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ABB ACS 501 Installation & Start-Up Manual
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ABB ACS 501 Installation & Start-Up Manual

ABB ACS 501 Installation & Start-Up Manual

Adjustable frequency ac drives 1 to 75 hp, series b
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ACS 501
ABB Drives
Installation & Start-up
Manual
ACS 501 Adjustable Frequency
AC Drives 1 to 75 HP, Series B
ACS 501-04E
EFFECTIVE 7/1/95
SUPERCEDES 9/1/94
ASEA BROWN BOVERI

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  • Page 1 ACS 501 Installation & Start-up Manual ACS 501 Adjustable Frequency AC Drives 1 to 75 HP, Series B ACS 501-04E EFFECTIVE 7/1/95 SUPERCEDES 9/1/94 ABB Drives ASEA BROWN BOVERI...
  • Page 2 ACS 501 Adjustable Frequency AC Drives 1 to 75 HP, Series B Installation & Start-up Manual ACS 501-04E EFFECTIVE: 1995-07-01 SUPERCEDES: 1994-09-01 © 1995 ABB Drives Inc. All Rights Reserved.
  • Page 3 ACS 501 Adjustable Frequency AC Drives 1 to 75 HP, Series B Installation & Start-up Manual ACS 501-04E EFFECTIVE: 1995-07-01 SUPERCEDES: 1994-09-01 © 1995 ABB Drives Inc. All Rights Reserved.
  • Page 4 This symbol informs you of high voltage conditions, situations, and locations that may cause death or serious injury if you do not follow precautions and proper steps. This warning symbol indicates a general warning. This warning symbol indicates an electrostatic discharge hazard. ACS 501 Installation & Start-up Manual...
  • Page 5 Only a qualified electrician should carry out the electrical installation. Note that the Motor Control Card of the ACS 501 is at DC bus voltage potential. The DC bus capacitors contain dangerous DC voltage levels (1.35 x V After disconnecting the supply, wait at least five minutes after the display readout on the control panel has disappeared before taking any measurements.

  • Page 6: Table Of Contents

    General Information About Your ACS 501 ........
  • Page 7 Motor Disconnected from the ACS 501 ........
  • Page 8 Index ..............I-1 ACS 501 Installation & Start-up Manual...
  • Page 9 Table of Contents This page intentionally left blank. viii ACS 501 Installation & Start-up Manual...

  • Page 10: Chapter 1 - Introduction

    Application Macros which is provided with the drive. Chapter 1 – Introduction, the chapter you are reading now, introduces you to the ACS 501 Adjustable Frequency AC Drives 1 to 75 HP Installation & Start-up Manual and conventions used throughout the manual.

  • Page 11: Intended Audience

    • No experience or training in installing, operating, or servicing the ACS 501. The audience for this manual will install, start-up, and service the ACS 501. Conventions Used Listed below are terms and language conventions used in this manual. These...

  • Page 12: Terminal Block

    For related information, refer to the ABB ACS 500 Adjustable Frequency AC Drives 2 to 350 HP Programming Manual Including Application Macros (ACS 500-05) and the ACS 501 with Option Pack Users Manual (ACS 500- 08). ACS 501 Installation & Start-up Manual...
  • Page 13 Chapter 1 – Introduction This page intentionally left blank. ACS 501 Installation & Start-up Manual...

  • Page 14: Chapter 2 - Overview Of The Acs 501

    Chapter 2 – Overview of the ACS 501 This chapter describes the features and functions of the ACS 501, and includes illustrations and block diagrams. It also describes the ACS 501 hardware components and the Control Panel displays and keys. The last part of this chapter presents an overview of the Parameters menu system and Application macros.

  • Page 15: General Information About Your Acs 501

    A Motor Control Card controls the Inverter Stage and monitors the operation of the ACS 501. A Control Interface Card is the link between the operator and the ACS 501. It features a Control Panel with an alphanumeric display and keypad. A terminal block for external control connections is also located on the Control Interface Card.
  • Page 16 Chapter 2 – Overview of the ACS 501 Table 2-1 Rating Table Constant Torque Variable Torque Amps Amps Dimension Drive Type (Current Rating (Current Rating Reference of Drive) of Drive) INSQ 208/230 VAC ACS501-001-2 ACS501-002-2 10.6 10.0 ACS501-003-2 10.6 16.8 15.2...
  • Page 17 Chapter 2 – Overview of the ACS 501 Figure 2-2 Diagram of ACS 501 Hardware Components and Control Functions Line Connection Brake Connection Motor Connection 3 φ A A AAAAAAA *See Note 3 φ A A AAAAAAA 3 φ I,V DC...

  • Page 18: Control Panel Operation

    Chapter 2 – Overview of the ACS 501 Control Panel Operation Control Panel Display The Control Panel, located on top of the Control Interface Card, has a 2x20 character alphanumeric LCD and a keypad. The operation information, parameters and fault indications are displayed in nine languages: English, German, Italian, Spanish, Dutch, French, Danish, Finnish, and Swedish.

  • Page 19: Control Panel Keys

    Chapter 2 – Overview of the ACS 501 Control Panel Keys Table 2-2 illustrates each Control Panel Key, how the keys are used in this manual's text, and describes the function of each key. Table 2-2 Control Panel Keys Control Panel...
  • Page 20 Chapter 2 – Overview of the ACS 501 Figure 2-4 Parameter Settings Indent to Main level. Select the required Main. Indent to Group level. Select the required Group by [Up Arrow] and [Down Arrow] keys. Indent to Parameter level. Select the required Parameter by [Up Arrow] and [Down Arrow] key.

  • Page 21: Application Macros Overview

    To adjust contrast, press and hold [ * ] and then press [Up Arrow] or [Down Arrow]. You may need to adjust the display contrast if the ACS 501 has been installed in a location with high ambient temperatures. The factory default setting is optimum for an ambient temperature between 59°F and 86°F (15°C and 30°C).

  • Page 22: Chapter 3 - Installation Instructions

    Ground Faults connected to the ground terminal. If the ACS 501 is connected to a system without system ground, the ground fault protection must be capable of starting at ground fault currents containing high frequency and DC components. The ACS 501 ground fault protection guards the variable frequency drive against ground faults occurring in the motor or the motor wiring.

  • Page 23: Environment

    If the cooling air contains dust, clean the cooling surfaces of the unit regularly using compressed air and a brush. If the ACS 501 is in a NEMA 1 enclosure, cover the vents to prevent the dust from entering the unit.

  • Page 24: Mounting Area

    • DO NOT mount in direct sunlight. • DO NOT mount on surfaces with temperature above 104°F (40°C). • DO NOT allow the ambient temperature around the ACS 501 to exceed the ambient temperature as stated in Environment above. • Mount the ACS 501 vertically with the factory supplied conduit knockouts at the bottom.
  • Page 25 Chapter 3 – Installation Instructions Figure 3-2 shows the ACS 501 with dimensions coded by letters. Table 3-3 lists the actual dimensions for each ACS 501 unit. The table shows dimensions in inches and mm. Figure 3-2 ACS 501 Dimensions...

  • Page 26: Installation Site Power

    At least three (3) separate conduits are required; one each for input power, output power, and control wiring. Conduit Size Figure 3-3 shows a bottom view of R2 and R3 ACS 501 drives, and conduit sizes to fit wire-entry holes. Figure 3-3 ACS 501 R2 and R3 Conduit Sizes 1/2 in.

  • Page 27: Power Wiring

    Chapter 3 – Installation Instructions Figure 3-4 shows a bottom view of an ACS 501 R4 drive, and conduit sizes to fit wire-entry holes. Figure 3-4 ACS 501 R4 Conduit Sizes 1 in. 3/4 in. 1/2 in. (25.4 mm) (19.0 mm) (12.7 mm)
  • Page 28 Chapter 3 – Installation Instructions Table 3-5 Wire Sizes for ACS 501 Units Drive Type Unit Drive Fuse Size Wire Sizes ACS501-002-4 – 005-4 22 AWG – 10 AWG ACS501-001-2 – 002-2 ACS501-007-4 – 010-4 ACS501-003-2 – 005-2 20 AWG – 8 AWG ACS501-005-6 –...

  • Page 29: Output Power Wiring

    • Nuisance activation of current limits or electronic motor overload function If the motor wire lengths in Table 3-8 must be exceeded, chokes should be installed in the drive output. Contact ABB for more information. Table 3-8 Maximum Recommended Motor Wire Lengths...

  • Page 30: Control Wiring

    Chapter 3 – Installation Instructions Control Wiring Control wires for ACS 501 should be 16 – 22 AWG shielded, multi-core cables, Belden type 8761 or 8771 or equivalent, rated for 140°F (60°C). Torque control wiring to 4 in.-lbs (0.5 Nm).

  • Page 31: Mechanical Installation

    Input Wiring The ACS 501 is designed for use on a three-phase system. Four wires (three phase plus a ground wire) are required for the input wiring. When sizing wire, always conform to local regulations.
  • Page 32 WARNING! Before connecting a resistor load bank to the DC bus terminals, measure the voltage at the terminals with power applied to the ACS 501. Use a meter rated greater than 1000 VDC. The voltage should be zero volts. If the voltage is 1.35 x V...

  • Page 33: Insulation Checks

    ACS 501 is disconnected from incoming line power. Failure to disconnect line power could result in death or serious injury. 1. Check that the motor wires are disconnected from the ACS 501 output on Terminals U and W 2.

  • Page 34: Terminal Connections

    600 volt units only Motor Line Connection Connection U2 V2 W2 + U1 V1 W1 L1 L2 L3 Heatsink AC CHOKE Metallic Metallic Conduit Conduit AAAAAAAAAA 3φ Motor L1 L2 L3 Ground Line Input ACS 501 Installation & Start-up Manual 3-13...

  • Page 35: Control Connections

    Chapter 3 – Installation Instructions Control Connections Available Control The available control locations for the ACS 501 are the: Locations • ACS Keypad located on the front of the drive. • X50 screw terminals on the Control Interface Card SNAT-759.
  • Page 36 10 megohm resistor. The common points are not isolated from each other. Note: The ACS 501 is shipped with a wire from X50:8 to chassis ground, or with a jumper labeled S9 next to X50. This connects the circuit common to chassis ground.

  • Page 37: X50

    If a diode is used, it should have a voltage rating greater than or equal to the supply voltage, and be connected as shown below: diode (24 VDC in this case) 24 VDC 3-16 ACS 501 Installation & Start-up Manual...

  • Page 38: Control Interface Card Snat-759 Connections

    AA AA RO 21 Relay output 2 AAAA AAAA AAAA AAAA RO 22 Run indication A A A AAAAAAAAAAAAAAAAAAAAAAAAAA RO 23 RO 31 Relay output 3 RO 32 Fault (Inv) -indication RO 33 ACS 501 Installation & Start-up Manual 3-17...
  • Page 39 Chapter 3 – Installation Instructions This page intentionally left blank. 3-18 ACS 501 Installation & Start-up Manual...

  • Page 40: Chapter 4 - Start-Up Procedure

    Before start-up, observe the following: The Motor Control Card (bottom card) is at DC bus potential (1.35 x V when the ACS 501 is connected to supply voltage. This voltage is extremely dangerous and can cause death or serious injury.

  • Page 41: Installation Inspection

    • Quantity and quality of cooling air for the ACS 501. • Verify that it is safe to run the motor. • Connect the ACS 501 to supply voltage. Check that the voltage between ± 10%. – L –...

  • Page 42: Start-Up Data Parameters

    VAC for 230-volt units. Press [Up Arrow] or [Down Arrow] to select the voltage value which matches the line voltage providing power to your ACS 501. Press [ * ] to confirm the selection and move to the next parameter.
  • Page 43 DC bus voltage level which is × 110% × 1.35 × 1.3 minimum (input voltage × ±10% tolerance × peak of rectified wave × overvoltage limit). ACS 501 Installation & Start-up Manual...

  • Page 44: Keypad Control Tests

    After setting the Start-up Data parameters, test the drive as follows: from the ACS 501 1. Disconnect and lock out power from the ACS 501, wait at least five minutes after disconnecting power. Verify that the DC Bus voltage is at a safe level by measuring the voltage between positive (+) and negative (-) on Terminal Block X2, labeled “Brake.”...

  • Page 45: Motor Connected To The Acs 501

    10. Measure the output current in all three phases. The current should be balanced, and should not exceed the motor or drive rating. If the drive operates according to these steps, your ACS 501 is ready to use with pre-set or modified macro adjustments.

  • Page 46: Default Drive Parameters

    Connect all external wiring based on the configuration selected, and test all external interfacing. Customizing Application At some point during the installation of your ACS 501 you can select one of Macro Parameters the pre-set application macros closely suited to your application. You select Application macros from Start-up Data Parameter B (Applications).
  • Page 47 Chapter 4 – Start-up Procedure This page intentionally left blank. ACS 501 Installation & Start-up Manual...

  • Page 48: Chapter 5 - Fault Tracing

    (RS 485), or if necessary, switching the input voltage off for a while. If the fault has been corrected, the ACS 501 will resume normal operation. If the fault has not been corrected, the ACS 501 will trip again.

  • Page 49: Fault History

    Stop] or by external fault reset. The source of external fault reset can be set at Parameter 10.4.2 (Fault Reset Select). Fault Erasing You can erase fault messages from the ACS 501 memory. To erase fault messages: 1. Select Operating Data Parameter 17 (Last-Recd Fault).

  • Page 50: Fault Tracing

    • Check DC bus voltage. EEPROM has failed. • If voltage is OK, try to store again. • If warning occurs again, try to restore factory settings. • If the warning persists, contact ABB Technical Support. ACS 501 Installation & Start-up Manual...

  • Page 51: Fault Messages

    The motor load has dropped • Fix mechanical problem below the Supervision Limit set causing underload. by Parameters 30.1.12 and • Check motor load cycle and 30.1.13. increase Parameter 30.1.12 (Underload Time) or Parameter 30.1.13 (Underload Curve). ACS 501 Installation & Start-up Manual...
  • Page 52 Refer to Figure 5-3 at the end motor cable, or in the ACS 501. of this chapter. Too short acceleration time may also cause an overcurrent trip.
  • Page 53 • Call ABB Technical Support. seconds after connecting the input power. 24 GND FAULT Ground Fault has been detected • Check the motor and motor in the motor or motor wiring. wiring for grounds faults. ACS 501 Installation & Start-up Manual...
  • Page 54 Chapter 5 – Fault Tracing Figure 5-2 ACS 501 Temperature Warning/Fault Flowchart ACS 501 Temp Warning/Fault. Check ambient temperature per chart below. Check cooling air flow. Clear restrictions Air flow OK? to air flow. Clean dust from Heat fins heatsink fins.
  • Page 55 Chapter 5 – Fault Tracing Figure 5-3 Overcurrent Fault Flowchart Overcurrent trip. Stop the drive. Disconnect ACS 501 from input power. If Auto Reset is on, death or serious injury could result if power is not disconnected before removing a mechanical fault. Motor...

  • Page 56: Chapter 6 - Service And Maintenance

    Chapter 6 – Service and Maintenance This chapter explains procedures for servicing ACS 501 components. It also includes spare parts information and general technical data. CAUTION: Electrostatic Discharge (ESD) can damage electronic circuits. Do not handle any components without following the proper ESD precautions.

  • Page 57: Acs 501 - 002, 003, And 005

    Control Interface Card. 4. Remove the screws fastening the left side of the Control Interface Card to the ACS 501 chassis, disconnect the cable from X4 on the Motor Control Card, and swing the Control Interface Card open to access the Motor Control Card.

  • Page 58: Acs 501 - 007 To 040

    ACS 501 – 007 to 040 Diode Test 1. Disconnect and lock out power from the ACS 501. WARNING! Wait at least five minutes after disconnecting power from the drive before you attempt to service the drive. Bus capacitors in the intermediate circuit must discharge before servicing the drive.
  • Page 59 Control Interface Card. 4. Remove the screws fastening the left side of the Control Interface Card to the ACS 501 chassis, disconnect the cable from X4 on the Motor Control Card, and swing the Control Interface Card open to access the Motor Control Card.
  • Page 60 4. Connect the multimeter positive test probe to the rectifier negative terminal and measure each rectifier phase pole with the multimeter negative test probe. The meter should register a range from 100 to 10,000 ohms and infinity, accordingly. ACS 501 Installation & Start-up Manual...

  • Page 61: Dc Bus Capacitor Tests

    A resistance test, together with a Meggar test for DC insulation, reveals enough information to determine the condition of electrolytic capacitors. When testing DC bus capacitors, always do the Resistance Test and the Insulation Test. ACS 501 Installation & Start-up Manual...

  • Page 62: Acs 501 - 002, 003, And 005

    Control Interface Card. 4. Remove the screws fastening the left side of the Control Interface Card to the ACS 501 chassis, disconnect the cable from X4 on the Motor Control Card, and swing the Control Interface Card open to access the Motor Control Card.
  • Page 63 Table 6-1 Resistance Values ACS 501 Rating R3 Value, Ohms R11 Value, Ohms 220k 220k 100k 100k 100k 100k 7. If your readings differ from the values in the table above, contact ABB Technical Support. ACS 501 Installation & Start-up Manual...

  • Page 64: Acs 501 - 007 To 040

    Card edge side of R3 Terminal X2:(-) 3. Continue with each measurement until the reading stabilizes or until the reading suddenly falls. 4. If the reading suddenly falls, replace the capacitors. Contact your ABB Technical Support. ACS 501 – 007 to 040 Resistance Test 1.
  • Page 65 Control Interface Card. 4. Remove the screws fastening the left side of the Control Interface Card to the ACS 501 chassis, disconnect the cable from X4 on the Motor Control Card, and swing the Control Interface Card open to access the Motor Control Card.

  • Page 66: Igbt Module Tests

    ACS 501 – 002, 003, and 005 1. Disconnect and lock out power from the ACS 501. WARNING! Wait at least five minutes after disconnecting power from the drive before you attempt to service the drive. Bus capacitors in the intermediate circuit must discharge before servicing the drive.
  • Page 67 Control Interface Card. 4. Remove the screws fastening the left side of the Control Interface Card to the ACS 501 chassis, disconnect the cable from X4 on the Motor Control Card, and swing the Control Interface Card open to access the Motor Control Card.
  • Page 68 Meter (-) Test Probe Reading X3:W2 X2:(+) X3:V2 X2:(+) X3:U2 X2:(+) X3:W2 X2:(-) X3:V2 X2:(-) X3:U2 X2:(-) Figure 6-6 Motor Control Card Motor Control Card U2 V2 W2 Brake Line Input Chopper L1 L2 ACS 501 Installation & Start-up Manual 6-13...

  • Page 69: Acs 501 - 007 To 040

    Chapter 6 – Service and Maintenance 7. If your readings differ from the values in the table, contact your ABB Technical Support. ACS 501 – 007 to 040 1. Disconnect and lock out power from the ACS 501. WARNING! Wait at least five minutes after disconnecting power from the drive before you attempt to service the drive.
  • Page 70 Meter (-) Test Probe to Reading IGBT Terminal: IGBT Terminal: Over 0.35 Over Over 10. Repeat the tests in Step 9 for each IGBT. If your readings differ from the values in Table 6-5, replace the IGBT. ACS 501 Installation & Start-up Manual 6-15...
  • Page 71 Chapter 6 – Service and Maintenance This page intentionally left blank. 6-16 ACS 501 Installation & Start-up Manual...

  • Page 72: Appendix A - Acs 501 Technical Data

    Overcurrent Trip: 3.75 x I instantaneous, 2.65 x I (RMS) Field Weakening Point: ACS 501, 30 – 500 Hz Field Weakening Point: ACS 502, 30 – 180 Hz Continuous Loadability of Motor: 100% at rated speed (for F class motor) Modulation Frequency: ACS 501, 1 –...

  • Page 73: Auxiliary Voltage (For Controls

    Appendix A – ACS 501 Technical Data Resolution: AI1 = 10 Bit; AI2 = 12 Bit Accuracy: • Analog Control: ± 0.5% • Digital Control: ± 0.01% Reference Signal Update: < 20 mSec 24 VDC ± 10%, 200 mA Auxiliary Voltage...
  • Page 74 Glossary Analog Input (AI) An Analog Input is an input to the ACS 501 for a user-supplied DC signal. The signal may be a speed reference or a process feedback. This signal can be from: • Manual speed pot • DC voltage (0 to 10 VDC) •...
  • Page 75 Refer to Chapter 2 – Overview of the ACS 501. IGBT An IGBT is a fast switching power transistor. ACS 501 drives use these in the inverter section as part of the process of changing DC voltage to AC voltage.
  • Page 76 Main A Main is the first of four display levels in the ACS 501 programming. Mains provide access to Groups in the same way that Groups provide access to Parameters. For example, to access Main 10 while viewing any of the 28 Operating Data Parameters, press [Right Arrow] on the Control Panel Keypad.
  • Page 77 The ACS 501 uses six rectifiers, configured into a three-phase bridge configuration, as the power converter section of the drive. Slip Compensation Slip compensation is a feature in the ACS 501 that allows the drive to compensate for motor slip caused by increased load. Start-up Data Start-up Data parameters allow you to set certain parameter values prior to starting the ACS 501.
  • Page 78 3-10 Digital inputs 3-15 Motor Digital outputs 3-16 insulation check 3-12 Dimensions output wiring connections from ACS 501 3-14 Display contrast, adjusting MOTOR BASE FREQUENCY Display indications MOTOR BASE R.P.M. Drive code, nameplate identification ACS 501 Installation & Start-up Manual...
  • Page 79 Programming example Publications related to this manual 3-15, 3-17 Relay outputs 3-16 Safety instructions general grounding warning symbols Service DC Bus capacitor tests IGBT module tests 6-11 precautions rectifier tests ACS 501 Installation & Start-up Manual...
  • Page 80 ASEA BROWN BOVERI ABB Industrial Systems Inc. 16250 West Glendale Drive New Berlin, WI 53151 Telephone: (414) 785-3416 Fax: (414) 785-0397...

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