See Parameter 10.04.
+255.255.31 / C.-32768
… C.32767
14.19 RO PTR4 Selects the source for parameter 14.10.
-255.255.31 … Parameter pointer or constant value. See Parameter 10.04.
+255.255.31 / C.-32768
… C.32767
14.20 RO PTR5 Selects the source for parameter 14.11.
-255.255.31 … Parameter pointer or constant value. See Parameter 10.04.
+255.255.31 / C.-32768
… C.32767
14.21 RO PTR6 Selects the source for parameter 14.12.
-255.255.31 … Parameter pointer or constant value. See Parameter 10.04.
+255.255.31 / C.-32768
… C.32767
14.22 RO PTR7 Selects the source for parameter 14.13.
-255.255.31 … Parameter pointer or constant value. See Parameter 10.04.
+255.255.31 / C.-32768
… C.32767
14.23 RO PTR8 Selects the source for parameter 14.14.
Actual signals and parameters in ACS800 Standard Application Program
34
Index Parameter name / Description FbEq
value
-255.255.31 … Parameter pointer or constant value. See Parameter 10.04.
+255.255.31 / C.-32768
… C.32767
14.24 RO PTR9 Selects the source for parameter 14.15.
-255.255.31 … Parameter pointer or constant value. See Parameter 10.04.
+255.255.31 / C.-32768
… C.32767
15 ANALOGUE Parameters through which the Adaptive Program can control the standard
OUTPUTS analogue outputs of the drive.
15.01 ANALOGUE OUTPUT1
PARAM 15.11 Source selected by 15.11 17
15.06 ANALOGUE OUTPUT2
PARAM 15.12 Source selected by 15.12 16
15.11 AO1 PTR Selects the source for parameter 15.01.
-255.255.31 … Parameter pointer or constant value. See Parameter 10.04.
+255.255.31 / C.-32768
… C.32767
15.12 AO2 PTR Selects the source for parameter 15.06.
-255.255.31 … Parameter pointer or constant value. See Parameter 10.04.
+255.255.31 / C.-32768
… C.32767
16 SYSTEM CTRL Parameters through which the Adaptive Program can control the system
INPUTS control inputs of the drive.
16.01 RUN ENABLE
PARAM 16.08 Source selected by parameter 16.08. 15
16.08 RUN ENA PTR Selects the source for parameter 16.01
-255.255.31 … Parameter pointer or constant value. See Parameter 10.04.
+255.255.31 / C.-32768
… C.32767
20 LIMITS Parameters through which the Adaptive Program can control the operation
limits of the drive.
20.13 MIN TORQ SEL Selects the torque minimum limit
PARAM 20.18 Limit given by 20.18 20
20.14 MAX TORQ SEL Selects the torque maximum limit
PARAM 20.19 Limit given by 20.19 19
20.18 TORQ MIN PTR Selects the source for 20.13 100 = 1%
-255.255.31 … Parameter pointer or constant value. See Parameter 10.04.
+255.255.31 / C.-32768
… C.32767
20.19 TORQ MAX PTR Selects the source for 20.14 100 = 1%
-255.255.31 … Parameter pointer or constant value. See Parameter 10.04.
+255.255.31 / C.-32768
… C.32767
22 ACCEL/DECEL Parameters through which the Adaptive Program can control the acceleration
and deceleration of the drive.
22.01 ACC/DEC 1/2 SEL
Actual signals and parameters in ACS800 Standard Application Program
35
Index Parameter name / Description FbEq
value
PAR 22.08&09 Acceleration and deceleration times given by parameters 22.08 and 22.09 15
22.08 ACC PTR Selects the source for 22.01 100 = 1 s
-255.255.31 … Parameter pointer or constant value. See Parameter 10.04.
+255.255.31 / C.-32768
… C.32767
22.09 DEC PTR Selects the source for 22.01 100 = 1 s
-255.255.31 … Parameter pointer or constant value. See Parameter 10.04.
+255.255.31 / C.-32768
… C.32767
26 MOTOR CONTROL Parameters through which the Adaptive Program can control the flux of the
drive.
26.06 FLUX REF PTR Selects the source for the flux reference.
-255.255.31 … Parameter pointer or constant value. See Parameter 10.04.
+255.255.31 / C.-32768
… C.32767
40 PID CONTROL Parameters through which the Adaptive Program can affect on the process
PID control.
40.07 ACTUAL1 INPUT SEL
PARAM 40.25 Source selected by parameter 40.25. 6
40.25 ACTUAL1 PTR Selects the source for 40.07 100 = 1%
-255.255.31 … Parameter pointer or constant value. See Parameter 10.04.
+255.255.31 / C.-32768
… C.32767
83 ADAPT PROG CTRL Execution control of the Adaptive Program.
83.01 ADAPT PROG CMD Selects the operation mode for the Adaptive Program.
STOP Stop. The program cannot be edited.
START Run. The program cannot be edited.
EDIT Stop to edit mode. The program can be edited.
83.02 EDIT COMMAND Selects the command for the block placed in the location defined by
parameter 83.03. The program must be in edit mode. (See parameter 83.01.)
NO Home value. The value automatically restores to NO after an editing
command has been executed.
PUSH Shifts the block in the location defined by parameter 83.03 and the
subsequent blocks one location up. A new block can be placed in the emptied
location by programming the Block Parameter Set as usual.
Example: A new block needs to be placed in between the current block
number four (parameters 84.20…84.25) and five (parameters 84.25…84.29).
In order to do this:
- Shift the program to the edit mode by parameter 83.01.
- Select location number five as the desired location for the new block by
parameter 83.03.
- Shift the block in location number 5 and all subsequent blocks one location
forward by parameter 83.02 (selection PUSH).
- Program the emptied location number 5 by parameters 84.25 to 84.29 as
usual.
DELETE Deletes the block in the location defined by parameter 83.03 and shifts the
subsequent blocks one step down.
Actual signals and parameters in ACS800 Standard Application Program
36
Index Parameter name / Description FbEq
value
83.03 EDIT BLOCK Defines the block location number for the command selected by parameter
83.02.
1 … 15 Block location number.
83.04 TIMELEVEL SEL Selects the execution cycle time for the Adaptive Program. The setting is
valid for all blocks.
12 ms 12 milliseconds
100 ms 100 milliseconds
1000 ms 1000 milliseconds
84 ADAPTIVE PROGRAM Creation and diagnostics of the Adaptive Program.
84.01 STATUS Shows the value of the Adaptive Program status word. The table below
shows the alternative bit states and the corresponding values on the panel
display.
Bit Display Meaning
0 1 Stopped
1 2 Running
2 4 Faulted
3 8 Editing
4 10 Checking
5 20 Pushing
6 40 Popping
8 100 Initialising
84.02 FAULTED PAR Points out the faulted parameter in the Adaptive Program.
84.05 BLOCK1 Selects the function block for Block Parameter Set 1.
ABS See the chapter Function blocks.
ADD See the chapter Function blocks.
AND See the chapter Function blocks.
COMPARE See the chapter Function blocks.
EVENT See the chapter Function blocks.
FILTER See the chapter Function blocks.
MAX See the chapter Function blocks.
MIN See the chapter Function blocks.
MULDIV See the chapter Function blocks.
NO See the chapter Function blocks.
OR See the chapter Function blocks.
PI See the chapter Function blocks.
PI-BAL See the chapter Function blocks.
SR See the chapter Function blocks.
SWITCH-B See the chapter Function blocks.
SWITCH-I See the chapter Function blocks.
TOFF See the chapter Function blocks.
TON See the chapter Function blocks.
TRIGG See the chapter Function blocks.
XOR See the chapter Function blocks.
Actual signals and parameters in ACS800 Standard Application Program
37
Index Parameter name / Description FbEq
value
84.06 INPUT1 Selects the source for input I1 of Block Parameter Set 1 (BPS1).
-255.255.31 … Parameter pointer or constant value:
+255.255.31 / C.-32768 - Parameter pointer: Inversion, group, index and bit fields. The bit number is
… C.32767 effective only for blocks handling boolean inputs.
- Constant value: Inversion and constant fields. The inversion field must have
value C to enable the setting of the constant.
Example: The state of digital input DI2 is connected to Input 1 as follows:
- Set the source selection parameter (84.06) to +.01.17.01. (The application
program stores the state of digital input DI2 to bit 1 of actual signal 01.17.)
- Invert the value by switching the sign of the pointer value (-01.17.01.).
84.07 INPUT2 See parameter 84.06.
-255.255.31 … See parameter 84.06.
+255.255.31 / C.-32768
… C.32767
84.08 INPUT3 See parameter 84.06.
-255.255.31 … See parameter 84.06.
+255.255.31 / C.-32768
… C.32767
84.09 OUTPUT Stores and displays the output of Block Parameter Set 1.
… … Stores and displays the output of Block Parameter Set 15.
84.79 OUTPUT Stores the output of Block Parameter Set 15. See parameter 84.09.
85 USER CONSTANTS Storage of the Adaptive Program constants and messages.
85.01 CONSTANT1 Sets a constant for the Adaptive Program.
-8388608 to 8388607 Integer value.
85.02 CONSTANT2 Sets a constant for the Adaptive Program.
-8388608 to 8388607 Integer value.
85.03 CONSTANT3 Sets a constant for the Adaptive Program.
-8388608 to 8388607 Integer value.
85.04 CONSTANT4 Sets a constant for the Adaptive Program.
-8388608 to 8388607 Integer value.
85.05 CONSTANT5 Sets a constant for the Adaptive Program.
-8388608 to 8388607 Integer value.
85.06 CONSTANT6 Sets a constant for the Adaptive Program.
-8388608 to 8388607 Integer value.
85.07 CONSTANT7 Sets a constant for the Adaptive Program.
-8388608 to 8388607 Integer value.
85.08 CONSTANT8 Sets a constant for the Adaptive Program.
-8388608 to 8388607 Integer value.
85.09 CONSTANT9 Sets a constant for the Adaptive Program.
-8388608 to 8388607 Integer value.
85.10 CONSTANT10 Sets a constant for the Adaptive Program.
-8388608 to 8388607 Integer value.
85.11 STRING1 Stores a message to be used in the Adaptive Program (EVENT block).
Actual signals and parameters in ACS800 Standard Application Program
38
Index Parameter name / Description FbEq
value
MESSAGE1 Message
85.12 STRING2 Stores a message to be used in the Adaptive Program (EVENT block).
MESSAGE2 Message
85.13 STRING3 Stores a message to be used in the Adaptive Program (EVENT block).
MESSAGE3 Message
85.14 STRING4 Stores a message to be used in the Adaptive Program (EVENT block).
MESSAGE4 Message
85.15 STRING5 Stores a message to be used in the Adaptive Program (EVENT block).
MESSAGE5 Message
96 EXTERNAL AO Parameters through which the Adaptive Program can control the optional
analogue outputs of the drive.
96.01 EXT AO1
PARAM 96.11 Source selected by parameter 96.11. 16
96.06 EXT AO2
PARAM 96.12 Source selected by parameter 96.11. 16
96.11 EXT AO1 PTR Selects the source for 96.01.
-255.255.31 … Parameter pointer or constant value. See Parameter 10.04.
+255.255.31 / C.-32768
… C.32767
96.12 EXT AO2 PTR Selects the source for 96.06.
-255.255.31 … Parameter pointer or constant value. See Parameter 10.04.
+255.255.31 / C.-32768
… C.32767
Actual signals and parameters in ACS800 Standard Application Program
39
Customer diagrams
Chapter overview
This chapter includes three blank block diagram sheets on which the Adaptive
Program can be documented.
Customer diagrams
3AFE 64527274 Rev C / EN
EFFECTIVE: 08.04.2005
ABB Oy ABB Inc.
AC Drives Automation Technologies
P.O.Box 184 Drives & Motors
FI-00381 Helsinki 16250 West Glendale Drive
FINLAND New Berlin, WI 53151
Telephone: +358 10 22 11 USA
Fax: +358 10 22 22681 Telephone: 262 785-8378
Internet: http://www.abb.com 800-HELP-365
Fax: 262 780-5135
ABB Drives
User’s Manual
PROFIBUS-DP Adapter Module
RPBA-01
PROFIBUS-DP Adapter Module
RPBA-01
User’s Manual
3AFE 64504215 REV E EN
EFFECTIVE: 13.10.2003
ã 2003 ABB Oy. All Rights Reserved.
5
Safety instructions
Overview
This chapter states the general safety instructions that must be
followed when installing and operating the RPBA-01 PROFIBUS-
DP Adapter module.
The material in this chapter must be studied before attempting any
work on, or with, the unit.
In addition to the safety instructions given below, read the
complete safety instructions of the specific drive you are working
on.
General safety instructions
WARNING! All electrical installation and maintenance work on the
drive should be carried out by qualified electricians.
The drive and adjoining equipment must be properly earthed.
Do not attempt any work on a powered drive. After switching off
the mains, always allow the intermediate circuit capacitors 5
minutes to discharge before working on the frequency converter,
the motor or the motor cable. It is good practice to check (with a
voltage indicating instrument) that the drive is in fact discharged
before beginning work.
The motor cable terminals of the drive are at a dangerously high
voltage when mains power is applied, regardless of motor
operation.
There can be dangerous voltages inside the drive from external
control circuits even when the drive mains power is shut off.
Exercise appropriate care when working on the unit. Neglecting
these instructions can cause physical injury or death.
Safety instructions
6
Safety instructions
7
Table of contents
Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
General safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Table of contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Intended audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Before you start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
What this manual contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Terms used in this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Further information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
PROFIBUS standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
The RPBA-01 PROFIBUS-DP Adapter module . . . . . . . . . . . . . . . . . . . . . . 14
Compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Delivery check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Warranty and liability information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Mechanical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Electrical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
General cabling instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Bus termination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Table of contents
8
Node selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
PROFIBUS connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Configuring the system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
PROFIBUS connection configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Control locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
PROFIBUS-DP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Service Access Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Communication start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
PPO message types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
The Control Word and the Status Word . . . . . . . . . . . . . . . . . . . . . . . . . . 36
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Actual Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Parameter handling in cyclic communication (DP) . . . . . . . . . . . . . . . . . . . . 41
Fault tracing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
LED indications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
PROFIdrive parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Definitions and abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
PROFIBUS definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
PROFIBUS abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
RPBA-01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
PROFIBUS link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Table of contents
9
Introduction
Intended audience
The manual is intended for the people who are responsible for
commissioning and using an RPBA-01 PROFIBUS-DP Adapter
module. The reader is expected to have a basic knowledge of
electrical fundamentals, electrical wiring practices and how to
operate the drive.
Before you start
It is assumed that the drive is installed and ready to operate before
starting the installation of the extension module.
In addition to conventional installation tools, have the drive
manuals available during the installation as they contain important
information not included in this manual. The drive manuals are
referred to at various points of this document.
What this manual contains
This manual contains information on the wiring, configuration and
use of the RPBA-01 PROFIBUS-DP Adapter module.
Safety instructions are featured in the first few pages of this
manual.
Overview contains a short description of the PROFIBUS protocol
and the RPBA-01 PROFIBUS-DP Adapter module, a delivery
checklist, and information on the manufacturer’s warranty.
Mechanical installation contains placing and mounting
instructions for the module.
Electrical installation contains wiring, bus termination and
earthing instructions.
Programming explains how to program the master station and
the drive before the communication through the adapter module
can be started.
Introduction
10
Communication contains a description of how data is
transmitted through the RPBA-01 module.
Fault tracing explains how to trace faults with the status LEDs on
the RPBA-01 module.
PROFIBUS parameters presents the PROFIBUS Profile-specific
parameters.
Definitions and abbreviations explains definitions and
abbreviations concerning the PROFIBUS protocol family.
Technical data contains information on physical dimensions,
configurable settings and connectors of the module and the
specification of the PROFIBUS link.
Introduction
11
Terms used in this manual
Communication Module
Communication Module is a name for a device (e.g. a fieldbus
adapter) through which the drive is connected to an external
communication network (e.g. a fieldbus). The communication with
the module is activated with a drive parameter.
Data Sets and Data Words
Each data set consists of three 16-bit words, ie. data words. The
Control Word (sometimes called the Command Word) and the
Status Word, References and Actual Values (see chapter
Communication) are types of data words; the contents of some
data words are user-definable.
RPBA-01 PROFIBUS-DP Adapter module
The RPBA-01 PROFIBUS-DP Adapter module is one of the
optional fieldbus adapter modules available for ABB drives. The
RPBA-01 is a device through which an ABB drive is connected to
a PROFIBUS network.
Parameter
A parameter is an operating instruction for the drive. Parameters
can be read and programmed with the drive control panel, or
through the RPBA-01 module.
Further information
Further information is available on the World Wide Web from
www.profibus.com.
Introduction
12
Introduction
13
Overview
Overview
This chapter contains a short description of the PROFIBUS
standard and the RPBA-01 Adapter module, a delivery checklist
and warranty information.
PROFIBUS standard
PROFIBUS is an open serial communication standard that
enables data exchange between all kinds of automation
components. There are three main variations of PROFIBUS:
PROFIBUS-FMS (Fieldbus Message Specification), PROFIBUS-
DP (Decentralised Periphery) and PROFIBUS-PA (Process
Automation). The RPBA-01 PROFIBUS-DP Adapter module
supports the PROFIBUS-DP protocol only.
The physical transmission medium of the bus is a twisted pair
cable (according to the RS-485 standard). The maximum length of
the bus cable is 100 to 1200 metres, depending on the selected
transmission rate (see Technical data chapter). Up to 31 nodes
can be connected to the same PROFIBUS network segment
without the use of repeaters. With repeaters, it is possible to
connect 127 nodes (including repeaters and master station) to the
network.
In PROFIBUS communication, the master station – usually a
programmable logic controller (PLC) – polls the nodes which
respond and take the actions requested by the master. It is also
possible to send a command to several nodes at the same
broadcast; in this case the nodes do not send a response
message to the master. Communication between nodes is not
possible on a PROFIBUS network.
The PROFIBUS protocol family is specified in the EN 50170
standard. The communication with a drive is defined in the
PROFIDRIVE-PROFILE – The PROFIBUS Profile for Adjustable
Overview
14
Speed Drives. For further information on PROFIBUS, refer to the
above-mentioned standards.
The RPBA-01 PROFIBUS-DP Adapter module
The RPBA-01 PROFIBUS-DP Adapter module is an optional
device for ABB drives which enables the connection of the drive to
a PROFIBUS network. The drive is considered as a slave on the
PROFIBUS network. Through the RPBA-01 PROFIBUS-DP
Adapter module, it is possible to:
• give control commands to the drive
(Start, Stop, Run enable, etc.)
• feed a motor speed or torque reference to the drive
• give a process actual value or a process reference to the PID
controller of the drive
• read status information and actual values from the drive
• change drive parameter values
• reset a drive fault.
The PROFIBUS commands and services supported by the
RPBA-01 PROFIBUS-DP Adapter module are discussed in
chapter Communication. Please refer to the user documentation
of the drive as to which commands are supported by the drive.
The adapter module is mounted into an option slot on the motor
control board of the drive. See the Hardware Manual of the drive
for module placement options.
The type definition (GSD) file required for configuration of the
master station is available from www.profibus.com or your local
ABB representative. The filename is ABB_0812.GSD.
Overview
15
PROFIBUS Slave Bus connector X1
master stations (see chapter
Electrical installation)
Fixing screw
(GND)
(frame)
DIP switch for
ABB Drive selecting bus
termination
Rotary node
ABB Drive
address
selection switches
Diagnostic LEDs
Top view (See chapter Side view
Fault tracing)
Figure 1. The construction of the PROFIBUS link and the
RPBA-01 Adapter module.
Compatibility
The RPBA-01 is compatible with all master stations that support
the PROFIBUS-DP protocol.
Delivery check
The option package for the RPBA-01 PROFIBUS-DP Adapter
module contains:
• PROFIBUS-DP Adapter module, type RPBA-01
• two screws (M3x10)
• this manual.
Overview
16
Warranty and liability information
The manufacturer warrants the equipment supplied against
defects in design, materials and workmanship for a period of
twelve (12) months after installation or twenty-four (24) months
from date of manufacturing, whichever first occurs. The local ABB
office or distributor may grant a warranty period different to the
above and refer to local terms of liability as defined in the supply
contract.
The manufacturer is not responsible for
• any costs resulting from a failure if the installation,
commissioning, repair, alternation, or ambient conditions of the
drive do not fulfil the requirements specified in the
documentation delivered with the unit and other relevant
documentation
• units subjected to misuse, negligence or accident
• units comprised of materials provided or designs stipulated by
the purchaser.
In no event shall the manufacturer, its suppliers or subcontractors
be liable for special, indirect, incidental or consequential damages,
losses or penalties.
If you have any questions concerning your ABB drive, please
contact the local distributor or ABB office. The technical data,
information and specifications are valid at the time of printing. The
manufacturer reserves the right to modifications without prior
notice.
Overview
17
Mechanical installation
WARNING! Follow the safety instructions given in this manual and
in the Hardware Manual.
Mounting
The RPBA-01 is to be inserted into its specific position in the drive.
The module is held in place with plastic retaining clips and two
screws. The screws also provide the earthing of the I/O cable
shield connected to the module, and interconnect the GND signals
of the module and the control board of the drive.
On installation of the module, the signal and power connection to
the drive is automatically made through a 34-pin connector.
Mounting procedure:
• Insert the module carefully into its position inside the drive until
the retaining clips lock the module into position.
• Fasten the two screws (included) to the stand-offs.
• Set the bus termination switch of the module to the required
position.
Note: Correct installation of the screws is essential for fulfilling the
EMC requirements and for proper operation of the module.
Mechanical installation
18
Mechanical installation
19
Electrical installation
Overview
This chapter contains:
• general cabling instructions
• instructions for setting module node address number and bus
termination
• instructions for connecting the module to the PROFIBUS-DP
network.
WARNING! Before installation, switch off the drive power supply.
Wait five minutes to ensure that the capacitor bank of the drive is
discharged. Switch off all dangerous voltages connected from
external control circuits to the inputs and outputs of the drive.
General cabling instructions
Arrange the bus cables as far away from the motor cables as
possible. Avoid parallel runs. Use bushings at cable entries.
Bus termination
The DIP switch on the front of the RPBA-01 module is used to
switch on bus termination. Bus termination prevents signal
reflections from the cable ends. Bus termination must be set to ON
if the module is the last or first module on the network. When using
PROFIBUS specific D-sub connectors with built-in termination, the
RPBA-01 termination must be switched off.
Electrical installation
20
Note: The built-in termination circuitry of the RPBA-01 is of the
active type, so the module has to be powered for the termination
to work. If the module needs to be switched off during operation of
the network, the bus can be terminated by connecting a 220 ohm,
1/4 W resistor between the A and B lines.
Bus termination OFF Bus termination ON
ON ON
Figure 2. Bus termination switch
Node selection
Use the rotary node address selectors on the module to select the
node address number. The node address number is a decimal
number ranging from 01 to 99. The left selector represents the first
digit and the right selector the second digit. The node address can
be changed during operation, but the module must be re-initialised
for changes to take effect.
Note: When 00 is selected, the node number is defined by a
parameter in the fieldbus parameter group of the drive.
10x 1x
901 901
23
23
78
78
45 6 45 6
Figure 3. Node selectors
Electrical installation
21
PROFIBUS connection
The bus cable is connected to connector X1 on the RPBA-01.
The connector pin allocation described below follows the
PROFIBUS standard.
5 1
X1
9 6
X1 Description
1 Not used
2 Not used
3 B Data positive (Conductor 1 in twisted pair).
4 RTS Request To Send
5 GND Isolated ground
BUS
6 +5V Isolated 5V DC voltage supply
7 Not used
8 A Data negative (Conductor 2 in twisted pair).
9 Not used
Housing SHLD PROFIBUS cable shield. Internally connected
to GND BUS via an RC filter and directly to
CHGND.
+5V and GND BUS are used for bus termination. Some devices,
like optical transceivers (RS485 to fibre optics) might require
external power supply from these pins.
RTS is used in some equipment to determine the direction of
transmission. In normal applications only the line A, line B and
shield are used.
Electrical installation
22
PROFIBUS wiring example
The PROFIBUS cable shields are directly earthed at all nodes.
In the example below a recommended Siemens 6ES7 972-
0BA12-0XA0 connector (not included in the delivery) is connected
to the RPBA-01 module. The cable is a standard PROFIBUS
cable consisting of a twisted pair and screen.
Siemens 6ES7 972-0BA12-0XA0 connector
X1 SHLD X1 SHLD
A 1 A 1
RPBA-01 RPBA-01
B 2 B 2
A 3 A 3
PROFIBUS B 4 B 4
MASTER
A
B
GND
Figure 4. Connection diagram for the standard PROFIBUS cable
Electrical installation
23
Programming
Overview
This chapter gives information on configuring the PROFIBUS
master station and the drive for communication through the
RPBA-01 PROFIBUS-DP Adapter module.
Configuring the system
After the RPBA-01 PROFIBUS-DP Adapter module has been
mechanically and electrically installed according to the instructions
in previous chapters, the master station and the drive must be
prepared for communication with the module.
The type definition (GSD) file required for configuration of the
master station is available from www.profibus.com or your local
ABB representative. The filename is ABB_0812.GSD.
Please refer to the master station documentation for more
information.
PROFIBUS connection configuration
The detailed procedure of activating the module for
communication with the drive is dependent on the drive type.
(Normally, a parameter must be adjusted to activate the
communication. See the drive documentation.)
As communication between the drive and the RPBA-01 is
established, several configuration parameters are copied to the
drive. These parameters – shown below in Table 5 – must be
checked first and adjusted if necessary. The alternative selections
for these parameters are discussed in more detail below the table.
Note: The new settings take effect only when the module is
powered up the next time or when the module receives a ‘Fieldbus
Adapter parameter refresh’ command from the drive.
Programming
24
Data transfer rates supported
The RPBA-01 supports the following PROFIBUS communication
speeds: 9.6 kbit/s, 19.2 kbit/s, 45.45 kbit/s, 93.75 kbit/s, 187.5
kbit/s, 500 kbit/s, 1.5 Mbit/s, 3 Mbit/s, 6 Mbit/s, 12 Mbit/s.
The RPBA-01 automatically detects the communication speed
and PPO-type used.
Table 5. The RPBA-01 configuration parameters.
Par. Parameter name Alternative settings Default
no. setting
1 MODULE TYPE (Read-only) PROFIBUS-DP
2 Node address 0 to 126 3
3 Baud rate (12000) 12 Mbit/s; (6000) 6 Mbit/s; 1500
(3000) 3 Mbit/s; (1500) 1.5 Mbit/s;
(500) 500 kbit/s; (187) 187.5 kbit/s;
(93) 93.75 kbit/s; (45) 45.45 kbit/s;
(19) 19.2 kbit/s; (9) 9.6 kbit/s 1)
4 PPO-type (1) PPO 1; (2) PPO 2; (3) PPO 3; (1) PPO 1
(4) PPO 4; (5) PPO 5; (Read-only) 1)
5 PZD3 OUT 0 to 32767 with format xxyy, where 0
xx = Parameter Group and
yy = Parameter Index.
See description below.
6 PZD3 IN See PZD3 OUT above 0
7 PZD4 OUT See PZD3 OUT above 0
8 PZD4 IN See PZD3 OUT above 0
... ...
19 PZD10 OUT See PZD3 OUT above 0
20 PZD10 IN See PZD3 OUT above 0
1) The value is automatically updated (Read-only).
Programming
25
Note: Set also the extended Parameter Data (see page 31) to
ensure proper operation of the RPBA-01 with the drive.
1 MODULE TYPE
This parameter shows the module type as detected by the drive.
The value cannot be adjusted by the user.
If this parameter is undefined, the communication between the
drive and the module has not been established.
2 Node address
Each device on the PROFIBUS network must have a unique node
number. This parameter is used to define a node number for the
drive it is connected to, if the node address selection switches are
set to the zero position. When the node address selector switches
are used to define the node address (node address selectors not
in zero position) this parameter indicates the set node address.
3 Baud rate
The speed of communication. The value is given in kbit/s:
12000 = 12 Mbit/s
6000 = 6 Mbit/s
3000 = 3 Mbit/s
1500 = 1.5 Mbit/s
500 = 500 kbit/s
187 = 187.5 kbit/s
93 = 93.75 kbit/s
45 = 45.45 kbit/s
19 = 19.2 kbit/s
9 = 9.6 kbit/s
4 PPO-type
This parameter indicates the selected PPO message type for the
PROFIBUS communication. See Figure 6 in chapter
Communication for the supported PPO message types.
Programming
26
5 PZD3 OUT
This parameter represents process data word 3 of the PPO type
received by the drive over the PROFIBUS network. The content is
defined by a decimal number in the range of 0 to 32767 as follows:
0 not used
1 - 99 data set area of the drive
101 - 9999 parameter area of the drive
10000 - 32767 not supported by the drive
The data set area is allocated as follows:
1 data set 1 word 1
2 data set 1 word 2
3 data set 1 word 3
4 data set 2 word 1
5 data set 2 word 2
6 data set 2 word 3
7 data set 3 word 1
...
99 data set 33 word 3
The parameter area is allocated as follows:
Parameter number with format xxyy, where xx is the parameter
group number (1 to 99) and yy is the parameter number index
inside the group (01 to 99).
Programming
27
6 PZD3 IN
Process data word 3 of the PPO type sent from the drive to the
PROFIBUS network.
The content is defined by a decimal number in the range of 0 to
32767. See parameter PZD3 OUT for description of decimal
number allocation.
7 to 20 PZD4 OUT to PZD10 IN
See parameters PZD3 OUT and PZD3 IN.
Control locations
ABB drives can receive control information from multiple sources
including digital inputs, analogue inputs, the drive control panel
and a communication module (e.g. RPBA-01). ABB drives allow
the user to separately determine the source for each type of
control information (Start, Stop, Direction, Reference, Fault Reset,
etc.). In order to give the fieldbus master station the most
complete control over the drive, the communication module must
be selected as source for this information. See the user
documentation of the drive for information on the selection
parameters.
Programming
28
Programming
29
Communication
Overview
This chapter describes the PROFIBUS messaging used in the
communication with the drive.
PROFIBUS-DP
The RPBA-01 module supports the PROFIBUS-DP protocol
according to EN 50170 standard. PROFIBUS-DP is a distributed
I/O system which enables the master to use a large number of
peripheral modules and field devices. The data transfer is mainly
cyclic: the master reads the input information from the slaves and
sends the output information back to the slaves.
The PROFIBUS-DP protocol uses so-called PPOs
(Parameter/Process Data Objects) in cyclic communication. See
Figure 6 for the different PPO types and their composition.
Service Access Points
The services of the PROFIBUS Data Link Layer (Layer 2) are
used by PROFIBUS-DP through Service Access Points (SAPs).
Precisely defined functions are assigned to individual SAPs.
For further information on Service Access Points, refer to the
manual of the PROFIBUS master, PROFIDRIVE – The
PROFIBUS Profile for Adjustable Speed Drives, or the EN 50170
standard.
Communication
30
Communication start-up
The following Service Access Points (SAPs) are used to initiate
DP communication:
SAP no. Short Name Name
61 Set_Prm Send Parameter Data
62 Chk_Cfg Check Configuration Data
60 Slave_Diag Read Slave Diagnostic
128 Data_Exch Transfer Input and Output Data
SAP 61 (Set_Prm)
This SAP is used in the parameterisation of the drive.
Prm_Data (Parameter Data Standard)
Type: Octet String - Length: 8
Byte Value Description
0 B8h Station_Status
1 0 1 1 1 0 0 0
Reserved
WD_On
1 = Watchdog on
Freeze_Req
1 = Slave is requested to process in freeze mode
Sync_Req
1 = Slave is requested to process in SYNC mode
00 = Min TSDR and slave-related
Unlock_Req parameters may be overwritten
10 = Slave locked for other masters. All
Lock_Req parameters can be carried over
x1 = Slave released for other masters
1-2 Watchdog Factors 1 and 2 (set by the PROFIBUS master)
WdFactor1 × WdFactor2 × 10 ms = monitoring time of the
slave to verify that the master is still active.
3 0Bh Minimum Station Delay Respond Time
Time after which a slave station is allowed to send response
frames to the master. Calculated by multiplying the Hex
value with tBit (time required for transmitting one bit).
4-5 0812h Vendor Identification (for the RPBA-01: 0812h)
6 00h Group Identification
7 - Reserved
Communication
31
Prm_Data (Parameter Data Extended)
Type: Octet String - Length: 23
8 10h Header byte
(default) 0 0 0 1 0 0 0 0
Fail-safe mode. Defines the action taken when the PLC
is switched from ‘RUN’ to ‘STOP’ mode.
00 = STOP (default)
01 = LAST SPEED
02 = USE FAIL-SAFE. The values of the PZDs are
defined by bytes 11-30 in the Prm_Data telegram.
Control zero mode. Defines the action taken if a
PROFIBUS telegram containing only zeros is received.
00 = USE FRAME (default). Note that, with this setting,
the drive might not be stopped (if it is running) since
also bit 10 (Remote Command) in the control word
is zero. However, the other PZD’s may still be
updated, but have the value zero.
01 = IGNORE
Operation mode. Determines which control/status word
and reference/actual values are used.
00 = PROFIDRIVE (i.e. Generic drive profile)
01 = VENDOR SPECIFIC (i.e. ABB Drives profile)
(default). With this setting,
• Fail-safe mode ‘STOP’ equals ‘LAST SPEED’
• the control word is forwarded unchanged to the
drive
• if the drive has a parameter for selection of
operation mode (i.e. communication profile),
make sure that the operation modes of the
RPBA-01 and the drive match.
Reserved
9 - 10 0-65536 Cut off time out in milliseconds.
11 - 12 0-65536 Fail-safe, PZD1 (CW)
13 - 14 0-65536 Fail-safe, PZD2 (REF)
15 - 16 0-65536 Fail-safe, PZD3
17 - 18 0-65536 Fail-safe, PZD4
19 - 20 0-65536 Fail-safe, PZD5
21 - 22 0-65536 Fail-safe, PZD6
23 - 24 0-65536 Fail-safe, PZD7
25 - 26 0-65536 Fail-safe, PZD8
Communication
32
27 - 28 0-65536 Fail-safe, PZD9
29 - 30 0-65536 Fail-safe, PZD10
The extended Parameter Data bytes are configured via the
PROFIBUS network configuration tool. The functions are defined
in the GSD file.
SAP 62 (Chk_Cfg)
SAP 62 selects the PPO type to be used. The table below gives
the Hex frame that must be sent to the drive to select the PPO
type.
Cfg_Data (Configuration Data)
Type: Octet String - Length: 1 to 32
PPO Type Hex Frame
1 F3 F1
2 F3 F5
3 F1
4 F5
5 F3 F9
Communication
33
SAP 60 (Slave_Diag)
This SAP gives diagnostic information on the slave station.
Diag_Data (Diagnostic Data)
Type: Octet String - Length: 6 (Standard) + 2 (Extended Diagnosis)
Byte Description
1 Station_Status_1
x x x x x x x x
Diag.Station_Non_Existent (Set by Master, reset by Slave)
Slave not found
Diag.Stagion_Not_Ready (Set by Slave)
Slave not ready for data exchange
Diag.Cfg_Fault (Set by Slave)
Received configuration data does not match original configuration data
Diag.Ext_Diag (Set by Slave)
Diagnostic entry present in slave-specific diagnostic area
Diag.Not_Supported (Set by Slave)
Service not supported by slave
Diag.Invalid_Slave_Response (Set by Master, reset by Slave)
Invalid response by slave
Diag.Prm_Fault (Set by Slave)
Invalid parameter or parameter value
Diag.Master_Lock (Set by Master, reset by Slave)
Slave is parameterised by another master
2 Station_Status_2
x 0 x x x 1 x x
Diag.Prm_Req (Set by Slave)
Slave requires re-configuration and re-parameterisation
Diag.Stat_Diag (Set by Slave)
Static diagnosis. Slave (temporarily) unable to provide valid
data
Always set to 1 by slave
Diag.WD_On (Set by Slave)
Watchdog on
Diag.Freeze_Mode (Set by Slave)
Freeze command received by slave
Diag.Sync_Mode (Set by Slave)
Sync command received by slave
Reserved
Diag.Deactivated (Set by Master, reset by Slave)
Slave is inacive
Communication
34
Diag_Data (Diagnostic Data)
Type: Octet String - Length: 6 (Standard) + 2 (Extended Diagnosis)
Byte Description
3 Station_Status_3
x 0 0 0 0 0 0 0
Reserved
Diag.Ext_Diag_Overflow (Set by Slave)
4 Diag.Master_Add
The address of the master that parameterised this slave
5 - 6 Ident_Number (for RPBA-01: 0812h)
7 Ext_Diag_Data
The number of bytes reserved for Extended Diagnosis
(including this byte)
Fixed to 2
8 Ext_Diag_Data
Bit 0 = Communication temporarily lost
Bit 1 = Communication permanently lost
Bit 2 - 7 = Not used
SAP 128 (Data_Exchange)
Allows the master to send output data to a slave station and to
simultaneously request input data from the same station.
Outp_Data (Output Data)
Type: Octet String - Length: 0 to 32 (depending on the selected PPO Type)
Inp_Data (Input Data)
Type: Octet String - Length: 0 to 32 (depending on the selected PPO Type)
Communication
35
PPO message types
Parameter Process data
Fixed area Freely mappable area
identification
DW1.1 DW1.2 DW1.3 DW3.1 DW3.2 DW3.3 DW5.1 DW5.2 DW5.3 DW7.1
OUT area IND VALUE CW REF PZD3 PZD4 PZD5 PZD6 PZD7 PZD8 PZD9 PZD10
IN area ID IND VALUE SW ACT PZD3 PZD4 PZD5 PZD6 PZD7 PZD8 PZD9 PZD10
DW2.1 DW2.2 DW2.3 DW4.1 DW4.2 DW4.3 DW6.1 DW6.2 DW6.3 DW8.1
Type 1
Type 2
Type 3
Type 4
Type 5
OUT area – Data sent from Master to Slave (control data)
IN area – Data sent from Slave to Master (actual data)
Parameter Identification:
ID – Parameter Identification
IND – Index for Arrays
VALUE – Parameter Value (Max. 4 bytes)
Process Data:
CW – Control Word (see Table 7.)
SW – Status Word (see Table 8.)
REF – Reference
ACT – Actual Value
PZD – Process Data (application-specific)
DS – Data Set
DW – Data Word
Figure 6. PPO message types
Communication
36
The Control Word and the Status Word
The Control Word (PROFIBUS Parameter 967) is the principal
means for controlling the drive from a fieldbus system. It is sent by
the fieldbus master station to the drive, the adapter module acting
as a gateway. The drive switches between its states according to
the bit-coded instructions on the Control Word, and returns status
information to the master in the Status Word (PROFIBUS
Parameter 968).
The contents of the Control Word and the Status Word are
detailed in Tables 7 and 8 respectively; see the drive
documentation for information on the drive-specific bits. The drive
states are presented in the PROFIBUS State Machine (Figure 9).
References
References are 16-bit words containing a sign bit and a 15-bit
integer. A negative reference (indicating reversed direction of
rotation) is formed by calculating the two’s complement from the
corresponding positive reference.
ABB drives can receive control information from multiple sources
including analogue and digital inputs, the drive control panel and a
communication module (e.g. RPBA-01). In order to have the drive
controlled through PROFIBUS, the communication module must
be defined as the source for control information, e.g. Reference.
In the Vendor Specific mode, the scaling of the integer received
from the master as Reference is drive-specific. See its
programming manual for available control source selections and
Reference scaling factors.
In PROFIdrive mode, the speed reference (REF) in hexadecimal
(0…4000h) corresponds to 0…‘motor nominal speed’.
Actual Values
Actual Values are 16-bit words containing information on the
operation of the drive. The functions to be monitored are selected
by a drive parameter. The scaling of the integers sent to the
Communication
37
master as Actual Values depends on the selected function, refer to
the drive documentation.
In PROFIdrive mode, the actual speed (ACT) in hexadecimal
(0…4000h) corresponds to 0…‘motor nominal speed’.
Table 7. The Control Word (PROFIBUS Parameter 967). The
upper case boldface text refers to the states shown in Figure 9.
Bit Name Value Proceed to STATE/Description
0 ON 1 Proceed to READY TO OPERATE
OFF1 0 Emergency OFF, stop by the selected deceleration ramp.
Proceed to OFF1 ACTIVE; proceed further to READY
TO SWITCH ON unless other interlocks (OFF2, OFF3)
are active
1 OFF2 1 Continue operation (OFF2 inactive)
0 Emergency OFF, coast to stop.
Proceed to OFF2 ACTIVE; proceed further to SWITCH-
ON INHIBIT
2 OFF3 1 Continue operation (OFF3 inactive)
0 Emergency stop, stop according to fastest possible
deceleration mode. Proceed to OFF3 ACTIVE; proceed
further to SWITCH-ON INHIBIT. Warning: Ensure motor
and driven machine can be stopped using this stop
mode.
3 OPERATION_ 1 Proceed to ENABLE OPERATION
ENABLE
0 Inhibit operation. Proceed to OPERATION INHIBIT
4 RAMP_OUT_ 1 Normal operation.
ZERO Proceed to RAMP FUNCTION GENERATOR: ENABLE
OUTPUT
0 Stop according to selected stop type
5 RAMP_HOLD 1 Normal operation.
Proceed to RAMP FUNCTION GENERATOR: ENABLE
ACCELERATOR
0 Halt ramping (Ramp Function Generator output held)
Communication
38
Bit Name Value Proceed to STATE/Description
6 RAMP_IN_ 1 Normal operation. Proceed to OPERATING
ZERO
0 Force Ramp Function Generator input to zero
7 RESET 0 Þ 1 Fault reset if an active fault exists. Proceed to SWITCH-
ON INHIBIT.
0 (Continue normal operation)
8 INCHING_1 Inching 1. (See the drive documentation for information)
9 INCHING_2 Inching 2. (See the drive documentation for information)
10 REMOTE_ 1 Fieldbus control enabled
CMD 0 Control Word <> 0 or Reference <> 0: Retain last Control
Word and Reference
Control Word = 0 and Reference = 0: Fieldbus control
enabled
11 Drive-specific. (See the drive documentation for
to information)
15
Table 8. The Status Word (PROFIBUS Parameter 968). The upper
case boldface text refers to the states shown in Figure 9.
Bit Name Value STATE/Description
0 RDY_ON 1 READY TO SWITCH ON
0 NOT READY TO SWITCH ON
1 RDY_RUN 1 READY TO OPERATE
0 OFF1 ACTIVE
2 RDY_REF 1 ENABLE OPERATION
0 DISABLE OPERATION
3 TRIPPED 1 FAULT
0 No fault
4 OFF_2_STA 1 OFF2 inactive
0 OFF2 ACTIVE
Communication
39
Bit Name Value STATE/Description
5 OFF_3_STA 1 OFF3 inactive
0 OFF3 ACTIVE
6 SWC_ON_INHIB 1 SWITCH-ON INHIBIT ACTIVE
0 SWITCH-ON INHIBIT NOT ACTIVE
7 ALARM 1 Warning/Alarm
0 No Warning/Alarm
8 AT_SETPOINT 1 OPERATING. Actual value equals reference value
(i.e. is within tolerance limits)
0 Actual value differs from reference value
(= is outside tolerance limits)
9 REMOTE 1 Drive control location: REMOTE
0 Drive control location: LOCAL
10 ABOVE_LIMIT 1 Actual frequency or speed value equals or is greater
than supervision limit.
0 Actual frequency or speed value is within supervision
limit.
11 Drive-specific
to
15
Communication
40
SWITCH-ON
MAINS OFF INHIBIT (SW Bit6=1)
Power ON OFF1 (CW Bit0=0)
PROFIBUS
State Machine
NOT READY
TO SWITCH ON (SW Bit0=0) CW = Control Word
A B C D
SW = Status Word
n = Speed
(CW=xxxx xxxx xxxx x110) I = Input Current
(CW Bit3=0) RFG = Ramp Function
Generator
READY TO
SWITCH ON f = Frequency
OPERATION (SW Bit0=1)
INHIBIT (SW Bit2=0)
from any state
operation ON (CW=xxxx xxxx xxxx x111)
inhibited
Fault
READY TO Main contactor ON FAULT
OPERATE (SW Bit1=1) (SW Bit3=1)
from any state
(CW Bit7=1)
OFF1 (CW Bit0=0)
OFF1 from any state from any state
ACTIVE (SW Bit1=0) Emergency Stop Emergency Stop
Enable operation OFF3 (CW Bit2=0) OFF2 (CW Bit1=0)
n(f)=0 / I=0 (CW Bit3=1) OFF3 OFF2
ACTIVE (SW Bit5=0) ACTIVE (SW Bit4=0)
B C D
n(f)=0 / I=0
Main contactor OFF
(CW Bit4=0)
C D ENABLE
OPERATION (SW Bit2=1)
A (CW Bit4=0 Bit5=0 Bit6=0)
(CW Bit5=0) (CW Bit4=1)
Inching 1 or 2 ON
(CW Bit8=1 or Bit9=1)
D RFG: ENABLE
OUTPUT INCHING 1
B or
(CW Bit6=0) (CW Bit5=1) INCHING 2
ACTIVE
RFG: ENABLE Inching 1 or 2 OFF
state ACCELERATION (CW Bit8=0 or Bit9=0)
C
(CW Bit6=1) Inching pause
condition
rising edge OPERATING ‘n=0 or f =0’ and ‘I=0’
of the bit (SW Bit8=1) and inching pause expired
D
Figure 9. The PROFIBUS state machine
Communication
41
Parameter handling in cyclic communication (DP)
In cyclic PROFIBUS-DP communication, parameter data is
transferred in PPO message types 1, 2 and 5 (see Figure 6.). The
Parameter Identification part consists of eight bytes (see below).
Parameter
Identification Process Data
CW REF
ID IND VALUE SW ACT (PD1, PD2...)
15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0
Request Label
Response Label Parameter Number (PNU)
*Request Signal
*Not used (=0)
The Request Label is used by the master when transmitting data
to the slave, while the Response Label is used by the slave as a
positive or negative acknowledgement. The tables below show the
Request/Response functions.
Request labels (from Master to Slave)
Request Function Response labels
Ackn. (+) Ackn. (-)
0 No task 0 –
1 Request parameter value 1, 2 7
2 Change parameter value (word) 1 7, 8
3 Change parameter value (double word) 2 7, 8
4 Request description element 3 7
5 Change description element 3 7, 8
6 Request parameter value (array) 4, 5 7, 8
7 Change parameter value (array word) 4 7, 8
8 Change parameter value (array double word) 5 7,8
9 Request number of array elements 6 7
Communication
42
Response label (Acknowledgement from Slave to Master)
Ackn. Function
0 No response
1 Transfer parameter value (word)
2 Transfer parameter value (double word)
3 Transfer description element
4 Transfer parameter value (array word)
5 Transfer parameter value (array double word)
6 Transfer number of array elements
7 Task cannot be executed, followed by error number
0 = Illegal parameter number
1 = Parameter value cannot be changed
2 = Lower or upper limit violated
3 = Erroneous subindex
4 = No array
5 = Incorrect data type
6 = Setting not allowed (can only be reset)
7 = Descriptive element cannot be changed
9 = Descriptive data not available
11 = No parameter change rights
15 = Text array not available
17 = Task cannot be executed due to operating status
(e.g. parameter is currently read-only)
18 = Other error
101 = Vendor specific error
102 = Request not supported
103 = Request cannot be completed due to communication error
110 = Failure during write to non-volatile memory
111 = Request aborted due to time-out
120 = Parameter cannot be mapped to PZD
(size mismatch or non-existent)
121 = Parameter cannot be mapped to PZD.
123 = Parameter cannot be mapped to PZD.
130 = Cannot map Control Word bit (parameter 933 - 937,
e.g. double mapping of bits)
140 = Cannot change mode to TORQUE (frequency is used)
8 No parameter change rights for PKW interface
9 Parameter data signal (word)
10 Parameter data signal (double word)
Communication
43
The allocation of data sets, drive parameters and PROFIdrive
parameters to the Parameter Identification part of the PPO type is
shown below. The Index column corresponds to the parameter
number (PNU) in the ID part of Parameter Identification. The Sub-
index column corresponds to the IND part of Parameter
Identification. The Example No. column refers to the examples on
the following pages.
Data set area
Range Example
Index Sub-index Request Label
(Decimal) No.
0h 1h 1
0h 2h 2
R/W 6/7 1, 2
•••
0h 63h 99
Drive parameters
Range Example
Index Sub-index Request Label
(Decimal) No.
0h 65h 101
0h 66h 102
R/W 6/7 1, 2
•••
27h 0Fh 9999
Communication
44
PROFIdrive parameters
Range Example
Index Sub-index Request Label
(Decimal) No.
2h 2
3h 3
393h 915 R/W 6/7 6
••• •••
9h 9
2h 2
3h 3
394h 916 R/W 6/7 7
••• •••
9h 9
396h 0h 918 R/W 1/2 3, 4
•••
0h 1
9h 9
11h 17
3B3h 947 R 6 5
19h 25
21h 33
29h 41
•••
3CCh 0h 972 R/W 1/2 3,4
The complete PROFIdrive parameter list for the RPBA-01 can be
found as a separate chapter elsewhere in this manual.
Note: Continuous (cyclic) writing of PROFIdrive parameters
should be avoided as the values of these parameters are stored in
the flash memory of the RPBA-01. The estimated lifetime of the
flash memory is 1,000,000 program/erase cycles, and continuous
writing will cause the memory to fail prematurely.
Communication
45
Example 1: Reading a drive parameter (or data set)
To determine the parameter number and subindex for drive
parameter reading, multiply the parameter number by one
hundred and then convert it to hexadecimal. The low byte is the
subindex (IND), and the high byte is the parameter number (PNU).
For example reading parameter 84.11 INPUT 1 from the drive:
84.11 × 100 = 8411 = 20DB Hex.
Parameter number is 20 and subindex is DB.
Request (Read parameter value [array])
Parameter Number (20 Hex)
Subindex (DB Hex)*
CW REF PZD3 PZD4 PZD5 PZD6
Req 60 20 DB 00 00 00 00 00 04 7F 34 15 00 00 00 00 00 00 00 00
Resp 60 20 DB 00 00 00 00 64 03 37 34 15 00 00 00 00 00 00 00 00
SW ACT PZD3 PZD4 PZD5 PZD6
Parameter Value (100 Dec)
Subindex (DB Hex)*
Parameter Number (20 Hex)
Response (Change parameter value [array])
*2nd byte reserved
Communication
46
Example 2: Writing a drive parameter (or data set)
To determine the parameter number and subindex for drive
parameter writing, multiply the parameter number by one hundred
and then convert it to hexadecimal. The low byte is the subindex
(IND), and the high byte is the parameter number (PNU). For
example write parameter 12.02 CONSTANT SPEED.1:
12.02 × 100 = 1202 = 04B2 Hex.
Parameter is 04 and subindex is 2B.
Request (Change parameter value [array])
Parameter Number (04 Hex)
Subindex (B2 Hex)*
Parameter Value (100 Dec)
CW REF PZD3 PZD4 PZD5 PZD6
Req 70 04 B2 00 00 00 00 64 04 7F 34 15 00 00 00 00 00 00 00 00
Resp 40 04 B2 00 00 00 00 64 03 37 34 15 00 00 00 00 00 00 00 00
SW ACT PZD3 PZD4 PZD5 PZD6
Parameter Value (100 Dec)
Subindex (B2 Hex)*
Parameter Number (04 Hex)
Response (Transfer parameter value [array])
*2nd byte reserved
Communication
47
Example 3: Reading a PROFIdrive parameter (word)
In this example, PROFIBUS Parameter No. 918 is used to read
the station number of the slave.
Request (Parameter value read)
Parameter Number (918 Dec)
IND Param. Value CW REF
Request 13 96 00 00 00 00 00 00 04 7F 34 15
Read:
Response 13 96 00 00 00 00 00 02 03 37 34 15
IND Param. Value SW ACT
Parameter Number (918 Dec)
Response (Parameter value updated)
The slave returns its station number (2).
Communication
48
Example 4: Writing a PROFIdrive parameter (word)
In this example, current parameter settings are saved to the
FLASH memory of the drive. This is done by setting the value of
PROFIBUS Parameter No. 971 (3CBh) to 1.
Note that the drive always observes the Control Word (CW)
and Reference (REF) bytes. The values shown below are
examples.
Request (Parameter value write)
Parameter Number (971 Dec)
IND Param. Value CW REF
Request 23 CB 00 00 00 00 00 01 04 7F 34 15
Write:
Response 13 CB 00 00 00 00 00 00 03 37 34 15
IND Param. Value SW ACT
Parameter Number (971 Dec)
Response (Parameter value updated)
Communication
49
Example 5: Reading a PROFIdrive parameter (array)
In this example, PROFIBUS Parameter No. 947 is used to read
the code of the latest acknowledged fault. As shown in Table 10
on page 57, parameter 945 is of the array type with subindexes 1,
9, 17 and 25.
Request (Request parameter value [array])
Parameter Number (945 Dec)
Subindex (Latest acknowledged fault)*
Param. Value CW REF
Request 63 B1 09 00 00 00 00 00 04 7F 34 15
Read:
Response 43 B1 09 00 00 00 23 00 03 37 34 15
Param. Value SW ACT
Subindex (Latest acknowledged fault)*
Parameter Number (945 Dec)
Response (Transfer parameter value [array])
*2nd byte reserved
The slave returns the code of the latest acknowledged fault
(2300h). The fault codes are according to the DRIVECOM
standard. See also the User’s Manual of the drive for drive specific
fault codes.
The implementation of the PROFIdrive profile in the RPBA-01
supports the storage of the active and the five latest occurred
different faults in the fault buffer. The fault codes can be accessed
by PROFIdrive parameters 945, 947 and 948 (see Table 10 on
page 55). The value zero indicates no fault. The subindexes of
these parameters are related to each other, i.e. parameter 945
with subindex 1 relates to subindex of parameter 947 and 948. For
an explanation on the subindexes, refer to Table 10 on page 55.
Communication
50
Example 6: Configuring the process data written to the drive
PROFIBUS parameter 915 can be used to define which data is
written cyclically to a drive parameter as application-specific
process data.
In the example below, the value of drive parameter
12.02 CONSTANT SPEED 1 (4B2h) is selected to be taken from
PZD3. The parameter will continue to be updated with the
contents of PZD3 in each Request frame until a different selection
is made.
Subindex (IND) defines which process data word the required
data is taken from. Parameter Value selects the drive parameter to
which that word is mapped.
Request (Change parameter value [array])
Parameter Number (915 Dec)
Subindex (03 = PZD3)*
Parameter Value (104 Dec)
CW REF PZD3 PZD4 PZD5 PZD6
Req 73 93 03 00 00 00 04 B2 04 7F 34 15 00 00 00 00 00 00 00 00
Resp 43 93 03 00 00 00 04 B2 03 37 34 15 00 00 00 00 00 00 00 00
SW ACT PZD3 PZD4 PZD5 PZD6
Parameter Value (104 Dec)
Subindex (03 = PZD3)*
Parameter Number (915 Dec)
Response (Transfer parameter value [array])
*2nd byte reserved
Subsequently, the contents of PZD3 in each Request frame are
written to drive parameter 12.02 CONSTANT SPEED 1 until a
different selection is made.
Communication
51
Example 7: Configuring the process data read from the drive
PROFIBUS Parameter No. 916 can be used to define which data
is read cyclically from the drive as application-specific process
data.
In the example below, drive parameter 1.04 CURRENT (68h) is
selected to be transmitted by the drive as PZD3. The selection is
in force until it is superseded by another selection.
Subindex (IND) defines which process data word the required
data is transmitted in, and Parameter Value defines which drive
parameter is mapped to that word.
Request (Change parameter value [array])
Parameter Number (916 Dec)
Subindex (03 = PZD3)*
Parameter Value (104 Dec)
CW REF PZD3 PZD4 PZD5 PZD6
Req 73 94 03 00 00 00 00 68 04 7F 34 15 00 00 00 00 00 00 00 00
Resp 43 94 03 00 00 00 00 68 03 37 34 15 00 00 00 00 00 00 00 00
SW ACT PZD3 PZD4 PZD5 PZD6
Parameter Value (104 Dec)
Subindex (03 = PZD3)*
Parameter Number (916 Dec)
Response (Transfer parameter value [array])
*2nd byte reserved
Subsequent response frames:
Resp xx xx xx xx xx xx xx xx xx xx xx xx 00 0B xx xx xx xx xx xx
PZD3 (Value of Drive Parameter 1.04)
Communication
52
Communication
53
Fault tracing
LED indications
The RPBA-01 module is equipped with three diagnostic LEDs.
The description of the LEDs is below.
Host
ERROR
Indication
Off-line On-line
Name Colour Function
Flashing 1 Hz - Error in configuration:
Internal configuration mismatch.
Flashing 2 Hz - Error in User Parameter data:
The length/contents of the User Parameter data
ERROR
set during initialisation of the module is not equal
Red
to the length/contents set during configuration of
the network.
Flashing 4 Hz - Error in initialisation of the
PROFIBUS communication ASIC.
Off - No diagnostics present
Lit - Module is On-Line and data exchange is
Off-Line On-Line
Green possible.
Off - Module is not On-Line
Lit - Module is Off-Line and no data exchange is
Red possible.
Off - Module is not Off-Line
Fault tracing
54
Host
ERROR
Indication
Off-line On-line
Name Colour Function
Host Indication
Green Lit - Link functional
Lit - Link lost permanently
Red
Flashing - Link lost temporarily
Fault tracing
55
PROFIdrive parameters
Table 10. PROFIdrive profile-specific parameters.
Para- R/W* Data type Description
meter
915 R/W Array [10] Unsigned16 Assignment PZD1 to PZD10 in PPO-write
916 R/W Array [10] Unsigned16 Assignment PZD1 to PZD10 in PPO-read
918 R/W Unsigned16 Node address. Writing this parameter will
change the node address if the rotary
switches have the setting 0. Module re-
start required.
919 R Octet String4 Device system number.
927 R/W Unsigned16 Operator control rights (parameter
identification, PKW).
Value Mode
0 Parameters cannot be
written, only read (927 can
be written)
1 Parameters can be written
and read (default).
928 R/W Unsigned16 Control rights (process data, PZD).
Value Mode
0 PZD part is disabled, i.e.
Receipt of new PZD data is
ignored
1 PZD part is enabled
(default).
929 R Unsigned16 Selected PPO-type
Value PPO-type Configuration
1 PPO1 F3h, F1h
2 PPO2 F3h, F5h
3 PPO3 F1h
4 PPO4 F5h
5 PPO5 F3h, F9h
PROFIdrive parameters
56
Para- R/W* Data type Description
meter
930 R/W Unsigned16 Selection switch for operation mode.
Value Mode
1 Speed control mode: Control
word and status word for
frequency/speed used.
8001h Speed control mode: Control
word and status word for
torque used.
933 R/W Unsigned16 Selection switch for Control word, bit 11.
Value Inverter Control word bit
0 Not in use
1 to 5 Vendor specific 1 to 5*
* function defined by drive application
software
934 R/W Unsigned16 Selection switch for Control word, bit 12.
(See parameter 933 for coding)
935 R/W Unsigned16 Selection switch for Control word, bit 13.
(See parameter 933 for coding)
936 R/W Unsigned16 Selection switch for Control word, bit 14.
(See parameter 933 for coding)
937 R/W Unsigned16 Selection switch for Control word, bit 15.
(See parameter 933 for coding)
939 R/W Unsigned16 Selection switch for Status word, bit 11.
Value Inverter Control word bit
0 Not in use
1 to 3 Vendor specific 1 to 3*
* function defined by drive application
software
940 R/W Unsigned16 Selection switch for Status word, bit 12.
(See parameter 939 for coding)
941 R/W Unsigned16 Selection switch for Status word, bit 13.
(See parameter 939 for coding)
942 R/W Unsigned16 Selection switch for Status word, bit 14.
(See parameter 939 for coding)
PROFIdrive parameters
57
Para- R/W* Data type Description
meter
943 R/W Unsigned16 Selection switch for Status word, bit 15.
(See parameter 939 for coding)
945 R Array[64] Unsigned16 Fault code (coded according to
DRIVECOM profile).
Subindex Contents
1 Active fault
9 **Last ackn. fault
17 **Second last ackn. fault
25 **Third last ackn. fault
33 **Fourth last ackn. fault
41 **Fifth last ackn. fault
947 R Array [64] Unsigned16 Fault number.
Subindex Contents
See parameter 945.
948 R Array [64] Unsigned16 Time difference. Seconds since the last
fault occured.
Subindex Contents
See parameter 945.
952 R/W Unsigned16 Number of faults occured. Writing a zero
clears the value.
953 R Unsigned16 **Last alarm
954 R Unsigned16 **Second last alarm
955 R Unsigned16 **Third last alarm
956 R Unsigned16 **Fourth last alarm
957 R Unsigned16 **Fifth last alarm
958 R Unsigned16 Sixth last alarm (not supported)
959 R Unsigned16 Seventh last alarm (not supported)
960 R Unsigned16 Eighth last alarm (not supported)
961 R Octet String4 Hardware configuration (manufacturer
specific ID of the drive)
PROFIdrive parameters
58
Para- R/W* Data type Description
meter
963 R Unsigned16 Detected baud rate:
0 = 12 Mbit/s
1 = 6 Mbit/s
2 = 3 Mbit/s
3 = 1.5 Mbit/s
4 = 500 kbit/s
5 = 187.5 kbit/s
6 = 93.75 kbit/s
7 = 45.45 kbit/s
8 = 19.2 kbit/s
9 = 9.6 kbit/s
255 = Invalid baud rate
964 R Unsigned16 Identification number of this device
(0812h)
965 R Octet String2 Profile number of this device (0302h)
Profile 3, Version 2
967 R Unsigned16 Control word (CW)
968 R Unsigned16 Status word (SW)
970 R/W Unsigned16 Load parameter record
Value Description
0 No action
1 Restore factory settings
The parameter must do a zero-to-one
transition and the motor must be stopped.
971 R/W Unsigned16 Save parameter record
Value Description
0 No action
1 Save the drive parameters
to non-volatile memory
The parameter must do a zero-to-one
transition and the motor must be stopped.
PROFIdrive parameters
59
Para- R/W* Data type Description
meter
972 R/W Unsigned16 Software reset
Value Description
0 No action
1 Re-boot PROFIBUS module
The parameter must do a zero-to-one
transition and the motor must be stopped.
* Read and/or Write
** Support depends on drive type
PROFIdrive parameters
60
PROFIdrive parameters
61
Definitions and abbreviations
PROFIBUS definitions
Acyclic Communication in which messages are sent only once
Communication on request
Array Parameter consisting of data fields of equal data type
Broadcast Non-acknowledged message from master to all bus
participants (compare Multicast)
Command Word See Control Word
Communication Any object of a real device that can be communicated
Object with (variable, program, data range, etc.). Stored locally
in the Object Dictionary.
Control Word 16-bit word from master to slave with bit-coded control
signals (sometimes called the Command Word).
Cyclic Communication in which Parameter-/Process Data-
Communication Objects are sent cyclically at pre-defined intervals
Device Class Classification according to the number of profile
functions included in the device
Drivecast Broad- and Multicast, a special message frame for
drives
Fault Event that leads to tripping of the device
GSD File ASCII-format device description file in a specified form.
Each device (active & passive stations) on PROFIBUS
has to have its own GSD File.
Index Access reference for Objects in PROFIBUS
Information Report Non-acknowledged message from master to one or all
groups of bus participants
Definitions and abbreviations
62
Master Control system with bus initiative. In PROFIBUS
terminology, master stations are also called active
stations.
Multicast Non-acknowledged message from master to one group
of bus participants (compare Broadcast)
Name Symbolic name of a parameter
Nibble Set of 4 bits
Object Dictionary Local storage of all Communication Objects recognised
by a device
Object List List of all accessible objects
Parameter Value that can be accessed as Object, e.g. variable,
constant, signal
Parameter Number Parameter address
Parameter/Process Special object that contains Parameter and Process
Data Object Data
Process Data Data that contains Control Word and Reference value
or Status Word and Actual value. May also contain
other (user-definable) control information.
Profile Adaptation of the protocol for certain application field,
e.g. drives
Request Label Coded information specifying the required service for
the parameter part sent from master to slave
Response Label Coded information specifying the required service for
the parameter part sent from slave to master
Slave Passive bus participant. In PROFIBUS terminology,
slave stations (or slaves) are also called passive
stations. Also referred to as node.
Status Word 16-bit word from slave to master with bit-coded status
messages
Definitions and abbreviations
63
Warning Signal caused by an existing alarm which does not lead
to tripping of the device
PROFIBUS abbreviations
The text in italics is the original German term.
.con Confirmation
.ind Indication
.req Request
.res Response
ACT Actual Value
Istwert
AK Request Label/Response Label
Auftragskennung/Antwortkennung
ALI Application Layer Interface
CR Communication Reference
Kommunikationsreferenz (Kommunikationsbeziehung)
DP Decentralised Periphery
Dezentrale Peripherie
DP-ALI Application Layer Interface for DP
DPV1 PROFIBUS-DP Extensions to the EN 50170 standard,
including e.g. acyclic data exchange
FDL Fieldbus Data Link
FMS Fieldbus Message Specification
FSU Manufacturer Specific Interface
Firmenspezifischer Umsetzer
HIW Main Actual Value
Hauptistwert
HSW Main Reference
Hauptsollwert
Definitions and abbreviations
64
ISW see ACT
KR (KB) see CR
PA Process Automation
Prozessautomatisierung
PD Process Data
Prozessdaten
PKE Parameter Identification
Parameter-Kennung
PKW Parameter Identification Value
Parameter-Kennung-Wert
PNU Parameter Number
Parameternummer
PPO Parameter/Process Data Object
Parameter-/Prozessdaten-Objekt
PWE Parameter Value
Parameter-Wert
PZD see PD
PZDO Process Data Object
Prozessdatenobjekt
SAP Service Access Point
SOW Reference
Sollwert
SPM Request Signal
Spontanmeldung
STW Control Word
Steuerwort
ZSW Status Word
Zustandswort
Definitions and abbreviations
65
Technical data
RPBA-01
Enclosure:
34 mm
95 mm
20 62 mm
mm
Mounting: Into the option slot on the control board of the drive.
Degree of protection: IP 20
Ambient conditions: The applicable ambient conditions specified
for the drive in its Hardware Manual are in effect.
Hardware settings:
• Rotary switches for node address selection (address range
00 to 99)
• DIP switch for bus termination selection
Software settings:
• Input/Output/User Parameter data/Diagnostics format
• Maximum cyclic I/O data size: 244 bytes in, max 244 bytes out,
max. 416 bytes total
• Maximum User Parameter data/Diagnostics length: 237 bytes
Technical data
66
Connectors:
• 34-pin parallel bus connector
• 9-pin female DSUB connector
Current consumption:
• 350 mA max. (5 V), supplied by the control board of the drive
General:
• Estimated min. lifetime: 100 000 h
• All materials UL/CSA-approved
• Complies with EMC standards EN 50081-2 and EN 50082-2
Technical data
67
PROFIBUS link
Compatible devices: All devices compatible with the PROFIBUS-
DP protocol
Size of the link: 127 stations including repeaters (31 stations and
1 repeater per segment)
Medium: Shielded, twisted pair RS-485 cable
• Termination: built in the module
• Specifications:
Line A Line B
Parameter Unit
PROFIBUS-DP DIN 19245 Part 1
Impedance 135 to 165 100 to 130 W
(3 to 20 MHz) (f > 100 kHz)
Capacitance < 30 < 60 pF/m
Resistance < 110 – Ω/km
Wire gauge > 0.64 > 0.53 mm
Conductor area > 0.34 > 0.22 mm2
• Maximum bus length:
Transfer rate
≤ 93.75 187.5 500 1500 3000 6000 12000
(kbit/s)
Line A (m) 1200 1000 400 200 100 100 100
Line B (m) 1200 600 200 – – – –
Topology: Multi-drop
Serial communication type: Asynchronous, half Duplex
Transfer rate: 9.6 kbit/s, 19.2 kbit/s, 45.45 kbit/s, 93.75 kbit/s,
187.5 kbit/s, 500 kbit/s, 1.5 Mbit/s, 3 Mbit/s, 6 Mbit/s, or 12 Mbit/s
(automatically detected by RPBA-01)
Protocol: PROFIBUS-DP
Technical data
68
Technical data
3AFE 64504215 REV E EN
EFFECTIVE: 13.10.2003
ABB Oy ABB Inc.
AC Drives Automation Technologies
P.O. Box 184 Drives & Motors
FIN-00381 HELSINKI 16250 West Glendale Drive
FINLAND New Berlin, WI 53151
Telephone +358 10 22 11 USA
Fax +358 10 22 22681 Telephone 262 785-3200
Internet http://www.abb.com 800-HELP-365
Fax 262 780-5135
ABB
ACS 1000
Medium Voltage Drives
315 to 5000 kW
400 to 6700 hp
User’s Manual
Frequency Converter
12-pulse and 24-pulse Water-Cooled Version
Document No.: 3BHS213400 ZAB E01 Rev. -
Issued: 08-06-2005
ABB Switzerland Ltd. All Rights Reserved.
ABB reserves all rights to this document, also in the event of patent issue
or registration of any other industrial property protection right. Misuse, in
particular duplication and forwarding to third parties, is not permitted.
This document has been checked with due care and attention. However,
should the user find any errors, these should be reported to ABB.
ABB aims to maintain the most modern standard, therefore, entries in this
manual may differ from the actual product.
3BHS213400 ZAB E01 Rev. - ACS 1000 User’s Manual
ABB
Table of Contents
General Information
Contact Information
Related Documentation
Quality Certificates and Applicable Standards
Chapter 1 - Safety 1-1
1.1 Intended Audience and Required Qualifications 1-1
1.2 Owner’s Responsibilities 1-1
1.3 Safety Instructions 1-2
1.4 Safety Labels and Signs 1-3
1.5 Danger Zones 1-4
Chapter 2 - Transportation, Storage and Disposal 2-1
2.1 Transportation 2-1
2.1.1 Transport Conditions 2-1
2.1.2 Unpacking and Inspection 2-1
2.1.3 Loading and Unloading 2-2
2.2 Storage 2-3
2.2.1 Storage Conditions 2-3
2.2.2 Storage 2-3
2.3 Storage and Handling Instructions for Spare Parts 2-4
2.4 Disposal of Packaging Materials 2-5
2.5 Disposal of Components 2-5
Chapter 3 - Mechanical Installation 3-1
3.1 Overview of Mechanical Installation 3-1
3.2 Installation Site 3-1
3.2.1 Ambient Conditions 3-1
3.2.2 Dimensions and Clearances 3-1
3.2.3 Foundation, Floor Levelling and Cable Ducts 3-1
3.3 Installing the Converter 3-2
3.3.1 Raw Water Circuit 3-2
3.3.2 Mechanical Door Interlock 3-2
3.3.3 Door Center Posts 3-2
3.3.4 Installation Procedure 3-3
ACS 1000 User’s Manual 3BHS213400 ZAB E01 Rev. - 1 (4)
ABB
3.3.5 Additional Rectifier Unit 3-5
Chapter 4 - Electrical Installation 4-1
4.1 Overview 4-1
4.2 Cables 4-2
4.3 Internal Wiring 4-3
4.4 Ground Connections 4-3
4.5 Power Cables 4-4
4.5.1 Cable Entry 4-4
4.5.2 Connecting Incoming Feeder and Motor Cables 4-6
4.6 Connecting Auxiliary Power and Control Cables 4-8
Chapter 5 - Information on Commissioning 5-1
5.1 Customer Assistance and Acceptance 5-1
Chapter 6 - Operation 6-1
6.1 Control Panel 6-2
6.2 Starting 6-3
6.2.1 Checks before Switching on 6-3
6.2.2 Starting-up the Converter 6-4
6.3 Stopping 6-6
6.4 De-energizing the Converter 6-7
6.5 Emergency Off 6-8
6.6 Alarms and Faults 6-9
Chapter 7 - CDP Control Panel 7-1
7.1 Overview 7-1
7.2 Identification Mode 7-2
7.3 Actual Signal Display Mode 7-3
7.4 Parameter Mode 7-6
7.4.1 Parameter Lock 7-8
7.5 Function Mode 7-8
7.6 Operational Commands 7-9
7.6.1 Selecting Local/Remote 7-9
7.6.2 Setting the Direction of Rotation 7-10
7.6.3 Entering a Setpoint 7-11
2 (4) 3BHS213400 ZAB E01 Rev. - ACS 1000 User’s Manual
ABB
Chapter 8 - I/O Interfaces and Application Macros 8-1
8.1 Terms and Abbreviations 8-1
8.2 Input/Output Boards 8-2
8.2.1 Standard I/O Boards 8-2
8.2.2 I/O Ratings 8-2
8.2.3 Control Voltage Output 8-2
8.2.4 Potentiometer Supply 8-2
8.2.5 Digital Output De-energized Position 8-3
8.2.6 Location of IOEC Boards 8-3
8.2.7 External Connections 8-4
8.3 Application Macros 8-4
8.3.1 Overview 8-4
8.3.2 Factory Macro 8-5
8.3.3 Speed Macro 8-7
8.3.4 Hand/Auto Macro 8-7
8.3.5 PID Macro 8-10
8.3.6 Torque Macro 8-13
8.3.7 Sequential Macro 8-15
8.3.8 Master/Follower Macro 8-17
8.3.9 User 1 and User 2 Macro 8-19
Chapter 9 - Maintenance and Troubleshooting 9-1
9.1 Safety Instructions 9-2
9.2 Specific Maintenance Tasks 9-3
9.2.1 Cleaning 9-3
9.2.2 Checking Wire and Cable Connections 9-3
9.3 Door Center Posts 9-3
9.4 Standard Procedure for Troubleshooting 9-4
Appendix A - Additional Manuals
Appendix B - Technical Data
Appendix C - Mechanical Drawings
Appendix D - Electrical Diagrams
Appendix E - Parts List
Appendix F - Test Reports
Appendix G - Signal and Parameter Table
ACS 1000 User’s Manual 3BHS213400 ZAB E01 Rev. - 3 (4)
ABB
4 (4) 3BHS213400 ZAB E01 Rev. - ACS 1000 User’s Manual
ABB
General Information
Contact Information
If information is required beyond the instructions in this manual, ABB can
be contacted as follows:
ABB Switzerland Ltd
Medium Voltage Drives
CH-5300 Turgi, Switzerland
Phone: +41 844 845 845
Fax: +41 58 589 2984
E-mail [email protected]
Related Documentation
The following documents can be optained from ABB for supplementary
information.
Document
Title
Number
Power Cable Specification 3BHS189994
Main Circuit Breaker Specification 3BHS197846
Asynchronous Motor Specification 3BHS103892
Tripping Loop 3BHS104786
Troubleshooting Manual
Quality Certificates and Applicable Standards
The following certificates and conformity declarations are available with
ABB:
• ISO 9001 / ISO 14001 certificates stating that ABB Switzerland Ltd has
implemented and maintains a management system which fulfills the re-
quirements of the normative standards
• EC Conformity Declaration
• List of standards the converter complies with
ACS 1000 User’s Manual 3BHS213400 ZAB E01 Rev. - 1 (2)
ABB
2 (2) 3BHS213400 ZAB E01 Rev. - ACS 1000 User’s Manual
ABB
Chapter 1 - Safety
1.1 Intended Audience and Required Qualifications
The user’s manual addresses personnel who are responsible for the
installation, operation and maintenance of the converter. The personnel
must be qualified and fully acquainted with medium voltage equipment.
Installation Personnel The installation personnel are mainly responsible for:
• Preparing the mounting site
• Transporting the converter
• Performing the mechanical and electrical installation
• Preparing the water cooling unit for operation (if present in the
converter)
Operating Personnel The operating personnel include all persons who operate the converter as
required for the application using the control panel(s) of the converter or a
supervisory control system. Operating the converter does not require
special knowledge of converter technology. However, the operator must
know the functions of the control panel.
Maintenance The maintenance personnel are mainly responsible for:
Personnel
• Periodical checks of the converter
• Maintenance tasks.
1.2 Owner’s Responsibilities
It is the owners responsibility to ensure that each person involved in the
installation, operation or maintenance of the converter has received the
appropriate training and has thoroughly read and clearly understood the
relevant safety instructions.
The technical specifications and the approved purpose of the converter
must be strictly adhered to.
The owner must ensure that the converter is operated under proper
conditions and in a fully serviceable state. The specified service intervalls
and ambient conditions for the converter must be followed.
Unauthorized modifications and constructional changes of the converter
are not permitted.
ACS 1000 User’s Manual 3BHS213400 ZAB E01 Rev. - 1-1 (4)
Chapter 1 - Safety ABB
1.3 Safety Instructions
Safety instructions are used to highlight a potentially dangerous situation
when working on the converter. Safety instructions must be strictly
followed! Non-compliance can jeopardise the safety of personnel, the
machine and the environment.
DANGER!
Indicates an imminent hazardous situation. If not observed, it will lead to
death or life-threatening injury.
WARNING!
Indicates a potentially dangerous situation. If not observed, it could result
in death or life-threatening injury.
CAUTION!
! Indicates a potentially dangerous situation. If not observed, it could lead to
minor or moderate injury or property damage.
NOTICE!
Indicates important information related to personal safety and protection
of property.
IMPORTANT!
! Emphazises hints and highlights information.
1-2 (4) 3BHS213400 ZAB E01 Rev. - ACS 1000 User’s Manual
ABB Chapter 1 - Safety
1.4 Safety Labels and Signs
Safety labels are attached to the converter enclosure to alert personnel of
potential hazards when working on the converter. The safety labels must
always be followed and kept in perfectly legible condition.
Depending on the scope of supply, the following additional safety signs are
provided:
Fire fighting:
The sign explains the procedure when fighting fire in electrical equipment.
The sign should be installed well visible near the converter.
Heart pacemaker:
The magnetic field of the converter can influence the functioning of heart
pacemakers. The sign should be installed at the entrance to the drive
room or at a minimum distance of 6 meters (20 ft) from the converter!
High voltage:
The sign should be installed well visible at the main circuit breaker in the
switchgear room. The sign alerts personnel to the high voltage which can
be present on the secondary side of the converter transformer until the
main circuit breaker has been opened and secured and the converter has
been de-energized and grounded.
ACS 1000 User’s Manual 3BHS213400 ZAB E01 Rev. - 1-3 (4)
Chapter 1 - Safety ABB
1.5 Danger Zones
Figure 1-1 indicates the danger zones of the converter.
Danger from auxiliary and control voltages
in water cooling unit!
Danger from auxiliary and control voltages Cooling system may start automatically
in control unit when front door is open! when auxiliary voltage is on.
Fan coasting down after shut-down.
Additional Control Filter and DC components unit Inverter unit Water
rectifier unit cooling
unit unit
Hot equipment inside the High voltage! High voltage!
converter Do not attempt to open doors of medium Do not remove any
voltage units by force when converter is bolted walls or plates
energized. when converter is ener-
The doors are electromechanically inter- gized or before converter
locked. When the light GROUNDING is grounded
SWITCH UNLOCKED is on, the converter
can be grounded and then the doors can
be opened..
Illustration shows 24-pulse version of the converter
12-pulse version is without additional rectifier unit
Figure 1-1 Danger Zones
1-4 (4) 3BHS213400 ZAB E01 Rev. - ACS 1000 User’s Manual
ABB
Chapter 2 - Transportation, Storage and Disposal
2.1 Transportation
2.1.1 Transport Conditions
The transport conditions are based on IEC 721-3-2 'Classification of
environmental conditions: Classification of groups of environmental
parameters and their severities; Transportation'.
Classification: 2K3 / 2B1 / 2M1
See also to Appendix B - Technical Data.
2.1.2 Unpacking and Inspection
When unpacking the converter proceed as follows:
1 Remove all packaging material carefully. Do not use sharp or pointed
tools. Proceed as follows if the converter is delivered in a wooden
box.
1 Remove the top of the box
2 Remove the end and the side walls
3 Remove the bottom of the box
Top of the box End wall
1000
ACS
End wall Bottom of the box Side wall
Figure 2-1 Unpacking the Converter
2 Check the converter and accompanying equipment for damage.
ACS 1000 User’s Manual 3BHS213400 ZAB E01 Rev. - 2-1 (6)
Chapter 2 - Transportation, Storage and Disposal ABB
3 Compare the complete delivery with the purchase order and the
packing list.
4 If parts are missing or damaged, immediately inform the shipping
company and the ABB service organization.
It is recommended to photograph the damages.
2.1.3 Loading and Unloading
Observe the following points when transporting the converter:
CAUTION!
! Do not lift and move the converter or a transport unit using a forklift. The
frame of the cabinets could be damaged. If a crane is not available contact
ABB for instructions on other means of moving. See section General
Information for contact address.
CAUTION!
! Converter components can be damaged during transportation. Therefore,
the converter must be transported in upright position.
CAUTION!
! When transporting the converter ensure that no dirt enters. Keep doors
closed. Metallic dust in particular may cause damage and lead to
malfunction when the converter is powered up.
• See Appendix C - Mechanical Drawings for dimensions and center of
gravity and Appendix B - Technical Data for weight details.
• Material and diameter of the lifting cables must correspond to the
weight of the converter.
• When lifting the converter always use the lifting rails on the roof of the
converter. The rails can be removed after the converter has been
installed at its final location.
• Do not pass a lifting cable through the fastening hole of a rail. Use a
safety hook to attach a cable to a rail.
• The lifting cables should be approximately at an angle as indicated in
Figure 2-2.
• Select the appropriate fastening holes to balance the weight.
• Lift the converter slowly and steadily to the required clearance height
maintaining the converter in upright position.
• Check the horizontal position of the converter. Reposition the cables
if necessary.
2-2 (6) 3BHS213400 ZAB E01 Rev. - ACS 1000 User’s Manual
ABB Chapter 2 - Transportation, Storage and Disposal
min. 30° min. 30°
Additional
rectifier
unit
Illustration shows 24-pulse version of the converter
12-pulse version is without additional rectifier unit
Figure 2-2 Lifting Angle
2.2 Storage
2.2.1 Storage Conditions
The minimum requirements for storage are based on IEC 721-3-1
'Classification of environmental conditions: Classification of groups of
environmental parameters and their severities; Storage'.
Classification: 1K4 / 1Z5 / 1B1 / 1M1
See also Appendix B - Technical Data.
The converter can be stored for up to 1 year in the original packaging as
long as it is not damaged or opened. For information on longer storage
periods contact the ABB service organization.
2.2.2 Storage
If the converter is taken out of service for a longer time proceed as follows:
1 Drain the cooling circuit completely (contact the ABB service
organization for information) or add the appropriate amount of glycol
for frostproofing, if the converter is to be stored in ambient
temperatures below 0 °C (32 °F).
See Appendix A - Additional Manuals for information on frostproofing.
2 Remove the batteries (if applicable).
ACS 1000 User’s Manual 3BHS213400 ZAB E01 Rev. - 2-3 (6)
Chapter 2 - Transportation, Storage and Disposal ABB
3 Cover all cable inlets and ventilation slots with an impermeable plastic
or aluminum foil and a wooden panel.
4 Add the desiccant of the appropriate quality: 1 unit desiccant (30g)
absorbs 6g water vapor. The following quantity is needed when using
a polyethylene foil:
• 10 units/sqm foil
5 Close and lock the doors of the converter.
6 Use polyethylene or equivalent for packaging:
• 0,3 g/sqm/24h water vapor diffusion
7 Attach humidity indicators to the packaging.
The storage conditions and the packaging should be checked regularly.
Any damages which occur during the storage period should be repaired
immediately.
2.3 Storage and Handling Instructions for Spare Parts
Inspect the spare parts immediately after receipt for damages. Report any
damage to the shipping company and the ABB service organization.
Observe the following to maintain spare parts in good condition and to
keep the warranty valid during the warranty period:
• Keep spare parts in their original packaging.
• Store printed circuit boards in antistatic bags or boxes.
• Storage temperature range: -5 °C to + 55 °C (23 °F to 131 °F)
• Storage place requirements:
• Free of vibration and shock.
• Protected against dust, sand, vermin and insects.
• Free of corrosive gases, salt or other impurities that
could damage electronic equipment.
• Dry; no condensation
Relative air humidity: 5 to 85 %
If in doubt if the maximum allowed humidity is
exceeded, protect spare parts by an external heater.
• Apply static-sensitive precautions when handling printed circuit
boards. Static electricity can damage these components.
• Do not touch a component without wearing a wrist
grounding strap.
• Put the component on a grounded working surface
protected against electrostatic discharges.
• Hold the component only at the edge.
2-4 (6) 3BHS213400 ZAB E01 Rev. - ACS 1000 User’s Manual
ABB Chapter 2 - Transportation, Storage and Disposal
2.4 Disposal of Packaging Materials
Dispose of the following materials according to local regulations:
• Wooden frame
• Wooden pallet
• Polyethylene sheet
• Plywood
• Silicagel
2.5 Disposal of Components
At the end of the life time of the converter dispose of the following
components according to local regulations:
• Batteries
• Capacitors
• Printed circuit boards
• Electronic devices
ACS 1000 User’s Manual 3BHS213400 ZAB E01 Rev. - 2-5 (6)
Chapter 2 - Transportation, Storage and Disposal ABB
2-6 (6) 3BHS213400 ZAB E01 Rev. - ACS 1000 User’s Manual
ABB
Chapter 3 - Mechanical Installation
NOTICE!
All installation work must be carried out by qualified personnel in
compliance with local regulations.
See Chapter 1 - Safety for explanation on how the safety messages are
categorized and used in this manual.
3.1 Overview of Mechanical Installation
The mechanical installation of the converter includes the following steps:
• Preparing the installation site
see 3.2 Installation Site
• Preparing the raw water connection
see 3.3.1 Raw Water Circuit
• Fixing the converter to the floor
see 3.3.4 Installation Procedure
3.2 Installation Site
3.2.1 Ambient Conditions
Ambient factors such as temperature, relative humidity, air contamination,
shock and vibration must be in compliance with the stated maximum
permissible levels. See Appendix B - Technical Data for limit values.
If the condition of the installation site is not within the specifications or if
the transportation or the installation require special measures, contact the
ABB service organization.
3.2.2 Dimensions and Clearances
The converter must be mounted with adequate free space. The
dimensions of transport units, the overall dimensions of the converter and
the clearances are provided in Appendix C - Mechanical Drawings.
3.2.3 Foundation, Floor Levelling and Cable Ducts
The floor must be of non-flammable material, with smooth and non-
abrasive surface, protected against humidity diffusion, levelled and able to
support the weight of the converter (min. 1’000 kg/m2).
ACS 1000 User’s Manual 3BHS213400 ZAB E01 Rev. - 3-1 (6)
Chapter 3 - Mechanical Installation ABB
The maximum allowable overall unevenness is ≤ 5 mm / 5 m. If the
mounting surface is uneven, the cabinet doors become misaligned and do
not open or close properly.
Cable ducts must be of non-flammable material with non-abrasive
surface.
Suitable fire protection measures must be applied to prevent fire from
spreading into the converter.
All cable entries and exits must be protected to prevent dust, humidity and
animals from entering into the converter.
See Layout Drawing in Appendix C - Mechanical Drawings for exact
dimensions, if holes and channels for cables and water pipes have to be
cut into the floor and mounting holes have to be drilled.
3.3 Installing the Converter
3.3.1 Raw Water Circuit
See the following when preparing the connection for the cooling water:
• User’s Manual, section Raw Water Connection in Appendix A -
Additional Manuals
• Layout Drawing in Appendix C - Mechanical Drawings for information
on dimensions of the raw water entry
• Datasheet in Appendix A - Additional Manuals for information on:
• Nominal values of flow rate, pressure range etc.
• Industrial cooling water specification
3.3.2 Mechanical Door Interlock
The doors of the medium voltage units are interlocked with the grounding
switch. If the doors of medium voltage units cannot be opened contact the
ABB service organization.
3.3.3 Door Center Posts
The filter and DC components unit and the converter unit are equipped
with center posts (see arrows in Figure 3-1). If a center post has been
removed for installation purposes it must be remounted again before the
converter is energized. The center posts are important to lock the doors
securely.
3-2 (6) 3BHS213400 ZAB E01 Rev. - ACS 1000 User’s Manual
ABB Chapter 3 - Mechanical Installation
Filter and DC components unit Converter unit
Figure 3-1 Center Posts
3.3.4 Installation Procedure
Obeserve the following points when installing the converter:
CAUTION!
! When installing the converter ensure that no dirt enters. Always close the
doors when work is discontinued and completely cover openings. Metallic
dust in particular may cause malfunction when the converter is powered
up and cause damage.
Proceed as follows:
1 Drill the floor fixing holes before moving the converter to the final loca-
tion.
2 Be careful when moving the converter.
See Chapter 2 - Transportation, Storage and Disposal, 2.1 Transpor-
tation for information to be observed.
3 Check if the doors are misaligned.
If the doors do not open and close properly place levelling plates
(80 x 300 x 0.5 mm) under the base:
1 Lift the converter by crane at the corresponding side
(see Figure 3-2).
2 Place the required number of plates under the base.
ACS 1000 User’s Manual 3BHS213400 ZAB E01 Rev. - 3-3 (6)
Chapter 3 - Mechanical Installation ABB
Additional
rectifier
unit
place levelling plates here
Additional
rectifier
unit
place levelling plates here
Illustration shows 24-pulse version of the converter
12-pulse version is without additional rectifier unit
Figure 3-2 Levelling the Converter
IMPORTANT!
! Do not place the levelling plates under the additional rectifier unit.
4 Remove the two angle brackets which secure the swing frame for
transportation, see Figure 3-3.
Keep the angle brackets for later use.
3-4 (6) 3BHS213400 ZAB E01 Rev. - ACS 1000 User’s Manual
ABB Chapter 3 - Mechanical Installation
Figure 3-3 Angle Brackets
5 Fix the converter to the floor.
6 Connect the raw water circuit.
3.3.5 Additional Rectifier Unit
IMPORTANT!
! This section is only applicable for 24-pulse converters when the additional
rectifier unit is delivered separately.
Proceed as follows to join the additional rectifier unit to the standard
converter:
1 Align the additional rectifier unit to the converter.
2 Join the unit to the converter using the supplied screws and fix it to
the floor.
3 Connect the pipes for cooling water entry (at the bottom of the
cabinet) and exit (at the top of the cabinet) to their corresponding
connectors inside the additional rectifier unit.
ACS 1000 User’s Manual 3BHS213400 ZAB E01 Rev. - 3-5 (6)
Chapter 3 - Mechanical Installation ABB
3-6 (6) 3BHS213400 ZAB E01 Rev. - ACS 1000 User’s Manual
ABB
Chapter 4 - Electrical Installation
NOTICE!
All installation work must be carried out by qualified personnel in
compliance with local regulations.
See Chapter 1 - Safety for explanation on how the safety messages are
categorized and used in this manual.
Power must not be applied to the drive system without the consent of the
ABB commissioning staff.
DANGER!
Hazardous voltage!
To ensure safety, the converter must be installed in accordance with the
instructions in this manual. Improper work can lead to life-threatening
injury or death.Take appropriate measures to prevent that mains and
auxiliary power can be switched on.
4.1 Overview
The electrical installation includes the following steps:
• Internal Wiring
see 4.3 Internal Wiring.
• Ground Cable
see 4.4 Ground Connections.
• Power Cables
see 4.5.2 Connecting Incoming Feeder and Motor Cables.
• Auxiliary Power Cables
see 4.6 Connecting Auxiliary Power and Control Cables.
• Control Cables
see 4.6 Connecting Auxiliary Power and Control Cables.
Understanding Designation, cross-reference and device-identification conventions are
Electrical Drawings defined on the diagrams in Appendix D - Electrical Diagrams.
ACS 1000 User’s Manual 3BHS213400 ZAB E01 Rev. - 4-1 (10)
Chapter 4 - Electrical Installation ABB
4.2 Cables
Power Cables See Power Cable Specification for information on suitable power cables
(incoming feeder cables, motor cables, braking resistor cables) or contact
ABB.
Auxiliary Power Cable A 3-phase cable is required for the auxiliary power supply. A neutral
connector is not required. Type and rating is to be selected according to
local regulations.
Control Cables Control cables should be provided in accordance with Table 4-1. Either
single or multiple twisted pair cables may be used.
Control cables should not be laid in parallel to the power cables. If this
cannot be avoided, a minimum distance of 30 cm (12 in) must be
maintained between control and power cables. Control and power cables
should be crossed at an angle of 90°.
Table 4-1 Control Cable Requirements
Signal Type General Cable Type Cross-Section
Analog In 0.5 to 2.5 mm2 /
Twisted pair(s) - Overall Shield
AWG 20 to AWG 12
Analog Out 0.5 to 2.5 mm2 /
Twisted pair(s) - Overall Shield
AWG 20 to AWG 12
Digital In 0.5 to 2.5 mm2 /
Twisted pair(s) - Overall Shield
AWG 20 to AWG 12
Digital Out 0.5 to 2.5 mm2 /
Twisted pair(s) - Overall Shield
AWG 20 to AWG 12
Speed Encoder Twisted pair cable with overall shield 0.5 mm2
and separately shielded pairs 4 x (2+1)
4-2 (10) 3BHS213400 ZAB E01 Rev. - ACS 1000 User’s Manual
ABB Chapter 4 - Electrical Installation
4.3 Internal Wiring
IMPORTANT!
! This section is only applicable for 24-pulse converters if the additional
rectifier cabinet is delivered separately.
The following connections have to be made according to Appendix D -
Electrical Diagrams.
• rectifier bridge in standard converter with additional rectifier,
• ground busbar of standard converter with ground busbar of additional
rectifier cabinet,
• door monitoring switch in additional rectifier cabinet with tripping loop
in standard converter.
The cables have been prepared for connection in the factory. They have
been cut to the proper length, equipped with cable lugs and coiled up
inside the power terminal section of the standard converter.
4.4 Ground Connections
It is important that the converter is properly grounded to maintain safety
and to ensure smooth functioning of the equipment. For this reason, the
converter’s ground cable must be securely tied to the grounding system of
the installation site (system ground).
The ground cable is tied to a ground busbar inside the power terminal
section. The connection must be in compliance with local regulations.
The ground cable is entered through an EMC sleeve of the entry plate. If
there is no free entry hole available, the ground cable is entered together
with a phase conductor. See section 4.5.2 Connecting Incoming Feeder
and Motor Cables for information on entering cables into the cabinet.
Figure 4-1 Ground Cable and Phase Conductor in one EMC Sleeve
ACS 1000 User’s Manual 3BHS213400 ZAB E01 Rev. - 4-3 (10)
Chapter 4 - Electrical Installation ABB
4.5 Power Cables
4.5.1 Cable Entry
12-pulse Version The incoming feeder and motor cables are connected to their
corresponding busbars in the power terminal section of the standard
converter.
24-pulse Version The incoming feeder cables are connected in the power terminal section
of the standard converter and in the additional rectifier cabinet (see Figure
4-2).
System 2-
Transformer
ground
= > ? = > ? =! >! ?! =" >" ?"
Armouring
Shielding
7 8 9 7 8 9 !7 !8 !9 "7 "8 "9
System
ground 2- ACS 1000 Additional rectifier unit
Figure 4-2 Transformer Connection Diagram
Cable entry into the power terminal section is through the top or the bottom
of the cabinet. The power terminal section is located behind the control
swing frame of the converter and is accessible after the separating door
behind the swing frame has been opened. The terminal bars can be
identified by their phase designations.
Details on entry plates (dimensions, number of entry holes, maximum
cable diameter) and on busbars (dimensions, layout) are provided in
Appendix C - Mechanical Drawings.
If cable entry is from below, the entry plate mounted on top of the control
section must be relocated to the base of the cabinet. The orientation of the
entry plate does not have to be changed.
The five removable spacers which are mounted on the top terminal bars
must be relocated symmetrically to the lower terminals of the cabinet (see
Figure 4-3) when entering the cables through the floor.
4-4 (10) 3BHS213400 ZAB E01 Rev. - ACS 1000 User’s Manual
ABB Chapter 4 - Electrical Installation
Busbar
Removable spacer
Figure 4-3 Power Terminals with Removable Spacers
Minimum Creepage When using spacers for cable connection to a busbar, the minimum
Distance required creepage distance must be observed. Depending on the
Comparative Tracking Index (CTI) of the insulation material of the cable
the following Minimum Creepage Distances (MCD) apply:
Table 4-2 Creepage Distance
MCD in mm CTI
63 600
71 400....600
80 175....400
If the CTI value of the insulation material is unknown, the values in row
three of the table apply.
ACS 1000 User’s Manual 3BHS213400 ZAB E01 Rev. - 4-5 (10)
Chapter 4 - Electrical Installation ABB
4.5.2 Connecting Incoming Feeder and Motor Cables
Proceed as follows:
1 Enter a cable into the respective terminal section to measure the
conductor length.
Mark the required conductor length and withdraw the cable. Cut it to
the correct length, strip the conductor ends and mount the cable lugs
suitable for M12 bolts. Cables must be terminated with lugs according
to the specification of the cable manufacturer.
NOTICE!
Do not cut cables inside the terminal section. Make sure that waste from
cable cutting and stripping cannot enter the converter. Any waste which
accidentally dropped into the converter must be retrieved. The waste
could cause damage or malfunction.
2 Enter the conductors through the EMC sleeves of the entry plate as
shown in Figure 4-4 and Figure 4-5:
• Strip the cable insulation at the point of entry. Tighten
the EMC sleeve on the stripped part of the cable with
cable ties.
• If necessary, remove the entry plate and slide it onto
the cable. Fasten the entry plate, after the ground
connections have been made.
• IP 54: Remove the rubber grommets from the entry
plates and cut them to adequate diameter for the
transformer and the motor cables (Figure 4-5). To
ensure proper sealing, cut along the diameter
marking that corresponds to the cable diameter. Slide
the grommet onto the cable (Figure 4-4). The
grommet must fit tight to prevent water from entering
the cabinet. If necessary, seal the junctions with
silicone rubber.
4-6 (10) 3BHS213400 ZAB E01 Rev. - ACS 1000 User’s Manual
ABB Chapter 4 - Electrical Installation
Outer sheath
1st. insulated conductor
2nd. insulated conductor
Mounting bracket
3rd. insulated conductor
Strip conductor
Rubber grommet insulation to
expose shield
Entry plate
EMC sleeve
3rd. insulated conductor
Strip conductor
insulation to
2nd. insulated conductor
expose shield
1st. insulated conductor
Mounting bracket
Outer sheath
Top entry Bottom entry
Figure 4-4 Cable Entry for Power Cables (IP 20 and IP 22).
A B C
Figure 4-5 Cutting Rubber Grommets to Size
3 Check the insulation of each cable before connection and verify that
the results are within the specifications of the cable manufacturer.
NOTICE!
Do not drill inside the terminal section. Make sure that waste from drilling
cannot enter the converter. Any waste which accidentally dropped into the
converter must be retrieved. The waste could cause damage or
malfunction.
ACS 1000 User’s Manual 3BHS213400 ZAB E01 Rev. - 4-7 (10)
Chapter 4 - Electrical Installation ABB
If holes have to be drilled into busbar terminations, remove the
busbars and drill the holes outside of the cabinet.
4 Connect the phase conductors to the corresponding busbars.
See the specification of the manufacturer of the cable lugs for
tightening torques.
CAUTION!
! High voltages will be present in the terminal section. High voltages can
cause flashover between the potential of a phase conductor and ground.
A minimum clearance of 20 mm must be maintained between each cable
and the terminals of any other phase. Adequate distance is obtained with
spacers as shown in Figure 4-3.
5 Connect the shield ends of all conductors to the ground busbar.
6 Fasten entry and blanking plates with the supplied screws (M6).
IMPORTANT!
! All provided screws must be mounted and tightened to achieve best EMC.
4.6 Connecting Auxiliary Power and Control Cables
Cable entry is through the roof or through the bottom of the control unit.
Proceed as follows:
1 Enter the cables through the EMC slot of the entry plate that leads to
the front area of the control unit.
• Shielded cables: Remove the outer cable sheath in
the entry area. The conductive cushions of the EMC
slot must be in contact with the cable shield (see
Figure 4-6).
Side view Bottom view
Entry plate
EMC conductive cushions
Screw holes
Base plate
Entry plate
Figure 4-6 Auxiliary Power Cable and Control Cable Entry
4-8 (10) 3BHS213400 ZAB E01 Rev. - ACS 1000 User’s Manual
ABB Chapter 4 - Electrical Installation
Stripped cable Conductive surface of Stripped part covered
screen made visible with copper foil
Copper foil
Cable Screened twisted pair
Ground wire
Figure 4-7 EMC Cable Preparation
• IP 54 and cable entry from above: Remove the
rubber grommets from the entry plate and cut them to
adequate diameter of the cable (see Figure 4-5). To
ensure proper sealing, cut along the diameter
marking that corresponds to the cable diameter. Slide
the grommet onto the cable. The grommet must fit
tight to prevent water from entering the cabinet. If
necessary, seal the junctions with silicone rubber.
• Loosen the screws of the entry plate and enter the
cables.
• Push the two halves of the entry plate together and
tighten the screws. The EMC conductive cushions
should press tightly around the bare screens.
2 Connect the cables. For easy identification, it is recommended to
mark each conductor appropriately before connection.
Auxiliary power cable:
Connect the auxiliary power cable Connect the auxiliary power cable
according to Appendix D - Electrical Diagrams.
To identify the terminals see Figure 4-8 and Location Drawings in
Appendix C - Mechanical Drawings.
If a shielded cable is used connect the cable shield to PE.
Control cables:
Connect the control cables to terminals X300, X301 and to the IOEC
boards (see Figure 4-8).
For identification, see Figure 4-8 and Appendix C - Mechanical Draw-
ings. For connection details see Appendix D - Electrical Diagrams.
ACS 1000 User’s Manual 3BHS213400 ZAB E01 Rev. - 4-9 (10)
Chapter 4 - Electrical Installation ABB
IOEC board 2
Aux. power terminals
Terminals X300, X301
IOEC board 3
IOEC board 4
Figure 4-8 Control Unit
4-10 (10) 3BHS213400 ZAB E01 Rev. - ACS 1000 User’s Manual
ABB
Chapter 5 - Information on Commissioning
5.1 Customer Assistance and Acceptance
Commissioning, parameter adjustments and functional tests are to be
carried out by certified commissioning personnel. Information on the
commissioning procedure and conditions for the commissioning to start
can be obtained from ABB. For address see section General Information.
During the commissioning period, the customer is requested to provide
qualified personnel for assistance, who are
• familiar with medium and low voltage equipment and with local safety
regulations,
• familiar with the driven process,
• authorized to operate associated medium and low voltage equipment
(MCB, other medium and low voltage switchgear etc.),
• authorized to operate the driven process for functional tests.
When commissioning is completed, the commissioning report is signed by
the responsable commissioning engineer and by the customer as a sign
of acceptance. A copy of the report and a copy of the actual parameter
settings are handed out to the customer.
ACS 1000 User’s Manual 3BHS213400 ZAB E01 Rev. - 5-1 (2)
Chapter 5 - Information on Commissioning ABB
5-2 (2) 3BHS213400 ZAB E01 Rev. - ACS 1000 User’s Manual
ABB
Chapter 6 - Operation
NOTICE!
Only qualified personnel shall operate the drive system, i.e. personnel
who are familiar with the machine and the operation of the drive system
and the hazards involved.
See Chapter 1 - Safety for explanation on how the safety messages are
categorized and used in this manual.
This chapter outlines the local operation of the converter using the CDP
control panel and the control switches as illustrated in section 6.1 Control
Panel after the converter has been installed and commissioned. If the
control interface has been modified to accommodate project-specific
requirements see the applicable Operating Instructions in Appendix A -
Additional Manuals.
Remote control of the converter via a PLC or remote stations is not
described in this chapter. If the converter is controlled from remote, see
the applicable manuals for information.
ACS 1000 User’s Manual 3BHS213400 ZAB E01 Rev. - 6-1 (10)
Chapter 6 - Operation ABB
6.1 Control Panel
Control Panel
• used to start and stop the motor
• displays status messages of the converter
• displays alarm and fault messages
• used to reset alarm and fault messages
Illuminated Pushbuttons
• OFFline opens main circuit breaker
• ONline closes main circuit breaker
Lamp Grounding Switch Unlocked
• indicates when DC link is discharged and
grounding switch can be turned to position
“grounded”
Emergency Off Button
• prevents start-up if actuated at standstill
• main circuit breaker opens and DC link dis-
charges, if activated during operation
Figure 6-1 Control Panel
6-2 (10) 3BHS213400 ZAB E01 Rev. - ACS 1000 User’s Manual
ABB Chapter 6 - Operation
6.2 Starting
6.2.1 Checks before Switching on
Proceed as follows:
1 Check that no tools and foreign objects are left inside the converter.
2 Verify that:
• all internal circuit breakers of the converter have
been closed,
• the auxiliary power supply of the converter has been
switched on.
See Appendix D - Electrical Diagrams to identify the circuit breakers.
3 Check that the water cooling system is ready for operation.
See also User’s Manual in Appendix A - Additional Manuals.
NOTICE!
The cooling system may start automatically as soon as the auxiliary
voltage has been switched on.
4 Check that all doors have been closed and locked and all covers have
been mounted.
Medium voltage units of the converter include an interlocking system
which operates in conjunction with the grounding switch and the
electrical interlocks from the main circuit breaker.
The interlocking system ensures that power cannot be initialized to
the converter unless all doors have been closed and the grounding
switch has been turned to position (not grounded).
The interlocking system also ensures that the doors of medium
voltage units cannot be opened until the main power source has been
disconnected, the DC link capacitors have been discharged and
the grounding switch has been turned to position (grounded).
Doors of control and cooling cabinets are not integrated into the
interlocking system and can always be opened.
DANGER!
High Voltage!
All bolted covers must be fitted to prevent unintended touching of
energized components.
ACS 1000 User’s Manual 3BHS213400 ZAB E01 Rev. - 6-3 (10)
Chapter 6 - Operation ABB
5 Check that the grounding switch is in position “not grounded”.
Figure 6-2 Grounding Switch in Position Not Grounded
6 Check that the main circuit breaker is in operating position.
6.2.2 Starting-up the Converter
LOC
7 Set the CDP control panel to LOCAL mode by pressing the REM
button.
See also Chapter 7 - CDP Control Panel for information on selecting
this mode.
8 Check that the converter is ready.
No alarm or fault message on the CDP control panel must be present.
9 If a fault message is displayed on the CDP control panel reset the
RESET
fault, by pressing the .button.
See Chapter 7 - CDP Control Panel for information on resetting a
fault.
If a fault cannot be reset, it must be rectified by the responsible
personnel.
When the converter is ready, the CDP control panel displays Rdy
MCB on meaning that the main circuit breaker can be closed:
1 L -> 0.0 rpm 0
Status... Rdy MCB on
MotorSpeed 0.00 rpm
Power 0.0 %
6-4 (10) 3BHS213400 ZAB E01 Rev. - ACS 1000 User’s Manual
ABB Chapter 6 - Operation
10 Press the ONLlNE button to close the main circuit breaker. After the
main circuit breaker has been closed, the DC link of the converter is
charged. The status line of the display changes to Charging:
1 L -> 0.0 rpm 0
Status... Charging
MotorSpeed 0.00 rpm
Power 0.0 %
After charging has been finished, the converter is Ready to Start:
1 L -> 0.0 rpm 0
Status... Rdy to Strt.
MotorSpeed 0.00 rpm
Power 0.0 %
11 Enter a setpoint according to the selected application macro.
See Chapter 8 - I/O Interfaces and Application Macros for information
on macros.
See Chapter 7 - CDP Control Panel for information on entering a
setpoint.
1 L -> [ 600.0 rpm ]
Status... Rdy to Strt.
MotorSpeed 0.00 rpm
Power 0.0 %
12 Press the button of the CDP control panel to start the motor.
First, the motor is magnetized:
1 L -> 600.0 rpm 0
Status... Magnetizing
MotorSpeed 0.00 rpm
Power 0.0 %
ACS 1000 User’s Manual 3BHS213400 ZAB E01 Rev. - 6-5 (10)
Chapter 6 - Operation ABB
After the motor has been magnetized, the motor speed is ramped up
to the setpoint. As soon as the motor starts to turn, the display
indicates that the motor is Running:
1 L -> 600.0 rpm 1
Status... Running
MotorSpeed 600.00 rpm
Power 30.0 %
6.3 Stopping
Proceed as follows to stop the motor:
To stop the motor, press the button of the CDP control panel.
The motor stops according to the preset stop function and the
converter stops modulating. Stop modes are preset in parameters.
While the motor stops, the status line of the display shows Stopping:
1 L -> 600.0 rpm 1
Status... Stopping
MotorSpeed 300.00 rpm
Power 20.0 %
As long as the stopping sequence is in progress, the converter can
always be restarted by pressing the button of the CDP control
panel.
When the converter has stopped modulating, the CDP control panel
displays Ready to Start:
1 L -> 600.0 rpm 0
Status... Rdy to Strt
MotorSpeed 0.00 rpm
Power 0.0 %
As long as the main circuit breaker has not been opened, the motor
can be started again.
6-6 (10) 3BHS213400 ZAB E01 Rev. - ACS 1000 User’s Manual
ABB Chapter 6 - Operation
6.4 De-energizing the Converter
DANGER!
Hazardous voltage!
Do not try to gain access to the converter transformer, the medium voltage
units of the converter nor the motor as long as the drive system is
energized and not grounded.
To disconnect the converter from the main power supply, do the following:
1 Stop the motor as described in the previous section.
2 Press the Offline button to disconnect the converter from the main
power supply. The following happens:
• Main circuit breaker opens
• DC link discharges
• Offline button lights up
After the DC link has been discharged, the display shows:
1 L -> 600.0 rpm 0
Status... Rdy MCB on
MotorSpeed 0.00 rpm
Power 0.0 %
3 Rack-out, lock-out and tag-out the main circuit breaker.
4 Turn the grounding switch to position “grounded”.
IMPORTANT!
! Do not turn the grounding switch to position “grounded”, before the
light GROUNDING SWITCH UNLOCKED is on. Otherwise, the switch will
be damaged.
Figure 6-3 Grounding Switch in Position “Grounded”
ACS 1000 User’s Manual 3BHS213400 ZAB E01 Rev. - 6-7 (10)
Chapter 6 - Operation ABB
After the grounding switch is in position “grounded”, the CDP control
panel displays:
1 L -> 600.0 rpm 0
Status... ErthIsoClos
MotorSpeed 0.00 rpm
Power 0.0 %
5 Switch off all auxiliary voltages from external sources.
See Appendix D - Electrical Diagrams to identify the circuit breakers.
The converter is now dead, and safe access is possible.
6.5 Emergency Off
The emergency off button is located on the control section of the converter
(see also Figure 6-1).
Figure 6-4 Emergency Off Pushbutton
If the pushbutton is pressed during operation, the following happens:
• The main circuit breaker opens.
• The drive coasts down.
• The message Emergency Off comes up on the control panel display.
1 L -> 600.0 rpm 0
ACS 1000 9133WR
*** Fault “**
Emerg Off
• The DC link discharges.
The converter can be started again after the emergency off button has
been extracted and the reset button on the control keypad has been
pressed. The emergency off button returns to its initial position when
turned to the right.
6-8 (10) 3BHS213400 ZAB E01 Rev. - ACS 1000 User’s Manual
ABB Chapter 6 - Operation
6.6 Alarms and Faults
When a malfunction occurs in the converter or in the equipment monitored
by the converter, the control panel displays a corresponding alarm or fault
message. The message can also be viewed and saved in the fault logger
of the converter when a PC with the DriveWindow or DriveDebug tool is
available.
Two error message levels are used in the converter:
• Alarm (warning): an alarm does not shut down the converter.
However, a persisting alarm condition can often lead to a fault if the
condition causing the alarm is not corrected. An alarm cannot be
manually reset. The alarm message will be deleted from the display
as soon as the alarm condition has been corrected.
• Fault: a fault always shuts down the whole drive. The type of shut-
down depends on the origin of the fault.
In general, a fault condition must be corrected and the fault be
manually reset before the converter can be started again.
Depending on the type of fault, the main circuit breaker (MCB) is
opened by the converter or stays closed. Since the MCB is controlled
and monitored entirely by the converter, no external opening
command must be given to the MCB when a fault condition occurs.
Some of the alarm and fault messages are related to other equipment in
use (MCB, transformer, cooling system) and the configuration of the drive
system. For more information on alarms and faults see Signal and
Parameter Table.
ACS 1000 User’s Manual 3BHS213400 ZAB E01 Rev. - 6-9 (10)
Chapter 6 - Operation ABB
6-10 (10) 3BHS213400 ZAB E01 Rev. - ACS 1000 User’s Manual
ABB
Chapter 7 - CDP Control Panel
7.1 Overview
The CDP control panel is the basic user interface for operating, controlling
and monitoring the converter.
The panel messages and parameter settings used in this chapter are
typical examples to illustrate the related instructions and display functions.
They may differ from the actual messages and parameter settings in your
converter.
1 L -> 1242,0 rpm I
MotCurr 76.00 A Alphanumeric display
MotSpeed 1242.0 rpm (4 lines x 20 characters)
Torque 86.00 %
Mode selection buttons
Selection and changing buttons Enter button
Reset button Setpoint setting button
Local, remote button Start button
Forward, reverse buttons Stop button
Figure 7-1 CDP Control Panel
ACS 1000 User’s Manual 3BHS213400 ZAB E01 Rev. - 7-1 (12)
Chapter 7 - CDP Control Panel ABB
Keypad Modes The CDP control panel provides the following modes:
• Identification mode
• Actual Signal Display mode, selected by the ACT button
• Parameter mode, selected by the PAR button
• Function mode, selected by the FUNC button
• Drive Selection mode, selected by the DRIVE button.
7.2 Identification Mode
After the converter has been energized or after the panel has been
connected to the converter for which the auxiliary voltage has been
switched on already, the identification display appears showing the panel
version and then the ID-number of the converter. When the control panel
is being initialized the display changes as follows:
CDP312 PANEL V5.30
........
After 2-3 seconds:
ACS 1000 xxxx
< Device Name >
ID-NUMBER 1
After another few seconds, the display changes to the Actual Signal
Display mode.
1 L -> 0.0 rpm 0
Status... Earth Iso clos
MotorSpeed 0.00 rpm
Power 0.0 %
7-2 (12) 3BHS213400 ZAB E01 Rev. - ACS 1000 User’s Manual
ABB Chapter 7 - CDP Control Panel
7.3 Actual Signal Display Mode
Two displays can be selected in the Actual Signal Display mode:
• Actual Signal Display
• Fault History Display.
The Actual Signal Display appears first when the Actual Signal Display
mode has been selected. However, when the converter is in a fault
condition, the Fault Display will be shown instead.
The Actual Signal Display is used to monitor the converter without
interferring the operation of the converter.Three preselectable actual
values are shown continuously on the display.
The panel will automatically return to the Actual Signal Display mode
from other modes within one minute when no buttons are pressed
(exceptions: Status Display and Common Reference Display when in
Drive Selection mode and Fault Display mode).
A complete list of selectable actual signals can be found in Signal and
Parameter Table.
The fault memory includes information on the 64 most recent fault events
that occurred in the converter. The name of the fault and the actual time
are displayed. The procedure for selecting and clearing the fault history is
described in Table 7-3.
When a fault or warning is generated in the converter, the message will be
displayed immediately, except when in Drive Selection mode.
Changing from the Fault Display mode to other display modes is possible
without resetting the fault first. When no buttons are pressed, the fault or
warning text is displayed as long as the fault is pending.
The Actual Signal Display mode is selected by pressing the ACT button.
1 L -> 600.0 rpm 0
ACT Status... Rdy MCB on
MotorSpeed 0.00 rpm
Power 0.0 %
ACS 1000 User’s Manual 3BHS213400 ZAB E01 Rev. - 7-3 (12)
Chapter 7 - CDP Control Panel ABB
When in Actual Signal Display mode, the fast UP/DOWN buttons allow
to toggle between Actual Signal Display and Fault History Display.
1 L -> 600.0 rpm 0
1 LAST FAULT
Overspeed
001231 12:30:02.3256
Table 7-1 Displaying three Actual Signals
Button to be
Step Function Display
pressed
1. to display the full name of HOLD
the three actual signals 1 L -> 600.0 rpm 1
ACT
DriveStatusWord
MotorSpeed
Power
2. to return to the Actual RELEASE
Signal Display mode 1 L -> 600.0 rpm 1
ACT
DriveStatus Running
MotorSpeed 600.00 rpm
Power 75.0 %
Table 7-2 Selecting Actual Signals
Button to be
Step Function Display
pressed
1. to enter the Actual
Signal Display mode 1 L -> 600.0 rpm 0
ACT
Status ReadyOn
MotorSpeed 0.00 rpm
Power 0.0 %
2. to select a row where the
actual signal is to be 1 L -> 600.0 rpm 0
displayed (a blinking Status ReadyOn
cursor indicates the MotorSpeed 0.00 rpm
selected row) Power 0.0 %
3. to enter the actual signal
selection function 1 L -> 600.0 rpm 0
1 Actual Signals
ENTER
13 Power
0.0 %
4. to select a parameter
group 1 L -> 600.0 rpm 0
2 Actual Signals
01 Excitation Cur
7-4 (12) 3BHS213400 ZAB E01 Rev. - ACS 1000 User’s Manual
ABB Chapter 7 - CDP Control Panel
Table 7-2 Selecting Actual Signals (Continued)
Button to be
Step Function Display
pressed
5. to select an actual signal
1 L -> 600.0 rpm 0
1 Actual Signals
09 NP Voltage
0.0 V
6.a to accept the selection
and to return to the 1 L -> 600.0 rpm 0
Actual Signal Display Status ReadyOn
ENTER
mode MotorSpeed 0.00 rpm
NP Voltage 0.0 V
6.b to cancel the selection
and keep the original ACT PAR 1 L -> 600.0 rpm 0
selection, press any of Status ReadyOn
the mode buttons MotorSpeed 0.00 rpm
FUNC DRIVE Power 0.0 %
the selected keypad
mode is entered
Table 7-3 Displaying a Fault and Resetting Fault History
Button to be
Step Function Display
pressed
1. to enter the Actual
Signal Display mode 1 L -> 600.0 rpm 0
ACT
Status ReadyOn
MotorSpeed 0.00 rpm
Power 0.0 %
2. to enter the Fault
History Display 1 L -> 600.0 rpm 0
1 Last Fault
+ Panel Lost
Power 0.0 %
3. to select the previous
(UP) or next fault 1 L -> 600.0 rpm 0
(DOWN) 2 Last Fault
Speed Ref Lost
980224 10:45:32.0705
to clear the fault history 1 L -> 600.0 rpm 0
RESET 1 Last Fault
the fault history is empty
H Min S
ACS 1000 User’s Manual 3BHS213400 ZAB E01 Rev. - 7-5 (12)
Chapter 7 - CDP Control Panel ABB
Table 7-3 Displaying a Fault and Resetting Fault History (Continued)
Button to be
Step Function Display
pressed
4. to return to the Actual
Signal Display mode 1 L -> 600.0 rpm 0
Status ReadyOn
MotorSpeed 0.00 rpm
Power 0.0 %
Table 7-4 Displaying and Resetting an Active Fault
Button to be
Step Function Display
pressed
1. to display an active fault
1 L -> 600.0 rpm 0
ACT
ACS 1000
*** Fault ***
Panel Lost
2. to reset the fault
1 L -> 600.0 rpm 0
RESET
Status ReadyOn
MotorSpeed 0.00 rpm
Power 0.0 %
7.4 Parameter Mode
NOTICE!
Parameters must only be set by qualified personnel. Do not change any
parameter, if the meaning of the parameter and the effects of the change
are not fully understood. Running the drive system with incorrect data can
result in improper operation, reduction of control accuracy and damage of
equipment.
Parameters allow the converter to be configured and set-up specifically for
an application (see also Signal and Parameter Table).
Parameters are organized in functional groups. All control functions are
represented by a parameter group and can be activated and set-up
individually.
Selecting Parameters The Parameter mode is used to check and change parameters. When this
mode is entered for the first time after the auxiliary voltage of the converter
has been switched on, the display will show the first parameter of
parameter group 11. The next time, the Parameter mode is entered, the
previously selected parameter is shown.
7-6 (12) 3BHS213400 ZAB E01 Rev. - ACS 1000 User’s Manual
ABB Chapter 7 - CDP Control Panel
Some parameter values cannot be changed while the converter is running.
If tried, the following warning will be displayed:
** Warning **
Write Access Denied
Parameter Setting
Not Possible
Table 7-5 Selecting a Parameter and Changing the Value
Button to be
Step Function Display
pressed
1. to enter the Parameter
mode 1 L -> 600.0 rpm 0
PAR
75 OPTION MODULES
01 IOEC3 OptionBoard
YES
2. to select a different
group 1 L -> 600.0 rpm 0
75 OPTION MODULES
01 IOEC3 OptionBoard
YES
3. to select a parameter
1 L -> 600.0 rpm 0
75 OPTION MODULES
02 IOEC4 OptionBoard
NO
4. to enter the parameter
setting function 1 L -> 600.0 rpm 0
75 OPTION MODULES
ENTER
02 IOEC4 OptionBoard
[NO]
5. to change the parameter
value 1 L -> 600.0 rpm 0
(slow change for 75 OPTION MODULES
numbers and text) 02 IOEC4 OptionBoard
(fast change for numbers [YES]
only)
6.a to accept the selection
and to return to the 1 L -> 600.0 rpm 0
Actual Signal Display 75 OPTION MODULES
ENTER
mode 02 IOEC4 OptionBoard
YES
ACS 1000 User’s Manual 3BHS213400 ZAB E01 Rev. - 7-7 (12)
Chapter 7 - CDP Control Panel ABB
Table 7-5 Selecting a Parameter and Changing the Value (Continued)
Button to be
Step Function Display
pressed
6.b to cancel the setting and
keep the original ACT PAR
1 L -> 600.0 rpm 0
selection, press any of 75 OPTION MODULES
the mode buttons 02 IOEC4 OptionBoard
FUNC DRIVE NO
the selected keypad
mode is entered
7.4.1 Parameter Lock
Unwanted parameter entry can be prevented by activating the Parameter
Lock function which is part of group 16 SYSTEM CTR INPUTS.
The Parameter Lock is activated by setting parameters 16.02 and 16.03
accordingly. The user pass code can be changed by setting parameters
16.04 and 16.05. For more details see Signal and Parameter Table.
To activate the Parameter Lock:
1 Select parameter 16.02 PARAMETER LOCK
2 Set parameter 16.02 to LOCKED
3 Save the setting and exit the Parameter mode
To open the Parameter Lock:
1 Select parameter 16.03 PASS CODE
2 Set the correct pass code. If not known see Signal and Parameter
Table for details.
3 Save the setting and exit the Parameter mode.
7.5 Function Mode
Setting the Display The Function mode is used to set the contrast of the display.
Contrast
Table 7-6 Setting the Contrast of the Panel Display
Button to be
Step Function Display
pressed
1. to enter the Function
mode 1 L -> 0.0 rpm 0
FUNC
UPLOAD <= <=
DOWNLOAD => =>
CONTRAST 4
7-8 (12) 3BHS213400 ZAB E01 Rev. - ACS 1000 User’s Manual
ABB Chapter 7 - CDP Control Panel
Table 7-6 Setting the Contrast of the Panel Display (Continued)
Button to be
Step Function Display
pressed
2. to select a function (a
blinking cursor indicates 1 L -> 0.0 rpm 0
the selected function) UPLOAD <= <=
DOWNLOAD => =>
CONTRAST 4
3. to enter the contrast
setting function 1 L -> 0.0 rpm 0
CONTRAST [4]
ENTER
4. to set the contrast
1 L -> 0.0 rpm 0
CONTRAST [6]
5.a to accept the selection
and to return to the 1 L -> 0.0 rpm 0
Actual Signal Display UPLOAD <= <=
ENTER
mode DOWNLOAD => =>
CONTRAST 6
5.b to cancel the setting
and keep the original ACT PAR
1 L -> 0.0 rpm 0
selection, press any of UPLOAD <= <=
the mode buttons DOWNLOAD => =>
FUNC DRIVE CONTRAST 4
the selected keypad
mode is entered
7.6 Operational Commands
7.6.1 Selecting Local/Remote
LOC
Local control mode is selected by pressing the REM button of the control
panel.
Local Control When the panel is switched to LOCAL, operation via the pushbuttons on
the front door of the COU and the CDP control panel is possible. Control
commands from remote have no effect. LOCAL can only be selected
when the converter has been stopped and no remote run command is
active. Switching from LOCAL to REMOTE while the converter is running
stops the converter.
ACS 1000 User’s Manual 3BHS213400 ZAB E01 Rev. - 7-9 (12)
Chapter 7 - CDP Control Panel ABB
Remote Control When the panel is switched to REMOTE, the pushbuttons on the front
door of the control section and the operational buttons of the control panel
are disabled. Operational commands and reference value from a remote
control station are transmitted via fieldbus or remote I/O to the converter.
Switching from REMOTE to LOCAL while the converter is running is not
possible.
Table 7-7 Selecting Local/Remote
Button to be
Step Function Display
pressed
1. to select LOCAL control
1 ->L 550.0 rpm 1
LOC
(the local control location Status Running
is indicated by the letter L) REM MotorSpeed 0.00 rpm
Power 0.0 %
2. to select REMOTE control
1 -> 550.0 rpm 1
LOC
(the remote control Status Running
location is indicated by a REM MotorSpeed 0.00 rpm
blank) Power 0.0 %
7.6.2 Setting the Direction of Rotation
The direction of rotation is selected on the control panel using the
button for forward direction and the button to reverse the direction.
Both buttons can be used when the control panel is in LOCAL mode
An arrow on the display indicates the direction:
• When the motor is running, the arrow indicates the actual sense of
rotation.
• When the motor is not running, the arrow indicates the preselected
sense of rotation.
In the example below, reverse direction is shown.
1 L <- 600.0 rpm 1
Status Running
MotorSpeed 600.00 rpm
Power 40.0 %
When the direction of rotation is changed while the motor is running, the
speed will automatically ramp to zero and the motor will accelerate in
opposite direction to the preset speed. The direction of the arrow on the
display changes to the new direction when the motor has reached zero
speed.
7-10 (12) 3BHS213400 ZAB E01 Rev. - ACS 1000 User’s Manual
ABB Chapter 7 - CDP Control Panel
7.6.3 Entering a Setpoint
The setpoint can be changed via the control panel at any time, when set
to LOCAL.
Table 7-8 Entering a Setpoint
Button to be
Step Function Display
pressed
1. to enter a keypad mode
displaying the status ACT PAR 1 L -> 600.0 rpm 1
row, press a mode Status Running
button FUNC MotorSpeed 600.00 rpm
Power 50.0 %
2. to enter the Setpoint
Setting function 1 L -> [ 600.0 rpm] 1
REF
Status Running
MotorSpeed 600.00 rpm
Power 50.0 %
3. to change the setpoint
1 L -> [ 550.0 rpm] 1
(slow change) Status Running
MotorSpeed 550.00 rpm
(fast change) Power 50.0 %
4. to exit the Setpoint
Setting mode, press any ACT PAR 1 L -> 550.0 rpm 1
of the mode buttons Status Running
MotorSpeed 550.00 rpm
the selected keypad FUNC DRIVE Power 50.0 %
mode is entered
ACS 1000 User’s Manual 3BHS213400 ZAB E01 Rev. - 7-11 (12)
Chapter 7 - CDP Control Panel ABB
7-12 (12) 3BHS213400 ZAB E01 Rev. - ACS 1000 User’s Manual
ABB
Chapter 8 - I/O Interfaces and Application Macros
This chapter provides information on I/O boards, macro-specific I/O
configurations and application macros. Typical applications for each
macro are listed as well.
It is recommended to have the wiring diagrams at hand when reading this
chapter. For signal allocation see Appendix D - Electrical Diagrams.
NOTICE!
Parameters must only be set by qualified personnel. Do not change any
parameter, if the meaning of the parameter and the effects of the change
are not fully understood. Running the drive system with incorrect data can
result in improper operation, reduction of control accuracy and damage of
equipment.
8.1 Terms and Abbreviations
The following terms and abbreviations are used in this chapter:
I/O: Input/Output
DI: Digital Input
DO: Digital Output
AI: Analog Input
AO: Analog Ouput
MCB:Main Circuit Breaker
If a reference is made to an I/O, for instance DI 2.1, ‘2’ refers to the board
(in this case IOEC 2) and ‘1’ refers to the 1st. digital input of the same
board.
ACS 1000 User’s Manual 3BHS213400 ZAB E01 Rev. - 8-1 (20)
Chapter 8 - I/O Interfaces and Application Macros ABB
8.2 Input/Output Boards
8.2.1 Standard I/O Boards
The converter can be fitted with up to four I/O boards.
Each board provides the following number of I/Os:
• Digital Inputs: 14
• Digital Outputs: 6
• Analog Inputs: 4
• Analog Outputs: 2
IOEC 1 is mainly used for internal control signals and the I/Os cannot be
accessed by the customer, except for the following:
• DI 1.8 Disable Local, wired to terminal block X301
• AI 1.1 Ref Value 2, wired to terminal block X301
• AO 1.1 programmable analog output
• AO 1.2 programmable analog output
If an output of an I/O board is not predefined for a standard function, a
macro or an option, the output can be assigned to a binary status signal of
the converter by setting the corresponding parameter(s) accordingly.
In general, all I/Os marked PROGRAMMABLE can be used. Digital inputs
marked FREE in the wiring diagrams cannot be programmed by
parameters.
8.2.2 I/O Ratings
See Appendix B - Technical Data for ratings.
8.2.3 Control Voltage Output
All IOEC boards have a built in DC control voltage output which can be
used for digital input signals. See Appendix B - Technical Data for ratings.
8.2.4 Potentiometer Supply
Each IOEC board provides a 10 VDC supply at terminals X31/1 (+10 VDC)
and X32/2 (0 V).
The 10 VDC supply on IOEC 1 can be used for an external setpoint
potentiometer which is wired to AI 1.1 (reference value 2).
A potentiometer connected to AI 2.1 (reference value 1) can be supplied
by the 10 VDC output of IOEC 2.
8-2 (20) 3BHS213400 ZAB E01 Rev. - ACS 1000 User’s Manual
ABB Chapter 8 - I/O Interfaces and Application Macros
8.2.5 Digital Output De-energized Position
A digital output is shown in the de-energized position, provided it is not
inverted, as illustrated in Figure 8-1:
• When signal READY is not active contact X21/1-2 is closed.
• When signal READY is active contact X21/2-3 is closed.
Terminal Signal Function
X21/1 DO 2.1
Relay output 1
V+ X21/2 DO 2.1
READY
DRIVE READY X21/3 DO 2.1
Figure 8-1 Digital Output in De-energized Position: IOEC 2, DO 2.1.
8.2.6 Location of IOEC Boards
The IOEC boards are installed in the control unit of the converter, as
shown in Figure 8-2.
IOEC board 2
Aux. power terminals
Terminals X300, X301
IOEC board 1
IOEC board 3
IOEC board 4
Figure 8-2 Location of IOEC Boards
ACS 1000 User’s Manual 3BHS213400 ZAB E01 Rev. - 8-3 (20)
Chapter 8 - I/O Interfaces and Application Macros ABB
8.2.7 External Connections
The default I/O configuration of IOEC 1, IOEC 2, IOEC 3 and IOEC 4 can
be seen from the corresponding wiring diagrams in Appendix D - Electrical
Diagrams. The wiring diagrams show the terminals for all inputs and
outputs together with the corresponding signal name.
All contacts are shown in their de-energized position.
The default I/O configuration of IOEC 2 depends on the selected
application macro (see section 8.3 Application Macros).
8.3 Application Macros
8.3.1 Overview
Application macros provide preprogrammed sets of parameters,
specifically adapted for various applications. Depending on the process,
the appropriate macro can be selected thus enabling a quick and easy
start-up of the converter.
All application macros have factory-set parameter values. These default
values can be left unchanged or they can be set individually according to
the needs by the commissioning engineer. Contact the local ABB service
organization when more information is required.
The converter can be operated using one of the following macros:
• Factory
• Speed Control
• Hand/Auto
• PID Control
• Sequential Control
• Torque Control
• Master/Follower
• User 1
• User 2
There are six digital inputs on IOEC board 2 marked STANDARD INPUT
which are assigned to the application macros. The function of each digital
input can change depending on the macro.
When I/Os which are not located on IOEC board 2 are used a reference
to the corresponding board is made.
Besides the standard and the macro specific I/Os, various optional I/Os
may be defined depending on the converter configuration. See the
applicable manuals in Appendix A - Additional Manuals for more details.
8-4 (20) 3BHS213400 ZAB E01 Rev. - ACS 1000 User’s Manual
ABB Chapter 8 - I/O Interfaces and Application Macros
All other customer interface signals are the same for each application
macro.
The tables in the macro description only show the macro specific signal
allocations of digital and analog inputs. The digital outputs for status
indications and for opening and closing the MCB as well as the analog
outputs are the same for all macros.
For detailed information on macro specific parameter settings, see
Appendix G - Signal and Parameter Table, Chapter 3 - Default Parameter
Settings of Application Macros.
8.3.2 Factory Macro
Suitable Applications The Factory Macro is the default-set macro. It covers most of the common
applications such as pumps, fans, conveyors and other industrial
applications where constant speed is required.
Description All commands and reference settings can be given from the CDP control
panel or from an external control station.
LOC
The control station is selected with the REM
button on the control panel.
The control panel can be disabled by energizing DI 1.8. The digital input
can be accessed via terminals X301:1 and X301:2.
In remote control the following default signal interface applies:
• The reference value is connected to AI 2.1.
• The start/stop command is wired to DI 2.1.
• The sense of rotation can be changed with DI 2.2.
The default setting is FORWARD.
It can be changed to REVERSE either by setting parameter 11.03 to
REVERSE or via DI 2.2, if parameter 11.03 has been set to
REQUEST before.
• Three constant speeds can be selected via DI 2.5 and DI 2.6 when
the converter is in remote control.
• Two preset acceleration/deceleration ramps can be selected via
DI 2.4.
When the Factory Macro is active, the converter is speed controlled.
ACS 1000 User’s Manual 3BHS213400 ZAB E01 Rev. - 8-5 (20)
Chapter 8 - I/O Interfaces and Application Macros ABB
Input 1 L -> 600.0 rpm 1
power Status... Running
MotorSpeed 600.00 rpm
Ext. controls
MotCurr 75.0 A
Reference value, start/stop and direction commands are given from
LOC
the control panel. To change to EXTERNAL, press REM
button.
1 -> 600.0 rpm 1
Status... Running
MotorSpeed 600.00 rpm
MotCurr 75.0 A
M
3~ Reference value is read from analog input AI 2.1. Start/stop and
direction commands are given through digital inputs DI 2.1 and
Motor DI 2.2.
Figure 8-3 Factory Macro, Control Overview
Input and Output The default I/O signals of the Factory Macro regarding opening/closing the
Signals MCB, starting/stopping the converter, speed, control location, reference
and actual values are shown in the following table. The corresponding
parameters are listed as well. For further settings see Appendix G - Signal
and Parameter Table.
Table 8-1 Factory Macro, I/O Signals
Digital Inputs Terminal Parameter Remarks
DI 2.1 START/STOP IOEC 2 11.01 1 = start
X11/1-2 0 = stop
DI 2.2 DIRECTION IOEC 2 11.01 0 = forward
X11/3-4 1 = reverse
DI 2.4 IOEC 2 22.01 0 = accel / decel ramp 1 selected
ACCEL/DECELERATION RAMP 1/2 X11/7-8 1 = accel / decel ramp 2 selected
DI 2.5 IOEC 2 33.01 Sel1 Sel2 Selection
CONST SPEED SEL 1 X11/9-10
DI 2.6 IOEC 2 33.01 0 0 Analog Ref.
CONST SPEED SEL 2 X12/1-2 1 0 Const. Speed 1
0 1 Const. Speed 2
1 1 Const. Speed 3
DI 1.8 X301 - 0 = control panel is enabled
DISABLE LOCAL X1-2 1 = control panel is disabled
DI 2.8 IOEC 2 16.01 Process stop or run enable
/PROCESS STOP X12/5-6 0 = converter will not start. If running
converter will stop
DI 2.7 IOEC 2 11.04 Pulse -> 1 = command for closing the main
REMOTE ORD MCB CLOSE X12/3-4 circuit breaker
8-6 (20) 3BHS213400 ZAB E01 Rev. - ACS 1000 User’s Manual
ABB Chapter 8 - I/O Interfaces and Application Macros
Table 8-1 Factory Macro, I/O Signals (Continued)
Digital Inputs Terminal Parameter Remarks
DI 2.13 IOEC 2 11.04 Pulse -> 1 = command for opening the
REMOTE ORD MCB OPEN X13/5-6 main circuit breaker
DI 2.9 IOEC 2 21.07 Feedback from MCB
MCB IS OPEN X12/7-8 0 = MCB is open
1 = MCB is closed
DO 2.5 IOEC 2 21.06 Command to open the MCB
/MCB ORD OPEN X25/2-3 Pulse -> 0 = MCB is opened
DO 2.6 IOEC 2 21.06 Command to close the MCB
MCB ORD CLOSE X26/2-3 Pulse -> 1 = MCB is closed
Analog Inputs Terminal Parameter Remarks
AI 2.1 IOEC 2 - For selection see parameter 12.3 / 12.6
EXTERNAL SPEED REFERENCE 1 X31/2-X32/2 Parameter 33.1 must be set to NOT SEL
AI 1.1 X301 - For selection see parameter 12.3 / 12.6
EXTERNAL SPEED REFERENCE 2 X3-X4 Parameter 33.1 must be set to NOT SEL
8.3.3 Speed Macro
Suitable Applications The Speed Macro can be used for the same applications as the Factory
Macro. The only difference to the Factory Macro is that the motor control
parameters of the converter will not be overwritten and set to 0 when the
macro is activated.
For further information see 8.3.2 Factory Macro.
8.3.4 Hand/Auto Macro
Suitable Applications The Hand/Auto Macro is suitable for applications where the speed has to
be controlled automatically by a process automation system and manually
by an external control panel. The active control station is selected via a
digital input.
The macro is also recommendable when two external control stations
exist from where the reference value can be set and the converter can be
started and stopped. The active control station for the reference value is
selected via a digital input.
Description Start/stop commands and reference settings can be given from the control
panel of the converter or from one of two external control stations, EXT1
(Hand) or EXT2 (Auto) (see Figure 8-4).
LOC
The button on the control panel is used to enable the control panel
REM
or the external control stations. The control panel can be disabled by
closing DI 1.8. The digital input can be accessed via terminals X301:1 and
X301:2.
ACS 1000 User’s Manual 3BHS213400 ZAB E01 Rev. - 8-7 (20)
Chapter 8 - I/O Interfaces and Application Macros ABB
The remote control station EXT1 or EXT2 is selected with DI 2.5.
The control signals of EXT1 (Hand) for starting and stopping are
connected to DI 2.1. Open/close commands for the MCB are wired to
DI 2.13 and DI 2.7. The reference value is connected to AI 2.1. The speed
reference value is given in rpm.
The commands from EXT 2 (Auto) for starting and stopping are connected
to DI 2.2 and for opening/closing the MCB to DI 2.3 and DI 2.4. The
reference value is connected to AI 1.1. The analog input on IOEC 1 is
accessible through terminals X301:3 and 4. The speed reference value is
given as a percentage of the maximum speed of the drive (see parameters
12.07 and 12.08).
One constant speed can be selected through DI 2.6.
The converter is speed controlled when the Hand/Auto Macro is selected.
By default, the direction is fixed to FORWARD (see parameter 11.03).
1 L -> 600.0 rpm 1
Status... Running
Input MotorSpeed 600.00 rpm
EXT1 (rpm) = power
Hand control MotCurr 75.0 A
Reference, start/stop and direction commands are given from the
LOC
control panel. To change to EXTERNAL, press REM
button.
Hand/Auto
Const.speed1 1 -> 600.0 rpm 1
Status... Running
PLC MotorSpeed 600.00 rpm
or MotCurr 75.0 A
ext. controls
EXT2 (%) = Panel display in REMOTE:
Auto control Hand control: Reference is read from analog input AI 1.1.
M Start/stop command is given through digital input DI 2.1.
3∼
Motor
Figure 8-4 Hand/Auto Macro, Control Overview
Input and Output The default I/O signals of the Hand/Auto Macro regarding opening/closing
Signals the MCB, starting/stopping the converter, speed, control location,
reference and actual values are shown in the following table. The
corresponding parameters are listed as well. For further settings see
Appendix G - Signal and Parameter Table.
8-8 (20) 3BHS213400 ZAB E01 Rev. - ACS 1000 User’s Manual
ABB Chapter 8 - I/O Interfaces and Application Macros
Table 8-2 Hand/Auto Macro, I/O Signals
Digital Inputs Terminal Parameter Remarks
DI 2.1 IOEC 2 11.01 1 = start
START/STOP HAND X11/1-2 0 = stop
DI 2.6 IOEC 2 11.02 1 = start
START/STOP AUTO X12/1-2 0 = stop
DI 2.7 IOEC 2 11.04 1 = request for closing the main circuit
REMOTE ORD MCB CLOSE X12/3-4 breaker
HAND
DI 2.13 IOEC 2 11.04 1 = request for opening the main circuit
REMOTE ORD MCB OPEN HAND X13/5-6 breaker
DI 2.3 IOEC 2 11.05 Pulse -> 1 = command for closing the
REMOTE ORD MCB CLOSE X11/5-6 main circuit breaker
AUTO
DI 2.4 IOEC 2 11.05 Pulse -> 1 = command for opening the
REMOTE ORD MCB OPEN AUTO X11/7-8 main circuit breaker
DI 2.5 IOEC 2 12.02 0 = hand selected
EXT1/EXT2 SELECTION X11/9-10 1 = auto selected
DI 2.2 IOEC 2 33.01 If set to “1” a predefined constant speed
CONSTANT SPEED 1 X11/3-4 reference is selected
DI 1.8 X301 - 0 = control panel is enabled
DISABLE LOCAL X1-2 1 = control panel is disabled
DI 2.8 IOEC 2 16.01 Process stop or run enable
/PROCESS STOP X12/5-6 0 = converter will not start. If running
converter will stop
DI 2.9 IOEC 2 21.07 Feedback from MCB
MCB IS OPEN X12/7-8 0 = MCB is open
1 = MCB is closed
Analog Inputs Terminal Parameter Remarks
AI 2.1 IOEC 2 - External reference 1 in rpm
REFERENCE 1 X31/2-X32/2
HAND
AI 1.1 X301: - External reference 2 in %
REFERENCE 2 X3-X4
AUTO
ACS 1000 User’s Manual 3BHS213400 ZAB E01 Rev. - 8-9 (20)
Chapter 8 - I/O Interfaces and Application Macros ABB
8.3.5 PID Macro
Suitable applications The PID Macro is intended for the use with closed loop control systems
such as pressure control, level control and flow control. For example:
• Booster pumps of municipal water supply systems
• Automatic level control of water reservoirs
• Booster pumps of district heating systems
• Speed control of different types of material handling systems where
the material flow has to be regulated.
Reference
Level
trans-
ducer
Actual value
Pump
Description The PID Macro allows to control a process variable - such as pressure or
flow - by adjusting the speed of the motor accordingly.
Start/stop commands and reference settings can be given from the control
panel of the converter or from an external control station.
LOC
The REM
button on the control panel is used to enable the control panel
or the external control station. The control panel can be disabled by
closing DI 1.8. The digital input can be accessed via terminals X301:1 and
X301:2.
Parameter group 40 provides the necessary settings for the PID Macro.
The PID Macro requires IOEC board 4.
The process reference value is connected to AI 1.1. The customer
terminals for AI 1.1 are available on terminal block X301.
Two process feedback signals can be used. Actual value 1 is connected
to AI 4.1 and actual value 2 to AI 4.2. Parameter 40.06 provides the
settings regarding the number of feedback signals and their
interconnections.
8-10 (20) 3BHS213400 ZAB E01 Rev. - ACS 1000 User’s Manual
ABB Chapter 8 - I/O Interfaces and Application Macros
When the PID controller is part of a higher-level control system and the
speed of the motor is to be controlled directly, the speed reference value
has to be wired to AI 2.1.
The internal PID controller is bypassed if external control station EXT1 is
selected (DI 2.3 is open). Then the converter no longer controls the
process variable but the speed of the motor directly.
Default actual signals shown on the control panel are MOTOR SPEED,
ACTUAL VALUE1 and CONTROL DEVIATION.
Input 0 L -> 600.0 rpm 1
power MotorSpeed 600.00 rpm
Actual Value 52.00 %
CtrlDev 0.1 %
EXT1
Ref. Reference value, start/stop and direction
commands are given from the control panel.
Actual value PT
PID EXT2
LOC
START/STOP(EXT1) To change to EXTERNAL , press the button.
REM
START/STOP(EXT2)
Speed/Process
(EXT1/EXT2) 0 -> 600.0 rpm 1
Run enable MotorSpeed 600.00 rpm
Const.speed
Actual Value 52.00 %
External Control CtrlDev 0.1 %
EXT1 (rpm) = Direct speed control
EXT2 (%) = Process PID control M Reference is read from analog input AI 1.1. Start/
3∼
Keypad Control stop command is given through DI 2.1 when in
REF1 (rpm) = Direct speed control direct speed control (EXT1) or through digital
Motor
REF2 (%) = Process PID control input DI 2.6 when in Process Control (EXT2).
Figure 8-5 PID Macro, Control Overview
Input and Output The default I/O signals of the PID Macro regarding opening/closing the
Signals MCB, starting/stopping the converter, speed, control location, reference
and actual values are shown in the following table. The corresponding
parameters are listed as well. For further settings see Appendix G - Signal
and Parameter Table.
Table 8-3 PID Macro, I/O Signals
Digital Inputs Terminal Parameter Remarks
DI 2.1 IOEC 2 11.01 1 = start
START/STOP X11/1-2 0 = stop
DI 2.2 IOEC 2 11.01 0 = forward
DIRECTION X11/3-4 1 = reverse
DI 2.3 IOEC 2 12.02 Selection of external reference
EXT 1/2 SELECTION X11/5-6 0 = EXT 1
1 = EXT 2
DI 2.4 IOEC 2 22.01 0 = accel / decel ramp 1 selected
ACCEL/DECELERATION RAMP 1/2 X11/7-8 1 = accel / decel ramp 2 selected
ACS 1000 User’s Manual 3BHS213400 ZAB E01 Rev. - 8-11 (20)
Chapter 8 - I/O Interfaces and Application Macros ABB
Table 8-3 PID Macro, I/O Signals (Continued)
Digital Inputs Terminal Parameter Remarks
DI 2.5 IOEC 2 33.01 Sel1 Sel2 Selection
CONST SPEED SEL 1 X11/9-10
DI 2.6 IOEC 2 33.01 0 0 Analog Ref.
CONST SPEED SEL 2 X12/1-2 1 0 Const. Speed 1
0 1 Const. Speed 2
1 1 Const. Speed 3
DI 1.8 X301 - 0 = control panel is enabled
DISABLE LOCAL X1-2 1 = control panel is disabled
DI 2.8 IOEC 2 16.01 Process stop or run enable
/PROCESS STOP X12/5-6 0 = converter will not start . If running
converter will stop
DI 2.7 IOEC 2 11.04 Pulse -> 1 = command for closing the main
REMOTE ORD MCB CLOSE X12/3-4 circuit breaker
DI 2.13 IOEC 2 11.04 Pulse -> 1 = command for opening the
REMOTE ORD MCB X13/5-6 main circuit breaker
OPEN
DI 2.9 IOEC 2 21.07 Feedback from MCB
MCB IS OPEN X12/7-8 0 = MCB is open
1 = MCB is closed
Analog Inputs Terminal Parameter Remarks
AI 2.1 IOEC 2 - External reference
ANALOG REFERENCE X31/2-X32/2
AI 4.1 IOEC 4 - Process feedback
ACTUAL VALUE X31/2-X32/2
AI 4.2 IOEC 4 - Process feedback
ACTUAL VALUE X31/3-X32/3
8-12 (20) 3BHS213400 ZAB E01 Rev. - ACS 1000 User’s Manual
ABB Chapter 8 - I/O Interfaces and Application Macros
8.3.6 Torque Macro
Suitable applications The Torque Macro is used for processes requiring torque control, e.g.
mixers and slave drives. The torque reference comes from a process
automation system or a control panel.
Description The settings for torque reference and torque reference handling can be
adjusted in parameter group 25 and 26 respectively.
The torque reference is given through AI 2.1 as a current signal. By
default, 0 mA correspond to 0% and 20 mA to 100% of the rated motor
torque.
The start and stop command is given through DI 2.1 and the sense of
rotation is changed by means of DI 2.2.
Changing from torque control to speed control is achieved by setting
DI 2.3 to low.
It is also possible to change the control location from external to local
LOC
(i.e. to control panel) by pressing the REM
button. When LOCAL is
selected on the control panel the converter is speed controlled by default.
If torque control is required, parameter 12.1 KEYPAD REF SELECT must
be changed to REF2 (%). The control panel can be disabled by closing DI
1.8. The digital input can be accessed via terminals X301:1 and X301:2.
Default settings for the display of the control panel are SPEED, TORQUE
and CONTROL LOCATION.
0 L -> 600.0 rpm 1
MotorSpeed 600.00 rpm
Input MotTorq 66.00 %
power
CtrlLoc LOCAL
Ext. controls Reference value, start, stop and direction commands are given
LOC
EXT1
Speed ref. from the control panel. To change to EXTERNAL press REM
Torque ref. EXT2 button.
0 -> 600.0 rpm 1
MotorSpeed 600.00 rpm
MotTorq 66.00 %
CtrlLoc EXT2
The reference value is read from AI 2.1 (if torque control is
M
selected) or AI 1.1 (if speed control is selected). Start, stop and
3∼ direction commands are given through DI 2.1 and DI 2.2. Selec-
tion between speed and torque control is done through DI 2.3.
Motor
External Control Keypad Control
EXT1 (rpm) = Speed control REF1 (rpm) = Speed control
EXT2 (%) = Torque control REF2 (%) = Torque control
Figure 8-6 Torque Macro, Control Overview
ACS 1000 User’s Manual 3BHS213400 ZAB E01 Rev. - 8-13 (20)
Chapter 8 - I/O Interfaces and Application Macros ABB
Input and Output The default I/Os of the Torque Macro regarding opening/closing the MCB,
Signals starting/stopping the converter, speed, control location, reference and
actual values are shown in the following table. The corresponding
parameters are listed as well. For further settings see Appendix G - Signal
and Parameter Table.
Table 8-4 Torque Macro, I/O Signals
Digital Inputs Terminal Parameter Remarks
DI 2.1 IOEC 2 11.01 1 = start
START/STOP X11/1-2 0 = stop
DI 2.2 IOEC 2 11.01 0 = forward
DIRECTION X11/3-4 1 = reverse
DI 2.3 IOEC 2 12.02 0 = speed control
EXT 1/2 SELECTION X11/5-6 1 = torque control
DI 2.4 IOEC 2 22.01 0 = accel / decel ramp 1 selected
ACCEL/DECEL 1/2 SELECTION X11/7-8 1 = accel / decel ramp 2 selected
DI 2.5 IOEC 2 33.01 If set to “1” the predefined constant speed
CONSTANT SPEED SELECTION X11/9-10 reference is selected
DI 1.8 X301 - 0 = control panel is enabled
DISABLE LOCAL X1-2 1 = control panel is disabled
DI 2.8 IOEC 2 16.01 Process stop or run enable
/PROCESS STOP X12/5-6 0 = converter will not start . If running
converter will stop
DI 2.7 IOEC 2 11.04 Pulse -> 1 = command for closing the main
REMOTE ORD MCB CLOSE X12/3-4 circuit breaker
DI 2.13 IOEC 2 11.04 Pulse -> 1 = command for opening the
REMOTE ORD MCB X13/5-6 main circuit breaker
OPEN
DI 2.9 IOEC 2 21.07 Feedback from MCB
MCB IS OPEN X12/7-8 0 = MCB is open
1 = MCB is closed
Analog Inputs Terminal Parameter Remarks
AI 1.1 IOEC 1 - Speed reference (EXT1)
SPEED REFERENCE X31/2-X32/2
AI 2.1 IOEC 2 - Torque reference (EXT2)
TORQUE REFERENCE X31/2-X32/2
8-14 (20) 3BHS213400 ZAB E01 Rev. - ACS 1000 User’s Manual
ABB Chapter 8 - I/O Interfaces and Application Macros
8.3.7 Sequential Macro
Suitable Applications The Sequential Macro is typically used in processes requiring different
constant speed settings and/or different acceleration/deceleration settings
in addition to an adjustable speed reference value. Up to seven constant
speed settings and two acceleration/deceleration settings are possible.
The selection of the different settings can be automated by a process
control system or can be made manually by selector switches which are
connected to the corresponding digital inputs.
Description The macro offers seven preset constant speeds which can be activated by
DI 2.4, DI 2.5 and DI 2.6.
The parameters assigned for constant speed settings are in group 33.
Two preset acceleration/deceleration ramps are selectable via DI 2.3.
The start/stop command is connected to DI 2.1 and the sense of rotation
can be changed via DI 2.2.
An external speed reference value can be wired to AI 2.1. It is active when
DI 2.4, DI 2.5 and DI 2.6 are low.
Operational commands and reference value can also be given using the
control panel if the control panel is set to local. The control panel can be
disabled by closing DI 1.8. The digital input can be accessed via terminals
X301:1 and X301:2.
Default actual values shown on the Control Panel are FREQUENCY,
CURRENT and POWER.
Input Speed
power
Ext. controls Speed 3
Speed 2 Stop with
deceleration
ramp
Speed 1
Time
Accel1 Accel1 Accel2 Decel2
Start/Stop
Accel1/Decel1
M
3∼ Speed 1
Speed 2
Motor Accel2/Decel2
Speed 3
External control
EXT1 (rpm) = Speed control
EXT2 (%) = Speed control Example of sequential control using constant speeds and different
Keypad control acceleration and deceleration times.
REF1 (rpm) = Speed control
REF2 (%) = Speed control
Figure 8-7 Sequential Macro, Control Overview
ACS 1000 User’s Manual 3BHS213400 ZAB E01 Rev. - 8-15 (20)
Chapter 8 - I/O Interfaces and Application Macros ABB
Input and Output The default I/O signals of the Sequential Macro regarding opening/closing
Signals the MCB, starting/stopping the converter, speed, control location,
reference and actual values are shown in the following table. The
corresponding parameters are listed as well. For further settings see
Appendix G - Signal and Parameter Table.
Table 8-5 Sequential Macro, I/O Signals
Digital Inputs Terminal Parameter Remarks
DI 2.1 IOEC 2 11.01 1 = start
START/STOP X11/1-2 0 = stop
DI 2.2 IOEC 2 11.01 0 = forward
DIRECTION X11/3-4 1 = reverse
DI 2.3 IOEC 2 22.01 0 = accel / decel ramp 1 selected
ACCEL/DECEL 1/2 X11/5-6 1 = accel / decel ramp 2 selected
SELECTION
DI 2.4 IOEC 2 33.01 Sel1 Sel2 Sel3 Selection
CONST SPEED SEL 1 X11/7-8
DI 2.5 IOEC 2 33.01 0 0 0 Analog Ref.
CONST SPEED SEL 2 X11/9-10 1 0 0 Const. Speed 1
0 1 0 Const. Speed 2
DI 2.6 IOEC 2 33.01 1 1 0 Const. Speed 3
CONST SPEED SEL 3 X12/1-2 0 0 1 Const. Speed 4
1 0 1 Const. Speed 5
0 1 1 Const. Speed 6
1 1 1 Const. Speed 7
DI 1.8 X301 - 0 = control panel is enabled
DISABLE LOCAL X1-2 1 = control panel is disabled
DI 2.8 IOEC 2 16.01 Process stop or run enable
/PROCESS STOP X12/5-6 0 = converter will not start or stop when
running
DI 2.7 IOEC 2 11.04 Pulse -> 1 = command to close the main
REMOTE ORD MCB CLOSE X12/3-4 circuit breaker
DI 2.13 IOEC 2 11.04 Pulse -> 1 = command to open the main
REMOTE ORD MCB X13/5-6 circuit breaker
OPEN
DI 2.9 IOEC 2 21.07 Feedback from MCB
MCB IS OPEN X12/7-8 0 = MCB is open
1 = MCB is closed
Analog Inputs Terminal Parameter Remarks
AI 2.1 IOEC 2 - External reference
ANALOG REFERENCE X31/2-X32/2
8-16 (20) 3BHS213400 ZAB E01 Rev. - ACS 1000 User’s Manual
ABB Chapter 8 - I/O Interfaces and Application Macros
8.3.8 Master/Follower Macro
Suitable Applications The Master/Follower Macro is used for applications with several
converters where the motor shafts are coupled to each other by gearing,
chain, belt etc. Thanks to the Master/Follower Macro the load can be
evenly distributed between the converters or at some adjustable other
ratio which depends on the process.
Description All commands and reference settings for a master follower drive
configuration can be given from the control panel of the master drive or
from an external control station connected to the master drive. The
follower drive(s) receive(s) the control signals via a fiber-optic link from the
master drive.
NOTICE!
Connect all control signals to the master drive only. The follower must
receive all commands exclusively from the master. Do not control the
follower(s) with its (their) own control panel(s). Disable the control panels
of all follower drive(s) by energizing DI 1.8. Do not control the follower
through a fieldbus system. Otherwise, the proper functioning of the drive
system is affected and the equipment may even be damaged.
Parameter settings and further information regarding the Master/Follower
Macro can be found in Appendix G - Signal and Parameter Table,
parameter group 70.
The active control station - control panel or external control station - is
LOC
selected by the REM
button on the control panel of the master. The
control panel can be disabled by closing DI 1.8. The digital input can be
accessed via terminals X301:1 and X301:2.
In remote control, the reference value is connected to AI 2.1, the start/stop
command is wired to DI 2.1 and the sense of rotation can be changed with
DI 2.2. The default setting for the sense of rotation (parameter 11.03) is
FORWARD. It can be changed to REVERSE either by setting
parameter 11.03 to REVERSE or via DI 2.2 when parameter 11.03 has
been set to REQUEST before (master and follower).
Three constant speeds can be selected via DI 2.5 and DI 2.6 when the
converter is in remote control.
Additionally, the Master/Follower Macro offers two preset acceleration/
deceleration ramps which can be selected via DI 2.4.
ACS 1000 User’s Manual 3BHS213400 ZAB E01 Rev. - 8-17 (20)
Chapter 8 - I/O Interfaces and Application Macros ABB
Input Input 1 L -> 600.0 rpm 1
power power Status... Running
Ext. controls Drive link
MotorSpeed 600.00 rpm
MotCurr 75.0 A
Reference value, start/stop and direction commands are given from
LOC
the control panel. To change to EXTERNAL, press REM
button.
1 -> 600.0 rpm 1
Status... Running
MotorSpeed 600.00 rpm
MotCurr 75.0 A
M M
3~ The reference value is read from AI 2.1. Start/stop and direction com-
3~
mands are given through DI 2.1 and DI 2.2.
Motor Motor
MASTER FOLLOWER
Figure 8-8 Master/Follower Macro, Control Overview
Input and Output The default I/O signals of the Master/Follower Macro regarding opening/
Signals closing the MCB, starting/stopping the converter, speed, control location,
reference and actual values are shown in the following table. The
corresponding parameters are listed as well. For further settings see
Appendix G - Signal and Parameter Table.
Table 8-6 Master/Follower Macro, I/O Signals
Digital Inputs Terminal Parameter Remarks
DI 2.1 START/STOP IOEC 2 11.01 1 = start
X11/1-2 0 = stop
DI 2.2 DIRECTION IOEC 2 11.01 1 = forward
X11/3-4 0 = reverse
DI 2.4 IOEC 2 22.01 Selection of ramp time
ACCEL/DECELERATION RAMP 1/2 X11/7-8 0 = ramp time set 1
1 = ramp time set 2
DI 2.5 IOEC 2 33.01 Sel1 Sel2 Selection
CONST SPEED SEL 1 X11/9-10
DI 2.6 IOEC 2 33.01 0 0 Analog Ref.
CONST SPEED SEL 2 X12/1-2 1 0 Const. Speed 1
0 1 Const. Speed 2
1 1 Const. Speed 3
DI 1.8 X301 - 0 = control panel is enabled
DISABLE LOCAL X1-2 1 = control panel is disabled
DI 2.8 IOEC 2 16.01 Process stop or run enable
/PROCESS STOP X12/5-6 0 = converter will not start. If running
converter will stop
8-18 (20) 3BHS213400 ZAB E01 Rev. - ACS 1000 User’s Manual
ABB Chapter 8 - I/O Interfaces and Application Macros
Table 8-6 Master/Follower Macro, I/O Signals (Continued)
Digital Inputs Terminal Parameter Remarks
DI 2.7 IOEC 2 11.04 Pulse -> 1 = command for closing the main
REMOTE ORD MCB CLOSE X12/3-4 circuit breaker
DI 2.13 IOEC 2 11.04 Pulse -> 1 = command for opening the
REMOTE ORD MCB X13/5-6 main circuit breaker
OPEN
DI 2.9 IOEC 2 21.07 Feedback from MCB
MCB IS OPEN X12/7-8 0 = MCB is open
1 = MCB is closed
8.3.9 User 1 and User 2 Macro
Each of these two macros allows a complete customized parameter set to
be saved and to be recalled at a later instant.
ACS 1000 User’s Manual 3BHS213400 ZAB E01 Rev. - 8-19 (20)
Chapter 8 - I/O Interfaces and Application Macros ABB
8-20 (20) 3BHS213400 ZAB E01 Rev. - ACS 1000 User’s Manual
ABB
Chapter 9 - Maintenance and Troubleshooting
Maintenance and parts replacement on the converter must only be carried
out by qualified personnel in compliance with local regulations.
It is strongly recommended to carry out all maintenance work according to
the maintenance schedule at the end of this chapter and the applicable
service instructions, on time and at the stated intervals.
During the warranty period, any repair work must be carried out
exclusively by ABB service personnel. After the warranty period, repair
work may only be carried out by qualified personnel.
ABB offers maintenance and service training courses. Customer staff
having successfully attended such courses, will be certified to do
maintenance and repair work on the converter. To maintain safe and
reliable operation of the converter, ABB recommends taking out a service
contract with the ABB service organization. For more information contact
the ABB service organization. For contact address see section General
Information.
All maintenance activity should be recorded in the maintenance log book
including:
• Date and time of the maintenance work
• Description of the maintenance work
• In case of water-cooled converters:
Conductivity, temperature, pressure and water level
of the cooling water before and after the maintenance
routine
Supplementary information on maintenance and troubleshooting can be
obtained from the following manuals:
• Service and Maintenance Manual with instructions on checking and
replacing semiconductors, changing phase modules and replacing
components
• User’s Manual for Water Cooling System in Appendix A - Additional
Manuals (only in case of water cooled converters)
• Signal and Parameter Table
• Troubleshooting Manual. The document supplements the Signal and
Parameter Table and provides explanations of alarm and fault
messages, associated parameters and I/Os and hints for rectification.
ACS 1000 User’s Manual 3BHS213400 ZAB E01 Rev. - 9-1 (6)
Chapter 9 - Maintenance and Troubleshooting ABB
9.1 Safety Instructions
DANGER!
Hazardous voltage!
Do not try to gain access to the converter transformer, the high voltage
unitss of the converter nor the motor as long as the drive system is
energized and not grounded.
DANGER!
Voltages from external control circuits may be present inside the
converter, even if mains and auxiliary power are shut off. Take appropriate
measures before working on the converter: de-energize and disconnect all
external devices!
DANGER!
The driven machine can cause the motor to rotate! Always disconnect,
short-circuit or block the motor before work is started.
NOTICE!
Before power is applied to the converter, check that:
• Mains and motor connections are ok
• Auxiliary power and control cable connections are ok
• No tools or other foreign objects are left in the cabinet
• All doors of the power sections are properly closed
NOTICE!
The cooling system may start automatically as soon as the auxiliary
voltage is switched on.
9-2 (6) 3BHS213400 ZAB E01 Rev. - ACS 1000 User’s Manual
ABB Chapter 9 - Maintenance and Troubleshooting
9.2 Specific Maintenance Tasks
9.2.1 Cleaning
Dust on electrical components and wiring can cause malfunction and
damage the components.
Proceed as follows:
1 De-energize the drive system according to Chapter 6 - Operation.
2 Carefully clean compartment floors with the vacuum cleaner fitted
with a soft nozzle to prevent component damage.
3 When finished, restart the drive system as described in Chapter 6 -
Operation.
9.2.2 Checking Wire and Cable Connections
Vibration can loosen electrical connections and cause occasional
malfunction or equipment failure. Dust and moisture can build up in loose
connections and cause loss of low-level signals.
Proceed as follows:
1 De-energize the drive system according to Chapter 6 - Operation.
2 Check all power and control cable connections and tighten them if
necessary. Check that all plugs and connectors are tight.
IMPORTANT!
! Capacitor bushings will be damaged when excessive force is applied. Do
not exceed the maximum tightening torque when tightening the capacitor
terminals. The tightening torque values are printed on a label which is
attached on the capacitor. If not otherwise specified, the maximum torque
must not exceed 20 Nm.
3 When finished, restart the drive system as described in Chapter 6 -
Operation.
9.3 Door Center Posts
The filter and DC components unit and the converter unit are equipped
with center posts (see arrows in Figure 9-1). If a center post has been
removed for maintenance purposes, it must be remounted again before
the converter is energized. The center posts are important to lock the
doors securely.
ACS 1000 User’s Manual 3BHS213400 ZAB E01 Rev. - 9-3 (6)
Chapter 9 - Maintenance and Troubleshooting ABB
Filter and DC components unit Converter unit
Figure 9-1 Center Posts
9.4 Standard Procedure for Troubleshooting
Proceed as follows:
1 Do not switch off the auxiliary voltage or try to reset a fault message
before all essential information at the time of the occurance of the
fault condition has been saved.
2 Call up the Fault History Display on the CDP control panel. See
Chapter 7 - CDP Control Panel for further information.
Do not clear the fault buffer now!
3 Identify the fault and make a logbook entry.
4 Save the content of the data logger, when a PC is available which has
the DriveWindow or DriveDebug tool installed.
The data logger provides useful information (e.g. waveforms of
voltage, current, torque etc.) for efficient troubleshooting.
5 Try to rectify the fault following the Troubleshooting Manual.
6 Contact ABB service if a fault cannot be rectified.
When calling ABB service, it is recommended to have the following
data available at the time when the fault occurred:
• Operating, ambient and load conditions
• Unusual events
• In case of water-cooled converters:
Conductivity, temperature, pressure and water level
of the cooling water
9-4 (6) 3BHS213400 ZAB E01 Rev. - ACS 1000 User’s Manual
ABB Chapter 9 - Maintenance and Troubleshooting
After the fault has been rectified, start the converter as described in
Chapter 6 - Operation.
ACS 1000 User’s Manual 3BHS213400 ZAB E01 Rev. - 9-5 (6)
Chapter 9 - Maintenance and Troubleshooting ABB
9-6 (6) 3BHS213400 ZAB E01 Rev. - ACS 1000 User’s Manual
ABB
Maintenance Schedule
Years from start-up
0 1 2 3 4 5 6 7 8 9 10 11 12
Start-up P
Estimated Working Time (hours) 20 30 20 30 20 30 20 30 20 30 20 50
Cooling
Air Cooled Unit:
Air filters R R R R R R R R R R R R
Cooling fan I I I R I I I R I I I R
Redundant cooling fans I I I I I I I R I I I I
Water Cooled Unit:
De-Ionizer I R I R I R I R I R I R
Micro filter I R I R I R I R I R I R
Cooling pump seal I R I I I R I I I R I I
Cooling pump I I I R I I I R I I I R
Redundant cooling pump seals I I I R I I I I I I I R
Redundant cooling pumps I I I I I I I R I I I I
Aux cooling fan I I I R I I I R I I I R
Redundant aux cooling fans I I I I I I I R I I I I
Strainer I I I I I I I I I I I I
Aging
Power capacitors (C, CR, CF) P P P P P P P P P P P R
Other capacitors (CCL, CM, CB) P P P P P P P P P P P R
Battery I R I R I R I R I R I R
Connections & Surroundings
Fiber optic cables P P P P P P P P P P P P
Cable connections I I I I I I I I I I I I
Dustiness, corrosion and
I I I I I I I I I I I I
temperature
Improvements
SW / HW upgrade I I I I I I I I I I I I
Based on product notes I I I I I I I I I I I I
Measurements
Basic measurements with aux.
P P P P P P P P P P P P
supply voltage
Insulation test - P - P - P - P - P - P
Spare Parts
Spare parts I I I I I I I I I I I I
Legend:
Replacement of component R
Inspection (visual inspection, correction and replacement if needed) I
Performance of on-site work (commissioning, tests, measurements, etc.) P
ACS 1000 User's Manual 3BHS206977 ZAB Rev. - 1 (2)
ABB
2 (2) 3BHS206977 ZAB Rev. - ACS 1000 User's Manual
ABB
ACS 1000
Medium Voltage Drives
315 to 5000 kW
400 to 6700 hp
User’s Manual
Water Cooling Unit
Document No.: 3BHS204366 ZAB E02 Rev. A
Issued: 29-06-2005
© ABB Switzerland Ltd. All Rights Reserved.
ABB reserves all rights to this document, also in the event of patent issue
or registration of any other industrial property protection right. Misuse, in
particular duplication and forwarding to third parties, is not permitted.
This document has been checked with due care and attention. However,
should the user find any errors, these should be reported to ABB.
ABB aims to maintain the most modern standard, therefore, entries in this
manual may differ from the actual product.
3BHS204366 ZAB E02 Rev. A ACS 1000 Water Cooling Unit
ABB
Table of Contents
Chapter 1 - Safety 1-1
Chapter 2 - Installation 2-1
2.1 Raw Water Connections 2-1
2.1.1 Hose Connection (Standard) 2-1
2.1.2 Hose Connection Side Entry 2-3
2.1.3 Flange Connection (Option 2-3
2.2 Drain Connection 2-4
Chapter 3 - Starting up the Cooling System 3-1
3.1 Checks before Start-up 3-1
3.2 Filling the Cooling System 3-1
3.3 Adding Water to the Cooling System 3-5
Chapter 4 - Draining the Cooling System 4-1
Chapter 5 - Checking Actual Values 5-1
5.1 Water Conductivity 5-1
5.2 Water Pressure 5-1
5.3 Water Temperature 5-2
5.4 Water Level 5-3
Chapter 6 - Tightening Torques, Threaded Connections 6-1
6.1 Tightening Torques 6-1
6.2 Sealing off Threaded Connections without O-rings and
Gaskets 6-1
Appendices
ACS 1000 Water Cooling Unit 3BHS204366 ZAB E02 Rev. A 1 (2)
ABB
2 (2) 3BHS204366 ZAB E02 Rev. A ACS 1000 Water Cooling Unit
ABB
Chapter 1 - Safety
This manual should be read thoroughly and understood before work on
the cooling system is started.
See ACS 1000 User's Manual, Chapter 1- Safety for explanation on how
the safety messages are categorized and used in this manual.
NOTICE!
The cooling system may start automatically as soon as the auxiliary
voltage is switched on. The pump is switched on depending on
temperature and conductivity of the pure water or internal air temperature.
NOTICE!
Valves, tubes and hoses are delicate parts. Do not bend or put any
pressure on the valves, tubes and hoses.
NOTICE!
Where possible, all components and sub-assemblies weighting over 25 kg
have been clearly marked with weight details. Pumps and electric motors
are equipped with lifting eyes as supplied by the manufacturers. If lifting of
heavy and/or awkwardly positioned items is necessary, extreme caution
shall be exercised. Safe, reliable mechanical lifting equipment shall be
used wherever possible. Under no circumstances shall items be lifted by
means of straps, ropes, chains etc. connected to piping or other system
components.
ACS 1000 Water Cooling Unit 3BHS204366 ZAB E02 Rev. A 1-1 (2)
Chapter 1 - Safety ABB
1-2 (2) 3BHS204366 ZAB E02 Rev. A ACS 1000 Water Cooling Unit
ABB
Chapter 2 - Installation
2.1 Raw Water Connections
2.1.1 Hose Connection (Standard)
When preparing the piping for the raw water supply, consider the
maximum length (2 m) of the flexible hoses and the specifications of the
raw water interface. See Water Cooling Datasheet in Appendix A - Water
Cooling Unit.
Top entry Bottom entry
Figure 2-1 Raw Water Entries
1 Connect the hoses for the raw water circuit following Figure 2-2 à
Figure 2-6.
Exchange duct plate (top) and
blanking plate when hoses are
Inlet
entered from below
Outlet
Figure 2-2 Duct Plates
ACS 1000 Water Cooling Unit 3BHS204366 ZAB E02 Rev. A 2-1 (6)
Chapter 2 - Installation ABB
Customer side piping
Enter flexible hoses
Figure 2-3 Connecting the Water Hoses
Customer side piping
Connect hoses to raw water
supply using appropriate
flanges (inner diameter of
hoses 32 mm)
Figure 2-4 Connecting the Water Hoses
Customer side piping
Cut hoses to length
Figure 2-5 Connecting the Water Hoses
2-2 (6) 3BHS204366 ZAB E02 Rev. A ACS 1000 Water Cooling Unit
ABB Chapter 2 - Installation
Customer side piping
Connect hoses to
inlet
Fasten hoses with supplied
clamps
Figure 2-6 Connecting the Water Hoses
Figure 2-7 Nipple Dimensions
2.1.2 Hose Connection Side Entry
If the hose cannot be entered through the standard openings, a cut-out in
the side wall can be made (not possible if the converter is equipped with
a braking chopper).
The drawing 3BHS127525 shows the cut-out.
If the duct plate (see Figure 2-2) is mounted on the side, an additional
blanking plate (3BHL000641) must be used to cover the standard entry
opening.
2.1.3 Flange Connection (Option
As an option, the converter can be equipped with flanges for raw water
connection through the side (not possible if the converter is equipped with
a braking chopper), back or bottom of the cooling unit. The external water
ACS 1000 Water Cooling Unit 3BHS204366 ZAB E02 Rev. A 2-3 (6)
Chapter 2 - Installation ABB
pipes can be connected directly to the flanges. An example is shown in
Figure 2-8.
Upward bend Downward bend
Figure 2-8 Flange Connections
The dimensions and position of the flanges are shown in the layout
drawing. The tightening torque of the bolds depends on the size and must
be determined by the installation personal.
2.2 Drain Connection
The water cooling unit is equipped with a drain connector. The drain
connector is located behind a cover below the door of the water colling
unit. The drain connector is suitable for a hose with an internal diameter of
13 mm (0.5118 ") (see Figure 2-10).The drain hose is not supplied with the
converter. To prevent water from leaking, a shut-off valve must be installed
Figure 2-9 Leaking Water Connection
2-4 (6) 3BHS204366 ZAB E02 Rev. A ACS 1000 Water Cooling Unit
ABB Chapter 2 - Installation
ØD Ø D1 C F L L1 ØT
(mm) (mm) (mm) (mm) (mm) (mm)
13 15 R1/2 22 50.5 29.5 12
Figure 2-10 Drain Connector
ACS 1000 Water Cooling Unit 3BHS204366 ZAB E02 Rev. A 2-5 (6)
Chapter 2 - Installation ABB
2-6 (6) 3BHS204366 ZAB E02 Rev. A ACS 1000 Water Cooling Unit
ABB
Chapter 3 - Starting up the Cooling System
NOTICE!
Do not run the pumps if the cooling circuit is empty, not even for a short
time. If a pump runs dry the pump seals will be damaged immediately.
3.1 Checks before Start-up
Information on the positions of all valves in the operating state can be
obtained from the Flow Diagram:
Flowdiagram for 1 pump and 2 way valve 3-9531-001
Flowdiagram for 2 pumps and 2 way valve 3-9531-002
Flowdiagram for 1 pump and 3 way valve 3-9531-003
Flowdiagram for 2 pumps and 3 way valve 3-9531-004
Filled valve symbols in the flow diagram indicate valves in shut position.
Proceed as follows:
1 Open valves V1, (V2), V5, V11 and V15.
2 Close valves V12, V14, V80, (V81), and V82.
3.2 Filling the Cooling System
Cooling Water Drinking water of good quality must be used in the main cooling circuit.
However, it is recommended to fill the circuit with deionized water to
extend the lifetime of the ion exchange resin.
The cooling water should conform to the values in Table 3-1.
If in doubt about the quality of the drinking water on your premises contact
your local water utility.
Table 3-1 Drinking Water Specification
Parameter Value
pH 7 – 8.5
Specific conductivity < 300 µS / cm
Hardness 3 – 10° dH
Chloride (Cl) < 300 mg/l
Copper (Cu) < 0.1 mg/l
Total dissolved salt < 1000 mg/l
ACS 1000 Water Cooling Unit 3BHS204366 ZAB E02 Rev. A 3-1 (6)
Chapter 3 - Starting up the Cooling System ABB
IMPORTANT!
! Inhibitors and other chemicals must not be added to the water.
Cooling Water with When the converter has been ordered with an anti-freeze, a container with
Anti-Freeze the appropriate type and amount of glycol is supplied with the converter.
CAUTION!
! Ethylene glycol is a hazard for humans and animals when swallowed.
Avoid skin and eye contact and wear protective clothing including rubber
gloves and goggles when handling ethylene glycol. Food stuffs and
beverages must be kept separate from the place of work.The safety data
sheet supplied by the supplier of ethylene glycol must be followed.
IMPORTANT!
! The conductivity of glycol as it is used in cars is too high.The converter
cannot be started if the conductivity level is too high.Only pure ethylene
glycol which acts only as an anti-freeze and has no inhibitors for corrosion
protection is permitted for the converter.
Table 3-2 Characteristic Values of the Anti-freeze
Parameter Value
Content > 99.8 %
Density at 20 °C (68 °F) 1.1133 - 1.1140 g/cm3
Viscosity at 20 °C (68 °F) 19 mm2/s
Specific heat capacity at 20 °C (68 °F) 2.3 kJ/kgK/l
Thermal conductivity 0.29 W/mK
pH-value neutral
When transferring, mixing and filling the anti-freeze, it must be
guaranteed, that no chips, grease, remnants or any other impurities
infiltrate the coolant.
For storing and mixing only clean containers specifically designated and
appropriately labelled must be used.
In the following table, the values for the desired frost proofing are listed:
3-2 (6) 3BHS204366 ZAB E02 Rev. A ACS 1000 Water Cooling Unit
ABB Chapter 3 - Starting up the Cooling System
Table 3-3 Water Glycol Concentration for the Desired Frost proofing
Frost proofing Pure Ethylene Glycol Distilled Water
- 10 °C (14 °F) 20 % 80 %
- 20 °C (-4 °F) 34 % 66 %
- 30 °C (-22 °F) 44 % 56 %
- 40 °C (-40 °F) 52 % 48 %
Ideally, the mixing procedure should take place at ambient temperature
(+ 5 °C to + 30 °C).
When mixing the following procedure must be observed:
1 Check that the type of ethylene glycol is appropriate (see Table 3-2).
2 Check that the blue 60 liter plastic container which is part of the
delivery contains approximately the same amount of glycol as
declared on the label (last two digits of the item number correspond
to the amount of glycol in liter; e.g. 3BHL001483P0021 corresponds
to 21 liter).
3 Fill in distilled water until the level in the container is at approx. 3/4.
4 Thoroughly mix the ethylene glycol mixture.
IMPORTANT!
! There will be negative effects on the thermal and hydraulic behaviour of
the coolant if the water-glycol mixture is not mixed thoroughly.
5 Fill the container completely.
Afterwards, thoroughly mix the liquid again!
The required frost proofing has been reached now.
After filling the system (see following section) the remaining liquid can be
used for refills after maintenance or repairs, if stored in a closed container.
Filling the System 6 Switch off the motor protection switch(es) -Q11 [-Q5021] /
( -Q12 [-Q5023] of the pump(s).
7 Switch on the auxiliary voltage.
8 Close valves V1, V11, V15, V80, V81*.
9 Open valves V2*, V5, V12.
(*only if redundant pump is present)
10 Connect the filling hose to the ISO-R1/2" connector of valve V14.
A pressure of approx. 1 to 2 bar is required for filling water into the
circuit. Using a small pump might be necessary.
11 Open valve V14 and start the filling.
ACS 1000 Water Cooling Unit 3BHS204366 ZAB E02 Rev. A 3-3 (6)
Chapter 3 - Starting up the Cooling System ABB
If the cooling unit is not equipped with the check valve V18 (as in the
previous version of the cooling unit) the water does not start to flow
through the filter Z2. Valve V15 has to be opened additionally..
IMPORTANT!
! Filling rate <= 15 l/min.
12 Stop filling water when the level in the expansion vessel is approx.
80 %.
13 Close valve V14 and open valve V1, V11 and V15 (if it has not been
opened yet).
14 Open the priming plug on the pump house(s) (see Figure 3-1) and
vent the pump(s). Close the plug again.
Figure 3-1 Pump with Priming Plug
15 Close the disconnected terminals -X2:22 to -X2:27.
16 Install a temporary jumper.
• Disconnect the connector X21 from IOEC board 1.
• Connect a jumper (cross-section 1 mm2) between
X21-1 and X21-3 of connector X21.
• Plug the connector X21 back into IOEC board 1.
17 Close the motor protection switch -Q11 (-Q5021).
18 Check the level in the expansion vessel. If the level drops below 10%
stop the pump and top up water.
19 Check the system pressure. If the pressure remains below trip level
(2 bar) the rotation of the pump is not correct. In this case, the rotation
of the pump must be reversed by changing two phases on the
terminal -X10.
3-4 (6) 3BHS204366 ZAB E02 Rev. A ACS 1000 Water Cooling Unit
ABB Chapter 3 - Starting up the Cooling System
DANGER!
Hazardous voltage!
Voltage can cause physical injury and death.The auxiliary supply must be
turned off before starting work on terminal X10.
20 Cooling unit with one pump: run the pump for 30 minutes to vent
the converter and proceed with step 25.
21 Cooling unit with two pumps: install a temporary jumper.
• Disconnect the connector X22 from IOEC board 1
• Connect a jumper (cross-section 1 mm2) between
X22-1 and X22-3 of connector X22.
• Plug the connector X22 back into IOEC board 1.
22 Let the first pump run for 10 minutes and then turn off -Q11 (-Q5021).
23 Switch on -Q12 (-Q5023).
24 Run the second pump for 30 minutes to vent the cooling system.
25 Close valve V11 and fill up the expansion vessel according to step 11
to 12.
26 Close valve V12.
27 Disconnect the hose.
28 Remove the temporary jumper.
IMPORTANT!
! The temporary jumper must be removed before the converter resumes
operation.
29 Cooling unit with one pump: close -Q11 (-Q5021).
30 Reset the alarm.
After filling the cooling circuit, the conductivity value might not be in the
permitted range (conductivity alarm level: 0.5 µS/cm, conductivity trip
level: 0.7 µS/cm). If this is the case, an auto-cooling sequence is started.
For more information see Appendix G - Signal and Parameter Table.
3.3 Adding Water to the Cooling System
If the level in the expansion tank is below 80 %, the cooling circuit must be
topped up with additional water via valve V14. Use cooling water as
specified in section 3.2 Filling the Cooling System.
ACS 1000 Water Cooling Unit 3BHS204366 ZAB E02 Rev. A 3-5 (6)
Chapter 3 - Starting up the Cooling System ABB
Cooling water can be added, while the converter is in operation, provided
the conductivity is below 0.4 µS/cm.
IMPORTANT!
! When filling cooling water while the converter is in operation, the
conductivity will rise due to the high conductivity of the added water. Using
deionized water is recommended. Fill the water in slowly to avoid a trip.
DANGER!
Hazardous voltage!
When the drive is in operation, voltages are present in the control section.
Do not touch any live circuitry!
Proceed as follows:
1 Connect the filling hose to the ISO-R1/2" connector of valve V14.
A pressure of approx. 1 to 2 bar is required for filling water into the
circuit. Using a small pump might be necessary.
2 Close valve V11.
3 Open valve V14 and start the filling.
IMPORTANT!
! When filling cooling water during operation, fill the water in slowly to
prevent that the converter shuts down on a conductivity fault.
Recommended filling rate: less or equal 2 l/min.
4 Stop the filling after about 5 l of water have been added.
5 Close valve V14.
6 Open valve V11.
7 After the conductivity is down to 0.4 µS/cm again, repeat steps 3 to 7.
Stop the filling when the water level in the expansion vessel is approx-
imately 80%.
8 Remove the hose.
3-6 (6) 3BHS204366 ZAB E02 Rev. A ACS 1000 Water Cooling Unit
ABB
Chapter 4 - Draining the Cooling System
WARNING!
If glycol is used in the cooling water, see section Cooling Water with Anti-
Freeze, page 3-2, for safety information.
Proceed as follows:
1 Shut down the converter according to the ACS 1000 User's Manual,
Chapter 6- Operation.
2 Switch off the motor protection switch(es) -Q11 [-Q5021] /
( -Q12 [-Q5023]) of the pump(s) to prevent the pumps from being
switched on accidentally.
CAUTION!
! Do not run the pumps if the cooling circuit is empty, not even for a short
time. If a pump runs dry the pump seals will be damaged immediately.
3 Remove the fastening screws of the swing frame and open it by
pulling strongly.
4 Connect a hose (long enough to reach out of the converter) to the
drain valve located inside the inverter section at the bottom (ISO G
½).
5 Open valve V12.
6 Open the drain valve and drain the inverter.
A pump can be used to speed up the procedure.
7 Open V80 / (V81) to drain the cooling unit.
Approx. water quantity to be expected: 7-8 liters.
8 Close the valves and remove the hoses.
9 Close the converter swing frame and remount the fastening screws.
Up to here, the converter has only been drained for repair purposes. To
drain the converter completely (for storage purposes) contact the ABB
service organization.
ACS 1000 Water Cooling Unit 3BHS204366 ZAB E02 Rev. A 4-1 (2)
Chapter 4 - Draining the Cooling System ABB
4-2 (2) 3BHS204366 ZAB E02 Rev. A ACS 1000 Water Cooling Unit
ABB
Chapter 5 - Checking Actual Values
It is recommended to record the values of conductivity, water temperature
and pressure regularly to determine when water has to be added or the
ion exchange resin renewed.
Actual values can be monitored while the converter is in operation.
Water conductivity and pressure depend on the water temperature. Only
values registered at the same temperature should be compared.
5.1 Water Conductivity
The actual value of the water conductivity (displayed in µS/cm) can be
read on the control panel.
Proceed as follows:
Reading the 1 Select the Actual Display mode on the control panel (see ACS 1000
Conductivity on the User's Manual, Chapter 7 - Parameter Viewing and Editing and
Control Panel Control Panel Functions, Actual Signal Display Mode).
2 Select parameter group 4 ACTUAL SIGNALS. In group 4, select
actual signal 04 InvWtrConductivity. The conductivity should be
below 0.5 µS/cm.
• If the conductivity exceeds the alarm threshold of 0.5
µS (see parameter 190.09), the control panel will
display the alarm message WtrConduct.
• If the conductivity exceeds the trip threshold of 0.7 µS
(see parameter 190.10), the converter will shut down
and the panel will display the message WtrConduct.
5.2 Water Pressure
The actual value of the water pressure (displayed in bar) can be read on
the control panel.
Proceed as follows:
Reading the Water 1 Select the Actual Display mode on the control panel (see ACS 1000
Pressure on the User's Manual, Chapter 7 - Parameter Viewing and Editing and
Control Panel Control Panel Functions, Actual Signal Display Mode).
2 Select parameter group 4 ACTUAL SIGNALS. In group 4, select
actual signal 03 InvWtrCoolPressure.
3 The reaction of the converter, if the water pressure decreases below
the trip threshold of 1.5 bar (see parameter 190.12), depends on the
number of pumps:
ACS 1000 Water Cooling Unit 3BHS204366 ZAB E02 Rev. A 5-1 (4)
Chapter 5 - Checking Actual Values ABB
• Cooling unit with two pumps: the control panel will
display the alarm WtrPressure and the second pump
will be switched on. If the water pressure does not
increase above the trip threshold after a
programmable time, the converter will trip.
• Cooling unit with one pump: the control panel will
display the alarm WtrPressure. If the water pressure
does not increase above the trip threshold after a
programmable time, the converter will shut down.
5.3 Water Temperature
The actual value of the water temperature (displayed in °C) can be read
on the control panel.
Proceed as follows:
Reading the Water 1 Select the Actual Display mode on the control panel (see ACS 1000
Temperature on the User's Manual, Chapter 7 - Parameter Viewing and Editing and
Control Panel Control Panel Functions, Actual Signal Display Mode).
2 Select parameter group 4 ACTUAL SIGNALS. In group 4, select
actual signal 02 InvWtrCoolTemp.
• If the temperature exceeds the alarm threshold (see
parameter 190.6), the control panel will display the
alarm message WtrTemp.
• If the temperature exceeds the trip threshold (see
parameter 190.7), the converter will trip and the
control panel will display the trip message WtrTemp.
5-2 (4) 3BHS204366 ZAB E02 Rev. A ACS 1000 Water Cooling Unit
ABB Chapter 5 - Checking Actual Values
5.4 Water Level
The water level can be checked while the converter is in operation.
DANGER!
Hazardous voltage!
When the drive is in operation, voltages are present in the control section.
Do not touch any live circuitry!
Proceed as follows:
1 Check the water level at the level sight-glass located at the front of
the expansion tank.
The water level should be approximately 80%.
2 If the water level is below 80 % the cooling circuit must be topped up.
See section 3.3 Adding Water to the Cooling System.
The minimum water level is monitored by level switch B10. If the switch is
activated, the converter will shut down.
ACS 1000 Water Cooling Unit 3BHS204366 ZAB E02 Rev. A 5-3 (4)
Chapter 5 - Checking Actual Values ABB
5-4 (4) 3BHS204366 ZAB E02 Rev. A ACS 1000 Water Cooling Unit
ABB
Chapter 6 - Tightening Torques, Threaded Connections
6.1 Tightening Torques
Table 6-1 Tightening Torque for Flanges
Hexagon Washer Gasket Tightening
DN Nut
Screw (D x d x t) (D x d x t) Torque
1 2 3 4
25 M12-55 M12 24 x 13 x 2 73 x 40 x 1.5 24 - 33 Nm
32 M16-65 M16 30 x 73 x 3 84 x 48 x 1.5 60 - 80 Nm
40 M16-65 M16 30 x 73 x 3 92 x 57 x 1.5 60 - 80 Nm
50 M16-70 M16 30 x 73 x 3 107 x 66 x 1.5 60 - 80 Nm
65 M16-70 M16 30 x 73 x 3 128 x 23 x 1.5 60 - 80 Nm
80 M16-75 M16 30 x 73 x 3 144 x 97 x 1.5 60 - 80 Nm
100 M16-80 M16 30 x 73 x 3 162 x 125 x 1.5 60 - 80 Nm
6.2 Sealing off Threaded Connections without O-rings and Gaskets
A sealant such as Loctite 755 and Loctite 401 activator spray is
recommended to ensure a leak proof joint between stainless steel to
stainless steel connections.
Thread tape is recommended to seal off:
• stainless steel to plastic connections,
• plastic to plastic connections.
ACS 1000 Water Cooling Unit 3BHS204366 ZAB E02 Rev. A 6-1 (2)
Chapter 6 - Tightening Torques, Threaded Connections ABB
6-2 (2) 3BHS204366 ZAB E02 Rev. A ACS 1000 Water Cooling Unit
ABB
Appendices
ACS 1000 Water Cooling Unit 3BHS204366 ZAB E02 Rev. A 1 (2)
ABB
2 (2) 3BHS204366 ZAB E02 Rev. A ACS 1000 Water Cooling Unit
G SERIES
Compressor chillers unit
INSTALLATION
AND
MAINTENANCE MANUAL
Rev.: feb. 22, 09
______________________________________________________
GEOCLIMA SRL _____________________________
VIA DELL’ INDUSTRIA , 12 - 34077 RONCHI DEI LEGIONARI (GO) – ITALY –
COS. FISC. E PARTITA IVA IT 00499560316 - CAPITALE INT. VERSATO € 46.800,00
ISCRIZIONE AL REGISTRO DELLE IMPRESE DI GORIZIA N° 00499560316
Foreword
Thanks for choosing our chiller, follow instruction book is given in order to be on
disposal of the strictly interested person to the unit se rvice and management.
This document has been made up by
technical department and, by the terms of the laws in forc e on the industrial
property, it could not be copied partially or totally, reproduced or given in s ight
to other person or competitor firms without our written leave.
Geoclima srl reserves the right to make modification in instruction book at any
time without prior notice and declin e any re sponsibility for printing errors. To
contact us:
www.geoclima.com
[email protected]
SECTIONS INDEX
Nomenclature
Release subindex
A General data of the chiller unit
B General description of the chiller unit
C General description of the refrigerating circuit
D List of working of the chiller unit
E General regulations
F Compressors overviews, checks and maintenance
G Plant operations
H Working limits
L Troubles shooting
M Feature of refrigerant fluid
N Enclosed
Nomenclature
G G
H CHIL LER
H S SPLIT
F FREE ( - COOLING)
A AIR
H WATER
A
E CONDE NSERLESS
C (FREE -) COOLING
04 R40 4A
22 R22
04
34 R13 4a
66 R40 7C
LN LOW NOISE
LN LLN LOW LOW NOISE
XLN EXTRA LOW NOISE
BT BT LOW TEMPERATURE
TP TP TANK AND PUMP
PU PU PUMP UNIT
SP SP SPECIAL VERSION
HR HR HEAT RECOVERY
HP HP HEAT PUMP
Release subindex
Editing data and respective addition:
01/07/2008 first release
08/09/2008 S about spli unit – split unit are unit without evaporator or without
condenser. Are not made other spec ifications. To have other
indication or special technical bulletin, please send an e-mail to
[email protected] with your request an univocal unit indication.
FC about Free Cooling section – section D
15/09/2008 Section G and section F
22/02/2009 versatile release and waste procedure in Section E
To have indication about (necessary) service tools, service
commissioning procedure or service dedicated trouble shooting, please
send an e-mail to [email protected] with your request an univocal
unit indication.
Read specific section of this manual with reference to your unit: verify
unit nomenclature and check list. To have other indication or special
technical bulletin, please send an e-mail to [email protected] with your
request an univocal unit indication.
SECTION A
General data of the chiller unit
General data of chiller unit c oncerning the specific unit. Look for these
document in enclosed section. Look for specific working limits in section H.
SECTION B
General description of the chiller unit
Description
Air cooled liqu id ch iller with axial fans or water cooled liquid chiller with wat er
exchanger, for outdoor installation equipped with semi-hermetic screw
compressors.
The structure of the GEOC LIMA cooling units cons ists of large dimens ioned,
electrically welded sections designed to bear the weight of the components.
The baseplate is provided with rainwa ter holes. Cladding and partitions are
made of galvanized sheet steel. Access to the switchboard, control panel,
compressors and cooling components (cocks, filters, indicators, etc.) is possible
even while the machine is wor king sinc e there is an airtight compartment
between the condensing coil and compressor areas.
The whole structure, i ncluding the switchboard and th e sheet steel cladding, is
painted with a spec ial epoxy primer and a special polyur ethane finish
particularly suitable for units to be installed indoors.
Units completely wired and ready to be co nnected to the user’s plant. Prior to
delivery ev ery machine is s ubmitted to a performance test, with intervention
tests of all the safety systems and devices installed.
It is proposed ad indicative figure to show all unit components installed on frame
base.
example of GHA
Example of GHH
SECTION C
General description of the refrigerant circuit
Indicative plant
Such refrigerant circuit is a standard indication to explain main component s
located in the unit and them meanings.
Referring to above mentioned circuit, and i n parallel to previous figures, the
refrigerating phases are as follow:
the fluid refrigerant is sucked by means of the compressor (1) and pumped into
condenser (2) e (3). In such condenser the refrigerant fluid changes its state
from vapour into liquid. At the liquid state, the refr igerant mean passes through
a thermostatic valve (4) (and boils into the evaporat or (5), ch anging itself in
vapour. The refrigerant fluid adsorbs heat from evaporator (water side) and has
sucked by means of the compressor to restart the cycle.
SECTION D
List of working of the chiller unit
Compressor specifications (1)
Airtight multi-cylinder refrigeration compressor with a 2-pole electric motor and
built in thermistor protection. The crankcase heater is self-regulating and
switched on all the time. The cocks are mounted on all compressors both on the
delivery and intake sides.
High efficiency "demister-type" oil separator (max oil carryover 2%). Hydraulic
slide valve capacity control with possibility of "infinity" or "4-step" configuration;
maximum flexibility in conversion between the two systems. High efficiency oil
filter (10 microns net) easily replaceable from outside. Generously sized rolling
contact bearings (up to 60.000 working hours without maintenance). Extended
application limits thanks to liquid injection or oil cooling. Different intrinsic
volumetric ratios available, granting the maximum efficiency for each
application.
Is possible to increase the efficiency through economizer application (ECO) -
optional.
Air condenser specifications (2) – A version
Condenser heat exchange device made with aluminium fins and tinned copper
finned tubes, connected among them with manifolds and curves.
Fins
They are provided of spacing rings, these guarantee a perfect fin spacing and
contact with the expanded tubes. A special high efficiency corrugated fin is used
for a higher performance if compared to normal corrugated fins.
Tubes
They are provided with internally finned surface.
Condenser fan and fan motors specifications (3)
Fan and motor
Axial fans with rotating stator motor, complete with thermal protection klixon,
equipped with safety protection fan guards. The fans are suitable for a speed
control system if required.
Consists of axial fans with aluminium blades directly coupled to the motor. The
motor is of a rotary stator type particularly suitable for this type of application
because of its limited overall dimensions and its perfect balancing of the fan
motor unit. This fact makes the fan particularly silent. The speed is 860 rpm.
The unit comes complete with a galvanized guard and an IP 54 box for the
electrical connections. Super Silent models are available on request. These are
particularly suited in cases where limited sound levels are required.
Guard
Serving as finger protection and for mounting the fan onto the inlet ring.
Water condenser specifications (2) – H version
Plate to plate or shell and tube water cooled condensers according to the
model, with one condenser for each compressor. Shell and tube condensers
are equipped with removable steel headers to enable easy access for
maintenance operations.
Condenser heat exchange device condenser for fresh water heaving suitable
safety valve. Copper tubes inserted in an aluminium fin block, provided with a
sub-cooling circuit to increase unit efficiency. Heat exchanger frame in
aluminium or stainless steel suitable for installation in a hostile atmosphere.
Copper or epoxy coated fins are available on request. On request, sea water
Cu/Ni shell and tube type can be factory fitted.
About accessories look for in your selection.
Expansion Valve specifications (4)
All units with an evaporator are equipped with a thermostatic T type expansion
valve made by Alco. Overheating is set in factory at 4.5 - 5°C on average.
If the valve overheating setting is too low, there
will be an excessive flow of liquid refrigerant to the
evaporator. The suction line will be too cold and
the refrigerant will return to the compressor
causing dangerous sluggings (defective
N.B. compressor).
On the other hand, an overheating value that is
too high will cause an insufficient refrigerant flow
to the evaporator. The suction line will be too hot
and the performance of the unit will be reduced.
CHECKING THE OVERHEATING SETTING
• Measure the suction line temperature near the bulb on the expansion valve.
• Read the suction pressure on the suction gauge of the circuit to be
controlled.
• Convert the above pressure into temperature by using a
pressure/temperature conversion table for refrigerant in use.
• Calculate the difference between the temperatures obtained at points 1 and
3. This difference represents the overheating value, which must normally be
4-5°C.
The overheating setting must be checked
with the chilled water temperature obtained
IMPORTANT: under operating conditions specified by the
customer and with the unit operating at full
power (without capacity control).
ADJUSTING THE OVERHEATING SETTING
Remove the cap nut covering the adjustment screw. Rotate the adjustment
screw with small movements until a stable overheating of 4-5°C is reached
(measured as indicated above). After each screw adjustment wait for the unit to
stabilize before further adjustment. Turn the adjustment screw clockwise to
increase the overheating value and anticlockwise to decrease it.
The overheating setting must be checked
with the chilled water temperature obtained
IMPORTANT: under operating conditions specified by the
customer and with the unit operating at full
power (without capacity control).
THESE ADJUSTMENTS MUST BE CARRIED OUT BY
QUALIFIED SERVICE PEOPLE ONLY
STANDARD – MOP
All units can provided for operation with refrigerant R407c, R134a and R22 and
a MOP value of 100, normal in the air conditioning range. 100 means that the
evaporating temperature limit is 10°C considering that the maximum
evaporating temperature for the compressor is approximately 12°C.
Evaporator specifications (5)
Smaller model have plate to plate type evaporators while the other models are
of shell and tube type. The plate to plate type use AISI 316 corrugated steel
baffles which are brazen between each other in a controlled atmosphere. This
ensures perfect air and water-tightness. The shell and tube type evaporators
are formed of copper tubes electronically expanded into a thick steel plate.
Both types are insulated by means of foam rubber mats with closed cells to
avoid condensation.
The water connections for the coaxial exchanger are female gas thread
connections. Shell and tube type evaporators have female gas threads of up to
2 inches and the remaining models use flange/counterflange PN10. The
pockets housing the operating and antifreeze thermostat bulbs are located at
the water inlet and outlet connections.
Airtight, multi compressor units with plate to plate type exchangers use more
exchangers as the water system is parallel connected. Semi-airtight multi
compressor units on the other hand have an individual tube type evaporator
with several freon systems and an individual water system.
About not standard application flooded evaporator
Thanks at definite development of special fin pipes and a dedicate lodging of a
level sensor it is possible take advantage whole exchange surface.
Such state of art technology allows to achieve rather high saturated suction
temperatures and higher COP values in any ambient and load conditions.
Even more thanks a new energy recovery device (optional) it is possible to
achieve very high performance. Such patent device allows a heat exchange
between saturated suction gas device and condensed liquid gas device,
overheating the suction gas and subcooling the liquid one (adiabatic and
isoentropic heat exchange).
Auxiliary, safety and control device description
All unit have specific target, component and accessories: as follow a general
outline of main auxiliary, safety and control device component of general
refrigerant plant.
As follow are indicated only main standard components. Particular attention to
safety device.
Gas pressure switch
These devices are fixed on the compressor.
Their propose are to safeguard the same
from the excessive high pressure of the
compression and from too low pressure on
the suction.
If owing to an insufficient air/water
circulation into the condenser, the delivery
pressure goes over safety limit, the high
pressure interview and stop the compressor.
After restored of nominal working condition
acting in the
apposite push
button placed on the side to the instrument.
The same thing happens on the contrary for the low
pressure. The difference between high or low
pressure switch is type of restart of unit. In last case
when the pressure of plant will have reached the
normal values will have an automatically start of the
compressor.
Automatic reset: on pressure rise above the upper
setpoint, contacts 1-2 open and contacts 1-4 close. On
decreasing pressure below lower setpoint contacts 1-4
open and contacts 1-2 close.
Manual reset high pressure: on increasing pressure
above the upper setpoint, contacts 1-2 open, contacts 1-
4 close and latch. Only on falling pressure below lower
setpoint and after pressing the manual reset button, contacts 1-4 will open and
contacts 1-2 will close again.
About pressure sensing all pressures mentioned in this data
sheet are understood as gauge pressures. PS1 / PS2
controls sense pressure by means of bellows which expand
or contract when exposed to medium pressure. High
pressure limiters and pressure cut outs with type approval
according to EN 12263 feature a double bellows design. The
inner bellows serves as the operating bellows and is
enclosed by the outer bellows featuring a larger surface area.
Should the inner bellows leak, then the larger surface area of the outer bellows
creates a larger force and causes the pressostat to a pre-empted cut out. This
represents a fail-safe function.
Standard controls for refrigeration applications are equipped with a bronze
bellows and can be used with all common HFC, HCFC refrigerants.
About nomenclature look for in follow figure:
Pressure controls
The ALCO PS3 is a Pressure Switch with fixed
switch-point
settings.
Features
• Maximum Operating Pressure up to 43
bar
• Test Pressure up to 48 bar
• Standard factory settings from stock in
small volumes
• High and low pressure switches
• High temperature version with snubber
for direct
• compressor mounting (Range 6)
• Direct mounting reduces the number
of joints and thus
• avoiding potential leakage
• Precise setting and repeatability
• IP 65 protection if used with the new PS3-Nxx and PS3-
• Lxx cables with plug (acc. EN 175301-803), no additional gasket required
(molded into plug)
To understand pressure switch device see follow table:
Solenoid valve
The solenoid valve of the refrigerating plant are fixed on the refrigerating liquid
pipe lines, which feed evaporator or heat recovery. As for the preceding
explication, the solenoid valves are driven by the thermostats and it can hold as
electric commanded valves, with two working position (all are nothing).
Solenoid valves are widely used in refrigerating plants to control automatically
not only fluid refrigerant flow (liquid line and evaporator outlet) but water, brine
or any other liquid flow, for instance in the condenser water cooling line. When
gas defrosting is used solenoid valves are fitted in the refrigeration circuit to
reverse refrigerant flow.
A solenoid valve is simply an electrically operated valve consisting of an
electromagnetic coil which when energized draws a plunger which opens the
valve port. Closing action is achieved by gravity when the coil is deenergized.
Solenoid valves controlling the refrigerant flow in the liquid line feeding the
evaporators are thermostatically activated.
Solenoids vary according to permitted pressure differences across the valve,
drop in pressure through the valve, the desired flow rate and the state of the
circulating fluid. The valves can be direct acting or pilot operated.
Solenoid valves are simple and robust, and their functioning is generally reliable
and accurate as they usually operate in an on-off mode. This is also true when
they work in a modulated fashion (applying a changeable voltage to the
electromagnetic coil of the valve).
They have some drawbacks. They are not gastight, particularly for large pipe
sections. Their most usual failure is coil breakdown, which is not foreseeable so
it is impossible to detect during maintenance operations. Solenoid valves must
be correctly installed. They must always be mounted in a vertical position with
the coil on top, unless they are especially. designed for horizontal installation.
They must also be mounted in line with the direction of flow, usually shown by
an arrow on the valve body.
Some operating faults may appear when a solenoid valve is at work. If the valve
fails to open the cause could be mechanical or electrical. Mechanical problems
follow when the valve is not mounted level on the pipe or when the plunger is
stuck to the valve seat. Electrical failures could be because of dirty or loose
electrical connections, no power supply, and/or a damaged coil. It is advisable
to have several coils in stock for each type of solenoid valve. If the valve does
not fully close the valve seat may be either dirty or worn. The valve should be
dismantled and the valve seat and plunger cleaned or renewed, or a new valve
should be fitted. When the valve is noisy during operation it has obviously not
been correctly installed and is not level on the pipe; an alternative could be that
the electrical connections are not sound.
Thermostat
Thermostats are temperature-activated controllers which regulate the
temperature level of a refrigerated space by cycling the compressor on and off.
They consist of a sensing element and an electric contactor.
Electric failure of the thermostats may be due to poor electrical connections
(clean and tighten them for correct operation) or to worn, pitted or corroded
contact points (replace them). These mechanical or electrical failures will cause
the thermostat to remain either open or closed. When it stays open the
compressor will shut down even if the room temperature is above the desired
level. The use of a jumper lead across the terminals should immediately restart
the compressor.
Differential pressure switch
The SFS differential pressure
switch closes or diverts an electric
contact when the differential
pressure between the two inlets
reaches the upper set-point
(intervention) and opens or
releases the contact when it drops
below the lower set-point (release).
It can be used in plumbing systems
when it is necessary to make sure
the pressure difference between
two points does not exceed or drop
below a specific value. A pair of
permanent magnets, placed in a
mutual-repulsion position one
inside the pressure switch body and one outside, replace the classic O-ring and
shaft solution and greatly increase the reliability and working life of the pressure
switch.
The difference in pressure that is
generated, ∆p = p1 - p2, moves a
diaphragm that pulls a small cap
containing a permanent magnet.
Diaphragm movement is obstructed
by an antagonist spring which are
sized depending on the intervention
characteristics specific to the
pressure switch (see table). Another
magnet is in the microswitch drive piston. Whenever the pressure difference ∆p
reaches the intervention value, the diaphragm movement will approach the two
magnets to a distance where their mutual repulsion force is greater than the
tripping force of the microswitch push-button and this will cause switching to
take place (Fig. 2). When the pressure difference ∆p decreases and drops
below the return value, the two magnets move away from each other and the
microswitch push-button returns to its normal position (Fig. 1).
All versions are available with one or two micro switches. SPDT MICRO
SWITCH: UL, CSA, SFV, VDE, SEMKO and BEAB approvals. Fast-on 6,3 mm
connections; 10 (3) A 250 V a.c. MICRO SWITCH BOX AND CABLE: IP 40 and
IP54 (max. 2 micro switches) European Standard Reference CEI EN 60529.
The IP40 version with one micro switch are supplied with a standard two-pole
cable measuring 650 mm (single-pole micro switch: connection C-NO), the
version with two micro switches is supplied without cable. The IP54 version is
available only with cable, as internal access is not possible.
Flow switch
Pressure transmitter
These piezoresistive pressure transmitter-heads are produced
on the new KELLER automatic brazing lines, making possible
the mass production of high quality pressure transmitters at
low cost. This new technology allows the crevice-free
construction of the pressure port without using seals or O-
rings. In the brass sensor line (Series 22 M), a steel insert and
a nickel diaphragm are brazed into a brass housing. In the
steel version (Series 22 S), all parts are of stainless steel (AISI
316 L). The header with the silicon pressure sensor and the
glass feedthrough
pins are welded to the steel insert underneath the oil filling.
The electronic print is soldered onto the Packard plug. The
EMC-protection-components are mounted on the plug side, the
amplifier and the compensation electronics on the sensor side.
A flexible printed circuit “TAB” (Tape Automated Bonding) connects the sensor
with the electronics.
About data sheet as follow:
Safety valve
The SV1 and SV2 types are safety devices according to the definition given in
Article 1, Point 2.1.3, 2nd dash of Directive PED 97/23/EC and are the subject
of Article 3, point 1.4 of aforesaid Directive. Their function is to protect the
equipments such as evaporators, condensers, liquid accumulators, liquid
receivers, oil separators, positive displacement compressors, heat exchangers
and simple unfired pressure vessels (ref. to Directive 87/404/CEE) to against
possible overpressures with regard to the operating conditions for which they
have been designed. These are unbalanced standard direct loaded, safety
valves. Valve opening is produced by the under pressure fluid on the surface of
the obturator, when the thrust, under setting condition, exceeds the opposing
force of the spring acting on the obturator.
Valves are identified by an alphanumerical coding that includes:
- In the first part the family identification e.g. SV1
- In the second part the type identity, that depending on the inlet and outlet
connections; for example: /24
- In the third part, the set pressure of the valve, in bar, e.g.:T21.0
A full alphanumerical code is, for example: SV1/24T21.0.
Free cooling operation
The operation of the free cooling system consists of finned pack heat exchangers
placed in front of the condensing coils. Air flows through the water coils before
crossing the condensing coils. When the outdoor temperature is lower than the
returning water temperature the free cooling system can operate. The free cooling
efficiency (EER) depends on the temperature difference between the ambient and
desired chilled water temperature (EER is higher than the water/air delta
temperature increase). The chiller can operate under three main conditions:
- mechanical cooling
- partial free cooling
- total free cooling
Mechanical cooling
Ambient temperature is higher than the returning water temperature
In this case the free cooling system is completely excluded and water cooling is
obtained by compressor action only,
Partial free cooling
Ambient temperature is lower than the returning water temperature
In this case the water cooling depends on a combined action between the free
cooling operation and the working compressor. The system runs in this way when
the water/air temperature difference is not so high and the water coils cannot
achieve the total required cooling capacity.
Total free cooling
Ambient temperature is lower than the returning water temperature
The water cooling and total cooling capacity depends on the free cooling operation
only. The compressor action is completely excluded. Normally, with standard
applications, total free cooling can be achieved when the ambient is at least 6°C
lower than the desired chilled water temperature.
The abovementioned type of operations are automatically managed by a
microprocessor control system designed to optimise energy consumption keeping
to the preset working conditions. The microprocessor receives four temperature
inputs from sensors reading the following parameters:
- ambient temperature TAE
- returning water temp. from user’s plant TFC
- evaporator entering water temperature RWT
- evaporator leaving water temperature LWT
When the ambient is at least 2°C lower than the returning water temperature, the
microprocessor allows the free cooling system to operate. Thanks to the three-way
the three-way valve opening, water flows into the water coils before crossing the
evaporator. Through the sensor monitoring the evaporator entering water
temperature, the microprocessor accordingly reduces the compressor action
(multistep capacity control) until they are completely excluded if total free cooling
operation is reached.
If the free cooling efficiency is too high (as the ambient or required cooling load is
very low) to keep a constant leaving water temperature, the microprocessor
proportionally reduces the air flow through the coils and if this is not sufficient, it
controls the water flow in the coils by means of the three-way valve opening.
Furthermore, during the partial free cooling operation, the microprocessor controls
the air flow to keep the condensing pressure within acceptable limits so avoiding
any problems for the compressors.
If the chiller is equipped with water pumps (two pumps - stand by operation), the
microprocessor manages the working pump including the starting sequence and
the automatic starting of the second pump if the operating one fails.
As follow a typical free cooling water circuit: schematic piping.
As follow an exemplifying photo of free cooling piping.
Three way valve components as follow figure:
To right replacement make attention to flow direction and Z361775 components as
indicated in follow figure.
Point of view of water flow is showed in figure 3.
Assemble electric drive as showed in figure 4.
The complete assembling is showed in follow figure.
Last step of assembling is completed with correct coupling between two lever (see
three way valve components figure). To guarantee made coupling apply a plastic
clamp (this clamp not permit to move in independent mode the levers. See above
figure to understand correct position where apply above mentioned plastic clamp.).
To have other information or specification send an e-mail to:
[email protected]
SECTION E
General regulations
While the designer can incorporate ev ery reasonable feature in a piece of
equipment to reduce regular inspection and maintenan ce operations, he cannot
eliminate them completely. T he in spection and prevent ive maintenance
represent the only way of keeping compre ssor operating at the efficient level for
which they were designed.
Is recommended that following operations have to be executed by specialized
staff.
The purchaser have to mark all dangerous parts with warning label.
Don’t remove these labels and maintain in suitable condition.
The commons risk are:
- hot surface
- electrical parts (generic)
- mechanical movement of machinery
Follow risk will be mark with warning label as follow:
NO REMOVE SAFETY PROTECTION
HOT SURFACE
UNDER VOLTAGE COMPONENT
All servic e operation have to be made in s afety condi tion either the rules and
the plant.
FIRST RULE
HAVE TO BE EXECUTE BY SPECIALIZED
STAFF
Before every service operation, for ev ery component, read the instructions on
this manual.
- Don’t touch piping or parts that contain process fluid.
- Don’t remove mobile protections during plant working.
- Check the plant before every ser vice operation: it have to be insulated from
every thermal or electric source.
- On the power supply line apply the earth connection how rules in force.
- Don’t touch the plant during its working.
- Don’t stay around or on machinery during its working.
- Don’t leave tools or other object on machinery during its working.
- Don’t leave bottle or fluid container on machinery during its working.
- During all service operation put in sight a signboard with this wording
“Not working condition during maintenance”
- Restore all safety condition and protection after the maintenance.
- Check nominal conditions after the maintenance.
- Use only recommended (original type) spare parts.
- The plant is designed to working with plan condition: the nominal conditions
can’t be during extreme ambient condition. (see section “H”)
Delivery
Declaration of delivery: this machinery isn’t dangerous for specialized staff that
use Geoclima s.r.l. instruction and check the nominal working c onditions of all
parts of plant.
Information about unit receipt
Upon receipt of the goods the customer have to check the unit. In case of
delivery damaged the customer have to signal to transport worker and to
Geoclima. In other case the unit have to be installed (as Geoclima
recommendation) or kept in a dry and cool place with suitable pr otection. T he
store (above mentioned indoor place) have to be without damp and vibration.
For other use Geoclima decline any responsibility.
For doubts, suggestion or specia l indication please contact
[email protected].
Identification tag
The machinery is defined in univocal mode by its identification tag (and its serial
number).
For all information or communications with Geoclima s.r.l. use “Sch. / Wir. /
Sch.” number of machinery and unit code
General notes
Upon receipt of the goods check as follow:
• the machinery is in c orrespondence wit h order number (ver ify packing list
and enclosed information)
• the machinery is in a good state of repair. In case of damage or missed parts
(documentation too) inform immediately Geoclima s.r.l.
All docum ents or drawings are made up by G eoclima s.r.l. technical
department.
All doc uments or drawings are ownership of Geoclima s.r.l. and cannot be
copied, duplicated or changed without our approval.
Packing and moving
The package is normally supply on pallet so it can be moved with machinery as
follow figures
(see details in relevant lifting instruction drawing attached)
- Dimension and weight are indicated on technical specification and on
packing list.
- During motion and displacement avoid impact or collision.
- During mot ion and displacement (to embark or position the pac kage) use
chain, rope or wire rope with resistance equal or higher of machinery weight.
- Please dispose of carefully
- During motion and displacement respect safety condition.
- Verify the good condition of tools lifting.
- Don’t stay around or on machinery during motion and displacement.
- Don’t lift the machinery more than is necessary.
- During motion and dis placement (to embar k or position the packa ge) fix the
chain, rope or wire rope in suitable point.
- During motion and displac ement c heck the rest of the plant and other
machinery to preserve their good state.
- Position the package with softly. If necessary use wood support.
- Storing the machinery in a natural position on its bedplate.
- Remove the protection only to connect the machinery to the rest of plant.
- Cover the machinery with protective plastic wrap during storing.
- Don’t charge the machinery with external loaded.
Installing
Hydraulic connections
Piping practices vary considerably in accordance with loca l standards and
regulations. When selecting and installing piping, local building and s afety
codes as well as regulations should be studied and complied with. The following
information should be taken as advice to prevent the unit from being damaged
but it is not comprehensive.
Design the piping carefully, paying a ttention above all to the corresponding
cross sections of the pipes in order to avoid unnec essary pressure losses.
Please not e in this c ontext that using a brine solution (glycol/water) increases
the flow volume and so causes a pressure drop in the system.
Water piping connections to the unit sh ould be flexible. Tube c ompensators
effectively prevent noise from pumps and c ompressors from being transmitted
to the whole chilled water system and vibr ations from being transmitted in t he
opposite direction, i.e. from the piping to the individual component s of the unit
which possibly involve the whole unit.
As follow typical water/refrigerant circuit diagram:
When installing the hydraulic circuit for the unit observe the following
prescriptions and adhere to national or local regulations:
- connect the pipelines to the chiller by m eans of flexib le couplings in order to
prevent the transmission of vibration and provide a means of compensation
for thermal expansion and contraction.
- the lines must be equipped with the following components:
o shut-off cocks and temperature and pres sure gauges for nor mal
maintenance and inspection of the unit.
o test point connections on the inle t and outlet lines for temperature
measurements (if temperature gauges are not installed).
o gate valves to isolate the unit from the hydraulic circuit.
o metal strai ner filter (i nlet line) with mesh no coarser than 1 mm to
protect the heat exc hanger from debr is an d other foreign material
that may be present in the pipes.
o bleed valv e, to be in stalled in the highest section of the hydraulic
circuit, to allow the expulsion of incondensable substances.
o expansion valve and autom atic filling valve to maintain the required
circuit pressure and compensate for thermal expansion and
contraction.
o drain cock and, where necessar y, drainage collection tank to allow
the circuit to be emptied for maintena nce work or seas onal
shutdowns.
All components are pointed in follow figure.
Illustration of typical water piping
Evaporator
(1) pressure gauge
(2) compensator connection
(3) flow switch
(4) thermostat
(5) shut-off valve
(6) pump
(7) strainer filter
Condenser
(1) pressure gauge
(2) compensator connection
(3) flow switch
(4) thermostat
(5) shut-off valve
(6) pump
(7) strainer filter
All connections have to be done by specialized staff.
Installation clearances
It is highly important to ensure the avail ability of an adequate vo lume of air at
the intake and exhaust sides of the condenser coil. It is essential to avoid air
recirculation between the intake and ex haust sides t o prevent degradation of
rated performance levels or even interr uption of normal operation. For this
reason, always chec k for the presence of the following service technical
clearances
(see details in relevant dimensional drawing clearances attached)
Information on disposal for user of waste procedure and electronic
equipment
This symbol on the products and/or accompanying documents
means that used elec trical and el ectronic products should not be
mixed with general waste. For the proper t reatment, recovery and
recycling, please take this produc ts to designated collection points,
where they will be ac cepted. Alter natively, in some c ountries you
may be able to return your products to your local retail upon the
purchase of an equivalent new product.
Disposing of this product correctly will help to save valuable resources and
prevent any potential negative effect s on human health and the environment
which could otherwis e arise from inapprop riate waste hand ling. Please contact
your local authority for fu rther details of your nearest designated collection
point.
Penalties may be ap plicable for incorrect d isposal of this waste, in accordance
with national legislation.
In general Geoclima propose follow table to make a selection of components
and material:
Item Building material Additional notes
Frame steel
Compressor various material contact compressor manufacturer
Coil copper
Coil aluminium
Condenser shell steel
Evporator shell steel
Condenser tubes copper
Evporator tubes copper
Fan various material contact fan manufacturer
Electronic board various material contact board manufacturer
Control panel component various material contact component manufacturer
Fluid refrigerant line copper
Water line steel
Line support plastic and steel
Auxiliary component various material contact component manufacturer
Safety element various material contact component manufacturer
Not specified component various material contact Geoclima factory
SECTION F
Compressors overviews, checks and maintenance
Operation and maintenance
While the designer can incorporate ev ery reasonable feature in a piece of
equipment to reduce regular inspection and maintenan ce operations, he cannot
eliminate them completely. T he in spection and preventive maintena nce
represent the only way of keeping compre ssor operating at the efficient level for
which they were designed.
Contact Geoclima before every operation - [email protected]
Compressor fundamentals
THE COMPRESSOR DOES NOT START
CAUSE SUGGESTED REMEDY
• Inc omplete timing Wait five minutes with active power supply
• No voltage Check the main switch, fuses and electrical connections
• Antifreeze thermostat blocked Reset again
• Working thermostat calibrated too high Calibrate the water temperature entering the evaporator up
• Flow switch contact open No water circulating in the evaporator. Check the hydraulic
circuit
• LP switch tripped Wait for automatic switching on
• HP switch tripped Identify the causes, resolve and reset the switch
THE COMPRESSOR OPERATES ALL THE TIME
CAUSE SUGGESTED REMEDY
• Excessive thermal load Check place to be air-conditioned for insulation
• Working thermostat calibrated low, danger Recalibrate the thermostat
of frost
• Insufficient filling (bubbles in sight glass) Check the gas system for any leaks and fill up
• Clogged filter (covered with frost outside) Replace filter or cartridges
Bitzer fundamentals
FRASCOLD fundamentals
Periodical checks and servicing
Schedule of periodical checks and servicing
The per iodical work ing pressure and lu bricant lev el check are sufficient
warranty for a long compressor operative life and f or the reliability of the
declared performances.
The requested maintenance interventions are:
• after approx. 100 working hours from the initial compressor start
• lubricant replacement to remove im purities remained in the s ystem and
collected in the oil separator from refr igerant and lubric ant flow, at the same
time replace the cartridge of the oil filter
• each 5000/10000 working hours
• tightness check for solenoid valve
• correct operation check for oil flow switch
• cleanliness check for suction filter
• cleanliness check for oil filter
• each 10000 working hours
• tightness check for gaskets
• tightness check for discharge check valve
• each 50000 working hours
• replacement of the bearings
Lubricant replacement
All lubricant replacement operations have t o be executed when t he compressor
is at standstill. All lub ricants, especia lly th e ones of synthetic type, are highly
hygroscopic; to avoid the lubric ant contam ination, it is necessar y to keep the
packages well sealed, open them just bef ore their use and therefore reclose
them after immediately.
The used lubricant has to be exclusively approved by the manufacturer.
oil level in to the separator
For lubricant replacement apply following procedure:
a) stop the compressor and close the suction valve
b) close the discharge line between the separator and the condenser
c) connect a refrigerant recovery unit to the service valve of the oil separator
d) power the coil of the solenoid valve of oil piping
e) start the recovery unit and reclaim the refrigerant contained in to the oil
separator and in to the compressor, st op the recovery unit, close the service
valve and disconnect the unit from the service valve
f) connect a suitable flexible hose to the oil outlet connection not used for
lubricant return to the compressor
g) place the flexible hose in to a suitable c ontainer; slowly open the valve and
drain the oil in to the container
h) close the valve and remove the flexible hose
i) place a s uitable container under the oil filter; loosen the swiv el connections of
the oilo filter and let le oil contained in to the external oil pipi ng flows down in to
the container
j) remove completely the o il filte r from the piping, uns crew the four screw and
remove the oil cartridge housing; replace the old oil cartridge with a new one
k) reassemble the cartridge hous ing apply ing to the four screw the tightening
torque of 35 Nm
l) assemble the swivel connections to t he oil filter applying the tightening torque
of 45 Nm
m) unscrew the four fixing screws of the suction valve and move the valve body
away from the compressor
n) remove the suction filt er and, by means compressed air, clean the filter or
replace it if necessary
o) position the suction valve and screw it on the compressor applying to the four
screws the tightening torque of 80 Nm
N.B. Operating alter nately on the screws apply progre ssively the tightening
torque.
p) connect the suction of the v acuum pu mp to the service v alve of the oil
separator; start the vacuum pump and evacuate for at least 1 hour
q) at the same time, connect a fle xible hose to the oil charge valve of the
separator and put the other end in to the container of new oil
r) open the valve and let the suitable quantity of oil flowing in to the separator
s) disconnect the vacuum pump and switch it off
t) close the discharge valve of the co mpressor and cut-off th e power to the
solenoid valve of external oil piping
u) open the shut-off valve on the discharge li ne and, briefly, power the solenoid
valve untill the lubricant (look ing at the sight glass) fl ows from the oil separator
to the compressor
v) open the shut-off valve on the discharge line and put back in operation of the
solenoid valve
w) open the suction valve of the compressor
y) start the compressor and after a suit able period control the oil level and t he
refrigerant charge
Check for tightness of solenoid valve
To perform this control, it is nec essary to look at the oil sight glas s straight after
the solenoid valve closing when the compressor stops. In case of oil bleeding,
the replac ement of the so lenoid valve is require d and the c ause must be
identified in order to avoid it to be repeated again.
Check for correct operation of oil flow switch
To check the correct operation for oil flow switch perform following procedure:
a) switch off the compressor
b) remove the compressors fuses F3
c) switch on the compressor and verify the cut-off of DR3 delay ed relay when
the setting time delay expires
d) switch off the compressor and put back in operation the electrical wiring.
In case of malfunctioning, the replacement of the flow switch is required and the
cause must be identified in order to avoid it to be repeated again.
Check for tightness of gaskets
Gasket tightness check could be exec uted with the compressor not working;
slowly move the sensor of the leak detector along all coupling of the
compressor body.
N.B. Perform the tightness check afte r every compressor reparation or part
replacement.
Check for tightness of discharge check valve
This operation must be performed dur ing the nor mal oper ation when the
compressor stops an d the counter-rota tion of the s crew occurs. If counter-
rotation takes more than 5 seconds, it is necessary proceed with the
replacement of the check valve but the cause must be identified in order to
avoid it to be repeated again.
Thermistors check
All c ompressors are supplied c omplete wit h integral protection, in accordance
with DIN44081 regulation and it is composed by PTC t hermistors introduced in
the electrical motor stator and connec ted to an electronic c ontrol module
KRIWAN.
To verify the thermistor chain continuity, proceed as follows:
a) disconnect the compressor from the electrical feeding net
b) remove the terminal box cover
c) remove the female quick connect termi nals from the thermistor T1 and T2
bayonet terminals
d) connect to T1 and T2 terminals the test prods of the ohmmeter, that has at
the ends a maximum tension of 2.5V; if the ohmmeter shows an infinite
strength, it means that t he thermistor chain is inte rrupted shows a suitable and
continue thermistor chain.
e) connect the quick connect terminals to the thermistor T1 and T2 terminals
f) assemble and fix the terminal box cover
g) connect the compressor to the electrical feeding net
Other useful information
FRASCOLD fundamentals
Operation and maintenance
Compressor start-up
PRE-START CHECKING - Table below s hows the required pr ocedures and
checkpoints before starting-up the comp ressor during commissioning or initial
operation of the unit.
In addition to the pre-start checking giv en in the abov e table, als o consider the
following:
a. It is necessary to pay more attention to the auxiliary facilities while the ch iller
is commissioning at
the job-site and the periodic maintenance after the initial start-up.
b. In order to keep the capacity c ontrol smoothly under the low am bient
temperature with the normal viscosity of oil, oil heater should be kept energiz ing
after compressor has been shut down for preparation for the next start-up.
c. Check that all the settings on each pressure switch are correct.
d. Check if all the stop valves in the system are already open.
e. Check the rotating direction of the compressor by starting the compressor for
a split second (approx. 0.5…1 sec.) and check the suction and discharge
pressure gauges. The correct rotating di rection is: suction pressure drops
immediately and the discharge pressure will going up.
f. The compressor lubrication oil should be check immediately after starting. Oil
level should be within sight glass range or higher than the middle line of oil level
sight glass.
g. Oil foaming can be gener ated during starting phase, but it should re duce
when the c ompressor is under stable oper ating conditions. Otherwise this c an
indicate excessive liquid in the suction gas.
h. The running condition of compressor after commissioning at the job-site
should be adjusted as; the discharge tem perature will be at least 20K above the
saturated condens ing temperat ure and the suction vapor superheat should be
within 10K to the saturated evaporating temperature.
i. The whole plant, especially the pipeli nes and capillary tubes must be checked
for abnormal v ibrations. Contact HANBELL or local dis tributor if any abnormal
vibrations or noise found while the compressor is running.
j. Regularly check-up the plant acco rding to national regulations and the
following items should also be checked:
- Operating data of the machine
- Check the lubrication/level of oil
- All compressor monitoring parts
- Check electrical cable connections and tightness
Lubricants
The main functions of the lubrication oil in the screw compressor are lubrication,
internal s ealing, cooling an d capacity cont rol. The po sitive oil pressure in the
cylinder pushes the piston and the slide va lve that is connected by a piston rod
to move forward and backward in t he com pression c hamber. The des ign with
positive pressure differential lubrication system in the RC2 series is available to
omit an extra oil pump in the compre ssor like reciprocating compressor.
However , in some special applications , it is still necessary to install an extra oil
pump to the compressor for safety.
The bearings used in RC2 compressor re quired a small but steady quant ity of
oil for lubrication; the oil injection into the compression chamber creates an oil
sealing film in the compression hous ing for increasing the efficiency and
absorbing a part of heat of compression. In order to separate the oil from the
mixed refrigerant gas, an oil separator is required to ensure the least amount of
oil carried into the system. Pay more attent ion to the oil tem perature, which has
a very significant factor to the c ompressor bearings’ life. High oil temperature
will reduce the oil vis cosity and cause t he poor lubric ation and heat absorption
in the compressor as well. The oil viscos ity is recommended to keep over 10
s/mm2 at any temperature. The oil temperature just keep above system
condensing temperatu re to avoid the refr igerant migration into system in the
summer.
There is high oil viscosity in the low am bient temperature circumstance, it could
cause compressor in heavy duty to be star ted up resulting less oil pressure in
oil line to load the com pressor. The better solution is to have higher condensing
temperature in a shor t time by warming up the oil. If the compressor operated
under the critical condition, then extra oil c ooler is required – please refer to
Hanbell selection software for the require d capacity and oil flow of extra oil
cooler. Some high viscosity oil is recommended to apply to the high working
condition due to the high dischar ge temperature that will cause low viscos ity of
oil. It happens more often that the return oil from evaporator is insufficient s uch
as refrigeration system flooded chiller…et c. , which is difficult to be carried
back, that causes the loss of oil in t he compressor. If the system encounters the
oil return problem then an extra 2nd oil separator is recommended to be
installed between the compressor discharge tube and condenser.
Each of HANBELL RC2-170 ~ RC2-930 c ompressors equipped two oil sight
glasses as a standard (the models from RC2-100 ~ RC2-140 a for second sight
glass are optional), one is the oil high leve l sight glass, and the ot her is the oil
low-level sight glass. The n ormal oil level in the compressor oil tank should be
maintained
above the top
of the low oil
sight glass and
in the middle
level of high oil
sight glass
when
compressor is
running. It is
recommended
strongly to
install the
optional
accessory of
oil leve l s witch
to prevent
compressor’s failure from getting low oil level in the compressor.
The used lubricant has to be exclusively approved by the manufacturer.
Changing of oil
1. Change oil periodically: Check the lubrication oil for every 10,000 hour s of
continuous running. For the first operation of the compressor, it is
recommended to change oil and clean oil f ilter after running at 20,000 hours.
Check the system whether clean or not and then change the oil every 20,000
hours or after 4 years of c ontinuous running while the system is operated under
good condition.
2. Avoid the debris to clogged in the oil f ilter, this may caused bearings failure,
an optional oil pressure differential switch are recommended to be installed. The
switch will trip when the oil pressure differential reaches the critical p oint
between th e primary and secon dary sides . The comp ressor will automatically
shut down to prevent the bearings from getting damaged due to the lack of
lubricating oil.
Troubleshooting
The table below shows some problem that might encounter in the jobsite during
commissioning or upon operation of compresso r. This table will only serve as a
guide for the Engineer to understand the si tuation once the problem occurred in
the site.
Other useful information
Refcomp fundamentals
As follow general indication about Refcomp screw compressor.
SECTION G
Plant operations
In order to ensure quiet and trouble-free operation with maximum capacity
and to avoid damage to equipment periodic maintenance is necessary.
The instructions provided are useful guidelines for plant operators who
on the basis of their experience should focus their attention on frequency
and type.
The drawing up of a maintenance contract and evidence of corresponding
maintenance and service reports are therefore the basis of any warranty
for the delivered units. The maintenance contract has to be undertaken
with an approved qualified refrigeration contractor, preferably with the
supplier being familiar with the units.
Evaporator
cleaning the evaporator
Through time water heat exchangers ar e prone to a decrease in cooling
capacity. T his is due to scale that develops in the tubes. This scale can be
removed by passing appropriate chemical s, selected depending on the type of
scale, through the exchanger. To do this it is sufficient to close th e cocks letting
the chemical solution circulate inside the exchanger through the two drains.
After completing this operation, rinse with cold water, then reconnect the unit t o
the user’s system via the two cocks. Giv en the noxious nature of the chemicals
used, GEOCLIMA advises that such operations be carried out by trained
authorized staff.
other information
The evaporator is a heat transfer system, and is that part of a refrigeration cycle
in
which liquid refrigerant is evaporated for the purpose of removing heat from the
refrigerated space or product.
Evaporators are manufactured in a wide variety of types, shapes, sizes and
designs,
and are classified in the following way:
• type of construction
• method of refrigerant feed
• operating conditions
• method of air (or liquid) circulation
• type of controls
• application
The capacity of any evaporator or cooling coil is the rate at which heat will pass
through the evaporator walls from the refrigerated space to the vaporising liquid.
A flooded evaporator is completely filled with liquid refrigerant, and the level of
the refrigerant is maintained in an accu mulator by a float-valve. Evaporators are
connected in parallel to the accumulato r. One pipe from the bottom of the
vessel supplies liquid refrigerant. The re turn pipe containing liquid refrigerant
and vapour enters the vessel near the top. The liquid f rom the accumulator is
quite often pumped around the evaporators.
The disadv antage of t he flooded evaporator is that it require s a considerable
charge of refrigerant and is bulk y. The ma in advantage is that the inside of the
pipes are c ompletely wetted with refriger ant and this produces a very high r ate
of heat transfer. grant t he highest C.O.P. levels, t hanks to reduced approaches,
from 1 to 1,5 K, between evaporation temperature and outlet fluid temperature.
The figure show an example of flooded evaporator.
Pump
Before opening the pump, it is essential that you respect all safety procedure.
If the liquid being handled lea ks out at the mechanical seal, it is damaged and
must be replaced.
motor bearings
After approx. 5 year s the grease in t he motor bearings is so aged, that a
replacement of the bearings is r ecommended. Howev er, the bearings must be
replaced after 25000 operating hours, at least, resp. acc. to the maintenance
instruction of the motor supplier , if that recommends a shorter maintenance
period.
cleaning of pump
Dirt on the outside of t he pump has an ad verse effect on transmission of heat.
The pump should therefore be cleaned with wat er at regular interv als
(depending on the degree of dirt). The pump mu st not be cleaned with
pressurised water-water will get into the bearings.
The figure show an example of pump.
Vacuum into the plant
Before the starting of the plants , we mu st do the followin g oper ations for' the
creating of the vacuum into the plant:
• maintain opened the suction and discharge valves
• shut off discharge valve put on the compressor's head
• take away the purge plugs on the discharge valve
• put in motion the plant in manual pos ition and inter put the working of the
plant when the suction gauge sign 0,70" - U, 72" and with control that through
the purge plugs holes will not go our air.
If the air continues to go out, after 10 - 15 minutes, without to go down the ov er
mentioned value, it m eans t hat there are s ome slacki ng of bolts and joints on
the circuit.
Without any slacking, tak en the vacuum at above ment ioned v alue, screw the
plugs and stop the plant, then open the di scharge valve and, in a second time,
charge the p1ant as the following paragraph shows.
Gas charge in the plant
To do the charge we must connect with copper pipes the reserve gas bottle and
open its valve, discharge the ai r from the pipe, leak ing at that ent rance of the
charge valve put on the drier filter panel.
Then we must shut the valve put on the drier filter and open the charge valve for
4 - 5 minutes.
At the end of the charge time, we mu st do the apposite operation for above
mentioned valve and wait fo r about ten (10) minutes, so that the charged gas
can go into the whole circuit.
The charge operation can end when we will verify through the glass of the liquid
indicator t:1e flow of the refrigerant fluid, at liquid state.
In fact we notice abundant formation of the small bubbles at sight glass the
plant will not be completely charged.
When we have taken off the connecting pipe, from the bottle to the valve, we
must supply it with a safety plugs.
Cartridges substitution of the dried filter
When the plant stopped, close t he first va lve preceding the drie r filter in the
discharge directions.
Put in motion the plant and when it stops, by pressure switch , on the zero line
of the vacuum gauge (as a precaution shut al so the main switch), shut the valve
placed immediately after the drier filter.
Unloose the flange's f astening s crews of the liters, unstring the cartridges and
provide to the substituti on with order, checking that, in the same time, some
residuals of refrigerant fluid don’t provok e an loz ing of the f ilter's walls, in
contact with the air.
With putting in of the new cartri dges, we must do ai r discharge through the
filters flange, before to ti ghten the filter’s bolts, fo r this purge open the valve on
back filter for a quarter of a turn.
Filling the unit with oil
At the beginning of the operat ion of a syste m it can happen that the refrigerant
gets mixed with oil and that a given am ount of oil is left in the system.
Consequently there is little oil left in the compressor. If a decrease in the oil
level is noted in the compressor casi ng, proceed as follows wit h the utmost
attention.
Take a hos e end fitted with a threaded c onnector and connect to the pressure
outlet on t he compressor intake cock. Dip the other end of the hose in the oil
filled can. Close the intake cock very sl owly until a s mall amount of refrigerant
gurgles in the oil. This operation assures the full disch arge of water present in
the hose. Open the compressor cock aga in. By-pas s the minimum pressure
switch and start the compressor after cl osing the cock on the fluid line. When a
pressure below zero on the pressure scale has been reached on the intake line,
stop the compressor. Close the intake co ck. At this point oil will enter the
compressor because of the vac uum. This operation is very slow and delicate
since any entering air, which could damage the cooling system, must be
avoided. Next clos e the compressor intake cock and open the fluid line cock.
Remove the by-pass from the minimum pressure switch and then restart the
unit.
While the designer can incorporate ev ery reasonable feature in a piece of
equipment to reduce regular inspection and maintenan ce operations, he cannot
eliminate them completely. T he in spection and preventive maintena nce
represent the only way of keeping plant ope rating at the efficient level for which
they were designed.
For general plant operations Geoclima suggests follows table1
Action Item Weekly Monthly Six Monthly Yearly
Compare refrigerant pressure read with display and pressure gauge, so record them A x
Read and record oil pressure B x
Read and record motor power supply voltage C x
Read and record motor power supply current D x
Check compressor oil level E x
Check refrigerant charge through liquid li ne sight glass F x
Check control panel electrical contacts G x
Check suction gas temperature for proper superheat H x
Check setting of all safety controls I x
Check all contacts and electrical connections L x
Check refrigerant moisture indicator M x
Check solenoid valve operation N x
Check compressor crankcase oil condition O x
Check condition of filter drier cartridges P x
Check evaporators pressure drop Q x
Check condition of condenser tubes R x
According to Warranty Procedure, as indicated inside control panel, you have to
fill out follow document:
- maintenance booklet
- plant booklet
In follow pages are presented facsimile document.
1
This is a general plant operation table: execute only possible operations. For example, in case of TT
compressor they are oil free, so not consider item “Check compressor oil level”.
Maintenance booklet
Date Item Result Notes and records Signature
08/09/2008 A OK Circ.1 SP=2bar DP=13bar Technical
15/09/2008 B To solve Circ.1 SP=4bar DP=9bar – informed Geoclima Technical
Additional notes:
…………………………………………………………………………………………………………
…………………………………………………………………………………………………………
…………………………………………………………………………………………………………
…………………………………………………………………………………………………………
…………………………………………………………………………………………………………
Plant booklet
Indication about plant manager / Notes
Name and surname
Address
Phone number
E-mail address
Chiller data
Type
Refrigeran type
Charge of refrigerant [kg]
Manager specifications
Name and surname
Firm
VAT
Rerigerant fluid recycling
Type
Quantity of recycling refrigerant [kg]
Date of recycling
Quantity of replaced refrigerant [kg]
Date of last check
Check of subcooling [°C]
Chck of superheating [°C]
Date of leak check
Outcome of leak checking operation
Type of leak detector
Outcome of inspection operation
Date
Sign
As ER 842/2006 the unit (and its chrge) have to be checked:
- once a year for total charge from 3 to 30 kg
- once a six month for total charge from 30 to 300 kg
- once a three month for total charge from 300 kg and greater
Additional notes:
…………………………………………………………………………………………………………
…………………………………………………………………………………………………………
…………………………………………………………………………………………………………
…………………………………………………………………………………………………………
…………………………………………………………………………………………………………
SECTION H
Working limits
Unit limits can have sensible difference from standard limits depending
on customer request. As follow we present only standard limits.
About standard operating limits as follow figure.
Compressor discharge temperature high alarm
Compressor high/low suction/discharge superheat
Compressor too many pump down alarm
No water circulation flow diagram
Pump don’t start flow diagram
Pump breaker fault alarm flow diagram
Low evaporator drop flow diagram
High evaporator drop flow diagram
High RWT flow diagram
High RWT flow diagram
Freeze protection alarm flow diagram
Fan protection alarm
Sim
EEV com alarm
SECTION M
Feature of refrigerant fluid
Physical properties – R404a
Chemical Formula [-]
CHF2CF3/CH3CF3/CH2FCF3
Molecular weight [kg/kmol] 97.6
Boiling point at 1.013 bar [°C] -46.6
Critical temperature [°C] 72.1
Critical pressure [bar] 37.4
Viscosity of saturated liquid 2 [mPas] 0.215
Viscosity of saturated liquid 1 [mPas] 0.124
Viscosity of saturated vapor 1 [mPas] 0.0128
Thermal conductivity of saturated liquid 2 [W/(mK)] 0.082
Thermal conductivity of saturated liquid 1 [W/(mK)] 0.066
Thermal conductivity of saturated vapor 1 [W/(mK)] 0.0158
Spec. heat capacity of saturated liquid cp 1 [kJ/(kgK)] 1.541
Spec. heat capacity of saturated vapor cp 1 [kJ/(kgK)] 1.200
Ratio cp/cv (saturated vapor) 1 [-] 1.35
Density of saturated liquid 1 [kg/m³ ] 1045
Density of saturated vapor 1 [kg/m³ ] 65.35
Enthalpy of evaporation 1 [kJ/kg] 140.1
Explosion limits in air 3 [% by vol.] none
Legend:
1: t = 25°C
2: t = – 15°C
3: t = 25°C; p = 1.013 bar
Physical properties – R22
Chemical Formula [-] CHClF2
Molecular weight [kg/kmol] 86.5
Boiling point at 1.013 bar [°C] -40.8
Critical temperature [°C] 96.1
Critical pressure [bar] 49.9
Viscosity of saturated liquid 2 [mPas] 0.247
Viscosity of saturated liquid 1 [mPas] 0.160
Viscosity of saturated vapor 1 [mPas] 0.0130
Thermal conductivity of saturated liquid 2 [W/(mK)] 0.103
Thermal conductivity of saturated liquid 1 [W/(mK)] 0.086
Thermal conductivity of saturated vapor 1 [W/(mK)] 0.0110
Spec. heat capacity of saturated liquid cp 1 [kJ/(kgK)] 1.260
Spec. heat capacity of saturated vapor cp 1 [kJ/(kgK)] 0.864
Ratio cp/cv (saturated vapor) 1 [-] 1.38
Density of saturated liquid 1 [kg/m³ ] 1191
Density of saturated vapor 1 [kg/m³ ] 44.23
Enthalpy of evaporation 1 [kJ/kg] 182.5
Explosion limits in air 3 [% by vol] none
Legend:
1: t = 25°C
2: t = – 15°C
3: t = 25°C; p = 1.013 bar
Physical properties – R134a
Chemical Formula [-] CH2F CF3
Molecular weight [kg/kmol] 102.0
Boiling point at 1.013 bar [°C] -26.1
Critical temperature [°C] 101.1
Critical pressure [bar] 40.6
Viscosity of saturated liquid 2 [mPas] 0.332
Viscosity of saturated liquid 1 [mPas] 0.197
Viscosity of saturated vapor 1 [mPas] 0.0120
Thermal conductivity of saturated liquid 2 [W/(mK)] 0.101
Thermal conductivity of saturated liquid 1 [W/(mK)] 0.084
Thermal conductivity of saturated vapor 1 [W/(mK)] 0.0140
Spec. heat capacity of saturated liquid cp 1 [kJ/(kgK)] 1.425
Spec. heat capacity of saturated vapor cp 1 [kJ/(kgK)] 1.011
Ratio cp/cv (saturated vapor) 1 [-] 1.23
Density of saturated liquid 1 [kg/m³ ] 1206
Density of saturated vapor 1 [kg/m³] 32.35
Enthalpy of evaporation 1 [kJ/kg] 177.5
Explosion limits in air 3 [%byvol.] none
Legend:
1: t = 25°C
2: t = – 15°C
3: t = 25°C; p = 1.013 bar
Physical properties – R407C
Chemical Formula [-] CHF2CF3/ CH2F 2/
CH2FCF3
Molecular weight [kg/kmol] 86.2
Boiling point at 1.013 bar [°C] -43.8
Critical temperature [°C] 86.0
Critical pressure [bar] 46.3
Viscosity of saturated liquid 2 [mPas] 0.249
Viscosity of saturated liquid 1 [mPas] 0.152
Viscosity of saturated vapor 1 [mPas] 0.0125
Thermal conductivity of saturated liquid 2 [W/(mK)] 0.103
Thermal conductivity of saturated liquid 1 [W/(mK)] 0.085
Thermal conductivity of saturated vapor 1 [W/(mK)] 0.0154
Spec. heat capacity of saturated liquid cp 1 [kJ/(kgK)] 1.533
Spec. heat capacity of saturated vapor cp 1 [kJ/(kgK)] 1.107
Ratio cp/cv (saturated vapor) 1 [-] 1.33
Density of saturated liquid 1 [kg/m³ ] 1138
Density of saturated vapor 1 [kg/m³ ] 43.80
Enthalpy of evaporation 1 [kJ/kg] 182.6
Explosion limits in air 3 [% by vol.] none
Legend:
1: t = 25°C
2: t = – 15°C
3: t = 25°C; p = 1.013 bar
Physical properties – R507
Chemical Formula [-] CHF2CF3/ CH3CF3
Molecular weight [kg/kmol] 98.9
Boiling point at 1.013 bar [°C] -47.1
Critical temperature [°C] 70.7
Critical pressure [bar] 37.1
Viscosity of saturated liquid 2 [mPas] 0.210
Viscosity of saturated liquid 1 [mPas] 0.122
Viscosity of saturated vapor 1 [mPas] 0.0129
Thermal conductivity of saturated liquid 2 [W/(mK)] 0.081
Thermal conductivity of saturated liquid 1 [W/(mK)] 0.065
Thermal conductivity of saturated vapor 1 [W/(mK)] 0.0159
Spec. heat capacity of saturated liquid cp 1 [kJ/(kgK)] 1.540
Spec. heat capacity of saturated vapor cp 1 [kJ/(kgK)] 1.217
Ratio cp/cv (saturated vapor) 1 [-] 1.37
Density of saturated liquid 1 [kg/m³ ] 1049
Density of saturated vapor 1 [kg/m³ ] 69.12
Enthalpy of evaporation 1 [kJ/kg] 136.2
Explosion limits in air 3 [% by vol.] none
Legend:
1: t = 25°C
2: t = – 15°C
3: t = 25°C; p = 1.013 bar
SECTION N
Enclosed
With own page sequence follow documents are enclosed:
• Chiller control technical specification (software manual)
• Dimension al drawing
• Lifting instruction drawing
• Refrigerant and hydraulic circuit
• Wiring diagram
• Parameter list
• Name Plate
All above mentioned document conc erning the specific unit. Loo k for these document in
dedicated unit folders.
Unit model Serial number Wiring Diagram
Technical Signature Date
COMMISSIONING,SERVICE AND FIELD-TEST
PROCEDURE
GEOCLIMA s.r.l.
VIA DELL’INDUSTRIA, 12 - 34077 RONCHI DEI LEGIONARI (GO) - ITALY -
COS. FISC. E PARTITA IVA IT 00499560316 - CAPITALE INT. VERSATO 46.800,00
ISCRIZIONE AL REGISTRO DELLE IMPRESE DI GORIZIA N 00499560316
July 21, 2008
Premise
This document is made up by and cannot be copied,
duplicated or changed without our approval.
This form have to be filled out in every part by technical with
charged to make unit commissioning. In future our firm will receive
status, alarm and event from your unit. In this mode Geoclima will
can monitor working of unit. A correct starting phase and calibra-
tion of system is useful both system and unit.
Before all service look service tools document.
This form, filled out, will be send to Geoclima by:
k [email protected]
v +39 0481 774455
To contact us use:
k [email protected]
v +39 0481 774455
T +39 0481 774411
Contents
0.1 Preliminary control and Unit fastening . . . . . . . . . . . . . . . . . 1
0.2 Water connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
0.3 Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
0.4 Oil heaters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
0.5 Plant heat load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
0.6 Starting up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
0.7 Working data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
0.7.1 Electric supply table . . . . . . . . . . . . . . . . . . . . . . . 7
0.7.2 Primary fluid table . . . . . . . . . . . . . . . . . . . . . . . . 7
0.7.3 Compressor table . . . . . . . . . . . . . . . . . . . . . . . . . 8
0.7.4 Fan table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
0.7.5 Evaporator pump table . . . . . . . . . . . . . . . . . . . . . . 10
0.7.6 Condenser pump table . . . . . . . . . . . . . . . . . . . . . . 11
0.7.7 Water circuit table - Condenser . . . . . . . . . . . . . . . . . 12
0.7.8 Water circuit table - Evaporator . . . . . . . . . . . . . . . . . 13
0.8 End user training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
0.9 Training shares table . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
0.1 Preliminary control and Unit fastening
√
Put a after relative check or value and measurement unit after measurement. For
specification use “Notes” space. Indication of diameter, flow, pressure drop, temper-
ature, electrical connection, gsm signal value...are useful to future service.
Is useful make a sufficient number of photo to map installation place.
Consider this aspect for fill out all section.
. safety of installation place
. boundary condition realization
safety elements .......................................................
hydraulic connection ..................................................
hydraulic condition ...................................................
electrical connection ..................................................
power supply .........................................................
. carter resistance 24 h
Notes:
.................................................................................
.................................................................................
.................................................................................
.................................................................................
.................................................................................
.................................................................................
0.2 Water connections
. Check glycol volume (technical data)
. Fill water (or different medium)
. Release air out
. Raise pressure (where required)
. Check water leaks
. Check water flow rate (technical data)
. Let the pump running (where required)
. Check water flow rate (live)
Notes:
.................................................................................
.................................................................................
.................................................................................
.................................................................................
.................................................................................
.................................................................................
0.3 Electrical connections
. Check all power cables connections (if they are tight properly)
. Check emergency switch (located outside on chiller frame)
. Check all circuit breakers (located inside the electrical cabinet)
. Check voltage (technical data, nameplate and wiring diagram)
. Give power (with main switch off)
. Check voltage (live, with multimiter, Volts and Cycles)
. Turn the main switch on (with red handle)
. Check if the system is off (on the display)
. Check of the connections with supervisor
bus communication ...................................................
modbus and gateway comunication ...................................
. Check of the main device
HP safety .............................................................
emergency button ....................................................
compressor overload ..................................................
flow switch ...........................................................
Notes:
.................................................................................
.................................................................................
.................................................................................
.................................................................................
0.4 Oil heaters
As above mentioned the crankcase heaters energized 24 h before compressors (at
least).1
. Check if they are working (with multimiter)
. Touch the compressor body (to feel hot)
Notes:
.................................................................................
.................................................................................
.................................................................................
0.5 Plant heat load
. To keep the unit running we need heating load (from the plant)
. Without load the unit reaches the set point in a short time and we can not check
any running device (safety and control devices)
. With water up to 35 ◦ C the compressors will run automatically in partload to evoid
overload alarms. (evaporator side)
. With water over 35 ◦ C the unit will not run at all (too dangerous)
. Condenser water over the range lets the unit runing in the wrong way (for water
cooled units only)
Notes:
.................................................................................
.................................................................................
.................................................................................
1
Turbocor compressor has not oil heater (it is oil free!). Oil heaters ore off while compressors
are on!
0.6 Starting up
. Check of the connections with supervisor (if required)
. Check all pumps rotation
. Check all fan motors rotation (air cooled units only)
. Switch external consents on
. Switch the system on
. If required2 check and regulate refrigerant fluid charge
. Regulation
. Board programming and saving
Notes:
.................................................................................
.................................................................................
.................................................................................
.................................................................................
.................................................................................
.................................................................................
2
For split unit.
0.7 Working data
Figure 1: Indicative refrigerant fluid circuit.
With reference to indicative refrigerant fluid circuit proposed in figure 1 technical
with charged to make unit commissioning have to fill out all field of follow tables.3
Every table is associated to figure 1 and particular section figure. For every compo-
nent of plant is useful record main working data. Use figure 2 also to mark point of
misure and make useful note.
Notes:
.................................................................................
.................................................................................
.................................................................................
.................................................................................
.................................................................................
3
The figure 1 not present all components of your plant. This is only useful to associate acronyms
and terms with point of misure.
Figure 2: Indicative refrigerant fluid circuit.
0.7.1 Electric supply table
Alimentation
V
Hz
Ph
0.7.2 Primary fluid table
Refrigerant fluid
Evaporator medium
Condenser medium
0.7.3 Compressor table
Compressor number 1 2 3 4 5 6
Cooling capacity %
Discharge temp. [℃]
Suction temp. [℃]
Liquid line Temp. [℃]
Superheating [℃]
Subcooling [℃]
HP [bar]
LP [bar]
OIL [bar]
Nom. Current [A]
Notes:
.................................................................................
.................................................................................
.................................................................................
.................................................................................
0.7.4 Fan table
Fan number 1 2 3 4 5 6
Nom. Current [A]
Fan speed %
Ambient temp. (Tin ) [℃]
Exaust temp. (Tout ) [℃]
Fan number 7 8 9 10 11 12
Nom. Current [A]
Fan speed %
Ambient temp. (Tin ) [℃]
Exaust temp. (Tout ) [℃]
Notes:
.................................................................................
.................................................................................
.................................................................................
0.7.5 Evaporator pump table
Pump number 1 2 3 4
Discharge press. [bar]
Suction press. [bar]
Nom. Current [A]
Notes:
.................................................................................
.................................................................................
.................................................................................
.................................................................................
.................................................................................
0.7.6 Condenser pump table
Pump number 1 2 3 4
Discharge press. [bar]
Suction press. [bar]
Nom. Current [A]
Notes:
.................................................................................
.................................................................................
.................................................................................
.................................................................................
.................................................................................
0.7.7 Water circuit table - Condenser
With refernce to figure 1 the pressure drop is difference in pressure between inside
pressure and outside pressure.
Condenser line 1 2 3 4 5 6
Tin [℃]
Tout [℃]
Pressure drop [kPa]
Cooling capacity %
Notes:
.................................................................................
.................................................................................
.................................................................................
.................................................................................
.................................................................................
0.7.8 Water circuit table - Evaporator
With refernce to figure 1 the pressure drop is difference in pressure between inside
pressure and outside pressure.
Evaporator line 1 2 3 4 5 6
Tin [℃]
Tout [℃]
Pressure drop [kPa]
Cooling capacity %
Notes:
.................................................................................
.................................................................................
.................................................................................
.................................................................................
.................................................................................
0.8 End user training
. General description of unit
. Dimensional drawing
. Refrigerant fluid circuit
. Hydraulic circuit
. Wiring diagram
. Working limits
. Microprocessor features
Notes:
.................................................................................
.................................................................................
.................................................................................
.................................................................................
.................................................................................
0.9 Training shares table
Date / /
Firm Name Surname Sign
Not solved or other communication:
.................................................................................
.................................................................................
.................................................................................
.................................................................................
.................................................................................
.................................................................................
.................................................................................
You might also like
- Max Fuse Specifications and Wiring Diagram100% (1)Max Fuse Specifications and Wiring Diagram13 pages
- 9829300122-01 GA90+-160 Service DiagramNo ratings yet9829300122-01 GA90+-160 Service Diagram33 pages
- Sanyo Blood Bank Refrigerator MBR-305GR Service ManualNo ratings yetSanyo Blood Bank Refrigerator MBR-305GR Service Manual42 pages
- ZT 22-55 VSD IMD Service Diagram EN Wuxi 9829319965No ratings yetZT 22-55 VSD IMD Service Diagram EN Wuxi 982931996523 pages
- Maintenance Schedule ACS580 ACH580 ACQ580 DrivesNo ratings yetMaintenance Schedule ACS580 ACH580 ACQ580 Drives4 pages
- Maintenance Schedule ACS580 ACH580 ACQ580 DrivesNo ratings yetMaintenance Schedule ACS580 ACH580 ACQ580 Drives4 pages
- Health - Annex 7 Rehapetilation Equipment 02-04-00001 Equipment: Telephone ExchangeNo ratings yetHealth - Annex 7 Rehapetilation Equipment 02-04-00001 Equipment: Telephone Exchange208 pages
- Installation, Operation & Maintenance ManualNo ratings yetInstallation, Operation & Maintenance Manual93 pages
- Toll Free (800) 445-4155 - Fax (631) 348-7160No ratings yetToll Free (800) 445-4155 - Fax (631) 348-7160100 pages
- Sm-Liebherr Pr724 Pr734 Pr744 Pr754 Pr764 Series 4 Litronic Crawler Dozer Service Repair45% (11)Sm-Liebherr Pr724 Pr734 Pr744 Pr754 Pr764 Series 4 Litronic Crawler Dozer Service Repair131 pages
- Max Fuse: ...... A: Main Power Supply ........... V ...... HZ 3100% (1)Max Fuse: ...... A: Main Power Supply ........... V ...... HZ 318 pages
- Instructors Solutions Manual To Physics For Scientists Engineers 3rd Randall D Knight PDF Download100% (1)Instructors Solutions Manual To Physics For Scientists Engineers 3rd Randall D Knight PDF Download83 pages
- Installation Guide Fluence Keith Merrow Custom Set: Downloaded From Manuals Search EngineNo ratings yetInstallation Guide Fluence Keith Merrow Custom Set: Downloaded From Manuals Search Engine12 pages
- Theory Resonance Semiconductors: General Theory : Quantum of Cyclotron in JNo ratings yetTheory Resonance Semiconductors: General Theory : Quantum of Cyclotron in J12 pages
- Albert Einstein The Man The Genius and The Theory of Relativity 1st Edition Walter Isaacson Instant Access 2025No ratings yetAlbert Einstein The Man The Genius and The Theory of Relativity 1st Edition Walter Isaacson Instant Access 2025150 pages
- Single Phase and Three Phase Electrodynamo Meter Type WattmeterNo ratings yetSingle Phase and Three Phase Electrodynamo Meter Type Wattmeter9 pages
- Leica EDM Specifications and Accuracy DataNo ratings yetLeica EDM Specifications and Accuracy Data1 page
- Operator'S Instruction Manual: Intelliscan Safety ZoneNo ratings yetOperator'S Instruction Manual: Intelliscan Safety Zone19 pages
- L3 - Phase Change at Reflection, Stoke's Law, Thin FilmNo ratings yetL3 - Phase Change at Reflection, Stoke's Law, Thin Film12 pages
- Electrostatic Potential and Capacitance QuizNo ratings yetElectrostatic Potential and Capacitance Quiz99 pages
- Small Circular Loop Antennas (Soumyajit Paul)No ratings yetSmall Circular Loop Antennas (Soumyajit Paul)15 pages
- 30 Very Useful and Most Frequently Asked McqsNo ratings yet30 Very Useful and Most Frequently Asked Mcqs6 pages
- FeCo Nanowire-Ferrite Magnet CompositesNo ratings yetFeCo Nanowire-Ferrite Magnet Composites10 pages
- Low-Frequency Magnetic Fields From Electrical Appliances and Power LinesNo ratings yetLow-Frequency Magnetic Fields From Electrical Appliances and Power Lines10 pages
- 02 P The Meter (Wheatstone-Type) Bridge and Potentiometer50% (2)02 P The Meter (Wheatstone-Type) Bridge and Potentiometer5 pages
- ECG Measurements and Biomedical RecordersNo ratings yetECG Measurements and Biomedical Recorders27 pages
