ABB ACS 400 User manual

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

Northern Industrial
Thwaites Close
Blackburn
Lancashire
BB1 2QQ
United Kingdom
ESTABLISHED IN 1978
NORTHERN INDUSTRIAL
Northern Industrial is a leading global supplier of industrial automation parts
and repairs based in the UK. We provide a wide range of automation solutions
from sourcing obsolete parts to express repairs and new part upgrades. Visit
nicontrols.com for more information.
[phone]
[email protected]
www.nicontrols.com
NI NORTHERN
INDUSTRIAL WWW.NICONTROLS.COM
Cert No. 11848
ISO 9001: 2008

http://nicontrols.com

ACS 400 AC Drives for Speed Control
of AC Induction Motors
User’s Manual
ACS400-US-04
3AUA489002B5310 R0101 Rev B
Effective: 01/16/01
Supersedes: 2/1/99
Copyright © 2001 ABB Automation Inc. All Rights Reserved.
http://nicontrols.com

http://nicontrols.com

ACS 400 User’s Manual iii
Safety
Warning! The ACS 400 should ONLY be installed by a qualified electrician.
Warning! Dangerous voltages are present when input power is connected. Wait at least 5
minutes after disconnecting the supply before removing the cover. Measure the
voltage at DC terminals (Uc+, Uc-) before servicing the unit. See Section E.
Warning! Even when the motor is stopped there are dangerous voltages present at Power
Circuit terminals U1, V1, W1 and U2, V2, W2 and Uc+, Uc-.
Warning! Even when power is removed from the input terminals of the ACS 400, there may
be dangerous external voltages at relay terminals RO1A, RO1B, RO1C, RO2A,
RO2B, RO2C.
Warning! The ACS 400 is not a field repairable unit. Never attempt to repair a
malfunctioning unit; contact the factory or your local Authorized Service Center for
replacement.
Warning! The ACS 400 can start up automatically after an input voltage interruption if
programmed for Automatic Restart after power outage.
Warning! When the control terminals of two or more ACS 100/140/400 units are connected
in parallel, the auxiliary voltage for these control connections must be taken from
a single source which can either be one of the units or an external supply.
Warning! The heat sink may reach a high temperature. See “Specifications”on page 21.
Note! For more technical information, contact the factory or your local ABB sales representative.
http://nicontrols.com

iv ACS 400 User’s Manual
http://nicontrols.com

ACS 400 User’s Manual v
Table of Contents
Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Reference Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Dimensions (in/mm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Mounting the ACS 400 on a Wall . . . . . . . . . . . . . . . . . . . . . . . . . 6
Removing the Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Terminal Interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Attaching a Warning Sticker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Type Code and Model Designation . . . . . . . . . . . . . . . . . . . . . . 10
Floating Network. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Installation of ACS 400 Conduit Box. . . . . . . . . . . . . . . . . . . . . . 12
Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Control Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Connection Examples. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Replacing the Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Applying Power. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Environmental Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Protection Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Motor Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Drive Overload Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Product Conformity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
ACS-PAN-A Control Panel. . . . . . . . . . . . . . . . . . . . . . . . 25
Control Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Output Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Menu Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Setting Parameter Value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
http://nicontrols.com

vi ACS 400 User’s Manual
Menu Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
LED Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Diagnostic displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Resetting the Drive from the Control Panel . . . . . . . . . . . . . . . . .29
Contrast Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
ACS100-PAN Control Panel . . . . . . . . . . . . . . . . . . . . . . 30
Control Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Output Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Menu Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Setting Parameter Value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Menu Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Diagnostic Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Resetting the Drive from the Control Panel . . . . . . . . . . . . . . . . .33
Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Fault Resetting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
Motor Will Not Run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Motor Stalls during Acceleration . . . . . . . . . . . . . . . . . . . . . . . . .42
Overvoltage Fault Indication . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
Overcurrent Fault Indication . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
Overload Fault Indication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
Undervoltage Fault Indication . . . . . . . . . . . . . . . . . . . . . . . . . . .46
External Fault Indication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
No Operator Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
ACS 400 Basic Parameters . . . . . . . . . . . . . . . . . . . . . . . 49
Application Macros . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Application Macro Factory (0) . . . . . . . . . . . . . . . . . . . . . . . . . . .54
Application Macro Factory (1) . . . . . . . . . . . . . . . . . . . . . . . . . . .55
Application Macro ABB Standard . . . . . . . . . . . . . . . . . . . . . . . . .56
Application Macro 3-wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
Application Macro Alternate . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
Application Macro Motor Potentiometer . . . . . . . . . . . . . . . . . . . .59
http://nicontrols.com

ACS 400 User’s Manual vii
Application Macro Hand - Auto . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Application Macro PID Control . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Application Macro Premagnetize . . . . . . . . . . . . . . . . . . . . . . . . . 62
Application Macro PFC Control . . . . . . . . . . . . . . . . . . . . . . . . . . 63
ACS 400 Complete Parameter List . . . . . . . . . . . . . . . . . 65
Group 99: Start-up Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Group 01: Operating Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Standard Serial Communication. . . . . . . . . . . . . . . . . . 129
Grounding and Termination . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Activating Modbus Protocol . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Communication settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Control Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Output signal source selection . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Diagnostic Counters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Communication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Introduction to Modbus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Register Read and Write . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Register Mapping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Exception Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Function Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
The Control Word and the Status Word . . . . . . . . . . . . . . . . . . . 141
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Actual Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Fault and Alarm Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Appendix A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Local Control vs. Remote Control . . . . . . . . . . . . . . . . . . . . . . . 151
Local Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Remote Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Internal Signal Connections for the Macros . . . . . . . . . . . . . . . . 154
Appendix B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
ACS 400 Pump and Fan Control (PFC) Macro . . . . . . . 157
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
http://nicontrols.com

viii ACS 400 User’s Manual
PID Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .159
Relay Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .160
Adding More I/O to ACS 400 . . . . . . . . . . . . . . . . . . . . . . . . . . .160
Setting up NDIO modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . .160
Appendix C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
ACS 400 EMC Instructions . . . . . . . . . . . . . . . . . . . . . . 161
Appendix D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
ACS 400 Dimensional Drawings . . . . . . . . . . . . . . . . . . . . . . . .167
http://nicontrols.com

ACS 400 User’s Manual 1
Installation
Study these installation instructions carefully before proceeding. Failure to observe the warnings
and instructions may cause a malfunction or personal hazard.
Preparation before installation
To install the ACS 400 you need the following: screwdrivers, wire stripper, tape measure, 4 pieces
of 5x12 mm screws or nuts and bolts (depending on the mounting surface), drill.
At this point it is a good idea to check the motor nameplate data and write down the following:
supply voltage, nominal current, nominal frequency, and nominal speed.
Unpacking the unit
The ACS 400 is packaged with this User’s Manual, Conduit Box, Warning Stickers, and a separate
Installation Guide. The Installation Guide gives a summary of the installation instructions described
here.
To help you mark the mounting holes for installation of your ACS 400, a Wall Mounting Template is
drawn on the lid of the box. Remove the lid from the box and save it.
Step by step instructions
The installation of the ACS 400 has been broken down in a number of steps that are listed on page
2. The steps must be carried out in the order shown. At the right of each step, reference is made to
one or more Reference Sections on the following pages of this User’s Manual. These sections give
detailed information needed for the correct installation of the unit.
Warning! Before you begin read all of the Safety instructions.
http://nicontrols.com

2ACS 400 User’s Manual
Figure 1 Step by step instructions for installing the ACS 400. The references after each step refer
to one or more of the Reference Sections on the following pages in this manual.
1
2
3
4
5
6
7
8
9
10
11
12
CHECK the environment.
MOUNT the ACS 400 to the wall.
REMOVE the cover.
ATTACH a warning sticker
in the language of your choice.
IDENTIFY power and control terminals.
CHECK voltage supply.
CHECK I/O jumpers J1 and J2.
CHECK the motor.
CONNECT power terminals.
CONNECT control wires.
REPLACE the cover.
TURN the power on.
See A
See B, C
See D
See E, F
See E, I, J
See G, T
See L, T
See E, K, M
See E, J
See J
See N
See O
http://nicontrols.com

ACS 400 User’s Manual 3
Reference Sections
A Installation Environment
Stationary Use
•Ambient temperature 32…104 °F (0...40 °C)
•Max. ambient temperature 122 °F (50 °C) if PN andI2derated to 90%
•Installation altitude 0…3300 ft (1000 m) if PN and I2100%
•Installation altitude 3300…6600 ft (1000...2000 m) if PN andI2derated 1% every 330 ft (100 m)
above 3300 ft (1000 m)
•Relative humidity less than 95% (non-condensing)
The ACS 400 must be installed in a heated, indoor controlled environment that is suitable for the
selected enclosure. Drives are available in either an IP21/NEMA Type 1 or an IP54/NEMA Type 12
enclosure. The drive must be protected from airborne dust, corrosive gases or liquids, and
conductive contaminants such as condensation, carbon dust, and metallic particles.
The IP54/NEMA Type 12 enclosure provides protection from airborne dust and light sprays or
splashing water from all directions.
Storage and Transportation
Storage Temperature -40 ...+158 °F (-40...+70 °C)
Transportation Temperature -40...+158 °F (-40...+70 °C)
http://nicontrols.com

4ACS 400 User’s Manual
B Dimensions (in/mm)
Units with IP 21/NEMA Type 1 Enclosures
Figure 2 IP 21/NEMA Type 1 enclosures
A complete set of dimensional drawings for the NEMA Type 1 ACS 400 drives is located in
“Appendix D”on page 167.
R1 R2 R3 R4
W 4.92" / 125 4.92" / 125 7.99" / 203 7.98" / 203
W1 3.86" / 98 3.86" / 98 6.30" / 160 6.30" / 160
H 14.14" / 359 18.07" / 459 22.48" / 571 26.08" / 662
H1 12.52" / 318 16.42" / 417 20.79" / 528 24.38" / 619
D 8.24" / 209 8.71" / 221 9.77" / 248 11.07" / 281
Mass (lb / kg) 12.8 / 5.8 19.8 / 9 40.8 / 18.5 59.5 / 27
Frame Size, IP21 / NEMA 1Dimensions
Reference (in / mm)
http://nicontrols.com

ACS 400 User’s Manual 5
Units with IP 54/NEMA Type 12 & NEMA Type 4 Enclosures
The IP 54/NEMA Type 12 & 4 protection class has a different outer plastic cover. The IP 54/NEMA
Type 12 & 4 enclosures use the same internal plastic shell as the IP21 enclosure, but an internal
fan is added to improve cooling. This structure increases the dimensions compared to the IP 21
enclosure, but does not require a de-rating.
Figure 3 IP 54/NEMA Type 12 & 4 enclosures
A complete set of dimensional drawings for the NEMA Type 12 & 4 ACS 400 drives is located in
“Appendix D”on page 167.
R1 R2 R3 R4
W 8.43" / 214 8.43" / 214 10.09" / 256 10.09" / 256
W1 3.86" / 98 3.86" / 98 6.30" / 160 6.30" / 160
H 17.72" / 450 21.65" / 550 25.27" / 642 29.21" / 742
H1 12.52" / 318 16.42" / 417 20.79" / 528 24.38" / 619
D 9.43" / 240 9.96" / 253 11.00" / 280 12.28" / 312
Mass (lb / kg) 12.8 / 5.8 19.8 / 9 40.8 / 18.5 59.5 / 27
Frame Size, IP54 / NEMA 12Dimensions
Reference (in / mm)
http://nicontrols.com

6ACS 400 User’s Manual
C Mounting the ACS 400 on a Wall
Warning! Before installing the ACS 400, ensure the input power supply to the drive is off.
1
The lid of the packing-box provides a Wall Mounting
Template.
Remove the lid from the box.
Figure 4 Removing the wall mounting template.
2
The ACS 400 should only be mounted vertically on a
smooth, solid surface, free from heat, dampness, and
condensation. Ensure minimum air flow gaps of 8 in
(200 mm) above and below, and 2 in (50 mm) around
the sides of the unit.
1 Using the mounting template, mark the position of
the mounting holes.
2 Drill the holes.
3 Screw in four screws or affix nuts and bolts
(depending on the mounting surface).
Figure 5 Marking and drilling the mounting holes.
3
IP 21
Position the ACS 400 onto the mounting screws or
bolts and securely tighten in all four corners.
Note! Lift the ACS 400 by its metal chassis.
Figure 6 Mounting type IP21 drives.
IP 54
1 Remove the front cover, see Figure 10.
2 Remove the rubber plugs by pushing from outside.
3 Screw in the screws.
4 Replace the rubber plugs.
Figure 7 Mounting type IP54 drives.
http://nicontrols.com

ACS 400 User’s Manual 7
D Removing the Cover
Opening frame size R1 and R2 units.
See Paragraph T for frame size assignments
of type codes.
1 Remove the control panel.
2 Press the retaining lever inside the hole located at
the top of the drive.
3 Remove the cover.
Figure 8 Opening the frame size R1 and R2 drives of type IP 21/NEMA Type 1.
Opening frame size R3 and R4 units.
See Paragraph T for frame size assignments of type codes.
1 Remove the control panel if needed.
2 Lift the retaining lever and simultaneously pull the upper front cover slightly.
3 Lift the other retaining lever with a screwdriver.
4 Open the upper part of the front cover and remove it.
5 Press the retaining lever and pull.
6 Remove the lower part of the front cover.
Figure 9 Opening the frame size R3 and R4 of type IP 21/NEMA Type 1.
4
1
3
25
6
6
http://nicontrols.com

8ACS 400 User’s Manual
Figure 10 Opening type IP 54/NEMA Type 12 & 4 drives.
IP 54/NEMA Type 12 & 4
1 Take the screws off.
2 Remove the front cover.
3 Remove panel if needed.
http://nicontrols.com

ACS 400 User’s Manual 9
E Terminal Interface
Figure 11 Terminal Interface.
F Attaching a Warning Sticker
The contents of the packing box include warning stickers in different languages. Attach a warning
sticker in the language of your choice on the inside plastic shell as indicated above.
Green LED
Red LED
X2 Panel connector
Warning sticker
X6 Connector for
X3 RS485 connector
X1 I/O connection, see I
Analog input
Termination jumper J2
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
Warning! Dangerous voltage
Wait 5 minutes after
disconnecting supply
before proceeding.
See User’s Manual.
DDCS
communication
module
U1 V1 W1 U2 V2 W2
I N P U T M O T O R
Uc+ Uc-
PE PE
Additional PE (ground)
terminals provided on
frame sizes R3 and R4
DIP switch J1
http://nicontrols.com