ABB ACS 300 User manual

ACS 300 User’s Manual
ACS 300 AC Drives for Speed Control of
1/2 Hp to 15 Hp Squirrel Cage Motors

ACS 300 AC Drives for Speed Control of
1/2 Hp to 15 Hp Squirrel Cage Motors
User’s Manual
ACS300-US-04
Effective: 1/1/1998
Valid from software version CDS02E.1 / CDH02E.1
© 1996 ABB Industrial Systems All Rights Reserved.

ACS 300 User’s Manual v
Safety Instructions
Overview This chapter states the safety instructions which must be fol-
lowed when installing, operating and servicing the ACS 300.
If neglected, physical injury and death may follow, or dam-
age may occur to the AC drive, the motor and driven equip-
ment. The material in this chapter must be studied before
attempting any work on or with the unit.
Warnings and Notes This manual distinguishes two sorts of safety instructions.
Warnings are used to inform of conditions which can, if
proper steps are not taken, lead to a serious fault condition,
physical injury and death. Notes are used when the reader
is required to pay special attention or when there is addi-
tional information available on the subject. Notes are less
crucial than warnings, but should not be disregarded.
Warnings Readers are informed of situations that can result in serious
physical injury and/or serious damage to equipment with the
following symbols:
Dangerous Voltage Warning warns of
situations in which a high voltage can cause
physical injury and/or damage equipment.
The text nextto this symbol describes ways to
avoid the danger.
General Warning warns of situations which
can cause physical injury and/or damage
equipment by means other than electrical.
The text nextto this symbol describes ways to
avoid the danger.

vi ACS 300 User’s Manual
Safety Instructions
Notes Readers are notified of the need for special attention or
additional information available on the subject with the fol-
lowing symbols:
General Safety
Instructions These safety instructions are intended for all work on the
ACS 300.
WARNING! All electrical installation and maintenance work
on the ACS 300 should be carried out by qualified
electricians.
The ACS 300 and adjoining equipment must
always be
properly grounded. The motor and all accessories must be
grounded through ACS 300.
All the ACS 300 units include capacitors connected between
the main circuit and the frame. These capacitors increase
the ground leakage current through the ground connection
to the power line and may cause some ground fault circuit
breakers to trip.
WARNING! All electrical installation and maintenance work
on the ACS 300 should be carried out by qualified
electricians.
Do not attempt any work on a powered ACS 300. After
switching off the power, always allow the DC bus capacitors
5 minutes to discharge before working on the AC drive, the
motor or the motor wiring. It is good practice to check (with a
voltage indicating instrument) that the AC drive is in fact
unpowered before beginning work.
CAUTION! Caution emphasizes a matter in order to
draw special attention to it.
Note! Note gives additional information or points
out more information available on the subject.

ACS 300 User’s Manual vii
Safety Instructions
WARNING! The ACS 300 motor cable terminals are at a
dangerously high voltage when power is applied regardless
of motor operation.
There can be dangerous voltages inside the ACS 300 from
external control circuits when the ACS 300 AC line power is
shut off. Exercise appropriate care when working with the
unit. Negligence to these instructions can cause physical
injury and death.
WARNING! The ACS 300 may introduce electric motors,
drive train mechanisms and driven machines to an extended
operating range. It should be confirmed that all equipment is
suitable for these conditions.
Do not make any voltage tolerance tests (Hi Pot or Meggar)
on any part of the ACS 300. Disconnect motor wires from
the ACS 300 before making any such tests on the motor or
motor wiring.
Failure to follow these instructions can result in permanent
damage to the ACS 300.
WARNING! Certain parameter settings and external control
signals may cause the ACS 300 to start up automatically
after an input power failure.
The motor rotational direction can be locked to forward only
by using the DIR parameter. See page 64 for more details.
Mechanical faults on the motor, power failure or other faults
may cause stoppages. Correcting the fault may cause the
motor to restart. Take all necessary precautions to ensure
personnel safety and to avoid damage to equipment and
property before motor restart.

viii ACS 300 User’s Manual
Safety Instructions
Disconnect Device A supply disconnecting device shall be installed in each sup-
ply, by which the electric parts of ACS 300 can be discon-
nected from the AC line during installation and maintenance
work. The disconnecting device shall conform to the require-
ments of all applicable electrical codes. The supply discon-
necting device shall be locked in the open position while
installation and maintenance work is going on.
Emergency Stop
Devices The ACS 300 start/stop control circuitry consists of elec-
tronic components. An additional hardwired electromechani-
cal stop circuit is required to remove AC line power from the
drive if there are hazards of personnel accidently contacting
the moving parts of the driven machinery or if there is any
other potential hazard that requires the installation of emer-
gency stop devices. When the drive is stopped by discon-
necting power, no braking is available and the motor will
coast to a stop. If emergency stop braking is required, a
spring set friction brake should be used.

ACS 300 User’s Manual ix
Table of Contents
Safety Instructions
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v
Warnings and Notes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v
General Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vi
Disconnect Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . viii
Emergency Stop Devices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . viii
Chapter 1 - Overview of This Manual
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Intended Audience. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
How to Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Limitation of Liability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Delivery Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Identification Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
General Information About ACS 300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Chapter 2 - Mechanical Installation
Cooling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Chapter 3 - Power Connections
Line Voltage Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Power Wiring Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Input Power Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Motor Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Insulation Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Grounding and Ground Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Chapter 4 - Control Connections
Control Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Control Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Parameter Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Analog Input. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Digital Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Relay Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

xACS 300 User’s Manual
Table of Contents
Chapter 5 - Start-up
Flowchart Commissioning Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Checking the Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
Chapter 6 - Control and Parameter Logic
Control Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
Panel Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Parameter Logic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
Example. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
Chapter 7 - Drive Parameters
Parameter Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
Detailed Parameter Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
Chapter 8 - Fault Tracing
Fault Indications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73
Fault Resetting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73
Fault Memory. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73
Fault Tracing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74
Chapter 9 - Technical Data
Incoming Power. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79
Output Power. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79
Environmental Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80
External Control Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80
Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82
Appendix A - Product Conformity in EEA
General Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83
Electromagnetic Compatibility, EMC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83
Low Voltage Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84
Machinery Directive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
Mains Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86
Motor Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87
Cable Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87

ACS 300 User’s Manual 1
Chapter 1 - Overview of This Manual
Introduction This chapter describes the purpose and the contents of this
manual and explains the conventions used within. This chapter
also identifies the intended audience and lists the related docu-
mentation.
The purpose of this manual is to provide you with the informa-
tion necessary to install, start-up, operate and service an ACS
300 AC drive. This manual also describes features and func-
tions of the AC drive, as well as requirements for external con-
trol connections, cabling, cable sizes and routing.
Intended Audience This manual is intended for those who are responsible for
installing, commissioning and servicing the ACS 300 AC drive.
The audience is expected to:
• Have a basic knowledge of physical and electrical
fundamentals, electrical wiring practices, electrical
components and electrical schematic symbols.
• Have no prior experience of ABB products.
• Have no prior experience of the ACS 300 family.
• Have no prior experience of installing, commissioning,
operating and servicing the ACS 300.
With the help of this manual you will be able to install, start-up
operate and service the ACS 300.

2ACS 300 User’s Manual
Chapter 1 - Overview of This Manual
How to Use This
Manual Safety instructions are at the beginning of this manual. In
this chapter the general instructions are stated and various
warnings and notations are described.
Chapter 1 - Introduction to This Manual, the chapter you are
reading now, contains general information on the purpose
and contents of this manual.
Chapter 2 - Mechanical Installation, describes the require-
ments and provides instructions for the mechanical mount-
ing of ACS 300 and the optional keypad control panel.
Chapter 3 - Power Connections, describes the requirements
and provides instructions for connecting wiring for input
power, output power to the motor, dynamic braking compo-
nents and grounding the equipment.
Chapter 4 - Control Connections , describes how ACS 300
can be controlled by the optional keypad control panel or by
external control signals. Instructions are provided for con-
necting the external control wiring.
Chapter 5 - Commissioning , includes safety precautions,
start-up check list and keypad control tests.
Chapter 6 - Control and Parameter Logic , describes how to
use the control panel.
Chapter 7 - Drive Parameters , lists and explains the drive
parameters .
Chapter 8 - Fault Tracing
, describes ACS 300 fault indica-
tions, fault memory and how to trace faults.
Chapter 9 - Technical Data , lists ACS 300 technical specifi-
cations and other useful data.
Appendix A - Product Conformity in EEA , provides informa-
tion regarding the installation of the ACS 300 in conform-
ance with the requirements of the European Economic Area.