ABB ACS255 drives Users Manual

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ABB Micro drives

User’s manual

ACS255 drives (0.5…30 hp) (115V-480V Variants)

Page 2

ABB Micro drives

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Option manuals and guides

Code (English)

ACS255 user’s manual for 600V variants

3AXD10000528265

ACS255 user’s manual for 115-480V variants

3AXD10000528266

Page 3

ACS255 drives

0.5…30 hp

User’s manual

3AXD10001010247 Rev A

EFFECTIVE: 2019-11-10

Page 4

Page 5

1. Table of Contents

1. Table of Contents __________________________________________________________________ 5 ACS255 – IP20 (115V) EASY START-UP GUIDE _________________________________________ 7 ACS255 – IP66 (115-480V Switched Variants) EASY START-UP GUIDE ____________________________ 8 ACS255 – IP66 (115-480V Non-Switched Variants) EASY START-UP GUIDE ________________________ 9

2. Safety ___________________________________________________________________________ 11

2.1. What this chapter contains______________________________________________________________ 11

2.2. Use of warnings _______________________________________________________________________ 11

2.3. Safety in installation and maintenance ____________________________________________________ 11

2.4. Safety in start-up and operation _________________________________________________________ 12

3. General Information and Ratings _____________________________________________________ 14

3.1. Type designation key __________________________________________________________________ 14

3.2. Drive Model Numbers – IP20 ____________________________________________________________ 14

3.3. Drive Model Numbers – IP66 ____________________________________________________________ 14

4. Mechanical Installation_____________________________________________________________ 15

4.1. General _____________________________________________________________________________ 15

4.2. Mechanical Dimensions and Mounting – IP20 Open Units _____________________________________ 15

4.3. Guidelines for Enclosure Mounting – IP20 Units _____________________________________________ 15

4.4. Mechanical Dimensions – IP66 (Nema 4X) Enclosed Units _____________________________________ 16

4.5. Guidelines for Mounting Enclosed Units ___________________________________________________ 16

4.6. Gland Plate and Lock Out _______________________________________________________________ 17

4.7. Removing the Terminal Cover ___________________________________________________________ 17

5. Power Wiring _____________________________________________________________________ 18

5.1. Grounding the Drive ___________________________________________________________________ 18

5.2. Wiring Precautions ____________________________________________________________________ 19

5.3. Connection Diagram ___________________________________________________________________ 20

5.4. Drive & Motor Connections _____________________________________________________________ 21

5.5. Motor Terminal Box Connections _________________________________________________________ 21

5.6. Using the REV/Off/FWD Selector Switch (IP66 Switched Version Only) __________________________ 22

5.7. Using the Internal Potentiometer (IP66 Switched Version Only) ________________________________ 23

6. Control Wiring ____________________________________________________________________ 24

6.1. Control Terminal Connections ___________________________________________________________ 24

6.2. RJ45 Data Connection __________________________________________________________________ 24

7. Operation ________________________________________________________________________ 25

7.1. Managing the Keypad __________________________________________________________________ 25

7.2. Changing Parameters __________________________________________________________________ 25

7.3. Resetting to Factory Default Settings ______________________________________________________ 25

8. Quick Start-up and Control __________________________________________________________ 26

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8.1. Motor Control Selection (Advanced Parameter Mode) _______________________________________ 26

8.2. Operating Mode Selection ______________________________________________________________ 26

8.3. Quick Start-up Terminal Control _________________________________________________________ 26

8.4. Quick Start-up Keypad Control ___________________________________________________________ 27

8.5. Drive Operating Displays. _______________________________________________________________ 27

9. Application Macros ________________________________________________________________ 28

9.1. Overview of macros ___________________________________________________________________ 28

10. Parameters ______________________________________________________________________ 31

10.1. Parameter Structure ___________________________________________________________________ 31

10.2. Parameters in the Short parameter mode __________________________________________________ 32

10.3. Read Only Status parameters ____________________________________________________________ 34

10.4. Parameters in the Long parameter mode __________________________________________________ 36

10.5. Adjusting the Voltage / Frequency (V/f) characteristics _______________________________________ 41

10.6. Motor Thermistor Connection ___________________________________________________________ 41

10.7. Parameters in the Advanced parameter mode ______________________________________________ 42

10.8. Preventing un-authorized parameter editing. _______________________________________________ 43

11. Modbus RTU Communications _______________________________________________________ 44

11.1. Introduction _________________________________________________________________________ 44

11.2. Modbus RTU Specification ______________________________________________________________ 44

11.3. RJ45 Connector Configuration ___________________________________________________________ 44

11.4. Modbus Telegram Structure _____________________________________________________________ 44

11.5. Modbus Register Map __________________________________________________________________ 44

11.6. Modbus Parameter Register Map ________________________________________________________ 45

12. Technical Data ____________________________________________________________________ 46

12.1. Environmental ________________________________________________________________________ 46

12.2. Rating Tables _________________________________________________________________________ 46

12.3. Overload ____________________________________________________________________________ 47

12.4. Additional Information for UL Compliance _________________________________________________ 47

12.5. Derating Information __________________________________________________________________ 47

12.6. Mains Line input Reactors ______________________________________________________________ 48

13. Appendix: Permanent magnet synchronous motors (PMSMs) ______________________________ 49

13.1. PMSM Motor nameplate data entry. ______________________________________________________ 49

13.2. PMSM Motor Auto-tune. _______________________________________________________________ 49

13.3. Troubleshooting ______________________________________________________________________ 49

14. Trouble Shooting __________________________________________________________________ 50

14.1. Fault Code Messages ___________________________________________________________________ 50

Page 7

ACS255 – IP20 (115V) EASY START-UP GUIDE

Fuses

AC SupplyVoltage

(50/60Hz)

L1LL2

Earth

Supply Voltage :

- 115 Volts

- 1 Phase

- Check the drive rating information on page 46

Fuses, Cable Sizes :

- Fuse Rating recommendation values given on page 46

- Cable size recommendation values given on page 46

- Always follow local and national codes of practice

Keypad operation can be found in sections 7 and 8

Control Terminals :

Based on the default, out of box settings –

- Connect a Start/Stop switch between terminals 1& 2

- Close the switch to start

- Open the switch to stop

- To vary the speed from minimum (0Hz) to maximum

(60Hz) Connect a 10kΩ potentiometer to terminals 5,6

& 7.

1 2

Stop - Run

65 7

10kΩ

Speed Pot

Motor Cable Sizes

- Cable size recommendation values given on page 46

Motor Connections

- Check for Star or Delta connection according to the

motor voltage rating (See page 21)

Motor Nameplate Details

- Enter the motor rated voltage in parameter 9905

- Enter the motor rated current in parameter 9906

- Enter the motor rated frequency in parameter 9907

Page 8

ACS255 – IP66 (115-480V Switched Variants) EASY START-UP GUIDE

Local Speed Potentiometer

The local speed potentiometer will adjust the output frequency from minimum (Parameter 2007, default setting = 0Hz) to maximum (Parameter 2008, default setting = 60Hz)

Run Reverse / Off / Run Forward Switch

With the factory parameter settings, this switch allows the drive to be started in the forward and reverse operating directions. Alternative switch functions can be programmed, such as Local/Remote, hand / Off/ Auto, see page 22.

Local Power disconnect with lock out provision

Mechanical Mounting

- Information can be found on

page 16

Keypad operation can be found in section 7 and 8

Fuses

Earth L N L1 L2 L3

AC Supply Voltage

(50 / 60Hz)

Motor

Motor Connections

- Check for Star or Delta connection

according to the motor voltage rating (See page 21)

Motor Nameplate Details

- Enter the motor rated voltage in

parameter 9905

- Enter the motor rated current in

parameter 9906

- Enter the motor rated frequency in

parameter 9907

Fuses, Cable Sizes :

- Fuse Rating recommendation

values given on page 46

- Cable size recommendation

values given on page 46

- Always follow local and national

codes of practice.

Supply Voltage :

- 115, 230, 400, 480 Volts

- 1 or 3 Phase

- Check the drive rating

information on page 46

Motor Cable Sizes

- Cable size recommendation values given

on page 46

Page 9

ACS255 – IP66 (115-480V Non-Switched Variants) EASY START-UP GUIDE

Fuses, Cable Sizes :

- Check the drive rating

information on page 46

Mechanical Mounting

- Information can be found on

page 16

Keypad operation can be found in section 7 and 8

Fuses

Earth L N L1 L2 L3

AC Supply Voltage

(50 / 60Hz)

Motor

Motor Connections

- Check for Star or Delta connection

according to the motor voltage rating (See page 21)

Motor Nameplate Details

- Enter the motor rated voltage in

parameter 9905

- Enter the motor rated current in

parameter 9906

- Enter the motor rated frequency in

parameter 9907

Fuses, Cable Sizes :

- Fuse Rating recommendation

values given on page 46

- Cable size recommendation

values given on page 46

- Always follow local and national

codes of practice.

Supply Voltage :

- 115, 230, 400, 480 Volts

- 1 or 3 Phase

- Check the drive rating

information on page 46

Motor Cable Sizes

- Cable size recommendation values given

on page 46

Page 10

Declaration of Conformity

The manufacturer hereby states that the ACS255 product range conforms to the relevant safety provisions of the following council directives:

2014/30/EU (EMC) and 2014/35/EU (LVD) 2011/65/EU (RoHS)

EN 61800-5-1: 2007

Adjustable speed electrical power drive systems. Safety requirements. Electrical, thermal and energy.

EN 61800-3 2nd Ed: 2004 / A1:2012

Adjustable speed electrical power drive systems. EMC requirements and specific test methods

EN 55011: 2007

Limits and Methods of measurement of radio disturbance characteristics of industrial, scientific and medical (ISM) radio-frequency equipment (EMC)

EN60529 : 1992

Specifications for degrees of protection provided by enclosures

Electromagnetic Compatibility

All drives are designed with high standards of EMC in mind. It is the responsibility of the installer to ensure that the equipment or system into which the product is incorporated complies with the EMC legislation of the country of use. Within the European Union, equipment into which this product is incorporated must comply with the EMC Directive 2004/108/EC. When using an ACS255 with an external filter, compliance with the following EMC Categories, as defined by EN618003:2004 can be achieved:

Drive Type / Rating

EMC Category

First Environment Category C1

First Environment Category C2

Second Environment Category C3

ACS255-_ _U…

Use External EMC Filter Use External EMC Filter Use External EMC Filter

Note

Compliance with EMC standards is dependent on a number of factors including the environment in which the drive is installed, motor switching frequency, motor, cable lengths and installation methods adopted.

For shielded motor cable lengths greater than 100m and up to 200m, an output dv/dt filter must be used (please refer to

http://www.abb.com/ProductGuide for further details)

All rights reserved. No part of this User Guide may be reproduced or transmitted in any form or by any means, electrical or mechanical including photocopying, recording or by any information storage or retrieval system without permission in writing from the publisher.

The manufacturer accepts no liability for any damage caused during or resulting from transport, receipt of delivery, installation or commissioning. The manufacturer also accepts no liability for damage or consequences resulting from inappropriate, negligent or incorrect installation, incorrect adjustment of the operating parameters of the drive, incorrect matching of the drive to the motor, incorrect installation, unacceptable dust, moisture, corrosive substances, excessive vibration or ambient temperatures outside of the design specification.

The contents of this User Guide are believed to be correct at the time of printing. In the interest of a commitment to a policy of continuous improvement, the manufacturer reserves the right to change the specification of the product or its performance or the contents of the User Guide without notice.

This User Guide is for use with version 2.02 Software.

User Guide Revision A

This user guide is the “original instructions” document. All non-English versions are translations of the “original instructions”.

The manufacturer adopts a policy of continuous improvement and whilst every effort has been made to provide accurate and up to date information, the information contained in this User Guide should be used for guidance purposes only and does not form the part of any contract.

Page 11

2. Safety

2.1. 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, motor or driven equipment. Read the safety instructions before you work on the unit.

2.2. Use of warnings

Warnings caution you about conditions which can result in serious injury or death and/or damage to the equipment and advice on how to avoid the danger. The following warning symbols are used in this manual:

Electricity warning warns of hazards from electricity 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.

2.3. Safety in installation and maintenance

These warnings are intended for all who work on the drive, motor cable or motor.

Electricity safety

• Never work on the drive, motor cable or motor when input power is applied. After disconnecting the input power, always

wait for 10 minutes to let the intermediate circuit capacitors discharge before you start working on the drive, motor or motor cable.

Always ensure by measuring with a multimeter (impedance at least 1 Mohm) that:

1. There is no voltage between the drive input phases L1, L2 and L3 and the ground.

2. There is no voltage between terminals + and BR and the ground.

• 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 carry dangerous voltage even when the input power of the drive is switched off.

• Do not make any insulation or voltage withstand tests on the drive.

• Be sure the system is properly grounded before applying power. Do not apply AC power before you ensure that all

grounding instructions have been followed. Electrical shock can cause serious or fatal injury.

Note:

Even when the motor is stopped, dangerous voltage is present at the power circuit terminals L1, L2, L3 and U, V, W and + and BR.

WARNING! Ignoring the instructions can cause physical injury or death, or damage to the equipment.

Only qualified electricians are allowed to install and maintain the drive!

Page 12

General safety

WARNING! Ignoring the following instructions can cause physical injury or death, or damage to the equipment.

• The drive is not field repairable. Never attempt to repair a malfunctioning drive; contact your local ABB representative or

Authorized Service Centre for replacement.

• Make sure that dust from drilling does not enter the drive during the installation. Electrically conductive dust inside the drive

may cause damage or lead to malfunction.

• Ensure sufficient cooling.

2.4. Safety in start-up and operation

These warnings are intended for all who plan the operation, start up 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 if dangerous situations can occur. When activated, these functions reset the

drive and resume operation after a fault.

• Do not control the motor with an AC contactor or disconnecting device (disconnecting means); use instead the control

panel start and stop keys and or external commands (I/O). The maximum allowed number of charging cycles of the DC capacitors (that is, power-ups by applying power) is two per minute.

Note:

• When parameter 1103 PRIMARY COMMAND SOURCE MODE is not set to 1 or 2, the stop key on the control panel will not

stop the drive. To stop the drive open terminal 2 of the drive control terminals.

Page 13

Danger: Indicates a risk of electric shock, which, if not avoided, could result in damage to the equipment and possible injury or death.

Danger: Indicates a potentially hazardous situation other than electrical, which if not avoided, could result in damage to property.

The ACS255 variable speed drive is intended for professional installation and commissioning into complete equipment or systems as part of a fixed installation. If installed incorrectly it may present a safety hazard. The ACS255 uses high voltages and currents, carries a high level of stored electrical energy, and is used to control mechanical plant that may cause injury. Close attention is required to system design and electrical installation to avoid hazards in either normal operation or in the event of equipment malfunction. Only qualified electricians are allowed to install and maintain this product.

System design, installation, commissioning and maintenance must be carried out only by personnel who have the necessary training and experience. They must carefully read this safety information and the instructions in this Guide and follow all information regarding transport, storage, installation and use of the ACS255, including the specified environmental limitations.

Do not perform any flash test or voltage withstand test on the ACS255. Any electrical measurements required should be carried out with the ACS255 disconnected.

Electric shock hazard! Disconnect and ISOLATE the ACS255 before attempting any work on it. High voltages are present at the terminals and within the drive for up to 10 minutes after disconnection of the electrical supply. Always ensure by using a suitable multimeter that no voltage is present on any drive power terminals prior to commencing any work.

Where supply to the drive is through a plug and socket connector, do not disconnect until 10 minutes have elapsed after turning off the supply.

Ensure correct grounding connections. The ground cable must be sufficient to carry the maximum supply fault current which normally will be limited by the fuses. Suitably rated fuses should be fitted in the mains supply to the drive, according to any local legislation or codes.

Do not carry out any work on the drive control cables when power is applied to the drive or to the external control circuits.

Within the European Union, all machinery in which this product is used must comply with the Machinery Directive 2006/42/EC, Safety of Machinery. In particular, the machine manufacturer is responsible for providing a main switch and ensuring the electrical equipment complies with EN60204-1.

The level of integrity offered by the ACS255 control input functions – for example stop/start, forward/reverse and maximum speed is not sufficient for use in safety-critical applications without independent channels of protection. All applications where malfunction could cause injury or loss of life must be subject to a risk assessment and further protection provided where needed.

The driven motor can start at power up if the enable input signal is present.

The STOP function does not remove potentially lethal high voltages. ISOLATE the drive and wait 10 minutes before starting any work on it. Never carry out any work on the Drive, Motor or Motor cable when the input power is still applied.

The ACS255 can be programmed to operate the driven motor at speeds above or below the speed achieved when connecting the motor directly to the mains supply. Obtain confirmation from the manufacturers of the motor and the driven machine about suitability for operation over the intended speed range prior to machine start up.

Do not activate the automatic fault reset function on any systems whereby this may cause a potentially dangerous situation.

The ACS255 has an Ingress Protection rating of IP20 or IP66 depending on the model. IP20 units must be installed in a suitable enclosure.

ACS255s are intended for indoor use only.

When mounting the drive, ensure that sufficient cooling is provided. Do not carry out drilling operations with the drive in place, dust and metal shavings from drilling may lead to damage.

The entry of conductive or flammable foreign bodies should be prevented. Flammable material should not be placed close to the drive

Relative humidity must be less than 95% (non-condensing).

Ensure that the supply voltage, frequency and number of phases correspond to the rating of the ACS255 as delivered.

Never connect the mains power supply to the Output terminals U, V, W.

Do not install any type of automatic switchgear between the drive and the motor

Wherever control cabling is close to power cabling, maintain a minimum separation of 4 in. (100 mm) and arrange crossings at 90 degrees Ensure that all terminals are tightened to the appropriate torque setting

Do not attempt to carry out any repair of the drive. In the case of suspected fault or malfunction, contact your local ABB representative for further assistance.

Page 14

3. General Information and Ratings

This chapter contains information about the ACS255 including how to identify the drive.

3.1. Type designation key

The type designation contains information on the specification and configuration of the drive. You find the type designation label attached to the drive. The first digits from the left express the basic configuration, for example ACS255-03U-05A8-4.

The explanations of the type designation label selections are described below.

ACS255-03 U-05A8-4+B063+F278+N828

ACS255 product series

1-phase/3 phase

01 = 1-phase input 03 = 3-phase input

EMC Filter

E = Filtered U = Non-Filtered

Output Current Rating

In format xxAy, where xx indicates the integer part and y the fractional part, For example, 05A8 means 5.8 A.

Input Voltage Range

1 = 110…115 V AC 2 = 200…240 V AC 4 = 380…480VAC

IP66 Enclosure

B063 = IP66 Indoor B068 = IP66 Outdoor

Input Switch Assembly (Speed potentiometer, run/stop and mains disconnect switch)

Low ambient Temperature version (-20deg C)

3.2. Drive Model Numbers – IP20

Mechanical Dimensions and Mounting information are shown in section 4. Further Electrical Specifications are shown in section 12.2.

Model Number

Power

(HP)

Output

Current

(A)

Input switch assembly

Internal DB

transistor

Frame Size

1-phase 110V…115V AC (+/-10%) - 3 Phase 230V Output

ACS255-01U-02A3-1

0.5

2.3

ACS255-01U-04A3-1

4.3

ACS255-01U-05A8-1

1.5

5.8

Yes

3.3. Drive Model Numbers – IP66

Mechanical Dimensions and Mounting information are shown in section 4. Further Electrical Specifications are shown in section 12.2.

Model Number

Power

(HP)

Output Current

(A)

Input switch assembly

Internal DB

transistor

Frame Size

3-phase 200…240V AC (+/-10%) - 3 Phase Output

ACS255-03U-24A0-2+B068

7.5

Yes

ACS255-03U-24A0-2+B068+F278

7.5

Yes

ACS255-03U-30A0-2+B068

Yes

ACS255-03U-30A0-2+B068+F278

Yes

ACS255-03U-46A0-2+B068

Yes

ACS255-03U-46A0-2+B068+F278

Yes

3-phase 380…480V AC (+/-10%) - 3 Phase Output

ACS255-03U-24A0-4+B068

Yes

ACS255-03U-24A0-4+B068+F278

Yes

ACS255-03U-30A0-4+B068

Yes

ACS255-03U-30A0-4+B068+F278

Yes

ACS255-03U-39A0-4+B068

Yes

ACS255-03U-39A0-4+B068+F278

Yes

ACS255-03U-46A0-4+B068

Yes

ACS255-03U-46A0-4+B068+F278

Yes

Page 15

4. Mechanical Installation

4.1. General

• Carefully Unpack the ACS255 and check for any signs of damage. Notify the shipper immediately if any exist.

• Check the drive rating label to ensure it is of the correct type and power requirements for the application.

• Store the ACS255 in its box until required. Storage should be clean and dry and within the temperature range –40°C to +60°C

• The ACS255 should be mounted in a vertical position only on a flat, flame resistant vibration free mounting using the integral holes.

• The ACS255 must be installed in a pollution degree 1 or 2 environment only.

• Do not mount flammable material close to the ACS255

• Ensure that the minimum cooling air gaps, as detailed in sections 4.3 and 4.5 are left clear

• Ensure that the ambient temperature range does not exceed the permissible limits for the ACS255 given on page 46.

• Provide suitable clean, moisture and contaminant free cooling air sufficient to fulfil the cooling requirements of the ACS255

according to sections 4.3 and 12.1.

4.2. Mechanical Dimensions and Mounting – IP20 Open Units

H G

Drive

Frame

Size

A B C D E F G H I

Weight

173

6.81

160

6.30

109

4.29

162

6.38 5 0.20

123

4.84

3.23

1.97

5.5

0.22

0.39

1.0

2.20

221

8.70

207

8.15

137

5.39

209

8.23

5.3

0.21

150

5.91

109

4.29

2.48

5.5

0.22

0.39

1.7

3.75

NOTE

Maximum Control Terminal Torque Settings of 0.5 Nm (4.5 lb-in) Maximum Power Terminal Torque Settings of 1 Nm (9 lb-in)

4.3. Guidelines for Enclosure Mounting – IP20 Units

• Installation should be in a suitable enclosure, according to EN60529 or other relevant local codes or standards.

• Enclosures should be made from a thermally conductive material.

• Where vented enclosures are used, there should be free space clearance above and below the drive to ensure good air circulation –

see the diagram below for minimum free space clearance. Air should be drawn in below the drive and expelled above the drive.

• In any environments where the conditions require it, the enclosure must be designed to protect the ACS255 against ingress of

airborne dust, corrosive gases or liquids, conductive contaminants (such as condensation, carbon dust, and metallic particles) and sprays or splashing water from all directions.

• High moisture, salt or chemical content environments should use a suitably sealed (non-vented) enclosure.

The enclosure design and layout should ensure that the adequate ventilation paths and clearances are left to allow air to circulate through the drive heatsink. ABB Drives recommend the following minimum mounting clearance requirements for drives mounted in non-ventilated metallic enclosures:-

Drive

Size X Above &

Below

Either

Side

Between

1.97

1.30

2.95

1.97

1.81

Note :

Dimension Z assumes that the drives are mounted side-by-side with no clearance.

Typical drive heat losses are 3% of operating load conditions.

Above are guidelines only and the operating ambient temperature of the drive MUST be maintained at all times.

Page 16

=/> 150mm (5.9 inches)

4.4. Mechanical Dimensions – IP66 (Nema 4X) Enclosed Units

Drive

Frame

Size

A B C

Weight

310.0

12.2

210.5

8.29

238

9.37

251.5

9.90

197.5

7.78

7.0

15.4

360.0

14.17

240

9.45

275

10.83

300.0

11.08

226.0

8.89

9.5

20.9

NOTE

The size 3 and 4 product has 4 symmetrical mounting points Maximum Control Terminal Torque Settings of 0.5 Nm (4.5 lb-in) Maximum Power Terminal Torque Settings of 1 Nm (9 lb-in) / Size 4 = 4.1 Nm (36.5 Ib-in)

4.5. Guidelines for Mounting Enclosed Units

• Before mounting the drive, ensure that the chosen location meets the environmental

condition requirements for the drive shown in section 12.1

• The drive must be mounted vertically, on a suitable flat surface

• The minimum mounting clearances as shown in the table below must be observed

• The mounting site and chosen mountings should be sufficient to support the weight

of the drives

• The Enclosed ACS255s can be installed side-by-side with their heatsink flanges

touching. This gives adequate ventilation space between drives.

• If the ACS255 is to be installed above another drive or any other heat-producing

device, the minimum vertical spacing (X) is 150mm (5.9 inches) above and below.

Page 17

4.6. Gland Plate and Lock Out

The use of a suitable gland system is required to maintain the appropriate IP / Nema rating. The gland plate has pre moulded cable entry holes for power and motor connections suitable for use with glands as shown in the following table. Where additional holes are required, these can be drilled to suitable size. Please take care when drilling to avoid leaving any particles within the product.

Cable Gland recommended Hole Sizes & types:

Moulded Hole Size

UL Gland Size

Frame Size 3

1.11in (28.2mm)

PG21

Frame Size 4

Power Entries: 1.11in (28.2mm) Control Entry : 0.87in (22mm)

PG21

PG16

• UL rated ingress protection ("Type ") is only met when cables are installed using a UL recognized bushing or fitting for a flexible-

conduit system which meets the required level of protection ("Type")

• For conduit installations the conduit entry holes require standard opening to the required sizes specified per the NEC.

• Not intended for rigid conduit system

Local Power Isolator Lock out

On the switched models the Local Power Isolator switch can be locked in the ‘Off’ position using a 20mm standard shackle padlock (not supplied).

IP66 / Nema 4X Unit Lock Out

4.7. Removing the Terminal Cover

To access the connection terminals, the drive front cover needs to be removed as shown.

IP66 / NEMA 4X Units

Removing the 2 screws on the front of the product allows access to the connection terminals, as shown below.

Page 18

5. Power Wiring

5.1. Grounding the Drive

This manual is intended as a guide for proper installation. ABB Drives Ltd cannot assume responsibility for the compliance or the non-compliance to any code, national, local or otherwise, for the proper installation of this drive or associated equipment. A hazard of personal injury and/or equipment damage exists if codes are ignored during installation.

This ACS255 contains high voltage capacitors that take time to discharge after removal of the main supply. Before working on the drive, ensure isolation of the main supply from line inputs. Wait ten (10) minutes for the capacitors to discharge to safe voltage levels. Failure to observe this precaution could result in severe bodily injury or loss of life.

Only qualified electrical personnel familiar with the construction and operation of this equipment and the hazards involved should install, adjust, operate, or service this equipment. Read and understand this manual and other applicable manuals in their entirety before proceeding. Failure to observe this precaution could result in severe bodily injury or loss of life.

5.1.1. Recommended installation for EMC compliance

Whenever possible use Shielded motor cablesmaintaining shield as far as possible along the cable.

=/>100mm

• Twisted-Pair shielded cables for analog control and motor feedback signals.

• Ensure Filter chassis is making metal-metal contact with Mounting panel.

RFI Filter

Option

Site Ground Bus-Bar bonded to Metal Back-Panel

panel which is bonded to main power ground.

U V W

360° bonding

EMC cable gland

(Best-Practice)

(Shield to Motor

Chassis)

• Avoid long parallel runs of motor cables with other cables

• Where control cables must cross power cables make sure they are arranged at an angle as near to 90 degrees as possible.

Metal Back-Panel

Page 19

5.1.2. Grounding Guidelines

The ground terminal of each ACS255 should be individually connected DIRECTLY to the site ground bus bar (through the filter if installed). ACS255 ground connections should not loop from one drive to another, or to, or from any other equipment. Ground loop impedance must

confirm to local industrial safety regulations. To meet UL regulations, UL approved ring crimp terminals should be used for all ground wiring connections. The drive Safety Ground must be connected to system ground. Ground impedance must conform to the requirements of national and local industrial safety regulations and/or electrical codes. The integrity of all ground connections should be checked periodically.

When installing the drive on any power supply where the phase-ground voltage may exceed the phase-phase voltage (typically IT supply networks or Marine vessels) it is essential that the internal EMC filter ground and surge protection varistor ground (where fitted) are disconnected. If in doubt, refer to your Local ABB representative for further information.

5.1.3. Protective Earth Conductor

The Cross sectional area of the PE Conductor must be at least equal to that of the incoming supply conductor.

5.1.4. Safety Ground

This is the safety ground for the drive that is required by code. One of these points must be connected to adjacent building steel (girder, joist), a floor ground rod, or bus bar. Grounding points must comply with national and local industrial safety regulations and/or electrical codes.

The safety ground terminal provides a grounding point for the motor cable shield. The motor cable shield connected to this terminal (drive end) should also be connected to the motor frame (motor end). Use a shield terminating or EMI clamp to connect the shield to the safety ground terminal.

5.1.5. Motor Ground

The motor ground must be connected to one of the ground terminals on the drive.

5.1.6. Ground Fault Monitoring

As with all inverters, a leakage current to earth can exist. The ACS255 is designed to produce the minimum possible leakage current while complying with worldwide standards. The level of current is affected by motor cable length and type, the effective switching frequency, the earth connections used and the type of RFI filter installed. If a GFCI (Ground Fault Current interrupter) is to be used, the following conditions apply: -

• The device must be suitable for protecting equipment with a DC component in the leakage current

• Individual GFCI’s should be used for each ACS255

The ACS255 product range has input supply voltage surge suppression components fitted to protect the drive from line voltage transients, typically originating from lightning strikes or switching of high power equipment on the same supply.

5.2. Wiring Precautions

Connect the ACS255 according to sections 5.3 and 5.4, ensuring that motor terminal box connections are correct. There are two connections in general: Star and Delta. It is essential to ensure that the motor is connected in accordance with the voltage at which it will be operated. For more information, refer to section 0.

Type MC continuous corrugated aluminium armor cable with symmetrical grounds or shielded power cable is recommended for the motor cables if metallic conduit is not used.

The power cables must be rated for 75˚C (167˚F).

5.2.1. EMC Filters

WARNING! EMC filters should not be used when there is a risk that the phase to earth voltage could exceed the phase to

phase voltage, Typically IT (ungrounded) or Marine vessels and corner-grounded TN systems, otherwise this may cause danger or damage to the EMC filter.

Page 20

5.3. Connection Diagram

5.3.1. IP66 (Nema 4X) Switched Units

Power Connections

Incoming Power Source

External Fuse

Optional Input Choke

Optional Input Filter

Internal Mains Disconnect

Optional Brake Resistor

Shielded Motor Cable

Relay Output

Control Connections

Internal Forward / Off / Reverse Switch

Internal Speed Control Pot

Analog Output 0 – 10 Volts

0 Volt

Relay Output ‘Drive READY’ = Closed

5.3.2. IP20 & IP66 (Nema 4X) Non- Switched Units

Power Connections

Incoming Power Source

External Mains Disconnect

External Fuse

Optional Input Choke

Optional Input Filter

Optional Brake Resistor

Shielded Motor Cable

Relay Output

Control Connections

+ 24 Volt (100mA) User Output

Digital Input 1 Drive Run / Stop

Digital Input 2 Forward / Reverse

Digital Input 3 Analog / Preset Speed

+ 10 Volt Output

Analog Input 1 0 – 10 Volt

0 Volt

Analog Output 0 – 10 Volts

0 Volt

Relay Output ‘Drive READY’ = Closed

+DC

Page 21

5.4. Drive & Motor Connections

For 1 phase supply, power should be connected to L1/L, L2/N. For 3 phase supplies power should be connected to L1, L2, L3. Phase sequence is not important. The Motor should be connected to U, V, W

For drives that have a dynamic brake transistor an optional external braking resistor will need be connected to +DC and BR when required.

The brake resistor circuit should be protected by a suitable thermal protection circuit. The “–DC”, “+” and “BR” connections are blanked off by plastic tabs when sent from the factory. The plastic tabs can be removed if/when required.

5.5. Motor Terminal Box Connections

Most general purpose motors are wound for operation on dual voltage supplies. This is indicated on the nameplate of the motor. This operational voltage is normally selected when installing the motor by selecting either STAR or DELTA connection. STAR always gives the higher of the two voltage ratings. Example Motor nameplate shown below (380V Delta illustrated):

Page 22

5.6. Using the REV/Off/FWD Selector Switch (IP66 Switched Version Only)

By adjusting the parameter settings the ACS255 can be configured for multiple applications and not just for Forward or Reverse. This could typically be for Hand/Off/Auto applications (also known and Local/Remote) for HVAC and pumping industries. The integrated switch operates in parallel with drive terminal 2 (T2) and terminal 3 (T3) as digital input 1 and digital input 2. By default, the integrated switch is enabled. If required, the built in control switch may be disabled using the following method:

Switch Position

Switch Left

Switch Centre

Switch Right

DI1

DI2

DI1

DI2

DI1

DI2 1 1 0 0 0 1

Lc-Off 0 0 0 0 0 0

Lc-On 0 1 0 0 1 0

Alert

NOTE

The table below applies to default setting “Lc-Off”

Switch Position

Parameters to Set

Notes

Switch Left

Switch Centre

Switch Right

1103

9902

Run Reverse

STOP

Run Forward

Factory Default Configuration Run Forward or Reverse with speed controlled from the Local POT

STOP

Run Forward

5,7

Run forward with speed controlled form the local POT Run Reverse - disabled

Preset Speed 1

STOP

Run Forward

Run Forward with speed controlled from the Local POT Preset Speed 1 provides a ‘Jog’ Speed set in parameter 1202

Run Reverse

STOP

Run Forward

6, 8

Run Forward or Reverse with speed controlled from the Local POT

Run in Auto

STOP

Run in Hand

Run in Hand – Speed controlled from the Local POT Run in Auto 0 Speed controlled using Analog input 2 e.g. from PLC with 4-20mA signal.

Run in Speed

Control

STOP

Run in PI Control

In Speed Control the speed is controlled from the Local POT In PI Control, Local POT controls PI set point

Run in Preset Speed

Control

STOP

Run in PI Control

0, 2, 4,5,

8..12

In Preset Speed Control, parameter 1202 sets the Preset Speed In PI Control, POT can control the PI set point (Parameter 4010=1)

Run in Hand

STOP

Run in Auto

Hand – speed controlled from the Local POT Auto – Speed Reference from Modbus

Run in Hand

STOP

Run in Auto

Hand – Speed reference from Preset Speed 1 (Parameter 1202) Auto – Speed Reference from Modbus

Page 23

5.7. Using the Internal Potentiometer (IP66 Switched Version Only)

On switched drives, the built in pot (indicated) may be used to directly control the signal level applied to analog input 1, and therefore the output frequency (motor speed).

To select the built in pot as the signal source for analog input 1, set 1300 = “”

Page 24

6. Control Wiring

6.1. Control Terminal Connections

Default Connections

Control Terminals

Description

+24V

+24V Output

+24V, 100mA.

DI1

Digital Input 1

Positive logic

“Logic 1” input voltage range: 8V … 30V DC “Logic 0” input voltage range: 0V … 4V DC

DI2

Digital Input 2

DI/AI 3

Digital/Analog

Input 3

Digital: 8 to 30V Analog: 0 to 10V, 0 to 20mA or 4 to 20mA

+10V

+10V Output

+10V, 10mA, 1kΩ minimum

DI/AI4

Digital/Analog

Input 4

Analog: 0 to 10V, 0 to 20mA or 4 to 20mA Digital: 8 to 30V

COM

User ground connected to terminal 9

Analog Output /

Digital Output

Analog: 0 to 10V, 20mA maximum Digital: 0 to 24V

AGND

User ground connected to terminal 7

ROC

Relay Common

RNO

Relay Contact

Contact 255Vac, 6A / 30Vdc, 5A

6.2. RJ45 Data Connection

For MODBUS RTU register map information please refer to page 44

When using MODBUS control the Analog and Digital Inputs can be configured as shown in section 9.1.3

No Connection

0 Volts 4 -RS485 (PC)

+RS485 (PC)

+24 Volt

-RS485 (Modbus RTU)

+RS485 (Modbus RTU)

Warning:

This is not an Ethernet connection. Do not connect directly to an Ethernet port.

Page 25

7. Operation

7.1. Managing the Keypad

The drive is configured and its operation monitored via the keypad and display.

NAVIGATE

Used to display real-time information, to access and exit parameter edit mode and to store parameter changes. (press for >1 second to toggle between status and parameter mode)

Used to increase speed in real-time mode or to increase parameter values in parameter edit mode

DOWN

Used to decrease speed in real-time mode or to decrease parameter values in parameter edit mode

RESET /

STOP

Used to reset a tripped drive. When in Keypad mode is used to Stop a running drive.

START

When in keypad mode, used to Start a stopped drive or to reverse the direction of rotation if bi-directional keypad mode is enabled

7.2. Changing Parameters

H StoPH

PAr SH

Use to select parameter for editing

“Parameter mode”

(End number flashing)

P9902H

Press to enter

parameter edit mode

P0000

(“Parameter edit mode”)

Short Press to exit “Parameter edit mode” and save selection

Use to change

parameter value

Press for >1s to return

to status mode

“Status Mode”

H StoPH

Press for >1sec to enter

“Short/Long/Advanced

Parameter group selection

mode”

Timeout (60s)

Use to select Short “ ”,

Long “ ”, Advanced “ “

group parameters

PAr SH

Press to exit “Short/Long Parameter group

selection mode” and save selection

Use to select parameter for editing

“Parameter mode”

(End number flashing)

P9902H

Press to enter

parameter edit mode

P0000

(“Parameter edit mode”)

Short Press to exit “Parameter edit mode” and save selection

Use to change

parameter value

PAr SH

PAr LH

Press for >1s to return

to status mode

Timeout (60s)

PAr AH

NOTE

When attempting to edit a parameter the drive must be stopped (not running), if not “L” will be shown on the left side of the display.

7.3. Resetting to Factory Default Settings

To reset factory default parameters, press , and for >2s. The display shows . Press the button to acknowledge and reset the drive.

Page 26

8. Quick Start-up and Control

8.1. Motor Control Selection (Advanced Parameter Mode)

When delivered, the drive is in the factory default state, meaning that it is set to operate in V/f mode. This may yield acceptable performance for variable torque applications like centrifugal pumps and fans or other equipment not subjected to dynamic loads. Vector speed control will provide enhanced performance for constant torque applications like conveyor, mixers, or other applications subjected to dynamic loading. 9903 Motor parameter autotune MUST be performed at first startup when 9903 Vector speed control mode is selected. All PMAC motors are run in PM sensorless vector control.

For most applications using the E4 frame drives, Vector speed control will yield better motor control.

1. Perform Mechanical and Electrical installation as per section 4 and 5. The motor must be connected to the drive.

2. Connect a control switch between the control terminals 1 and 2 ensuring that the contact is open (drive disabled).

3. Navigate to the Advanced parameter menu as shown in 10.1.1 Group Navigation.

4. For Vector speed control mode, select "0" in 9903 Operating Mode Select and select "1" in 9910 Motor parameter autotune. The Autotune function will immediately performs a non-rotating autotune and then returns 9910 to "0"

5. Proceed with Operating Mode Select (Macros)

8.2. Operating Mode Selection

Setup can be simplified by selecting the operating mode for the drive in 2605 Operating Mode Select. This function provides a quick set up to configure key parameters to the intended application of the drive. Parameters 2017 Current Limit, 2610 & 2611 Torque Characteristic, and 2101 Spin Start are preset according to the table on page 42.

8.3. Quick Start-up Terminal Control

When delivered, the drive is in the factory default state, meaning that it is set to operate in terminal control mode (Parameter 9902 DIGITAL INPUTS FUNCTION SELECT = 0 and 1103 PRIMARY COMMAND SOURCE MODE = 0) and all parameters have the default values as indicated in section 10.

1. Perform Mechanical and Electrical installation as per section 4 and 5.

2. Connect a control switch between the control terminals 1 and 2 ensuring that the contact is open (drive disabled).

3. Connect a potentiometer (1kΩ min to 10 kΩ max) between terminals 5 and 7, and the wiper to terminal 6.

4. With the potentiometer set to zero, switch on the supply to the drive. The display will show .

5. Press and hold the navigate key for >1s to enter parameter view mode and enter motor data from motor nameplate into parameter

9905 MOTOR RATED VOLTAGE, 9906 MOTOR RATED CURRENT, and parameter 9907 MOTOR RATED FREQUENCY. Enter the rated RPM (nameplate) of the motor in 9908 MOTOR RATED SPEED to allow the display of the estimated motor speed.

6. Close the control switch, terminals 1-2. The drive is now ‘enabled’ and the output frequency/speed are controlled by the

potentiometer. The display shows zero speed in Hz (.) with the potentiometer turned to minimum. If the display is not showing Hz, change it using the (Navigate) key.

7. Turn the potentiometer to maximum. The motor will accelerate to 60Hz (the default value of parameter 2008 MAXIMUM

FREQUENCY / SPEED LIMIT) under the control of the accelerating ramp time parameter 2202 ACCELERATION RAMP TIME. The display shows 60Hz (.) at max speed.

8. To display motor current (A), briefly press the (Navigate) key.

9. To display estimated motor speed (RPM), briefly press the (Navigate) key a second time.

(Motor nameplate speed (RPM) must be entered in 9908 Motor Rated Speed to display the estimated RPM).

10. To display power (Hp) briefly press the (Navigate) key a third time.

11. Press again to return to speed (Hz) display.

To stop the motor, either turn the potentiometer back to zero or disable the drive by opening the control switch (terminals 1-2).

If the enable/disable switch is opened the drive will decelerate to stop at which time the display will show . If the potentiometer is turned to zero with the enable/disable closed the display will show .(0.0Hz), if left like this for 60 seconds the drive will go into standby mode, display shows , waiting for a speed reference signal.

Page 27

8.4. Quick Start-up Keypad Control

To allow the ACS255 to be controlled from the keypad in a forward direction only, set parameter 1103 PRIMARY COMMAND SOURCE MODE =1:

1. Perform Mechanical and Electrical installation as per section 4 and 0.

2. Connect a control switch between the control terminals 1 and 2 ensuring that the contact is open (drive disabled).

3. Switch on the supply to the drive, Press and hold the navigate key for > 1 to enter parameter view mode and set parameter 1103

Primary Command Source Mode = 1

4. Enable the drive by closing the switch between control terminals 1 & 2. The display will show .

5. Press the key. The display shows .. If the display is not showing Hz, change it using the (Navigate) key.

6. Press to increase speed.

7. The drive will run forward, increasing speed until is released.

The rate of acceleration is controlled by the setting of parameter 2202 ACCELERATION RAMP TIME, check this before starting.

8. Press to decrease speed. The drive will decrease speed until is released. The rate of deceleration is limited by the setting in

2203 DECELERATION RAMP TIME.

9. Press the key. The drive will decelerate to rest at the rate set in parameter 2203 DECELERATION RAMP TIME.

10. The display will finally show  at which point the drive is disabled

11. To preset a target speed prior to enable, press the key while the drive is stopped. The display will show the target speed, use the

& keys to adjust as required then press the key to return the display to .

12. Pressing the key will start the drive accelerating to the target speed.

To allow the ACS255 to be controlled from the keypad in a forward and reverse direction, set parameter 1103 PRIMARY COMMAND SOURCE MODE =2:

13. Operation is the same as when parameter 1103 PRIMARY COMMAND SOURCE MODE =1 for start, stop and changing speed.

14. Press the key. The display changes to ..

15. Press to increase speed

16. The drive will run forward, increasing speed until is released. Acceleration is limited by the setting in parameter 2202

ACCELERATION RAMP TIME. The maximum speed is the speed set in parameter 2008 MAXIMUM FREQUENCY / SPEED LIMIT.

17. To reverse the direction of rotation of the motor, press the key again.

8.5. Drive Operating Displays.



Drive mains power applied, but no Enable or Run signal applied

..

Drive running, display shows output frequency (Hz)

Whilst the drive is running, the following displays can be selected by briefly pressing the button on the drive. Each press of the button will cycle the display through to the next selection.

..

Drive running, display shows motor current (Amps)

..

Drive Running, display shows motor power (kW)

 

If the enable/disable switch is opened the drive will decelerate to stop at which time the display will show . If the potentiometer is turned to zero with the enable/disable closed the display will show .. (0.0Hz), if left like this for 60 seconds the drive will go into

standby mode, display shows



, waiting for a speed reference signal.

Page 28

9. Application Macros

9.1. Overview of macros

Application macros are pre-programmed parameter sets. While starting up the drive, the user selects the macro best suited for the purpose with parameter 9902 DIGITAL INPUTS FUNCTION SELECT and 1103 PRIMARY COMMAND SOURCE MODE.

1103 (control Mode)

Selected Speed Reference

0 : Terminal Mode

Analog input 1

1 : Keypad Mode (uni-directional)

Digital Potentiometer

2 : Keypad Mode (bi-directional)

Digital Potentiometer

4 : Fieldbus Control

Speed reference via Fieldbus

5 : User PI mode

PI controller output

9.1.1. Terminal Mode 1103 PRIMARY COMMAND SOURCE MODE = 0.

9902

Digital input 1 (T2)

Digital input 2 (T3)

Digital input 3 (T4)

Analog input (T6)

Comments

Open: Stop (disable) Closed: Run (enable)

Open : Forward run Closed : Reverse run

Open : Analog speed ref Closed : Preset speed 1

Analog input 1 reference

Open: Stop (disable) Closed: Run (enable)

Open: Analog speed ref Closed : Preset speed 1/2

Open: Preset speed 1 Closed : Preset speed 2

Analog input 1 reference

Open: Stop (disable) Closed: Run (enable)

Digital Input 2

Digital Input 3

Preset Speed

Open: Preset speeds 1-4 Closed : Max Speed (parameter 2008)

4 Preset speeds selectable. Analog input used as digital input Closed status: 8V < Vin < 30V

Open

Preset Speed 1

Closed

Open

Preset Speed 2

Open

Closed

Preset Speed 3

Closed

Preset Speed 4

Open: Stop (disable) Closed: Run (enable)

Open : Analog speed ref Closed : Preset speed 1

External trip input :

Open: Trip, Closed: Run

Analog input 1 reference

Connect external motor thermistor PTC type or similar to digital input 3

Open: Stop (disable) Closed: Run (enable)

Open : Analog input 1 Closed : Analog input 2

Analog input 2 reference

Analog input 1 reference

Switches between analog inputs 1 and 2

Open: Fwd Stop Closed: Fwd Run

Open: Reverse Stop Closed: Reverse Run

Open : Analog speed ref Closed : Preset speed 1

Analog input 1 reference

Closing digital inputs 1 and 2 together carries out a fast stop (Parameter 2206)

Open: Stop (disable) Closed: Run (enable)

Open : Forward Closed : Reverse

External trip input :

Open: Trip, Closed: Run

Analog input 1 reference

Connect external motor thermistor PTC type or similar to digital input 3

Open: Stop (disable) Closed: Fwd Run (enable)

Open: Stop (disable) Closed: Rev Run (enable)

External trip input :

Open: Trip, Closed: Run

Analog input 1 reference

Closing digital inputs 1 and 2 together carries out a fast stop (Parameter 2206)

Open: Stop (disable) Closed: Run (enable)

Open : Forward Closed : Reverse

Digital Input 3

Analog Input 1

Preset Speed

Open

Preset Speed 1

Closed

Open

Preset Speed 2

Open

Closed

Preset Speed 3

Closed

Preset Speed 4

Open: Stop (disable) Closed: Forward Run (enable)

Open: Stop (disable) Closed: Reverse Run (enable)

Digital Input 3

Analog Input 1

Preset Speed

Closing digital inputs 1 and 2 together carries out a fast stop (Parameter

2206) Open

Open

Preset Speed 1

Closed

Open

Preset Speed 2

Open

Closed

Preset Speed 3

Closed

Preset Speed 4

Normally Open (NO) Momentary close to run

Normally Closed (NC) Momentary open to stop

Open : Analog speed ref Closed: Preset speed 1

Analog input 1 reference

Normally Open (NO) Momentary close to run

Normally Closed (NC) Momentary open to stop

Normally Open (NO) Momentary close to rev

Analog input 1 reference

Closing digital inputs 1 and 3 together carries out a fast stop (Parameter 2206)

Open: Stop (disable) Closed: Run (enable)

Open: Fast Stop (disable) Closed: Run (enable)

Open : Analog speed ref Closed : Preset speed 1

Analog input 1 reference

NOTE

Negative Preset Speeds will be inverted if Run Reverse selected

9902=0

9902 = 1

9902=2

+24 Volt

Run (Enable)

For / Rev

Analog / Preset

Preset Speeds 1 – 4 Select

Analog / Preset

Preset1 / Preset2

+ 10 Volts

Reference

Preset / Max

0 Volts

Analog speed input with 1 preset speed and

fwd/rev switch

Analog speed input with 2 preset speeds

4 preset speeds and max speed select switch.

Effectively giving 5 preset speeds

Page 29

9902=3

9902=4

9902=11

+24 Volt

Run (Enable)

Run Forward

Analog / Preset 1

Local / Remote (Hand / Auto)

Stop

External Trip

Remote (Auto) Reference

Run Reverse

+ 10 Volts

Reference

Local (Hand) Reference

Reference

0 Volts

Analog speed input with 1 preset speed and

motor thermistor trip

Local or remote analog speeds

(2 analog inputs)

Push button fwd/rev/stop with fast stop using

2nd deceleration ramp

9.1.2. Keypad Mode 1103 PRIMARY COMMAND SOURCE MODE = 1 or 2.

9902

Digital input 1 (T2)

Digital input 2 (T3)

Digital input 3 (T4)

Analog input (T6)

Comments

0, 1,

8..12

Open: Stop (disable) Closed: Run (enable)

Closed : remote UP pushbutton

Closed : remote DOWN push-button

Open : Forward +24V : Reverse

2 Open: Stop (disable) Closed: Run (enable)

Closed : remote UP pushbutton

Closed : remote DOWN push-button

Open : Keypad speed ref +24V : Preset speed 1

Open: Stop (disable) Closed: Run (enable)

Closed : remote UP pushbutton

External trip input : Open: Trip, Closed: Run

Closed : remote DOWN push-button

Connect external motor thermistor PTC type or similar to digital input 3

Open: Stop (disable) Closed: Run (enable)

Closed : remote UP pushbutton

Open : Keypad speed ref Closed : Analog input 1

Analog input 1

Open: Stop (disable) Closed: Run (enable)

Open : Forward run Closed : Reverse run

External trip input : Open: Trip, Closed: Run

Open : Keypad speed ref +24V : Preset speed 1

Connect external motor thermistor PTC type or similar to digital input 3

Open: Forward Stop Closed: Forward Run

Open: Reverse Stop Closed: Reverse Run

External trip input : Open: Trip, Closed: Run

Open : Keypad speed ref +24V : Preset speed 1

Closing digital inputs 1 and 2 together carries out a fast stop (2206)

9902=0

+24 Volt

Run (Enable)

Increase Speed

Reduce Speed

+ 10 Volts

Forward / Reverse

0 Volts

Remote push button speed control with

fwd/rev

NOTE

By default if the enable signal is present the drive will not Enable until the START button is pressed. To automatically enable the drive when the enable signal is present set Parameter 1100 KEYPAD MODE RESTART FUNCTION = 2 or 3. This then disables the use of the START & STOP buttons

9.1.3. Modbus Control Mode 1103 PRIMARY COMMAND SOURCE MODE = 4.

9902

Digital input 1 (T2)

Digital input 2 (T3)

Digital input 3 (T4)

Analog input (T6)

Comments

0..2,

4..5,

8..12

Open: Stop (disable) Closed: Run (enable)

No effect

Run and stop commands given via the RS485 link and Digital input 1 must be closed for the drive to run.

Open: Stop (disable) Closed: Run (enable)

Open : Master speed ref Closed : Preset speed 1

External trip input : Open: Trip, Closed: Run

No effect

Connect external motor thermistor PTC type or similar to digital input 3

Open: Stop (disable) Closed: Run (enable)

Open : Master speed ref Closed : Analog input

External trip input : Open: Trip, Closed: Run

Analog input reference

Master Speed Ref - start and stop controlled via RS485. Keypad Speed Ref - drive auto runs if digital input 1

closed, depending on Parameter

1100 setting

Open: Stop (disable) Closed: Run (enable)

Open : Master speed ref Closed : keypad speed ref

External trip input : Open: Trip, Closed: Run

No effect

For further information on the MODBUS RTU Register Map information and communication setup please refer to section 11.

Page 30

9.1.4. PI Mode 1103 PRIMARY COMMAND SOURCE MODE = 5.

9902

Digital input 1 (T2)

Digital input 2 (T3)

Digital input 3 (T4)

Analog input (T6)

Comments

0, 2,

9..12

Open: Stop (disable) Closed: Run (enable)

Open : PI control Closed : Preset speed 1

PI feedback analog input

Analog input 1

Analog Input 1 can provide an adjustable PI setpoint, by setting Parameter 4010 = 1

Open: Stop (disable) Closed: Run (enable)

Open : PI control Closed : Analog input 1

PI feedback analog input

Analog input 1

Analog Input 1 can provide an adjustable PI setpoint, by setting Parameter 4010 = 1

3, 7

Open: Stop (disable) Closed: Run (enable)

Open : PI control Closed : Preset speed 1

External trip input : Open: Trip, Closed: Run

PI feedback analog input

Connect external motor thermistor PTC type or similar to digital input 3

Normally Open (NO) Momentary close to run

Normally Closed (NC) Momentary open to stop

PI Feedback Analog Input

Analog Input 1

Normally Open (NO) Momentary close to run

Normally Closed (NC) Momentary open to stop

Open: PI Control Closed: Preset Speed 1

PI Feedback Analog Input

Normally Open (NO) Momentary close to run

Normally Closed (NC) Momentary open to stop

Open: External Trip Closed: Run

PI Feedback Analog Input

Normally Open (NO) Momentary close to run

Open: Stop (disable) Closed: Run (enable)

Open : Forward run Closed : Reverse run

PI feedback analog input

Analog input 1

Analog Input 1 can provide an adjustable PI setpoint, by setting Parameter 4010 = 1

PI Mode 1103=5, 9902=0

PI Mode 1103=5, 9902=1

PI Mode 1103=5, 9902=3

+24 Volt

Run (Enable)

PI / Preset Speed 1

PI / Local (Hand)

PI / Preset Speed 1

PI Feedback

External Trip

+10 Volt

Local (Hand) Ref

PI Feedback

0 Volt

Remote closed loop PI feedback control

with Local Preset speed 1

Remote closed loop PI feedback control with

Local Analog speed input

Remote closed loop PI feedback control with

Local Preset speed 1 and motor thermistor

trip

NOTE

By default the PI reference is set for a digital reference level set in Parameter 4011 PI DIGITAL REFERENCE (SETPOINT). When using an Analog reference set Parameter 4010 PI DIGITAL REFERENCE (SETPOINT)= 1 (analog) and connect reference signal to analog input 1 (T6). The default settings for proportional gain (parameter 4001), integral gain (Parameter 4002) and feedback mode (Parameter 4005) are suitable for most fan and pump applications. The analog reference used for PI controller can also be used as the local speed reference when parameter 9902 DIGITAL INPUTS FUNCTION SELECT =1.

Page 31

10. Parameters

10.1. Parameter Structure

The parameters within the drive are split into 3 groups, group 1 is titled “Short Parameter mode” displayed as “Par S” on the drive display, group 2 is titled “Long Parameter mode” displayed as “Par L” on the drive display and group 3 is titled “Advanced Parameter mode” displayed as “Par A”.

• “Par S” group brings together the most commonly used parameters to aid quick setup.

• “Par L” group includes all of the drive parameters (except those in “Par-A” group.

• “Par A” group includes the drives advanced functions.

10.1.1. Group Navigation.

H StoPH

PAr SH

“Parameter mode”

(End number flashing)

P9902H

“Status Mode”

H StoPH

Press for >1sec to enter

“Short/Long/Advanced

Parameter group selection

mode”

Timeout (60s)

Use to select Short “ ”,

Long “ ”, Advanced “ “

group parameters

PAr SH

Press to exit “Short/Long Parameter group

selection mode” and save selection

“Parameter mode”

(End number flashing)

P9902H

PAr SH

PAr LH PAr AH

10.1.2. Parameter Structure table.

PAr SH

Parameter No.

9902

9905

9906

9907

0401

1103

1202

1203

1204

1301

2008

2102

2202

ABB Short parameter group

(1611 not set to "101")

PAr LH

Parameter No.

0000

0401

1100

1103

1202

1203

1204

1205

3400

4001

4002

4005

4010

4011

4016

5302

9902

9905

9906

9907

9908

Long parameter group (1611 =

"101")>>(Currently selected

via keyapd "PAR L" on

ACS150)

PAr AH

Parameter No.

Page 32

10.2. Parameters in the Short parameter mode

The following table describes the parameters that are visible in the Short parameter mode. See page 25 for how to select the parameter mode. All parameters are presented in detail in section 10.4.

Parameters in the Short parameter mode

No.

Name/Value

Description

Def

99 START-UP DATA

Application macros.

9902

DIGITAL INPUTS FUNCTION SELECT

Defines the function of the digital inputs depending on the control mode setting in Parameter 1103 PRIMARY COMMAND SOURCE MODE. See Application macros on page 28.

9905

MOTOR RATED VOLTAGE

This parameter should be set to the rated (nameplate) voltage of the motor (Volts).

Drive Rating

Dependent

110V/230V rated drives 0…255V

400V rated drives 0…500V

Voltage

Note : The stress on the motor insulation is always dependent on the drive supply voltage. This also applies in the case where the motor voltage rating is lower than the rating of the drive and the supply of the drive.

9906

MOTOR RATED CURRENT

This parameter should be set to the rated (nameplate) current of the motor.

Drive Rating

Dependent

0.2*drive rated output

current…1.0*drive rated

output current

Current 9907

MOTOR RATED FREQUENCY

This parameter should be set to the rated (nameplate) frequency of the motor

60Hz

25…500Hz

Frequency

04 FAULT HISTORY

Fault history (read only)

0401

TRIP HISTORY LOG

Displays the last four fault codes for the drive. Refer to page 50 for further information.

11 REFERENCE SELECT

The drive can accept a variety of references in addition to the conventional analog input, potentiometer and keypad signals.

1103

PRIMARY COMMAND SOURCE MODE

0: Terminal Control

0: TERMINAL CONTROL.

The drive responds directly to signals applied to the control terminals.

1: UNI-DIRECTIONAL KEYPAD CONTROL

The drive can be controlled in the forward direction only using an external or remote Keypad

2: BI-DIRECTIONAL KEYPAD CONTROL.

The drive can be controlled in the forward and reverse directions using an external or remote Keypad. Pressing the keypad START button toggles between forward and reverse.

3: MODBUS NETWORK CONTROL.

Control via Modbus RTU (RS485) using the internal accel / decel ramps

4 : MODBUS NETWORK CONTROL.

Control via Modbus RTU (RS485) interface with accel / decel ramps updated via Modbus 5 : PI CONTROL

User PI control with external feedback signal

6 : PI ANALOG SUMMATION CONTROL.

PI control with external feedback signal and summation with analog input 1

12 CONSTANT SPEEDS

Constant speeds. Constant speed activation overrides the external speed reference. Constant speed selections are ignored if the drive is in the local control mode.

Refer to section 9.1 for how to make constant speed selections from the drive control terminals.

Preset Speeds / Frequencies selected by digital inputs depending on the setting of Parameter 9902 DIGITAL INPUTS FUNCTION SELECT. If Parameter 9908 MOTOR RATED SPEED = 0, the values are entered as Hz. If Parameter 9908 > 0, the values are entered as Rpm. Setting a negative value will reverse the direction of motor rotation.

1202

PRESET / JOG FREQUENCY / SPEED 1

Defines constant speed 1 (that is the drive output frequency)

5.0Hz/RPM

2007…-2008

Output Frequency

1203

PRESET / JOG FREQUENCY / SPEED 2

Defines constant speed 2 (that is the drive output frequency)

10.0Hz/RPM 2007…-2008

Output Frequency

1204

PRESET / JOG FREQUENCY / SPEED 3

Defines constant speed 3 (that is the drive output frequency)

25.0Hz/RPM

2007…-2008

Output Frequency

Page 33

Parameters in the Short parameter mode

No.

Name/Value

Description

Def

13 ANALOG INPUTS

Analog input signal offset

1301

ANALOG INPUT 1 OFFSET

Sets an offset, as a percentage of the full scale range of the input, which is applied to the analog input signal

0.0%

-500…500 %

Value in percent of the full scale range of the input Example: If the analog input signal format is 0-10V, offset = 20% . An analog input signal level of 7 Volts gives the following result :Analog input level (%) = 7/10 = 70% Result = 70-20 (%) = 50%

20 LIMITS

Maximum frequency

2008

MAXIMUM FREQUENCY / SPEED LIMIT

Maximum output frequency or motor speed limit – Hz or rpm. If parameter 9908 MOTOR RATED SPEED >0, the value entered / displayed is in Rpm

60.0 Hz 2007…500.0 Hz

Maximum frequency

21 START/STOP

Stop mode of the motor

2102

STOP MODE

Selects the motor stop function

0 = Ramp to stop

0 : RAMP TO STOP

When the enable signal is removed, the drive will ramp to stop, with the rate controlled by parameter 2203 DECEL RAMP TIME as described above. In this mode, the drive brake transistor is disabled

1 : COAST TO STOP

When the enable signal is removed, the drive output is immediately disabled, and the motor will coast (freewheel) to stop. If the load can continue to rotate due to inertia, and the drive may possibly be re-enabled whilst the motor is still rotating, the spin start function (Parameter 2101 SPIN START ENABLE) should be enabled. In this mode, the drive brake transistor is disabled.

2 : RAMP TO STOP

When the enable signal is removed, the drive will ramp to stop, with the rate controlled by Parameter 2203 DECEL RAMP TIME as described above. The ACS255 Brake chopper is also enabled in this mode.

3 : COAST TO STOP

When the enable signal is removed, the drive output is immediately disabled, and the motor will coast (freewheel) to stop. If the load can continue to rotate due to inertia, and the drive may possibly be re-enabled whilst the motor is still rotating, the spin start function (Parameter 2101 SPIN START ENABLE) should be enabled. The drive brake chopper is enabled in this mode, however it will only activate when required during a change in the drive frequency setpoint, and will not activate when stopping.

22 ACCEL/DECEL

Acceleration and deceleration times

2202

ACCELERATION RAMP TIME

Acceleration ramp time from 0 to base speed (Parameter 9907 MOTOR RATED FREQUENCY) in seconds.

5.0 s

0.00…600.0 s

Time

2203

DECELERATION RAMP TIME

Deceleration ramp time from base speed (Parameter 9907 MOTOR RATED FREQUENCY) to standstill in seconds. When set to zero, fastest possible ramp time without trip is activated.

5.0 s

0.00…600.0 s

Time

Page 34

10.3. Read Only Status parameters

10.3.1. Read Only Status parameter access and navigation.

The user must be in the Long Parameter group to gain access to the Read only status parameters, See section 10.1.1 for how to navigate to the Long Parameter group.

In the Long Parameter Group when the user scrolls to parameter “0000”, pressing will display “0104”, the User can then scroll to the required Read only status parameter (as listed in the table above). Pressing once more will then display the value of that particular Read only status parameter.

For those parameters which have multiple values (e.g. software ID parameter 3301), pressing the and keys will display the different values within that parameter.

Pressing returns to the next level up. If is then pressed again (without pressing or ), the display changes to the next level up (main parameter level, i.e. Parameter “0000”).

The following table includes the descriptions of all Read Only status parameters.

Actual signals

No.

Name/Value

Description

01 OPERATING DATA

Basic signals for monitoring the drive (read-only). For selection of an actual signal to be displayed on the control panel, see parameter 3405 DISPLAY SCALING SOURCE.

0102

ROTOR SPEED (ESTIMATED)

In vector control mode, this parameter displays the estimated rotor speed of the motor.

0104

MOTOR CURRENT

8 most recent values prior to trip, updated every 255ms

0107

DC BUS VOLTAGE

Displays the instantaneous DC Bus Voltage internally within the drive in V DC. (0…1000V dc)

0109

APPLIED MOTOR VOLTAGE

Displays the instantaneous output voltage from the drive to the motor V AC. (0…600V AC)

0110

INTERNAL HEATSINK TEMPERATURE

Temperature of heatsink in °C (-20 … 100 °C)

0111

SPEED REFERENCE INPUT

Displayed in Hz if Parameter 9908 MOTOR RATED SPEED = 0, otherwise displayed in RPM. (-2008 …

2008)

0115

kWh/MWh METER

Total number of kWh/MWh consumed by the drive.

0120

ANALOG INPUT 1 APPLIED SIGNAL LEVEL

Displays the signal level applied to analog input 1 (Terminal 6) in % after scaling and offsets have been applied.

0121

ANALOG INPUT 2 APPLIED SIGNAL LEVEL

Displays the signal level applied to analog input 2 (Terminal 4) in % after scaling and offsets have been applied.

0126

PI CONTROLLER OUTPUT

Displays the output level of the PI Controller in %.

0140

HOURS RUN METER

Not affected by resetting factory default parameters. (0 to 99 999 hours)

0145

THERMISTOR TEMPERATURE LOG

8 most recent values prior to trip, updated every 500ms. (-20 … 120 °C)

0160

DIGITAL INPUT STATUS

Binary value. Displays the status of the drive inputs, starting with the left hand side digit = Digital Input 1 etc.

0183

DC BUS VOLTAGE RIPPLE LEVEL

Displays the level of ripple present on the DC Bus Voltage in VDC. This parameter is used by the drive for various internal protection and monitoring functions.

0188

OPERATING TIME ACCUMULATED WITH HEATSINK TEMPERATURE ABOVE 85°C

Displays the amount of time in hours and minutes that the ACS255 has operated for during its lifetime with a heatsink temperature in excess of 85°C. This parameter is used by the ACS255 for various internal protection and monitoring functions. (HH:MM:SS)

0189

OPERATING TIME ACCUMULATED WITH AMBIENT TEMPERATURE ABOVE 80°C

Displays the amount of time in hours and minutes that the ACS255 has operated for during its lifetime with an ambient temperature in excess of 80°C. This parameter is used by the ACS255 for various internal protection and monitoring functions. (HH:MM:SS)

0190

DRIVE INTERNAL COOLING FAN TOTAL OPERATING TIME

Displays the total operating time of the ACS255 internal cooling fans. The first value shown is the number of hours. Pressing the Up key will display the minutes and seconds. This is used for scheduled maintenance information (HH:MM:SS)

0192

DC BUS VOLTAGE RIPPLE LOG (22ms) (V DC)

8 most recent values prior to trip, updated every 22ms.

0193

HEATSINK TEMPERATURE LOG (30s) (°C)

8 most recent values prior to trip, updated every 30s.

0194

AMBIENT TEMPERATURE LOG (30s) (°C)

8 most recent values prior to trip, updated every 30s.

Page 35

04 FAULT HISTORY

Fault history (read-only)

0402

RUN TIME SINCE LAST TRIP (1)

Run-time clock stopped by drive disable (or trip), reset on next enable only if a trip occurred. Reset also on next enable after a drive power down. (0 to 99 999 hours)

0406

DC BUS VOLTAGE LOG

8 most recent values prior to trip, updated every 255ms. (0 … 1000V)

0415

RUN TIME SINCE LAST TRIP (2)

Run-time clock stopped by drive disable (or trip), reset on next enable only if a trip occurred (undervolts not considered a trip) – not reset by power down / power up cycling unless a trip occurred prior to power down.( 0 to 99 999 hours)

0416

RUN TIME SINCE LAST DISABLE

Run-time clock stopped on drive disable, value reset on next enable. (0 to 99 999 hours)

0417

DRIVE EFFECTIVE SWITCHING FREQUENCY

Actual drive effective output switching frequency. This value maybe lower than the selected frequency in parameter 2606 EFFECTIVE SWITCHING FREQUENCY if the drive is too hot. The drive will automatically reduce the switching frequency to prevent an over temperature trip and maintain operation. (4 to 32 kHz)

33 INFORMATION

Firmware package version, serial number etc..

3301

SOFTWARE ID, IO & MOTOR CTRL

e.g. “1.00”, “47AE” Version number and checksum.

“1” on LH side indicates I/O processor, “2“ indicates motor control

3303

DRIVE SERIAL NUMBER

000000 … 999999 00-000 … 99-999 Unique drive serial number e.g. 540102 / 32 / 005

3304

DRIVE IDENTIFIER

Drive rating (Drive rating, drive type e.g. 0.37, 1 230,3P-out)

Page 36

10.4. Parameters in the Long parameter mode

The following table includes the complete descriptions of all parameters that are visible only in the Long parameter mode. See page 31 for how to select the parameter mode.

Parameters in the Long parameter mode

Index

Name/Selection

Description

Def

0000 Read only parameters access

Press the button when in this parameter to access the read only parameters as listed on page 34.

FAULT HISTORY

Fault history (read-only)

0401

TRIP HISTORY LOG

Displays the last four fault codes for the drive. Refer to page 50 for further information. Press UP or DOWN to step through all four. The most recent trip is always displayed first. The Under Voltage (F0006) trip is only stored once.

REFERENCE SELECT

The drive can accept a variety of references in addition to the conventional analog input, potentiometer and keypad signals.

1100

KEYPAD MODE RESTART FUNCTION

This parameter is active only when operating in Keypad Control Mode (parameter 1103 PRIMARY COMMAND SOURCE MODE = 1 or 2).

1 : PREVIOUS SPEED, KEYPAD START

0 MINIMUM SPEED, KEYPAD START

Keypad Start and Stop keys are active, and control terminals 1 and 2 must be linked together.The drive will always start at the Minimum Frequency / Speed (parameter 2007 )

1 : PREVIOUS SPEED, KEYPAD START

Keypad Start and Stop keys are active, and control terminals 1 and 2 must be linked together. The drive will always start at the last operating Frequency / Speed

2 : MINIMUM SPEED, TERMINAL ENABLE

Allows the drive to be started from the control terminals directly, and the keypad Start and Stop keys are ignored. The drive will always start at the Minimum Frequency / Speed (parameter 2007)

3 : PREVIOUS SPEED, TERMINAL ENABLE

Allows the drive to be started from the control terminals directly, and the keypad Start and Stop keys are ignored. The drive will always start at the last operating Frequency / Speed.

1103

PRIMARY COMMAND SOURCE MODE

0: Terminal Control

0: TERMINAL CONTROL.

The drive responds directly to signals applied to the control terminals.

1: UNI-DIRECTIONAL KEYPAD CONTROL

The drive can be controlled in the forward direction only using an external or remote Keypad

2: BI-DIRECTIONAL KEYPAD CONTROL.

The drive can be controlled in the forward and reverse directions using an external or remote Keypad. Pressing the keypad START button toggles between forward and reverse.

3: MODBUS NETWORK CONTROL.

Control via Modbus RTU (RS485) using the internal accel / decel ramps

4 : MODBUS NETWORK CONTROL.

Control via Modbus RTU (RS485) interface with accel / decel ramps updated via Modbus 5 : PI CONTROL

User PI control with external feedback signal

6 : PI ANALOG SUMMATION CONTROL.

PI control with external feedback signal and summation with analog input 1

CONSTANT SPEEDS

Constant speeds. Constant speed activation overrides the external speed reference. Constant speed selections are ignored if the drive is in the local control mode.

Refer to section 9.1 for how to make constant speed selections from the drive control terminals.

1202

PRESET / JOG FREQUENCY / SPEED 1

Defines constant speed 1 (that is the drive output frequency)

0.0 Hz/RPM

2007…-2008

Output Frequency

1203

PRESET / JOG FREQUENCY / SPEED 2

Defines constant speed 2 (that is the drive output frequency)

0.0 Hz/RPM

2007…-2008

Output Frequency

1204

PRESET / JOG FREQUENCY / SPEED 3

Defines constant speed 3 (that is the drive output frequency)

0.0 Hz/RPM

2007…-2008

Output Frequency

1205

PRESET / JOG FREQUENCY / SPEED 4

Defines constant speed 4 (that is the drive output frequency)

0.0 Hz/RPM

2007…-2008

Output Frequency

Page 37

Parameters in the Long parameter mode

Index

Name/Selection

Description

Def

ANALOG INPUTS

1300

ANALOG INPUT 1 SIGNAL FORMAT

Selects the type of reference source into terminal 6.



0 to 10 Volt Signal(Uni-polar).The drive will remain at 0.0Hz if the analog reference after scaling and offset are applied is <0.0%.



0 to 10 Volt Signal (Bi-polar). The drive will operate the motor in the reverse direction of rotation if the analog reference after scaling and offset are applied is <0.0%



0 to 20mA Signal



4 to 20mA Signal, the ACS255 will trip and show the fault code  if the signal level falls below 3mA



4 to 20mA Signal, the ACS255 will ramp to stop if the signal level falls below 3mA



20 to 4mA Signal, the ACS255 will trip and show the fault code  if the signal level falls below 3mA



20 to 4mA Signal, the ACS255 will ramp to stop if the signal level falls below 3mA



Integrated potentiometer

1301

ANALOG INPUT 1 OFFSET

Sets an offset, as a percentage of the full scale range of the input, which is applied to the analog input signal

0.0%

-500…500 %

1302

ANALOG INPUT 1 SCALING

Scales the analog input by this factor, (as a percentage of the full scale range of this input).

100.0

0.0…2000.0 %

Example: If parameter 1300 ANALOG INPUT 1 FORMAT is set for 0 – 10V, and the scaling factor is set to 200.0%, a 5 volt input will result in the drive running at maximum speed as set in parameter 2008 MAX SPEED LIMIT

1304

ANALOG INPUT 2 SIGNAL FORMAT

Selects the type of reference source into terminal 4.



0 to 10 Volt Signal



0 to 20mA Signal



4 to 20mA Signal, the ACS255 will trip and show the fault code  if the signal level falls below 3mA



4 to 20mA Signal, the ACS255 will ramp to stop if the signal level falls below 3mA



20 to 4mA Signal, the ACS255 will trip and show the fault code  if the signal level falls below 3mA



20 to 4mA Signal, the ACS255 will ramp to stop if the signal level falls below 3mA

RELAY OUTPUTS

Status information indicated through relay output and relay operating delays

1401

OUTPUT RELAY FUNCTION SELECT

Selects the function assigned to the relay output. The relay has two output terminals, Logic 1 indicates the relay is active, and therefore terminals 10 and 11 will be linked together.

1 : Drive

READY

0 : DRIVE ENABLED (RUNNING)

Logic 1 when the motor is enabled 1 : DRIVE READY

Logic 1 when power is applied to the drive and no fault exists

2 : AT TARGET FREQUENCY (SPEED)

Logic 1 when the output frequency matches the setpoint frequency 3: DRIVE TRIPPED

Logic 1 when the drive is in a fault condition

4 : OUTPUT FREQUENCY >= LIMIT

Logic 1 when the output frequency exceeds the adjustable limit set in 3200 RELAY THRESHOLD LEVEL

5 : OUTPUT CURRENT >= LIMIT

Logic 1 when the motor current exceeds the adjustable limit set in 3200 RELAY THRESHOLD LEVEL

6 : OUTPUT FREQUENCY < LIMIT

Logic 1 when the output frequency is below the adjustable limit set in 3200 RELAY THRESHOLD LEVEL

7 : OUTPUT CURRENT < LIMIT

Logic 1 when the motor current is below the adjustable limit set in 3200 RELAY THRESHOLD LEVEL

Page 38

Parameters in the Long parameter mode

Index

Name/Selection

Description

Def

ANALOG/DIGITAL OUTPUTS

Analog output signal processing

1501

ANALOG OUTPUT FUNCTION SELECT

Selects the type of output signal information indicated from terminal 8. Note : When using settings 0 – 7 the output is a digital format (Logic 1 = 24V). When using settings 8-9 the output is an analog format.

8 : OUTPUT

FREQUENCY

(MOTOR

SPEED).

0 : DRIVE ENABLED (RUNNING).

Logic 1 when the ACS255 is enabled (Running) 1 : DRIVE READY.

Logic 1 When no Fault condition exists on the drive

2 : AT TARGET FREQUENCY (SPEED).

Logic 1 when the output frequency matches the setpoint frequency 3: DRIVE TRIPPED.

Logic 1 when the drive is in a fault condition

4 : OUTPUT FREQUENCY >= LIMIT

Logic 1 when the output frequency exceeds the adjustable limit set in parameter 3200 RELAY THRESHOLD LEVEL

5 : OUTPUT CURRENT >= LIMIT

Logic 1 when the motor current exceeds the adjustable limit set in parameter 3200 RELAY THRESHOLD LEVEL

6 : OUTPUT FREQUENCY < LIMIT

Logic 1 when the output frequency is below the adjustable limit set in parameter 3200 RELAY THRESHOLD LEVEL

7 : OUTPUT CURRENT < LIMIT.

Logic 1 when the motor current is below the adjustable limit set in parameter 3200 RELAY THRESHOLD LEVEL

8 : OUTPUT FREQUENCY (MOTOR SPEED).

0 to parameter 2008 MAXIMUM FREQUENCY / SPEED LIMIT

9 : OUTPUT (MOTOR) CURRENT.

0 to 200% of parameter 9906 MOTOR RATED CURRENT

SYSTEM CONTROLS

Parameter lock etc.

1602

PARAMETER ACCESS UNLOCK

If Parameter 1603 has had a value entered, then the matching value needs to be entered here in order to give read-write access to the parameters.

0…65535

See page 42 for more details

1603

PARAMETER ACCESS CODE DEFINITION

To make all parameters Read only, enter a value in this parameter.

0…65535

See page 42 for more details

20 LIMITS

Drive operation limits

2007

MINIMUM FREQUENCY / SPEED LIMIT

Minimum output frequency or motor speed limit – Hz or rpm. If parameter 9908 MOTOR RATED SPEED >0, the value entered / displayed is in Rpm

0.0 Hz

0.0 HZ…2008

Minimum frequency

2008

MAXIMUM FREQUENCY / SPEED LIMIT

Maximum output frequency or motor speed limit – Hz or rpm. If parameter 9908 MOTOR RATED SPEED >0, the value entered / displayed is in Rpm

60.0 Hz

2007…500.0 Hz

Maximum frequency

2020

BRAKE CHOPPER ENABLE

0 : DISABLED

1 : ENABLED WITH SOFTWARE PROTECTION.

Enables the internal brake chopper with software protection for a 200W continuous rated resistor

2 : ENABLED WITHOUT SOFTWARE PROTECTION.

Enables the internal brake chopper without software protection. An external thermal protection device should be fitted.

21 START/STOP

Start and Stop modes of the motor

2101

FLYING START (Size E2 & E3 ONLY) / DC INJECTION TIME ON START (Size E1 ONLY)

Starting the drive connected to a rotating motor.

0 : Disabled

0 : DISABLED

1 : ENABLED.

When enabled, on start up the drive will attempt to determine if the motor is already rotating, and will begin to control the motor from its current speed. A short delay may be observed when starting motors which are not turning/On Size E1 only this parameter Sets a time for which DC current is injected into the motor to ensure it is stopped when the drive is enabled.

Page 39

Parameters in the Long parameter mode

Index

Name/Selection

Description

Def

2102

STOP MODE

Selects the motor stop function

0 : RAMP TO STOP

When the enable signal is removed, the drive will ramp to stop, with the rate controlled by parameter 2203 DECEL RAMP TIME as described above. If the mains supply is lost, the drive will try to continue running by reducing the speed of the load, and using the load as a generator.

1 : COAST TO STOP

When the enable signal is removed, or if the mains supply is lost, the motor will coast (freewheel) to stop

2 : RAMP TO STOP

When the enable signal is removed, the drive will ramp to stop, with the rate controlled by parameter 2203 DECELERATION RAMP TIME. If the mains supply is lost the drive will ramp to stop using parameter 2206 2nd DECELERATION RAMP TIME (FAST STOP) (decel ramp with dynamic brake control).

3 : COAST TO STOP

When the enable signal is removed, the drive output is immediately disabled, and the motor will coast (freewheel) to stop. If the load can continue to rotate due to inertia, and the drive may possibly be re-enabled while the motor is still rotating, the spin start function (Parameter 2101 SPIN START ENABLE) should be enabled. The drive brake chopper is enabled in this mode, however it will only activate when required during a change in the drive frequency setpoint, and will not activate when stopping.

2104

DC INJECTION TIME ON STOP

Defines the time for which a DC current is injected into the motor once the output frequency reaches 0.0Hz. The voltage level is the same as the boost level set in parameter 2603.

0.0

0.0…25.0 s

2108

TERMINAL MODE RESTART FUNCTION

Defines the behavior of the drive relating to the enable digital input and also configures the Automatic Restart function.





Following Power on or reset, the drive will not start if Digital Input 1 remains closed. The Input must be closed after a power on or reset to start the drive.



Following a Power On or Reset, the drive will automatically start if Digital Input 1 is closed.

 to 

Following a trip, the drive will make up to 5 attempts to restart at 20 second intervals. The drive must be powered down to reset the counter. The numbers of restart attempts are counted, and if the drive fails to start on the final attempt, the drive will fault and will require the user to manually reset the fault.

22 ACCEL/DECEL

Acceleration and deceleration times

2202

ACCELERATION RAMP TIME

Acceleration ramp time from 0 to base speed (Parameter 9907 MOTOR RATED FREQUENCY) in seconds.

5.0 s

0.00…600.0 s

Time

2203

DECELERATION RAMP TIME

Deceleration ramp time from base frequency (Parameter 9907 MOTOR RATED FREQUENCY) to standstill in seconds. When set to zero, fastest possible ramp time without trip is activated. When set to 0.00, the value of 2206 is used.

5.0 s

0.00…600.0 s

Time

2206

2nd DECELERATION RAMP TIME (FAST STOP)

This parameter allows an alternative deceleration ramp down time to be programmed into the ACS255, which can be selected by digital inputs (dependent on the setting of Parameter 9902 DIGITAL INPUTS FUNCTION SELECT or selected automatically in the case of a mains power loss if parameter 2102 STOP MODE = 2.

0.00

0.00…25.0 s

When set to 0.00, the drive will coast to stop.

25 CRITICAL SPEEDS

Speed bands with which the drive is not allowed to operate. The Skip Frequency function is used to avoid the ACS255 operating at a certain output frequency, for example at a frequency which causes mechanical resonance in a particular machine.

2500

SKIP FREQUENCY HYSTERESIS BAND

The drive output frequency will ramp through the defined band at the rates set in parameter 2202 and 2203 respectively, and will not hold any output frequency within the defined band. If the frequency reference applied to the drive is within the band, the drive output frequency will remain at the upper or lower limit of the band.

0.0 Hz/Rpm

0.0…2008

2501

SKIP FREQUENCY

Defines the center point of the skip frequency band, and is used conjunction with parameter 2550 SKIP FREQUENCY HYSTERESIS BAND

0.0…2008

26 MOTOR CONTROL

Motor control variables

2601

ENERGY OPTIMIZER

Enables or disables Energy optimizer

0 : Disabled

0 : DISABLED

1 : ENABLED

The Energy Optimizer attempts to reduce the overall energy consumed by the drive and motor when operating at constant speeds and light loads. The output voltage applied to the motor is reduced. The Energy Optimizer is intended for applications where the drive may operate for some periods of time with constant speed and light motor load, whether constant or variable torque.

Page 40

Parameters in the Long parameter mode

Index

Name/Selection

Description

Def

2603

V/F MODE VOLTAGE BOOST

Voltage boost is used to increase the applied motor voltage at low output frequencies, in order to improve low speed and starting torque. Excessive voltage boost levels may result in increased motor current and temperature, and force ventilation of the motor may be required.

A suitable setting can usually be found by operating the motor under low load or no load conditions at approximately 5Hz, and adjusting parameter 2603 until the motor current is no more than 80% of the rated full load current.

3.0 %

0.0…20.0 %

2606

EFFECTIVE SWITCHING FREQUENCY

Sets maximum effective switching frequency of the drive. If “rEd” is displayed, the

switching frequency has been reduced to the level in Parameter 0417 INTERNAL EFFECTIVE SWITCHING FREQUENCY due to excessive drive heat sink temperature. Refer to parameter 0417 INTERNAL EFFECTIVE SWITCHING FREQUENCY for further information regarding operation at higher switching frequency.

Drive Rating Dependent

4…32 kHz

2610

V/F CHARACTERISTIC ADJUSTMENT VOLTAGE

Used in conjunction with parameter 2611 V/F CHARACTERISTIC ADJUSTMENT FREQUENCY

0 V 0 V…255/500

2611

V/F CHARACTERISTIC ADJUSTMENT FREQUENCY

This parameter in conjunction with parameter 2610 V/F CHARACTERISTIC ADJUSTMENT VOLTAGE sets a frequency point at which the voltage set in parameter 2611 V/F CHARACTERISTIC ADJUSTMENT FREQUENCY is applied to the motor. Care must be taken to avoid overheating and damaging the motor when using this feature. See section 10.5 for further information.

0.0 Hz

0.0 Hz…Value set in 9907

30 FAULT FUNCTIONS

Programmable protection functions

3005

THERMAL OVERLOAD VALUE RETENTION

1 : ENABLED

0 : DISABLED

Alternative means of protecting the motor from thermal overload must be applied (e.g. PTC thermistor)

1 : ENABLED

The drive will retain the motor thermal overload value following a mains power cycle.

32 SUPERVISION

Signal supervision. The drive monitors whether certain user selectable variables are within the user-defined limits. The user may set limits for speed, current etc. Supervision status can be monitored with relay output. See parameter group 14 RELAY OUTPUTS.

3200

RELAY THRESHOLD LEVEL

Adjustable threshold level used in conjunction with settings 4 to 7 of parameter 1401 OUTPUT RELAY FUNCTION SELECT

100.0 %

0.0…200.0 %

34 PANEL DISPLAY

Selection of actual signals to be displayed on the drives front panel e.g. to display conveyer speed in feet per second based on the output frequency

3400

DISPLAY SPEED SCALING FACTOR

Allow the user to display an alternative output unit scaled from an existing parameter,. This function is disabled if set to 0.000.

0.000

0.000…6.000

40 PROCESS PI SETUP

Process PI control parameter set

4001

PI PROPORTIONAL GAIN

PI Controller Proportional Gain. Higher values provide a greater change in the drive output frequency in response to small changes in the feedback signal. Too high a value can cause instability

1.0

0.0…30.0

4002

PI INTEGRAL TIME CONSTANT

PI Controller Integral Time. Larger values provide a more damped response for systems where the overall process responds slowly

1.0 s

0.0…30.0 S

4005

PI OPERATING MODE

0 : DIRECT OPERATION

Use this mode if an increase in the motor speed should result in an increase in the feedback signal

1 : INVERSE OPERATION

Use this mode if an increase in the motor speed should result in a decrease in the feedback signal

4010

PI REFERENCE (SETPOINT) SOURCE SELECT

Selects the source for the PID Reference / Setpoint 0

Digital Preset Setpoint. Parameter 4011 PI Digital Reference (Setpoint) is used

Analog Input 1 Setpoint

4011

PI DIGITAL REFERENCE (SETPOINT)

When parameter 4010 PID REFERENCE (SETPOINT) SOURCE SELECT = 0, this parameter sets the preset digital reference (setpoint) used for the PID Controller

0 %

0.0…100.0 %

4016

PI FEEDBACK SIGNAL SOURCE SELECT

0 0

Analog Input 2(Terminal 4)

Analog Input 1(Terminal 6)

2 Motor Current

Page 41

Parameters in the Long parameter mode

Index

Name/Selection

Description

Def

53 COMMUNICATIONS PARAMETERS

5302

SERIAL COMMUNICATIONS CONFIGURATION

This parameter has three sub settings used to configure the Modbus RTU Serial Communications. The Sub Parameters are :

Drive Address : Adr 0 to Adr 63 Baud Rate : 9.6kbps to 115.2kbps Watchdog Timeout : 0 (Disabled, 300, 3000 milliseconds)

99 START-UP DATA

Application macros. Definition of motor set-up data. As shown in the table below Parameter 9902 has a number of pre-programmed parameter sets (and terminal functions) which the user selects to best suit the application.

9902

DIGITAL INPUTS FUNCTION SELECT

Defines the function of the digital inputs depending on the control mode setting in Parameter 1103 PRIMARY COMMAND SOURCE MODE. See Application macros on page 28.

9905

MOTOR RATED VOLTAGE

This parameter should be set to the rated (nameplate) voltage of the motor (Volts).

Drive Rating

Dependent

110V/230V rated drives 0…255V 400V rated drives 0…500V

Voltage Note : The stress on the motor insulation is always dependent on the drive supply voltage. This also applies in the case where the motor voltage rating is lower than the rating of the drive and the supply of the drive.

9906

MOTOR RATED CURRENT

This parameter should be set to the rated (nameplate) current of the motor.

Drive Rating

Dependent

0.2*drive rated output

current…1.0*drive rated

output current

Current 9907

MOTOR RATED FREQUENCY

This parameter should be set to the rated (nameplate) frequency of the motor

60Hz

25…500Hz

Frequency

9908

MOTOR RATED SPEED

This parameter can optionally be set to the rated (nameplate) rpm of the motor. When set to the default value of zero, all speed related parameters are displayed in Hz, and the slip compensation for the motor is disabled. Entering the value from the motor nameplate enables the slip compensation function, and the ACS255 display will now show motor speed in estimated rpm. All speed related parameters, such as Minimum and Maximum Speed, Preset Speeds etc. will also be displayed in Rpm.

0 Rpm

0…30000 Rpm

10.5. Adjusting the Voltage / Frequency (V/f) characteristics

Voltage

The V/f characteristic is defined by several parameters as follows :Parameter 9905 : Motor Rated Voltage Parameter 9907 : Motor Rated Frequency The voltage set in parameter 9905 is applied to the motor at the frequency set Under normal operating conditions, the voltage is linearly reduced at any point below the motor rated frequency to maintain a constant motor torque output as shown by the line ‘A’ on the graph. By using parameters parameter 2610 and 2611, the voltage to be applied at a particular frequency can be directly set by the user, thereby altering the V/F characteristic. Reducing the voltage at a particular frequency reduces the current in the motor and hence the torque and power, hence this function can be used in fan and pump applications where a variable torque output is desired by setting the parameters as follows :Parameter 2610 = 9905 / 4 Parameter 2611 = 9907 / 2 This function can also be useful if motor instability is experienced at certain frequencies, if this is the case increase or decrease the voltage (Parameter 2610) at the speed of instability (Parameter 2611).

For applications requiring energy saving, typically HVAC and pumping, the energy optimizer (Parameter 2601) parameter can be enabled. This automatically reduces the applied motor voltage on light load.

Frequency

10.6. Motor Thermistor Connection

1 : + 24 Volt

The motor thermistor should be connected between terminals 1 and 4 as shown. A setting of Parameter 9902 where Digital Input 3 is programmed for ‘External Trip’ must be used. The current flow through the thermistor is automatically controlled to prevent a failure.

4 : External Trip

9905

2610

2611

9907

Page 42

10.7. Parameters in the Advanced parameter mode

The following table describes the parameters that are visible in the Advanced parameter mode. See page 25 for how to select the parameter mode. Advanced parameters are not included in the Long parameter mode.

Parameters in the Advanced parameter mode

Index

Name/Selection

Description

Def

2017

Maximum Current Limit

Defines the max current limit in vector control modes.

150 %

0.0…175.00

2105

DC Injection Speed

Sets the speed at which DC injection current is applied during braking to Stop, allowing DC to be injected before the drive reaches zero speed if desired.

0.0 Hz/Rpm

0.0…2008

2106

DC Injection Current

Sets the level of DC injection braking current applied according to the conditions set in 2104 and 2105.

20 %

0.0…100.0

2301

Vector Mode Gain

Single Parameter for Vector speed loop tuning. Affects P & I terms simultaneously. Not active when 9903 = 1.

50 %

0.0…200.0

2605

Operating Mode Select

Provides a quick set up to configure key parameters according to the intended application of the drive. Parameters are preset according to the table.

Setting

Application

Current Limit (2017)

Torque Characteristic (2610 &

2611)

Spin Start (2101)

General

150%

Constant

0 : Off

Pump

110%

Variable

0 : Off

Fan

110%

Variable

2 : On

0: Industrial Mode

Intended for general purpose applications.

1: Pump Mode

Intended for centrifugal pump applications.

2: Fan Mode

Intended for Fan applications.

9903

Motor Control Mode

Selects the motor control method.

0: Vector speed control mode

1: V/f mode

2: PM motor vector speed control

3: Reserved

9910

Motor parameter Autotune

Drive measures the motor parameters for optimum control and efficiency. Following completion of the autotune.

0: Disable

1: Enable

Drive immediately carries out a non-rotating autotune, parameter 9910 MOTOR PARAMETER AUTO-TUNE ENABLE returns to 0 when completed.

11201

MOTOR STATOR RESISTANCE (Rs)

Motor stator resistance value measured during the autotune.

11203

MOTOR STATOR INDUCTANCE (Lsd)

For induction motors: phase stator inductance value.

11206

MOTOR STATOR q-axis INDUCTANCE (Lsq)

measured during the autotune

Page 43

10.8. Preventing un-authorized parameter editing.

This function can be used to prevent an un-authorized person from changing the drive parameter values; this function is disabled when

delivered from the factory.

Relevant Parameters

1602

Parameter Access Unlock

0…65535

1603

Parameter Access code

0…65535

Locking Parameter Access

• Go to Parameter 1603 (Long Parameter group) and enter in your chosen parameter access code.

• Press the button to exit and parameter 1603 will then be hidden and all parameters will be “Read only” (except for

Parameter 1602 which will remain “Read Write”.

Unlocking Parameter Access

• Enter into Parameter 1602 the same value as 1603 (as chosen in “Locking Parameter Access” above).

• All parameters will now be “Read Write” and parameter 1603 will become visible and show the value which was originally

programmed as the parameter access code.

• To disable this feature set parameter 1603 PARAMETER ACCESS CODE to zero and then 1602 PARAMETER ACCESS UNLOCK to

zero.

Page 44

11. Modbus RTU Communications

11.1. Introduction

The ACS255 can be connected to a Modbus RTU network via the RJ45 connector on the front of the drive.

11.2. Modbus RTU Specification

Protocol

Modbus RTU

Error check

CRC

Baud rate

9600bps, 19200bps, 38400bps, 57600bps, 115200bps (default)

Data format

1 start bit, 8 data bits, 1 stop bits, no parity.

Physical signal

RS 485 (2-wire)

User interface

RJ45 (see page 24 for more information)

11.3. RJ45 Connector Configuration

Connection details are shown on page 24.

11.4. Modbus Telegram Structure

The ACS255 supports Master / Slave Modbus RTU communications, using the 03 Read Holding Registers and 06 Write Single Holding Register commands. Many Master devices treat the first Register address as Register 0; therefore it may be necessary to convert the Register Numbers detail in section 45 by subtracting 1 to obtain the correct Register address. The telegram structure is as follows:-

Command 03 – Read Holding Registers

Command 06 – Write Single Holding Register

Master Telegram

Length

Slave Response

Length

Master Telegram

Length

Slave Response

Length

Slave Address

Byte Slave Address

Byte

Function Code (03)

Byte Starting Address

Byte Function Code (06)

Byte

1st Register Address

Bytes 1st Register Value

Bytes Register Address

Bytes

No. Of Registers

Bytes 2nd Register Value

Bytes Value

Bytes Register Value

Bytes

CRC Checksum

Bytes Etc... CRC Checksum

Bytes CRC Checksum

Bytes

CRC Checksum

Bytes

11.5. Modbus Register Map

Par.

Type

Supported

Commands

Function

Range

Explanation

Low Byte

High Byte

1 - R/W

03,06

Drive Control Command

0..3

16 Bit Word. Bit 0 : Low = Stop, High = Run Enable Bit 1 : Low = Decel Ramp 1 (parameter 2203), High = Decel Ramp 2 (Parameter 2206) Bit 2 : Low = No Function, High = Fault Reset Bit 3 : Low – No Function, High = Coast Stop request

2 - R/W

03,06

Modbus Speed reference setpoint

0..5000

Setpoint frequency x10, e.g. 100 = 10.0Hz

4 - R/W

03,06

Acceleration and Deceleration Time

0..60000

Ramp time in seconds x 100, e.g. 255 = 2.5 seconds

6 - R

Error code

Drive status

Low Byte = Drive Error Code, see page 50 High Byte = Drive Status as follows :0 : Drive Stopped, 1: Drive Running, 2: Drive Tripped

7 R

Output Motor Frequency

0..20000

Output frequency in Hz x10, e.g. 100 = 10.0Hz

8 R

Output Motor Current

0..480

Output Motor Current in Amps x10, e.g. 10 = 1.0 Amps

11 - R

Digital input status

0..15

Indicates the status of the 4 digital inputs Lowest Bit = 1 Input 1

0120 R 03

Analog Input 1 value

0..1000

Analog input % of full scale x10, e.g. 1000 = 100%

0121 R 03

Analog Input 2 value

0..1000

Analog input % of full scale x10, e.g. 1000 = 100%

0111 R 03

Speed Reference Value

0..1000

Displays the setpoint frequency x10, e.g. 100 = 10.0Hz

0107 R 03

DC bus voltage

0..1000

DC Bus Voltage in Volts

0110 R 03

Drive temperature

0..100

Drive heatsink temperature in ºC

All user configurable parameters are accessible as Holding Registers, and can be Read from or Written to using the appropriate Modbus command. To access drive parameters refer to section 11.6 for parameter register map.

Depending on the operating mode of the drive – some parameters cannot be changed whilst the drive is enabled for example. Modbus RTU supports sixteen bit integer values, hence where a decimal point is used in the drive parameter; the register value will be multiplied by a factor of ten, E.g. Read Value of parameter 2008 MAXIMUM FREQUENCY / SPEED LIMIT = 500, therefore this is 50.0Hz

Page 45

11.6. Modbus Parameter Register Map

Parameter No

Description

129

0401

TRIP HISTORY LOG

130

1100

KEYPAD MODE RESTART FUNCTION

131

1103

PRIMARY COMMAND SOURCE MODE

132

1202

PRESET / JOG FREQUENCY / SPEED 1

133

1203

PRESET / JOG FREQUENCY / SPEED 2

134

1204

PRESET / JOG FREQUENCY / SPEED 3

135

1205

PRESET / JOG FREQUENCY / SPEED 4

136

1300

ANALOG INPUT 1 SIGNAL FORMAT

137

1301

ANALOG INPUT 1 OFFSET

138

1302

ANALOG INPUT 1 SCALING

139

1304

ANALOG INPUT 2 SIGNAL FORMAT

140

1401

OUTPUT RELAY FUNCTION SELECT

141

1501

ANALOG OUTPUT FUNCTION SELECT

142

1602

PARAMETER ACCESS UNLOCK

143

1603

PARAMETER ACCESS CODE DEFINITION

144

2007

MINIMUM FREQUENCY / SPEED LIMIT

145

2008

MAXIMUM FREQUENCY / SPEED LIMIT

146

2020

BRAKE CHOPPER ENABLE

147

2101

SPIN START (Size E2 & E3 ONLY) / DC INJECTION TIME ON START (Size E1 ONLY)

148

2102

STOP MODE

149

2104

DC INJECTION TIME ON STOP

150

2108

TERMINAL MODE RESTART FUNCTION

151

2202

ACCELERATION RAMP TIME

152

2203

DECELERATION RAMP TIME

153

2206

2nd DECELERATION RAMP TIME (FAST STOP)

154

2550

SKIP FREQUENCY HYSTERESIS BAND

155

2551

SKIP FREQUENCY

156

2601

ENERGY OPTIMISER

157

2603

V/F MODE VOLTAGE BOOST

158

2606

EFFECTIVE SWITCHING FREQUENCY

159

2610

V/F CHARACTERISTIC ADJUSTMENT VOLTAGE

160

2611

V/F CHARACTERISTIC ADJUSTMENT FREQUENCY

161

3005

THERMAL OVERLOAD VALUE RETENTION

162

3200

RELAY THRESHOLD LEVEL

163

3400

DISPLAY SPEED SCALING FACTOR

164

4001

PI PROPORTIONAL GAIN

165

4002

PI INTEGRAL TIME CONSTANT

166

4005

PI Operating Mode

167

4010

PI Reference (Setpoint) Source Select

168

4011

PI Digital Reference (Setpoint)

169

4016

PI Feedback Signal Source Select

170

5302

SERIAL COMMUNICATIONS CONFIGURATION

171

9902

DIGITAL INPUTS FUNCTION SELECT

172

9905

Motor Rated Voltage

173

9906

Motor Rated Current

174

9907

Motor Rated Frequency

175

9908

MOTOR RATED SPEED

Page 46

12. Technical Data

12.1. Environmental

Operational ambient temperature range (IP20) Open Drives : -10 … 50°C (frost and condensation free) (IP66) Enclosed Drives: -10 ... 40°C (frost and condensation free) Storage ambient temperature range : -40 … 60°C Maximum altitude : 2000m. Derate above 1000m : 1% / 100m Maximum humidity : 95%, non-condensing

NOTE

For UL compliance: the average ambient temperature over a 24 hour period for 200-240V, 3HP (IP20) drives is 45°C. Also Refer to section 12.5 for Output current Derating Information.

12.2. Rating Tables

The following tables provide the output current rating information for the various ACS255 models. ABB Drives always recommend that selection of the correct ACS255 is based upon the motor full load current at the incoming supply voltage.

Cable sizes shown are the maximum possible that may be connected to the drive. Cables should be selected according to local wiring codes or regulations at the point of installation

The rated fuse currents given in the table are the maximums for the mentioned fuse types. If smaller fuse ratings are used, check that the fuse rms current rating is larger than the nominal input current. If 150% output power is needed, multiply nominal input current by 1.5.

Check that the operating time of the fuse is below 0.5 seconds. The operating time depends on the fuse type, the supply network impedance as well as the cross-sectional area, material and length of the supply cable. In case the 0.5 seconds operating time is exceeded with the gG or T fuses, ultra rapid (aR) fuses in most cases reduce the operating time to an acceptable level.

Note: Larger fuses must not be used when the input power cable is selected according to this table.

Model Number

Power

(HP)

Nominal

Input

Current (A)

Nominal Input

Current with 3%

Line Choke (A)

Fuse

(A)

Maximum

Cable Size

Nominal

Output

Current

(A)

Maximum

Motor Cable

Length

Recommended

Brake Resistance

(Ω)

Frame

Size

Class

CC or J

mm2

AWG

Mtrs

1-phase 110V…115V AC (+/-10%) - 3 Phase 230V Output

ACS255-01U-02A3-1

0.5

7.8

7.1

10 8 8

2.3

100

N/A

ACS255-01U-04A3-1

15.8

15.0

20 8 8

4.3

100

N/A

ACS255-01U-05A8-1

1.5

21.9

20.1

30 8 8

5.8

100

1-phase 200…240V AC (+/-10%) - 3 Phase Output

ACS255-01U-02A3-2

0.5

3.7

2.9

10 6 8 8 2.3

100

N/A

ACS255-01U-04A3-2

1.0

7.5

6.6

10 8 8

4.3

100

N/A

ACS255-01U-06A1-2

1.5

11.0

9.7

15 8 8

6.1

100

N/A

ACS255-01U-07A0-2

2.0

12.9

11.4

17.5 8 8 7 100

*100

ACS255-01U-10A5-2

3.0

19.2

17.0

25 8 8

10.5

100

ACS255-01U-15A3-2

5.0

29.2

25.9

40 8 8

15.3

100

3-phase 200…240V AC (+/-10%) - 3 Phase Output

ACS255-03U-02A3-2

0.5

3.4

2.8

6 6 8 8 2.3

100

N/A

ACS255-03U-04A3-2

1.0

5.6

4.4

10 8 8

4.3

100

N/A

ACS255-03U-06A1-2

1.5

8.1

6.3

15 8 8

6.1

100

N/A

ACS255-03U-07A0-2

2.0

8.9

7.0

15 8 8 7 100

100

ACS255-03U-10A5-2

3.0

12.1

9.9

17.5 8 8

10.5

100

ACS255-03U-18A0-2

5.0

20.9

17.4

30 8 8

100

ACS255-03U-24A0-2

7.5

26.4

22.0

35 8 8

100

ACS255-03U-30A0-2

10.0

33.3

24.8

16 5 30

100

ACS255-03U-46A0-2

15.0

50.1

40.0

16 5 46

100

3-phase 380…480V AC (+/-10%) - 3 Phase Output

ACS255-03U-01A2-4

0.5

1.9

1.5

6 6 8 8 1.2

100

N/A

ACS255-03U-02A2-4

3.5

2.7

6 6 8 8 2.2

100

N/A

ACS255-03U-03A3-4

1.5

4.6

3.3

10 8 8

3.3

100

N/A

ACS255-03U-04A1-4

5.6

4.5

10 8 8

4.1

100

*200

ACS255-03U-05A8-4

7.5

5.5

10 8 8

5.8

100

200

ACS255-03U-09A5-4

11.5

9.2

15 8 8

9.5

100

ACS255-03U-14A0-4

7.5

17.2

14.5

25 8 8

100

ACS255-03U-18A0-4

21.2

17.2

30 8 8

100

ACS255-03U-24A0-4

27.5

35 8 8

100

ACS255-03U-30A0-4

34.2

24.8

16 5 30

100

ACS255-03U-39A0-4

44.1

16 5 39

100

ACS255-03U-46A0-4

51.9

16 5 46

100

*Internal Braking transistor only available on drives with “+D150” in the model type designation (see section 3.3).

Note For UL compliance, Motor Cable to be 75°C Copper.

Note Other fuse types 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 this table.

Page 47

12.3. Overload

The ACS255 can deliver 150% of the drive nominal output current for 60 seconds and 175% for 2 seconds.

12.4. Additional Information for UL Compliance

ACS255 is designed to meet the UL requirements. In order to ensure full compliance, the following must be fully observed.

• For an up to date list of UL compliant products, please refer to UL listing NMMS.E211945

• The drive can be operated within an ambient temperature range as stated in section 12.1

• For IP20 units, the drive must be installed in a cabinet to fulfil the requirements for shielding from contact and environment

contamination.

• For IP66 units, indoor installation in an environment free from icing and condensation.

• UL Listed ring terminals / lugs must be used for all bus bar and grounding connections.

Input Power Supply Requirements

Supply Voltage

110-115 Volts RMS for 110 Volt rated drives, + /- 10% variation allowed.

200 – 240 Volts RMS for 230 Volt rated drives, + /- 10% variation allowed.

380 – 480 Volts RMS for 400 Volt rated drives, + / - 10% variation allowed.

Imbalance

Maximum 3% voltage variation between phase – phase voltages allowed

All ACS255 units have phase imbalance monitoring. A phase imbalance of > 3% will result in the drive tripping. For input supplies which have supply imbalance greater than 3% (typically the Indian sub- continent & parts of Asia Pacific including China) ABB recommends the installation of input line reactors.

Frequency

50 – 60Hz + / - 5% Variation

Short Circuit Capacity

Voltage Rating

Min HP

Max HP

Maximum supply short-circuit current

115V

0.5

1.5

100kA rms (AC)

230V

0.5 5 100kA rms (AC)

400 / 460V

0.5

100kA rms (AC)

All the drives in the above table are suitable for use on a circuit capable of delivering not more than the above specified maximum short-circuit Amperes symmetrical with the specified maximum supply voltage.

Incoming power supply connection must be according to section 5.3

All ACS255 units are intended for indoor installation only and within controlled environments which meet the condition limits shown in section

12.1

Branch circuit protection must be installed according to the relevant national codes. Fuse ratings and types are shown in section 12.2

Suitable Power and motor cables should be selected according to the data shown in section 12.2

Power cable connections and tightening torques are shown in section 4.

ACS255 provides motor overload protection in accordance with the National Electrical Code (US).

• Where a motor thermistor is not fitted, or not utilized, It is recommended that the Thermal Overload Memory Retention is enabled

by setting 3005 THERMAL OVERLOAD VALUE RETENTION = 1

• Where a motor thermistor is fitted and connected to the drive, connection must be carried out according to the information shown

in section 10.6.

12.5. Derating Information

Derating of the drive maximum continuous output current capacity is required when

• Operating at ambient temperature in excess of 40°C / 104°F.

• Operating at Altitude in excess of 1000m/ 3281 ft.

• Operation with Effective Switching Frequency higher than the minimum setting.

The following derating factors should be applied when operating drives outside of these conditions.

12.5.1. Derating for Ambient Temperature

Enclosure Type

Maximum Temperature

Without Derating.

(UL Approved)

Derate by

Maximum Permissible Operating

Ambient Temperature with

Derating (Non UL Approved)

IP20

50°C / 122°F

N/A

50°C

IP66

40°C / 104°F

2.5% per °C (1.8°F)

50°C

12.5.2. Derating for Altitude

Enclosure Type

Maximum Altitude

Without Derating

Derate by

Maximum Permissible

(UL Approved)

Maximum Permissible

(Non-UL Approved)

IP20

1000m / 3281ft

1% per 100m / 328 ft

2000m / 6562 ft

4000m / 13123 ft

IP66

1000m / 3281ft

1% per 100m / 328 ft

2000m / 6562 ft

4000m / 13123 ft

12.5.3. Derating for Switching Frequency

Switching Frequency (Where available)

Enclosure Type

4kHz

8kHz

12kHz

16kHz

24kHz

32kHz

IP20

N/A

20%

30%

40%

50%

IP66

N/A

10%

25%

35%

50%

Page 48

12.5.4. Example of applying Derating Factors

A 5Hp, 400V/460V IP66 drive is to be used at an altitude of 2000 meters above sea level, with 12kHz switching frequency and 45°C ambient temperature.

From the table above, we can see that the rated current of the drive is 9.5 Amps at 40°C,

Firstly, apply the switching frequency derating, 12kHz, 25% derating

9.5 Amps x 75% = 7.1 Amps

Now, apply the derating for higher ambient temperature, 2.5% per °C above 40°C = 5 x 2.5% = 12.5%

7.1 Amps x 87.5% = 6.2 Amps

Now apply the derating for altitude above 1000 meters, 1% per 100m above 1000m = 10 x 1% = 10%

7.9 Amps x 90% = 5.5 Amps continuous current available.

If the required motor current exceeds this level, it will be necessary to either

- Reduce the switching frequency selected

- Use a higher power rated drive and repeat the calculation to ensure sufficient output current is available.

12.6. Mains Line input Reactors

An optional Line reactor is recommended to be installed on drives where any of the following site conditions occur:-

o The incoming supply impedance is low or the fault level / short circuit current is high. o If the transformer kVA rating is more than 10x the kVA rating of the drive or ensure that the per drive source

Impedance is less than 0.5%.

o The supply is prone to dips or brown outs. o An imbalance exists on the supply (3 phase drives).

o The power supply to the drive is via a busbar and brush gear system (typically overhead Cranes).

o Reduction in Harmonics generated by the drive.

In all other installations, it is good practice to install a line reactor as added protection of the drive against power supply faults.

12.6.1. Selecting a Line Reactor

The chosen Line reactor should be in the region of 3% impedance; higher values can be used but will result in less voltage (and less torque) to the motor as full load is reached.

The continuous current rating should be at least the value of the drives input current rating, with a peak current rating of at least 2 times the continuous current rating.

CAUTION: Due to the low harmonic film capacitor design, the use of input reactors is not recommended with the E4 frame drives!

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13. Appendix: Permanent magnet synchronous motors (PMSMs)

With PMSMs special attention must be paid on setting the motor nominal values correctly in parameter group 99 START-UP DATA. It is important that the nominal back-emf of the motor is available, further to ensure good performance a MOTOR PARAMETER AUTO-TUNE (9910=1) must be performed.

The following table lists the basic parameter settings needed for permanent magnet synchronous motors.

13.1. PMSM Motor nameplate data entry.

Action

Additional Information

 Enable PMSM motor control

Set 9903 to 2

 Enter motor backEMF voltage value

Enter Back EMF value into 9905

The phase to phase value (at motor rated Speed) should be obtained from the motor nameplate or datasheet. If the voltage is given as a proportional value, such as 103V/1000 rpm in a 3000rpm motor, set 309V here. Sometimes the value is given as the peak value. In this case divide the value by the square root of 2 (1.41).

Note: Incorrect value can result in abnormal motor operation (motor vibration)

 Enter Motor Rated Current

Enter value into 9906 Obtained from Motor nameplate (Amps).

 Enter Motor Rated Frequency

Enter value into 9907

Note : The drive uses 9907 to calculate the number of motor pole pairs.

Frequency (Hz) = speed (rpm) x (number of pole pairs) / 60

 Enter Motor Rated Speed

Enter value into 9908

Obtained from Motor nameplate (rpm)

Speed (rpm) = frequency (Hz) x 60 / (number of pole pairs)

 Set Motor Switching Frequency

Set 2606 to 16kHz

16kHz provides optimum motor control.

13.2. PMSM Motor Auto-tune.

A Motor Auto-tune must be carried out in order to measure the motor electrical characteristics.

Action

Additional Information

 Enable Motor Auto-tune

Set 9910 to a 1 and press the button.

The display will show . Once the Auto-tune is completed 9910 will return to 0 and the display will

show .

Note: Motor Auto-tune will need to be repeated if the motor, motor cables, motor parameters or drive control mode is changed in 9903.

13.3. Troubleshooting

Observation

Action

Poor torque performance at low speed/poor motor startup

Increase value in 2603 (Boost current level)

Motor Vibration/trips/Cogging at low speed

Check correct settings of motor nameplate data. Check correct value of 9905 (Motor Back EMF voltage). Reduce value of 2301 (Vector Speed Gain)(As much as 50% reduction in some instances)



Check correct settings of motor nameplate data. Check correct value of 9905 (Motor Back EMF voltage). Check Correct setting of 2603 (Boost current level)

Care should be taken not to apply to high of a value in 2603 (Boost current level) as excess motor heating may result.

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14. Trouble Shooting

14.1. Fault Code Messages

Fault Code

No.

Description

Corrective Action



0x00

Drive is READY and in a stopped condition. The motor is not energized. No enable signal is present to start the drive



0X0A

Factory Default parameters have been loaded

Press the STOP key, drive is ready to configure for particular application



0x03

Instantaneous Over current on the drive output. Excess load or shock load on the motor.

Fault occurs immediately on drive enable or run command

Check the output wiring connections to the motor and the motor for short circuits phase to phase and phase to earth.

Fault occurs during motor starting

Check the motor is free to rotate and there are no mechanical blockages. If the motor has a brake fitted, check the brake is releasing correctly. Check for correct star-delta motor wiring. Ensure the motor nameplate current is correctly entered in parameter 9906. Increase acceleration time in parameter 2202. Reduce motor boost voltage setting in parameter 2603

Fault occurs when motor operating at constant speed Investigate overload. Fault occurs during motor acceleration or deceleration

The accel/decel times are too short requiring too much power. If parameter 2202 or 2203 cannot be increased, a bigger drive may be required



0x04

Motor thermal overload protection trip. The drive has tripped after delivering >100% of value in 9906 for a period of time to prevent damage to the motor.

Ensure the correct motor nameplate current value is entered in parameter 9906. Check for correct Star or Delta wiring configuration. Check to see when the decimal points are flashing (which indicates the output current > parameter 9906 value) and either increase acceleration ramp (parameter 2202) or decrease motor load. Check the total motor cable length is within the drive specification. Check the load mechanically to ensure it is free, and that no jams, blockages or other mechanical faults exist



0x01

Brake channel over current (excessive current in the brake resistor)

Check the cabling to the brake resistor and the brake resistor for short circuits or damage. Ensure the resistance of the brake resistor is equal to or greater than the minimum value for the relevant drive shown in the table in section 12.2



0x02

Brake resistor thermal overload. The drive has tripped to prevent damage to the brake resistor

Only occurs if parameter 2020 = 1. The internal software protection for the brake resistor has activated to prevent damage to the brake resistor. Increase the deceleration time (parameter 2203) or 2nd deceleration time (parameter 2206). Reduce the load inertia

For Other Brake Resistors

Ensure the resistance of the brake resistor is equal to or greater than the minimum value for the relevant drive shown in the table in section 12.2. Use an external thermal protection device for the brake resistor. In this case, parameter 2020 may be set to 2







0x05

Hardware Over Current

Check the wiring to motor and the motor for phase to phase and phase to earth short circuits. Disconnect the motor and motor cable and retest. If the drive trips with no motor connected, it must be replaced and the system fully checked and retested before a replacement unit is installed.



0x06

Over voltage on DC bus

Check the supply voltage is within the allowed tolerance for the drive. If the fault occurs on deceleration or stopping, increase the deceleration time in parameter 2203 or install a suitable brake resistor and activate the dynamic braking function with parameter 2020



0x07

Under voltage on DC bus

The incoming supply voltage is too low. This trip occurs routinely when power is removed from the drive. If it occurs during running, check the incoming power supply voltage and all components in the power feed line to the drive.



0x08

Heatsink over temperature

The drive is too hot. Check the ambient temperature around the drive is within the drive specification. Ensure sufficient cooling air is free to circulate around the drive. Increase the panel ventilation if required. Ensure sufficient cooling air can enter the drive, and that the bottom entry and top exit vents are not blocked or obstructed.



0x09

Under temperature

Trip occurs when ambient temperature is less than -10°C. The temperature must be raised over

-10°C in order to start the drive.



0x10

Faulty thermistor on heatsink.

Refer to your local ABB representative



0x17

Drive internal temperature too high

Drive ambient temperature too high, check adequate cooling air is provided



0x0B

External trip (on digital input 3)

E-trip requested on control input terminals. Some settings of parameter 9902 DIGITAL INPUTS FUNCTION SELECT require a normally closed contactor to provide an external means of tripping the drive in the event that an external device develops a fault. If a motor thermistor is connected check if the motor is too hot.



0x0C

Comms loss trip

Check communication link between drive and external devices. Make sure each drive in the network has its unique address.



0x0E

Input phase loss trip

Drive intended for use with a 3 phase supply has lost one input phase.



0x0F

Spin start failed

Spin start function failed to detect the motor speed.



0x11

Internal memory fault.

Parameters not saved, defaults reloaded. Try again. If problem recurs, refer to your local ABB representative



0x12

Analog input current out of range

Check input current in range defined by parameter 1300.



Internal drive Fault

Refer to your local ABB representative



Internal drive Fault

Refer to your local ABB representative



Autotune Fault

Measured motor stator resistance varies between phases. Ensure the motor is correctly connected and free from faults. Check the windings for correct resistance and balance.



Measured motor stator resistance too large. Ensure motor is correctly connected and free from faults. Check that the power rating corresponds to the power rating of the connected drive.



Measured motor inductance too low. Ensure the motor is correctly connected & free of faults.



Measured motor inductance is too large. Ensure the motor is correctly connected and free from faults. Check that the power rating corresponds to the power rating of the connected drive.



Measured motor parameters are not convergent. Ensure the motor is correctly connected and free from faults. Check that the power rating corresponds to the power rating of the drive.



Modbus comms loss fault

Check the incoming Modbus RTU connection cable. Check that at least one register is being polled cyclically within the timeout limit set in 5302 Index 3

..

Stop is displayed with flashing dots

Check power and motor connections. Indicates cross connection.

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3AXD10001010247 Rev A (EN) 2019-10-11

3AXD10001010247