ABB Drives: Users Manual

ACS 501
Users Manual
ACS 501 with Option Pack

ACS 501-08D EFFECTIVE 10/1/95 SUPERCEDES 9/1/94
ABB Drives
ASEA BROWN BOVERI
ACS 501 with Option Pack Users Manual
ACS 501-08D
EFFECTIVE: 1995-10-01 SUPERCEDES: 1994-09-01 1995 ABB Drives Inc. All Rights Reserved.
Safety Instructions
General Safety Instructions
Warnings in this manual appear in either of two ways: Dangerous voltage warnings, preceded by a Dangerous Voltage symbol, indicate the presence of voltages which may cause death or serious injury. These warnings describe procedures to avoid death or serious injury. General warnings, preceded by a General Warning symbol, indicate situations or conditions which may cause death or serious injury. These warnings describe procedures to avoid death or serious injury.
CAUTIONS inform you of situations or conditions which will damage machinery or cause additional motor-operation down-time if you do not take suggested steps to correct or address such situations or conditions. Note: Notes provide you with additional and useful information. Although less urgent than cautions and warnings, notes are important and should not be ignored.
Warning Symbols
For your own safety please pay special attention to instructions containing these symbols: This warning symbol indicates the presence of dangerous voltage. 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.
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Safety Instructions
Warnings, Cautions, and Notes

WARNING! Your drive contains dangerous voltages when connected to the line power. Always check that the ACS 501 is safe, after disconnecting the power, by measuring the DC bus voltage and line input voltage. Failure to check voltages could cause death or serious injury. 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 VIN). After disconnecting the supply, wait at least five minutes after the display readout on the control panel has disappeared before taking any measurements. Dangerous external control voltages may be present on the relay outputs of the Control Interface Card and Option Cards.
CAUTION: Electrostatic Discharge (ESD) can damage electronic circuits. Do not handle any components without following the proper ESD precautions.
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Table of Contents
Chapter 1 Introduction How To Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Intended Audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Conventions Used In This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control Panel Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control Panel Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Press . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Terminal Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Warranty and Liability Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Related Publications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chapter 2 Overview of the ACS 501 with Option Pack General Information About the ACS 501 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Control Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Option Pack Features and Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Custom Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Control Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Disconnect Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 Bypass Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 Thermal Motor Overload Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 Meters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 Chapter 3 Installation Instructions Pre-Installation Planning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mounting Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation Site Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Wiring Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Initial Inspection Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mechanical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Input Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Output Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Available Control Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Option Pack Terminal Block Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 3-1 3-2 3-3 3-3 3-4 3-4 3-4 3-6 3-6 3-7 3-8 3-8 3-9 1-1 1-1 1-2 1-2 1-2 1-2 1-2 1-2 1-2 1-3 1-3 1-3
Table of Contents
Chapter 4 Start-up Procedure Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Installation Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Start-up Data Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Keypad Control Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Motor Disconnected from the ACS 501 with Option Pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Motor Connected to the ACS 501 with Option Pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 Keypad Control vs. External Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Option Pack Macro Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Password Protection (Parameter Lock) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 Chapter 5 Option Pack Parameter Settings Opt. Pack Parameter Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Start-up Data Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Operating Data Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Main 10 Control Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 10.3 PRESET SPEEDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 10.5 ANALOG INPUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 10.7 ANALOG OUTPUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 Main 20 Drive Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 20.1 FREQ/CURRENT LIMITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 20.3 ACCEL/DECEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 Main 30 Protection Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 30.2 AUTOMATIC RESET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-1
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Chapter 1 Introduction
This chapter explains the purpose and contents of this manual, intended audience, and conventions used in this manual, and lists related publications.
How To Use This Manual
The purpose of this manual is to provide you with the information necessary to install and start-up your ACS 501 with Option Pack. This manual also explains features and functions of the Option Pack and requirements such as external drive control connections, wiring, cable sizes, and cable routing. The ACS 501 with Option Pack user documentation also includes the ACS 501 Adjustable Frequency AC Drives 2 to 50 HP Installation and Start-up Manual, and the ACS 500 Adjustable Frequency AC Drives 2 to 350 HP Programming Manual Including Application Macros, which are included with the ACS 501 drive. Chapter 1 Introduction, the chapter you are reading now, introduces you to the ACS 501 with Option Pack Users Manual and conventions used throughout the manual. Chapter 2 Overview of the ACS 501 with Option Pack explains drive identification and the available features and functions, and lists and explains the available components of the Option Pack. Chapter 3 Installation Instructions explains Option Pack installation planning, inspection, and mounting. This chapter also includes requirements and connections for input and output wiring, terminal connections, external control wiring, and available control locations. Chapter 4 Start-up Procedure explains safety, installation inspection, Start-up Data parameters, keypad control, external control, Option Pack macro parameters, and Password Protection. Chapter 5 Option Pack Parameter Settings lists and explains the Option Pack parameter settings. The Index helps you locate the page numbers of topics contained in this manual.
Intended Audience
The audience for this manual has: Minimal knowledge of ABB product names and terminology. No experience or training in installing, operating, or servicing the ACS 501 with Option Pack. Basic knowledge of standard electrical wiring practices, electronic components, and electrical schematic symbols. The audience for this manual will install and start-up the ACS 501 with Option Pack.
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Conventions Used In This Manual

Control Panel Display
Listed below are terms and language conventions used in this manual. These terms and conventions are defined here to help you understand their meanings and applications throughout this manual. The Control Panel display is an LCD readout of drive functions, drive parameter selections, and other drive information. Letters or numbers appear in the display according to which Control Panel keys you press. Control Panel keys are flat, labeled, pushbutton-type devices that allow you to monitor drive functions, select drive parameters, and change drive macros and settings. These keys are located on the Control Panel Keypad. A main is the first level of programming. The Mains organize the Parameters into four main functional groups. A Main in this manual is the number corresponding to Group access. All Groups in the 10s range are accessed on the Control Panel through CONTROL CONNECTIONS/MAIN 10. Access Groups in the 20s range through DRIVE PARAMETERS/MAIN 20. Access Groups in the 30s range through PROTECTION PARAMETER/MAIN 30, and access Groups in the 40s range through APPLIC PARAMETERS/MAIN 40. Refer to the ACS 500 Adjustable Frequency AC Drives 2 to 350 HP Programming Manual Including Application Macros, Chapter 2 Overview of ACS 500 Programming and Chapter 5 Parameters, for a more detailed explanation of programming the ACS 501 drive. A Group is a sub-set of a Main. Groups are grouped within Mains according to their 10s, 20s, 30s, or 40s range. For example, Groups numbered 30.1, 30.2, 30.3, and 30.4 are found in PROTECTION PARAMETER/MAIN 30. Parameters are accessed through Groups. Refer to the ACS 500 Adjustable Frequency AC Drives 2 to 350 HP Programming Manual Including Application Macros, Chapter 2 Overview of ACS 500 Programming and Chapter 5 Parameters, for a more detailed explanation of programming the ACS 501 drive. A parameter is a sub-set of a Group, selected through the Control Panel keys. Parameters in this manual often are expressed as a number, a decimal (.), another number, a decimal, and another number. The first number at the left represents the Main. The number between the decimals represents the Group, for example, 20.2 (Start/Stop). The number at the right represents a Parameter within that group, for example, 4 (Brake Chopper). In this manual, Parameter 4 in Group 20.2 is expressed as Parameter 20.2.4. Refer to the ACS 500 Adjustable Frequency AC Drives 2 to 350 HP Programming Manual Including Application Macros, Chapter 2 Overview of ACS 500 Programming and Chapter 5 Parameters, for a more detailed explanation of programming the ACS 501 drive. Press a key on the Control Panel to achieve a desired result. In this manual, individual Control Panel keys are enclosed in square brackets. For example, the Setting mode key is expressed as [ * ]. Refer to the ACS 501 Adjustable Frequency AC Drives 2 to 50 HP Installation & Start-up Manual, Chapter 2 Overview of the ACS 501, Control Panel Operation, for details.
Control Panel Keys
Main
Group
Parameter
Press
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Terminal Block
A terminal block is a group of wire connections on a drive. This manual expresses specific terminal blocks and connections as a letter or letters, a number, a colon (:), and another number. The letter(s) and number to the left of the colon represent the name of the terminal block, for example TB1. The number to the right of the colon represents the terminal connection, for example 16, on the terminal block. In this manual, a terminal connection numbered 16, located on a terminal block named TB1, is expressed as TB1:16. The warranty for your ABB Option Pack covers manufacturing defects. The manufacturer carries no responsibility for damage due to transport or unpacking. In no event and under no circumstances shall the manufacturer be liable for damages and failures due to misuse, abuse, improper installation, or abnormal conditions of temperature, dust, or corrosives, or failures due to operation above rated capacities. Nor shall the manufacturer ever be liable for consequential and incidental damages. The period of manufacturer's warranty is 12 months, and not more than 18 months, from the date of delivery. Extended warranty may be available with certified start-up. Contact your local distributor for details. Your local ABB Drives company or distributor may have a different warranty period, which is specified in their sales terms, conditions, and warranty terms. If you have any questions concerning your ACS 501 with Option Pack, contact your local distributor or ABB Drives office. The technical data and specifications are valid at the time of printing. ABB reserves the right to subsequent alterations.
Warranty and Liability Information
Related Publications
For related information, refer to the ACS 501 Adjustable Frequency AC Drives 2 to 50 HP Installation & Start-up Manual (ACS 501-04) and the ACS 500 Adjustable Frequency AC Drives 2 to 350 HP Programming Manual Including Application Macros (ACS 500-05).
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Chapter 2 Overview of the ACS 501 with Option Pack
This chapter explains the numbers and letters on the control nameplate, describes available Option Pack features and functions, and includes illustrations. It also describes the ACS 501 with Option Pack hardware components and terminal block connections.
General Information About the ACS 501

Control Identification
The numbers and letters in the last seven spaces of the ACS 501 Model Number stand for the specific options included in your Option Pack. Locate the Control Nameplate on the Option Pack and use Figure 2-1 to verify the options included in your Option Pack.
2-1
Figure 2-1
Nameplate Codes
ACS501-002-4-00P2 S501002400P2
NEMA Type Enclosure 2=NEMA 1 5=NEMA 12 Type Controls A=Hand-Off-Auto Switch incl. 115V Control Transformer B=Hand-Off-Auto Switch & Speed Pot incl. 115V Control Transformer C=115 VAC Control Transformer & Terminal Board 1=Internal Brake Chopper M=A+1 N=B+1 P=C+1 0=None
Meters A=Analog Voltmeter B=Analog Speed Meter Y=Ammeter (Sized to unit) 1=A+B 2=A+Y 4=B+Y 6=A+B+Y 0=None
MOL HP* 1
Input Options A=Door Interlocked Disconnect Switch B=Door Interlocked Circuit Breaker C=Disconnect w/3% Line Reactor D=Circuit Breaker w/3% Line Reactor E=Input Terminal Block w/3% Line Reactor F=Disconnect w/5% Line Reactor G=Circuit Breaker w/5% Line Reactor H=Input Terminal Block w/5% Line Reactor 0=Extended Enclosure w/Input Terminal Block
3 5 7.5 10 15
Bypass A=Manual Bypass B=Manual Bypass w/Service Switch C=Automatic Bypass D=Automatic Bypass w/Service Switch E=Manual Bypass w/mechanical interlock F=Manual Bypass w/Service Switch w/mechanical interlock G=Automatic Bypass w/mechanical interlock H=Automatic Bypass w/Service Switch w/mechanical interlock 0=None
20 25 30 40 50 60 75
ACS 501 A=1.41 to 1.58 B=1.75 to 1.85 C=2.76 to 2.95 D=2.96 to 3.21 E=3.22 to 3.48 F=3.49 to 3.89 G=3.90 to 4.35 H=4.36 to 4.73 J=4.74 to 5.21 K=6.47 to 6.95 L=6.96 to 8.09 M=8.10 to 9.29 N=9.30 to 10.4 P=10.5 to 10.9 Q=12.1 to 14.5 R=14.6 to 16.8 S=16.9 to 18.4 T=18.5 to 20.9 U=22.6 to 24.3 V=24.4 to 27.2 W=29.3 to 32.0 X=32.1 to 34.9 Y=35.0 to 37.8 Z=37.9 to 41.7 2=46.0 to 49.0 3=49.1 to 54.2 4=57.1 to 62.8 5=62.9 to 69.1 6=69.2 to 75.0 7=75.1 to 83.3 8=87.0 to 92.9 9=93.0 to 100 0=None
* Horsepowers listed are estimated only for 460 volts. MOLs MUST be sized for the specific motor. Horsepowers for 230 V are half the horsepower at 460 V.
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Option Pack Features and Functions
The ACS 501 with Option Pack is an ACS 501 AC adjustable frequency drive with an extended enclosure for control options. Depending on the options chosen, the ACS 501 with Option Pack provides motor overload protection, disconnect switch or circuit breaker, bypass, analog meters, indicator lights, and external control connections. Figure 2-2 shows the door of the ACS 501 Option Pack, and indicates all possible options. Your Option Pack may not look exactly like the illustration.
Figure 2-2 Option Pack Cover with Options
ABB Drives
ACS 500
Ext. Fault Pilot Light Bypass Pilot Light Normal Pilot Light Disconnect Switch
Speed Meter Normal/Test/Bypass Switch Hand/Off/Auto Switch

AM1 AM2
VM
SPM
Manual Speed Pot

RESET
MOL Reset
Voltmeter Ammeters
2-3
Figure 2-3 shows the interior of the ACS 501 Option Pack, for the two enclosure sizes, and indicates all possible options. Your Option Pack may not look exactly like the illustration.
Figure 2-3 Option Pack Interior with Options
R2 - R5 R5.5
Control Transformer and Primary Fuses Auto Bypass Relay Normal/Off/ Test Switch Output Contactor
Line Reactor Fuses for Voltmeter Circuit Breaker, Disconnect Switch or Input Terminal Block Bypass Fuses
Input Contactor Normal/Off/ Test Switch Terminal Board
Circuit Breaker, Disconnect Switch or Input Terminal Block Bypass Fuses (not shown) Output Contactor Bypass Contactor
Bypass Contactor Input Contactor Terminal Board Ground Lugs MOL(S) or Output Terminal Block Auto Bypass Relay Control Transformer and Primary Fuses Fuses for Voltmeter MOL(S) or Output Terminal Block Ground Lugs
There are three enclosure sizes, although the component layout for the R2 through R5 are similar: One enclosure for R2 and R3 units One enclosure for R4 and R5 units One enclosure for R5.5 See the ACS 501 Installation and Start-up Manual (ACS501-04) that was included in the delivery to determine which frame size is used for each rating. The ACS 501 drive is mounted so the keypad is accessible through the door of the Option Pack enclosure.
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All control connections are made to either TB1 or X50, depending on the configuration of the ACS 501. TB1 is located on the Terminal Board in the Option Pack. The Terminal Board is supplied when the 115 VAC control is ordered. This is indicated in the thirteenth character of the part number, Control (see Figure 2-1). 115 VAC control is required with the Hand-OffAuto Control Option and Bypass Options. When the Terminal Board is supplied, all connections should be made to TB1. When the terminal board is not supplied, all control connections should be made to Terminal Board X50 as indicated in the ACS 501 Adjustable Frequency AC Drives 1 to 75 HP Installation & Start-up Manual.
Custom Options
Custom options for the ACS 501 with Option Pack fall into five main categories: Control Options Input Options Bypass Options Thermal Overload Relays Meters
Control Options
The Control Options are Hand/Off/Auto and Hand/Off/Auto with Speed Potentiometer. Both options include 115 VAC control power and control power transformer. The 115 VAC control can also be ordered without HOA or Speed Pot. When the 115 VAC Control is supplied, a Terminal Board is also supplied. This board (illustrated in Chapter 3 Installation Instruction) is the location of Terminal Block TB1, to which all connections are made. Terminal Board connections are described in this manual. 115 VAC Control is required with all Bypass options. If the Terminal Board is not supplied, all control connections are made to Terminal Block X50. Refer to the ACS 501 Adjustable Frequency AC Drives 2 to 50 HP Installation & Start-up Manual, Chapter 3 Installation Instructions, for information about control connections on Terminal Block X50.
Hand/Off/Auto
Hand/Off/Auto is a door mounted switch, wired at the factory. This switch allows you to select one of three modes. In the Hand mode, the Drive Enable signal enables the drive and the ACS 501 Keypad (Operating Data Parameter 14) controls the speed. In the Off mode, the drive is disabled even if you use an external speed reference or if you attempt to start the drive via the keypad. In the Auto mode, a remote contact closure starts the drive, provided you have connected a remote contact. A remote signal (voltage, current or pneumatic) controls speed. A 115 VAC control transformer provides control voltage. Hand/Off/Auto with Speed Potentiometer is the same switch as Hand/Off/ Auto with the addition of a manual speed potentiometer mounted on the drive enclosure. In the Hand mode, the speed potentiometer controls speed. The speed potentiometer is connected to Analog Input 2 (AI2).
Hand/Off/Auto with Speed Potentiometer
2-5
Input Options Door Interlocked Disconnect Switch Door Interlocked Circuit Breaker
The Disconnect Options are the Door Interlocked Disconnect Switch and the Door Interlocked Circuit Breaker. The Door Interlocked Disconnect Switch is a non-fused disconnect switch. Fuses are standard in the drive and additional fuses are supplied separately when bypass is ordered. The Door Interlocked Circuit Breaker is a thermal magnetic, molded case circuit breaker. Both options are a thru-the-door interlock design and can be padlocked in the OFF position.
Input Line Reactor Bypass Options
3% or 5% input line reactors to reduce the harmonics to the power line. Manual and Automatic Bypass are both available with and without a service switch (input contactor). If bypass is supplied, and a circuit breaker is not ordered, fuses are provided in the Option Pack. Table 2-1 shows fuse sizing.
Table 2-1 Fuse Sizes
Drive Type ACS 501-002-4 ACS 501-001-2 ACS 501-003-4 ACS 501-005-4 ACS 501-002-2 ACS 501-005-6 ACS 501-007-6 ACS 501-007-4 ACS 501-003-2 ACS 501-010-6 ACS 501-010-4 ACS 501-005-2 ACS 501-015-4 ACS 501-007-2 ACS 501-015-6 ACS 501-020-6 ACS 501-020-4 ACS 501-010-2 ACS 501-025-6 ACS 501-025-4 ACS 501-030-6 ACS 501-030-4 ACS 501-015-2 ACS 501-040-6 ACS 501-040-4 ACS 501-020-2 ACS 501-050-6 ACS 501-050-4 ACS 501-060-4 ACS 501-025-2 ACS 501-030-2 Rating 6A, 600V 10A, 600V 15A, 600V 17.5A, 600V 20A, 600V 25A, 600V 30A, 600V 40A, 600V 50A, 600V 60A, 600V 70A, 600V 80A, 600V 100A, 600V 125A, 600V 150A, 600V 175A, 600V Manufacturer Bussmann Bussmann Bussmann Bussmann Bussmann Bussmann Bussmann Bussmann Bussmann Bussmann Bussmann Bussmann Bussmann Bussmann Bussmann Bussmann LPJ-125SP LPJ-150SP LPJ-175SP LPJ-60SP LPJ-70SP LPJ-80SP LPJ-100SP LPJ-40SP LPJ-50SP LPJ-25SP LPJ-30SP LPJ-17SP LPJ-20SP Type (all Class J, Dual Element) LPJ-6SP LPJ-10SP LPJ-15SP
These fuses are UL Listed components.
2-6
Manual Bypass
The Manual Bypass option is a selector switch which transfers the motor to line power and allows the motor to operate at full speed. Note: If motor overload is not provided in the option pack, one must be installed external to the drive and sized in accordance with NEC. The Manual Bypass option has two contactors, electrically interlocked and controlled by a three position, door-mounted switch. Switch positions are NORMAL, TEST, and BYPASS. In the NORMAL position, the Bypass contactor is open, the Output contactor is closed, and the Normal indicator light is illuminated. In the TEST position, both contactors are open. In the BYPASS position, the Output contactor is open, the Bypass contactor is closed, the drive is disabled, and the Bypass indicator light is illuminated. Motor duty fuses or a circuit breaker protect the motor in the Bypass mode. An External Fault indicator light is included. The External Fault indicator light illuminates if any of the safety interlocks (FREEZE, FIRE, SMOKE) open, or if the Thermal Motor Overload Relay trips.
CAUTION: When changing from Bypass to Normal, place the Bypass Switch in the TEST position for five seconds before selecting Normal. Failure to do so could result in damage to the ACS 501. Note: The ACS 501 is disabled when BYPASS is selected. If the drive is to be run while in BYPASS, a connection must be made between TB1:42 and TB1:43. This should be done by a qualified service technician only.
CAUTION: Remove the jumper before switching from BYPASS to NORMAL. Failure to do so could result in damage to the ACS 501. Note: The Output contactor opens when the drive receives a stop command, which will cause the motor to coast to a stop. If ramp to a stop is required by the application, it will be necessary to install wires from TB1:25 to TB1:40 and from TB1:26 to TB1:41. This will cause the Output contactor to remain closed until the output frequency reaches 0 Hz when a stop command is received.
CAUTION: If BYPASS is selected, and the motor is not running because a stop command is given, the motor will start when the drive is started.
2-7
Manual Bypass with Service Switch
The Manual Bypass with Service Switch option is the same as the Manual Bypass option with the addition of another switch and a third contactor on the line power input side of the drive. The additional switch allows you to apply power to, or remove power from the drive for servicing while the motor continues to operate on line power. In the BYPASS position, the Drive Input contactor opens and removes power from the drive. The Drive Input contactor also is controlled by the three position Service Switch, with the positions labeled NORMAL, OFF, and TEST. This switch is mounted inside the enclosure. In the NORMAL position, the Bypass contactor controls the Drive Input contactor. In the TEST position, the Drive Input contactor is closed. In the OFF position, the Drive Input contactor is open. Note: The Drive Input contactor opens when BYPASS is selected, removing power from the drive. The service switch will energize the input contactor in the TEST position to allow the drive to be powered while in BYPASS for servicing. Note: The ACS 501 is disabled when BYPASS is selected. If the drive is to be run while in BYPASS, a connection must be made between TB1:42 and TB1:43. This should be done by a qualified service technician only.
CAUTION: Return the service switch to Normal and remove the jumper from TB1:42 to TB1:43 before switching from BYPASS to NORMAL. Failure to do so could result in damage to the ACS 501. Note: The Output contactor opens when the drive receives a stop command, which will cause the motor to coast to a stop. If ramp to a stop is required by the application, it will be necessary to install wires from TB1:25 to TB1:40 and from TB1:26 to TB1:41. This will cause the Output contactor to remain closed until the output frequency reaches 0 Hz when a stop command is received.
CAUTION: If BYPASS is selected, and the motor is not running because a stop command is given, the motor will start when the drive is started.
2-8
Automatic Bypass
An Automatic Bypass may be added to the Manual Bypass or Manual Bypass with Service Switch. The Automatic Bypass automatically transfers the motor to line power when the drive shuts down on a protective trip. If Automatic Restart is enabled on the drive, the drive will attempt to automatically restart before the motor transfers to line power. Bypass transfer occurs when the drive is in a fault condition and will not reset. When an automatic transfer occurs, the Bypass indicator light illuminates. The Thermal Motor Overload Relay options are relays rated 30, 60, or 100 amps. These options are standard, manually resettable, bimetallic motor overload relays with a Class 20 trip curve. The relays provide thermal motor protection when operating a motor from the drive. If a Bypass Option is included, the relays also provide thermal motor protection across the line power. If the overload trips, power is removed from the motor whether in Normal or Bypass mode. When the drive has the Bypass option, an external fault indicator is included. This indicator will illuminate if the overload relay trips. The overload relay is reset by a pushbutton on the enclosure cover. Thermal Motor Overload Relays have heater elements wired in series with the output wiring. The heater elements determine the trip level of the overload relay. The heater element type is stamped on the element. If the overload is not sized properly for the motor, purchase new heaters of the correct size. See Table 2-2 for heater sizes. Your Option Pack may have either one or two overload relays, depending upon how many motors the Option Pack controls.
Table 2-2 Heater Sizes
Heater Code E3 E4 E5 E6 E7 E8 E9 E11 E12 E13 E14 E16 E17 E18 E19 E23 E24 E26 E27 E28 Amps 30 .30 .32 .33 .35 .36 .38 .39 .41 .42 .44 .45 .49 .50 .54 .55 .58 .59 .63 .64 .67 .68 .73 .74 .81 .82 .87 .88 .94 .95 1.00 1.10 1.10 1.11 1.26 1.27 1.40 1.41 1.58 1.59 1.74 60 100
Thermal Motor Overload Relays
2-9
Heater Code E29 E31 E32 E33 E34 E36 E37 E38 E39 E41 E42 E44 E46 E47 E48 E49 E50 E51 E52 E53 E54 E55 E56 E57 E60 E61 E62 E65 E66 E67 E69 E70 E71 E72 E73 E73A E74 E76 E77 E78 E79 E80 E88 E89 E91
Amps 30 1.75 1.85 1.86 1.99 2.00 2.11 2.12 2.31 2.32 2.59 2.60 2.75 2.76 2.95 2.96 3.21 3.22 3.48 3.49 3.89 3.90 4.35 4.36 4.73 4.74 5.21 5.22 5.74 5.75 6.05 6.06 6.46 6.47 6.95 6.96 8.09 8.10 9.29 9.30 10.4 10.5 10.9 11.0 12.0 12.1 14.5 14.6 16.8 16.9 18.4 18.5 20.9 21.0 22.5 22.6 24.3 24.4 27.2 27.3 29.2 29.3 30.0
60
100
16.9 18.4 18.5 20.9 21.0 22.5 22.6 24.7 24.8 27.2 27.3 29.2 29.3 32.0 32.1 34.9 35.0 37.8 37.9 41.7 41.8 45.9 46.0 49.0 49.1 54.2 54.3 60.0
27.1 30.0 30.1 33.2 33.3 35.7 35.8 39.4 39.5 43.4 43.5 46.9 47.0 51.5 51.6 57.0 57.1 62.8 62.9 69.1 69.2 75.0 75.1 83.3
2-10
Heater Code E92 E93 E94 E96 E97 E98 E99 E101 E102 E103 E104 E106 E107
Amps 30
60
100
83.4 86.9 87.0 92.9 93.0 100.0
Meters
The Meter Options are Output Voltmeter, Output Speed Meter, and Output Ammeter. A total of four analog meters can be installed in the ACS 501 with Option Pack. The Output Voltmeter indicates motor voltage on a 0 500 VAC scale connected directly to the drive output. The Output Speed Meter is calibrated in percent of maximum speed with a 0 100 percent scale connected to one of the analog outputs. Note: This option uses one of the analog outputs on the ACS 501.
Output Voltmeter Output Speed Meter
Output Ammeters
The Ammeters have five calibration sizes ranging from 10 to 100 amps. Depending on the number of motors driven, one or two Output Ammeters can be installed in the Option Pack. If two ammeters are ordered, two Thermal Motor Overload Relays must be ordered; the ammeters are sized to the Thermal Motor Overload Relays. If two Thermal Motor Overload Relays are ordered and only one ammeter is ordered, the ammeter will indicate the sum of the current at the two relays.
2-11
2-12
Chapter 3 Installation Instructions
This chapter explains how to install the ACS 501 with Option Pack and connect all power, motor, and control wiring. It also explains the initial inspection procedures.
Pre-Installation Planning
The ACS 500 has been short circuit tested in accordance with UL508. The R3-R5.5 drives are suitable for use on a circuit capable of delivering not more than 65,000 rms symmetrical Amperes; R2 unit 20,000 rms symmetrical Amperes, (240 Volts, 500 Volts or 600 Volts maximum for 230 VAC, 480 VAC, and 600 VAC units respectively). When circuit breakers or disconnects are supplied, the drive package may be limited to the rating of that device.
Table 3-1 Drive package with Disconnect or Circuit Breaker ratings
230 VAC HP Ckt Brkr 1 2 3 5 7.5 10 15 20 25 30 40 50 60 20 kA 20 kA 10 kA 10 kA 25 kA 10 kA 25 kA 25 kA 25 kA 25 kA Disc. 10 kA 10 kA 10 kA 10 kA 10 kA 10 kA 10 kA 65 kA 65 kA 65 kA 18 kA 18 kA 18 kA 18 kA 18 kA 18 kA 18 kA 18 kA 18 kA 18 kA 18 kA 18 kA 10 kA 10 kA 10 kA 10 kA 10 kA 10 kA 10 kA 10 kA 10 kA 65 kA 65 kA 65 kA 14 kA 14 kA 14 kA 14 kA 14 kA 14 kA 14 kA 14 kA 14 kA 14 kA 10 kA 10 kA 10 kA 10 kA 10 kA 10 kA 10 kA 10 kA 10 kA 65 kA Ckt Brkr Disc. Ckt Brkr Disc. 460 VAC 600 VAC
Environment
These drives are to be used in a heated, indoor controlled environment that is relatively free of moisture and conductive contaminates such as condensation, carbon dust, and the like. The maximum ambient temperature allowed is 113F (45C) for an ACS 501 in a NEMA 1 enclosure for constant torque loads, when the load current is lower than or equal to the continuous rated constant torque current (IR). The maximum ambient temperature allowed is 104F (40C) for an ACS 501 in a NEMA 12 enclosure for constant torque loads; and an ACS 501 in a NEMA 1 enclosure for variable torque loads, when the load current is lower than or equal to the continuous maximum load current (IRSQ). The cooling air must be clean and free from corrosive materials. When necessary the required cooling should be provided by using clean, dry air.
3-1
Table 3-2 Required Cooling Air Volume for ACS 501 Units
Unit R2 R3 R4 R5 & R5.5 Cooling Air 30 CFM (51 m3/hr) 60 CFM (102 m3/hr) 240 CFM (406 m 3/hr) 330 CFM (560 m3/hr)
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. If the heatsink is not cleaned and is not able to dissipate the expended heat, the ACS 501s thermal protection will operate, causing a fault indication which stops the drive. The ACS 501 can be started again when the temperature of the heatsink has fallen below the tripping level, which is 158F (70C). The temperature of the heatsink can be read from the Control Panel Display Operating Data, Parameter 8 (Drive Temperature).
Mounting Area Mounting the Control

When mounting the control take the following precautions. DO NOT mount in direct sunlight. DO NOT mount on surfaces with temperature above 104F (40C). 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. See Figure 3-1 for the space requirements. If units are to be mounted next to each other, each unit must have two inches (50 mm) of clear space, so that a total of four inches (100 mm) between two units is available for proper cooling. If units are mounted one above the other, at least 12 inches (300 mm) is required between the units. At least three (3) separate grounded conduits are required. One each for input, output, and control wiring. Figure 3-1 shows the space requirement for adequate cooling of the ACS 501.
3-2
Figure 3-1
Cooling Air Outlet
ACS 501 Space Requirements
Unit R2 & R3
d in. 6 10 mm 150 250
ABB Drives
ACS 500
R4, R5 & R5.5
2 in.
2 in.
VM
SPM
AM1
AM2
RESET
Cooling Air Inlet
2 in.
Installation Site Power
The ACS 501 with Option Pack is designed for use on a three-phase system. Four wires (three phase wires plus a ground wire) are required for the input wiring. Input and output conductors, and branch circuit protection must be sized to local codes. Table 3-3 shows the minimum and maximum input and output wire sizes allowable for each size ACS 501 drive.
Table 3-3 Maximum and Minimum Wire Sizes
Unit R2 R4 R5 R5.5 Wire Sizes 14 AWG 8 AWG 14 AWG 1 AWG 6 AWG - 2/0
Power Wiring Sizes
All field power wiring shall be copper, rated for 140F (60C) for currents less than 100A, or 167F (75C) for currents 100A or more.
ACS 501 with Option Pack Users Manual 3-3
Control Wiring
Control wires for the ACS 501 with Option Pack should be 16 22 AWG shielded, multi-conductor cables, Belden type 8761 or equivalent, when connected to Terminal Block X50, or 12 22 AWG when connected to TB1. As you unpack the ACS 501 with Option Pack, check for any signs of damage and verify that the delivery is complete. In the event of damage, please contact the shipping company or the supplier. Locate the drive nameplate and confirm that the Option Pack is configured to the order specifications. Refer to Chapter 2 Overview of the ACS 501 with Option Pack in this manual. If the Option Pack is stored before start-up, verify that the environmental conditions in the storage room are acceptable: Temperature between -40F and +158F (-40C and +70C), Relative humidity is less than 95 percent, and No condensation. The warranty covers defects in manufacturing. The manufacturer carries no responsibility for damage incurred during transport or unpacking. If any questions arise concerning the ACS 501 with Option Pack, please contact your Distributor or Local ABB Drives Office.
Initial Inspection Procedure
Mechanical Installation
Mount the ACS 501 with Option Pack on a wall in a vertical position. Use the four mounting notches at the top and bottom of the unit. Before mounting the unit, verify that the environmental conditions conform to the specifications listed in Pre-Installation Planning in this chapter. To ensure safe installation, check that the surface of the mounting location is flat. The maximum size of the mounting bolts is 3/8 in. (8 mm). Attach the Option Pack enclosure at the mounting notches and tighten the bolts. Figure 3-2 shows the Option Pack dimensions.
3-4
Figure 3-2
Option Pack Dimensions

406.4 mm [16.000"] (TYP.) 11.1mm X 33.0mm KEYWAY (2 PLACES) E
ACS 500
76.2 mm [3.000"]
254.0 mm [10.000"]
ABB Drives
14.3 mm [0.563"]
B A
VM
SPM
AM1
AM2
C
RESET
25.4 mm [1.000"]
254.0 mm [10.000"]
D 11.1mm X 31.0mm SLOT (2 PLACES) R5.5 in. 65.0 63.6 26.6 11.7 13.8 mm 1727.2 1687.5 809.5 343.0 395.2 in. 68.0 66.6 31.9 13.5 15.6
R2 & R3 mm in. 50.0 48.4 20.1 9.5 11.5
R4 & R5 mm 1651.0 1611.3 675.3 298.0 350.2
A B C D E
1270.0 1230.3 510.2 240.2 292.4
Note: 20 HP (CT) 230 volt unit is R5.5 size optionpack
With Disconnect Drive Type lbs R2 R3 R4 R5 R5.5 95 107 158 176 198 Kg 43.1 48.5 71.7 79.8 89.8 lbs 106 118 170 198 235
With Bypass Kg 48.1 53.5 77.1 89.8 106.6
3-5
Power Connections
Input Wiring
The ACS 501 with Option Pack is designed for use on a three-phase system. Four wires (three phase wires plus a ground wire) are required for the input wiring.
WARNING! Do not connect or disconnect input or output power wiring, or control wires, when power is applied. Never connect line voltage to drive output Terminals U2, V2, and W2. Do not make any voltage tolerance tests (Hi Pot or Meggar) on any part of the unit. Disconnect motor wires before taking any measurements in the motor or motor wires. Make sure that power factor correction capacitors are not connected between the drive and the motor.
The tightening torque for the input power connections to the circuit breaker should be: 50 in.-lbs. for circuit breakers 15A-100A; 120 in.-lbs. for circuit breakers 125A-150A; and 275 in.-lbs. for circuit breakers from 175A-225A. Tightening torques to other termination points should be as labeled on the devices. The line input wiring connections are shown in Figure 3-3.
Figure 3-3 Input Power Wiring Connections
CIRCUIT BREAKER
DISCONNECT SWITCH
NO DISCONNECT
3-6
Output Wiring
Install the motor wiring away from other wire routes. Avoid long parallel runs with other wires. A dedicated conduit should be provided from the drive to the motor for the output wiring.
WARNING! Check the insulation on the motor wiring and the motor before connecting the ACS 501 to line power. Before proceeding with the insulation resistance measurements, check that the 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 Option Pack output on Terminals T1, T2, and T3. 2. Check that the motor wires are disconnected from the motor and remove bridging connections at the motor. 3. Measure the insulation resistances of the motor. The voltage range of the insulation resistance meter must be at least equal to the line voltage, but not exceeding 1000 V. The insulation resistance must be greater than 1 megohm. 4. Measure the insulation resistance of the motor wiring between the phases and between each phase and ground. The insulation resistance must be greater than 1 megohm. The rapid rate of voltage changes causes capacitive coupling between motor wiring and the grounded metallic conduit. This capacitive coupling increases with switching frequency and motor wire length. This phenomenon can cause substantially higher measured current than actual motor current, which may result in nuisance overcurrent trips. The motor wire lengths in Table 3-4 must not be exceeded.
Table 3-4 Maximum Recommended Motor Wire Lengths
Maximum Cable Length Switching Frequency, kHz Feet 1 3 12 200 175 100 Meters 61.0 53.3 30.5
Note: Do not connect the motor wires before proceeding with the Keypad Control Test, Motor Disconnected. Refer to Keypad Control Tests, Chapter 4 Start-up Procedure, in this manual. Figure 3-4 shows the Option Pack output power wiring connections.
3-7
Figure 3-4
Output Power Wiring Connections
NO MOL
ONE MOL
TWO MOL
Control Connections
Available Control Locations
The ACS 501 with Option Pack can be controlled from the ACS 501 Keypad located on the front of the enclosure or with an external control device. External control devices, for example a PLC or remote operator devices, can be connected to Terminal Block TB1, when supplied, or Terminal Block X50. These control devices can be Analog or Digital. Refer to Option Pack Terminal Connections in this chapter. If the Terminal Board is not supplied, follow the installation and start-up procedures in the ACS 501 Adjustable Frequency AC Drives 2 to 50 HP Installation & Start-up Manual. Refer to the ACS 500 Adjustable Frequency AC Drives 2 to 350 HP Programming Manual Including Application Macros, Chapter 3 Control Operations, for keypad control information. All external control wiring to TB1:1 through TB1:20 must be done with shielded cable and must not be run in the same conduit or raceway with any high power wiring. The shield connection must be terminated at the chassis ground lug provided, the other end of the shield should be cut and taped back at the signal source. TB1 terminals 2 and 8 are GND2 (circuit common), and TB1 terminals 4, 6, 18, and 20 are also connected to circuit common. Note: These terminals are optically isolated from power, and isolated from chassis ground by a 10 megohm resistor. They are not isolated from one another.
3-8
Option Pack Terminal Block Connections
The Terminal Block TB1 is located on the terminal board, which is supplied with any option with 115 VAC control (i.e., HOA, HOA with Speed Pot, 115 V control alone, and any Bypass option). Figure 3-5 shows the Terminal Block TB1 connections. Terminals TB1:1 through TB1:29 are the same as terminals X50:1 through X50:29.
Figure 3-5
Terminal Block TB1 Connections

380742 REV
TB2 CR1 START AUTO 1 2 3 4 5 6 7 8 9 CR2 115V RUN CR3 ENABLED CR4 EXT FAULT 50 49 48 47 46 TB1C
1 J1 22 RO12 23 RO13 24 RO21 25 RO22 26 RO23 27 RO31 28 RO32 29 RO33 17 AO1+ 19 AO2+ 21 RO11 18 AO120 AO2-
F1
55
54
53
52
51
SCHEMATIC 380771 ASSY. DWG 380743 SILKSCREEN 380745
115 VAC
EQUIVALENT
REPLACE WITH FNM1 OR
TB1A 7 +24V 200mA 8 COM2 12 DI2 13 DI3 14 DI4 15 DI5 16 DI6 SMOKE/FIRE FREEZE 39 30 31 32 33 34 35 36 37 OL 38 40 41 42 43 44 2 COM1 10 +24V 10mA 1 REF +10V 3 AI1+ 5 AI2+ 4 AI16 AI211 DI1 HOA RUN 115V START BYPASS SWITCH M1 EXT FLT XFMR 45
TB1B
ASEA BROWN BOVERI
ABB DRIVES INC NEW BERLIN, WI 53151 MADE IN USA
Terminals TB1:1 through TB1:20 are low voltage terminals (24 VDC maximum). Terminals TB1:21 through TB1:29 are relay output terminals. Ground terminals are located next to TB1:17 and TB1:29. These are to be used to connect the shields of shielded cables. Terminals TB1:30 through TB1:55 are 115 VAC control. Connection to all of these terminals is described in the following paragraphs. Note: When the Terminal Board is supplied, the Option Pack macro must be used so the terminal board connections operate properly.
Terminal Block TB1
Terminal Block TB1 can accept wire sizes from 12 22 AWG. All connections to Terminals TB1:1 to TB1:20 should be made with shielded cables. TB1:2, 4, 6, 18, and 20 are circuit common. These terminals are optically isolated from the power line potential and from chassis ground by a 10 megohm resistor. The common points are not isolated from each other. Note: The ACS 501 with Option Pack 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. To isolate the circuit common from ground, remove this connection. Figure 3-6 shows connections TB1:1 through TB1:29.
3-9
Figure 3-6
17 AO1+
TB1:1 Through TB1:29

RO12 RO13 RO21 RO22 RO23 RO31 RO32 RO33 DI5 19 AO2+ RO11 18 AO120 AO221 22 23 24 25 26 27 28 29
TB1A DI2 13 DI3 14 DI4 +24V 200mA 2 COM1 8 COM2 +24V 10mA REF +10V 3 AI1+ 5 AI2+ AI1AI210 1 4 6 7 DI1 16 DI6 12 15 11
Potentiometer
A manual speed potentiometer is connected to the reference at TB1:1 (+10 VDC) and TB1:2 (common), and to one of the analog inputs. When the speed potentiometer is supplied from the factory for manual (Hand) operation, it is connected to AI2 (TB1:5). The Option Pack has two analog inputs. AI1 is on Terminals TB1:3 and TB1:4. AI2 is on TB1:5 and TB1:6. AI2 is used by the Manual Speed Potentiometer when it is supplied. The analog inputs can accept a voltage signal (0 10 VDC) or a current signal (0 20 mA). Jumpers S1 and S2, located on the Control Interface Board in the ACS 501 (S1 for AI1 and S2 for AI2), determine the signal type. Place the jumper in the V position for voltage or the I position for current. Orientation may vary with different versions of the control board. Figure 3-7 shows jumper positions. The shaded areas represent jumper positioning.
Figure 3-7 Jumper Positions
I Voltage V I Current V
Analog Inputs
Auxiliary 24 VDC
An auxiliary +24 VDC supply is available on Terminals TB1:7 and TB1:8. This supply can drive auxiliary devices whose total current draw is less than 200 mA. TB1 has six digital inputs, DI1 through DI6 on Terminals TB1:11 through TB1:16 respectively. The digital inputs use 24 VDC logic from terminal TB1:10 and are active high. DI1, DI2, DI5, and DI6 are used by the logic on the Terminal Board, and DI3 and DI4 can be used for Preset Speeds or floating point control.
Digital Inputs
Analog Outputs
TB1 has two analog output signals. AO1 is on Terminals TB1:17 and TB1:18. AO2 is on TB1:19 and TB1:20. These signals are 0 20 mA (or 4 20 mA), and can operate into a maximum 500 ohm load. When the Speed Meter is supplied, it uses AO1.
3-10
Digital (Relay) Outputs
Three relay outputs are each Form C. Relay RO1 is on Terminals TB1:21, TB1:22, and TB1:23. Relay RO2 is on Terminals TB1:24, TB1:25, and TB1:26. Relay RO3 is on Terminals TB1:27, TB1:28, and TB1:29. The first terminal for each relay is the normally closed (NC) terminal, the second is the common, and the third is the normally open (NO) terminal. Maximum Switching Voltage: 300 VDC / 250 VAC. Maximum Switching Current/Power: 8 A @ 24 VDC, 0.4 A @ 250 VDC, or 2000 VA @ 250 VAC. Maximum Continuous Current: 2 A rms.
Figure 3-8 shows connections TB1:32 through TB1:40.

Figure 3-8 TB1:32 Through TB1:40
32
33
34
35
36
37
OL 38
FREEZE 39
RUN
115V START
Two-Wire Start (Dry Contact) 115 VAC Start Freeze/Fire/Smoke Protection
To start the ACS 501 by dry contact (maintained), connect contact to TB1:32 and TB1:34. This will start the drive in Auto when HOA is supplied, and will start and stop the motor in Bypass when Bypass is supplied. To start the ACS 501 by applying 115 VAC, connect the 115 VAC signal to TB1:35 and TB1:36. Operation is the same as Two-Wire Start. Safety interlocks, such as Freeze, Fire, and Smoke protection are normally closed dry contacts connected in series between TB1:38, TB1:39, and TB1:40. When the contact opens, the motor will stop, whether in NORMAL or BYPASS. When the External Fault indicator is provided (supplied with Bypass Option), the indicator will illuminate when any of these contacts open.
SMOKE/FIRE
40
3-11
115 VAC Auxiliary Power
115 VAC is available for customer use. There is approximately 100 VA available. TB1:46 through TB1:50 are ground, and TB1:51 through TB1:55 are hot. Figure 3-9 shows connections TB1:46 through TB1:55.
Figure 3-9 TB1:46 Through TB1:55
50 49 48 47 46 52 51
55
54
115 VAC
3-12
53
Chapter 4 Start-up Procedure
This chapter explains how to inspect the installation and how to start up the ACS 501 with Option Pack.
Safety Precautions
Before start-up, read and follow the precautions listed below. The Motor Control Card (bottom card) is at DC Bus potential (1.35 x VIN) when the ACS 501 with Option Pack is connected to supply voltage. This voltage is extremely dangerous and can cause death or serious injury. When the supply voltage is disconnected from the input Terminal Block X1, the DC Bus capacitors should discharge to a safe voltage in about five minutes. To ensure that the voltage level is safe, measure the voltage between positive (+) and negative (-) on Terminal Block X2. Terminal Block X2 is the Brake terminal. The testing meter must be rated for 1000 VDC. Note: If the internal brake option is installed, measure between the input Terminal Block X1 and positive (+) on Terminal Block X2. The testing meter must be rated for 1000 VDC.
WARNING! When the ACS 501 with Option Pack is connected to the line power, the Motor Terminals U1, V1, and W1 are live even if the motor is not running. Do not make any connections when the ACS 501 with Option Pack is connected to the line. Disconnect and lock out power to the drive before servicing the drive. Failure to disconnect power may cause death or serious injury.
Installation Inspection
Inspect the mechanical and electrical installation of the ACS 501 with Option Pack for compliance with the prevailing electrical installation regulations and codes. Note: Do not connect the motor wires before proceeding with the Keypad Control Test with Motor Disconnected. Refer to Keypad Control Tests in this chapter.
WARNING! The brake control terminals carry a dangerous DC voltage (1.35 x VIN). No device other than an ABB Drives dynamic braking device may be connected to the positive and negative terminals of Terminal Block X2.
4-1
After installation, inspect the following: ACS 501 with Option Pack and motor grounding. Supply and motor wire size and connections. Control cable connections, wire shield grounding, and control cable location away from the power wires. Quantity and quality of cooling air for the ACS 501 with Option Pack. Connect the ACS 501 with Option Pack to supply voltage. Check that the voltage between L1 L2, L1 L3, and L2 L3 is VN + 10%. Refer to Chapter 3 Installation Instructions in this manual for detailed installation instructions and requirements.
Start-up Data Parameters
Power up the ACS 501. The display shows Operating Data Parameter 1 (Output Frequency). Before proceeding with the start-up, check and complete the Start-up Data Parameter values. Do not change parameters at this time except as described in the following steps. While viewing Parameter 1 (Output Frequency) press and hold [ * ], then press [Right Arrow]. The display shows Parameter A (Language) in Setting mode.
A LANGUAGE
Press [Up Arrow] or [Down Arrow] to select your preferred language. The ACS 501 displays all information in the language you select. Press [ * ] to confirm the selection and move to the next parameter. The available languages are: English, German, Italian, Spanish, Dutch, French, Danish, Finnish, and Swedish. Leave this in the FACTORY setting to perform the start-up procedure. If anything other than FACTORY displays, press [Up Arrow] or [Down Arrow] to change the parameter to FACTORY. Press [ * ] to confirm the selection and move to the next parameter. This parameter restores all parameters of the current application to factory-set parameter values. Set this to YES by pressing [Up Arrow]. Press [ * ] to confirm the selection and move to the next parameter. This parameter offers choices of 440, 460, 480, and 500 VAC for 480-volt units; 380, 400, and 415 VAC for 380-volt units; or 208, 220, 230, and 240 VAC for 230-volt units. Press [Up Arrow] or [Down Arrow] to select the voltage value matching line voltage providing power to your ACS 501. Press [ * ] to confirm the selection and move to the next parameter.
B APPLICATIONS
C APPLIC. RESTORE
D SUPPLY VOLTAGE
4-2
E USER DISPLAY SCALE
This parameter is used to set the scaling factor for Operating Data Parameter 2 (Speed). When set to 0, the speed display will show RPM. When set to 100, the speed display will show %. When set to any other value from 0 10000, the display will show this value (minus slip unless slip compensation is ON) when the output frequency is at the frequency set by Start-up Data Parameter I (Motor Base Frequency). Press [Up Arrow] or [Down Arrow] to set the desired value of the speed display. Press [ * ] to confirm the selection and move to the next parameter.
F MOTOR CURRENT -FLA
This parameter matches the ACS 501 to the rated motor current, adjustable between 0 and 1000 amps. The drive uses this parameter for motor overload protection and current (amperage) information displays. Press [Up Arrow] or [Down Arrow] to select the current (amperage) value for your motor. Press [ * ] to confirm the selection and move to the next parameter.
G MOTOR POWER
This parameter matches the motor rated power, adjustable between 0.7 hp and 1340 hp. The drive uses this parameter for motor overload and kWh information displays. The left key switches the display between hp and kWh. To change the display, press and hold the left key for two seconds. Press [Up Arrow] or [Down Arrow] to select the motor power value for your motor. Press [ * ] to confirm the selection and move to the next parameter.
H MOTOR POWER FACTOR
This parameter matches the motor power factor (at rated speed and load on sinusoidal power), adjustable between 0.10 and 1.0. The drive uses this parameter for motor torque and power information displays. Press [Up Arrow] or [Down Arrow] to select the motor power factor value for your motor. Press [ * ] to confirm the selection and move to the next parameter.
I MOTOR BASE FREQUENCY
This parameter is used to set the designed frequency of the motor, adjustable from 30 Hz to 500 Hz in 10 Hz increments. Changing this value will automatically set the FWP to the same value. Press [Up Arrow] or [Down Arrow] to select the base frequency value for your motor. Press [ * ] to confirm the selection and move to the next parameter.
J MOTOR BASE R.P.M.
This parameter is used to set the nameplate speed of the motor and is adjustable from 200 to the maximum 2-pole motor speed based on Start-up Data Parameter I (Motor Base Frequency). Press [Up Arrow] or [Down Arrow] to set the motor nameplate speed value for your motor. Press [ * ] to confirm the selection and move to the next parameter.
4-3
K MOTOR NOM. VOLTAGE
The default is 460 V for 480-volt units, 380 V for 380-volt units, and 230 V for 230-volt units. Changing this parameter automatically changes the Maximum Output Voltage. Press [Up Arrow] or [Down Arrow] to select the motor rated voltage for your motor. Press [ * ] to confirm the selection and return to Operating Data Parameter 1 (Output Frequency).
Keypad Control Tests

Motor Disconnected from the ACS 501 with Option Pack
After setting the Start-up Data parameters, test the drive as follows: 1. Disconnect and lock out power from the ACS 501 with Option Pack. 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 Brake Terminal Block X2. Check for zero volts at Terminals X50:21 29 before continuing. Note: If the internal brake option is installed, measure between the Input Terminal Block X1 and positive (+) on Terminal Block X2. Your measuring meter must be rated for 1000 VDC. 2. Disconnect the motor from the ACS 501 with Option Pack. 3. Power up the ACS 501 with Option Pack. 4. Press [Start/Stop] to issue a start command. The Run Status indicator on the LCD Display displays the Start (I) symbol. 5. Press [ * ] to enter setting mode. Press [Up Arrow] until the frequency display shows 60 Hz, then press [ * ] to enter the value. 6. Press [Up Arrow] or [Down Arrow] to scroll through and check the Operating Data parameters. Check that Operating Data Parameter 7 (Output Voltage) is equal to the input voltage. If the drive operates according to these steps, disconnect and lock out power to the ACS 501 with Option Pack to prepare for the next test.
WARNING! Wait at least five minutes after disconnecting power from the drive before you attempt to service the drive. Bus capacitors in the intermediate DC circuit must discharge before servicing the drive. Check for zero volts at Terminals TB1:21 29 and X2:(+) and (-), or between the input Terminal Block X1 and Terminal Block X2:(+) if an internal brake option is installed. Your measuring meter must be rated for 1000 VDC. Failure to check voltages may result in death or serious injury. If the drive does not operate according to these steps, refer to the ACS 501 Adjustable Frequency AC Drives 2 to 50 HP Installation & Start-up Manual, Chapter 5 Fault Tracing, for additional information.
4-4
Motor Connected to the ACS 501 with Option Pack
After successfully testing the drive with the motor disconnected, continue testing the drive as follows: 1. Disconnect and lock out power from the ACS 501 with Option Pack. Check for zero volts at Terminals X50:21 29 and X2:(+) and (-) before continuing. If a Bypass option is supplied, set the Drive Switch to NORMAL and the Bypass Switch to NORMAL. 2. Connect the motor to the ACS 501 with Option Pack. 3. Power up the ACS 501 with Option Pack. 4. Set Operating Data Parameter 10 (Keypad Ref 1) to 0.5 Hz.
CAUTION: Check motor rotation direction as soon as the motor begins to move. If motor rotation direction is critical and the motor does not run in the direction indicated by the Rotation Direction indicator on the ACS 501 with Option Pack LCD Display: Shut down the drive. Disconnect and lock out power to the drive. Wait five minutes. Check for zero volts at Terminals TB1:21 29 and X2:(+) and (-). When the drive has reached zero volts, swap any two motor output wires at the Output Terminals. Incorrect motor rotation direction may cause equipment damage. 5. Press [Start/Stop] to issue a start command. The Run Status indicator on the LCD Display displays the Start (I) symbol. 6. Check the monitored values of Operating Data Parameters 1 8 for normal drive and motor operation. 7. Return to Operating Data Parameter 1 (Output Frequency). 8. Slowly increase the frequency value of Parameter 1. Verify that motor speed varies as frequency varies. 9. Increase the Parameter 1 frequency value to 60 Hz and return to Display mode. 10. Measure the output current in all three phases. The current should be balanced, and should not exceed the motor or drive rating. 11. If a Bypass option is supplied, check the motor rotation in bypass. Set the Bypass switch to BYPASS, then to TEST. If the motor turns in the wrong direction, swap any two input power wires. If the drive operates according to these steps, your ACS 501 with Option Pack is ready to use with preset or modified macro settings.
4-5
If the drive does not operate according to these steps, refer to the ACS 501 Adjustable Frequency AC Drives 2 to 50 HP Installation & Start-up Manual, Chapter 5 Fault Tracing. Note: If you plan to use an external control device for your drive, you must wire the control to the drive according to the wiring scheme of the macro you select. If the terminal board is supplied in the Option Pack, the Option Pack macro should be selected. Refer to Chapter 3 Installation Instructions in this manual for more information on specific Option Pack external control wiring schemes. Refer to the ACS 501 Adjustable Frequency AC Drives 2 to 50 HP Installation & Start-up Manual, Chapter 2 Overview of the ACS 501, Control Panel Operation for more information on accessing and changing parameters. Refer to Option Pack Macro Parameters in this chapter for more information about the commonly modified parameters for the Option Pack macro.
Keypad Control vs. External Control
The ACS 501 can be controlled from two external control locations or from the Control Panel keypad. Refer to the ACS 500 Adjustable Frequency AC Drives 2 to 350 HP Programming Manual Including Application Macros, Chapter 3 Control Operations, for additional information. The selection between KEYPAD and EXTERNAL is made through Operating Data Parameter 9 (Control Location). KEYPAD R1 is a direct frequency reference, set by Operating Data Parameter 10 (Keypad Ref 1). KEYPAD PI goes through an application block, where it can be manipulated when the PI-controller is selected, set by Operating Data Parameter 11 (Keypad PI (REF 2)). Refer to the ACS 500 Adjustable Frequency AC Drives 2 to 350 HP Programming Manual Including Application Macros, Chapter 3 Control Operations, for additional information. EXTERNAL selection will cause the ACS 501 to follow commands connected to X50 (or TB1), such as a manual speed pot, HOA switch, Automatic Start, and Speed Signals, etc.
Option Pack Macro Parameters
Change Parameter B (Applications) in the Start-up Data Menu to the Option Pack macro. Press [Up Arrow] or [Down Arrow] to change the parameter to OPT PACK. Press [ * ] to confirm the selection and move to the next parameter. The other parameters can be modified to meet the needs of your application. For example, the Option Pack macro default for Start-up Data Parameter D (Supply Voltage) is 480 V. If your supply voltage is 460 V, you need to change this parameter to 460 V. You may need to change other parameter values to customize the Option Pack macro for your application. The application determines which parameters to change. To complete the start-up, select the Option Pack macro, and make any parameter changes necessary for your application. Connect all external wiring based on the configuration selected and test all external interfacing.
4-6
Refer to Chapter 3 Installation Instructions in this manual for detailed wiring instructions. Figure 4-1 shows all possible external control wiring connections without Terminal Board TB1 according to Option Pack macro parameters.
Figure 4-1 External Control Wiring Connections Without Terminal Board TB1 (Connect to X50)
Terminal X50
Function Reference voltage + 10 VDC 10 mA
Hand Reference
AAAAAAAAAAAAAAAAAAAAA A A A A AAAAAAAAAAAAAAAAA AAAA A AAAA A AAAAAAAAAAAAAAAAA AAAA AA AAA AAAuto AAAA A AA AAA AAReference AA AAAAAAA AA A AA AA AAAAAAAAAAA AAAA A AA AAAAAAAAAAA AAAA AA A AAAAAA A A A A A AAAAAAAAAAAAAAAAAAAAA A A A A A A A A A A A A A A AAAAAAAAAAAAAAAAAA A A A A A A A AAAAAAAAAAAAA AA A A A A A A A AAAAAAAAAAAAA AA A A A A A AAAAAAAAAAAAA AA AAAAAAAAA A A AAAA AA A A A A AAAAAAAAAAAAA AA A A A A A A A AAAAAAAAAAAAA AA A A A A A A AAAAAAAAAAAAA AA A A A A A A A A f A A AAAAAAAAAAAAAAAAAA A A A A A A A AAAAAAAAAAAAAAAAAA A A A A A A A A AAAAAAAAAAAAAAAAAA A A A A A A A A A AAAAAAAAAAAAAAAAAA A A A A A A A A A A A A A A A A A A Ready A AAAAAA A A A A A A AAAAAAAAAAAAAAAAAAAAA A A A A A A A A A A A A A A A A A A AAAAAA A A Run A AAAAAA A A A AAAAAAAAAAAAAAAAAAAAA A A
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
REF GND 2 AI 1+ AI 1AI 2+ AI 2SPL GND 2 N.C. SPL DI 1 DI 2 DI 3 DI 4 DI 5 DI 6 AO 1+ AO 1AO 2+ AO 2-
Auto Reference*
Hand Reference*
Auxiliary voltage output +24 V DC @ 200mA
+24 V max. 10 mA START HAND AUTO SELECT PRESET SPEED SELECT** PRESET SPEED SELECT** RUN ENABLE START AUTO Output Frequency
Output Current
21 22 23
RO 11 RO 12 RO 13
READY
24 25 26
RO 21 RO 22 RO 23 RUN
27
RO 31 RO 32 RO 33 FAULT
AAAAAAAAAAAAAAAAAAAAA A A 120V AC AAAAAAAAAAAAAAAAAAAAA A A AA AA AA AA AAAAAAAAAAAA A AAAAAA A AA

* Select voltage or current reference with plugs S1 and S2 on the customer interface board (beside the screw terminals 1-6 of X50. ** Operation: D15 0 1 0 = Open 1 = Closed 0 1 D16 0 0 1 1 Output set freq. through AI1 Preset Speed 1 Preset Speed 2 Preset Speed 3
Fault
28 29
Terminal X51 1 2 3 4 5 6 7 +8V GND2 Shield1 GND3 SGNA SGNB Shield2 RS-485 Serial Link Connections Power to remote panel
4-7
Figure 4-2 shows all possible external control wiring connections with Terminal Board TB1 according to Option Pack macro parameters. The functions of terminals TB1:1 to TB1:29 are the same as X50:1 to X50:29 in Figure 4-1.
Figure 4-2 External control wiring connections with Terminal Board TB1
380742 REV
TB2 1 J1 22 RO12 23 RO13 24 RO21 25 RO22 26 RO23 27 RO31 28 RO32 29 RO33 17 AO1+ 19 AO2+ 21 RO11 18 AO120 AO2F1 CR1 START AUTO 1 2 3 4 5 6 7 8 9 CR2 115V RUN CR3 ENABLED CR4 EXT FAULT 50 49 48 47 46 TB1C
55
54
53
52
51
SCHEMATIC 380771 ASSY. DWG 380743 SILKSCREEN 380745
115 VAC
EQUIVALENT
REPLACE WITH FNM1 OR
TB1A 7 +24V 200mA 8 COM2 12 DI2 13 DI3 14 DI4 15 DI5 16 DI6 FREEZE 39 SMOKE/FIRE 31 32 33 34 35 36 37 OL 38 40 41 42 43 44 2 COM1 10 +24V 10mA 1 REF +10V 3 AI1+ 5 AI2+ 4 AI16 AI211 DI1 30 HOA RUN 115V START BYPASS SWITCH M1 EXT FLT XFMR 45
TB1B
ASEA BROWN BOVERI
ABB DRIVES INC NEW BERLIN, WI 53151 MADE IN USA
Password Protection (Parameter Lock)
Parameter Lock prevents unauthorized persons from altering the parameters. When Parameter Lock is active the Setting mode cannot be selected and ACS 501 with Option Pack parameters can not be changed. The ACS 501 with Option Pack Parameter Lock can be controlled with the Keypad (Operating Data Parameter 20 (Parameter Lock)) or a digital input. Parameter 10.4.3 (Param. Lock Sel) (Keypad, DI1 DI6) selects the control location. To activate the Parameter Lock, set operating Data Parameter 20 (Parameter Lock) to LOCKED xxx if the control location is the Keypad or activate the selected digital input if the control location is a DI setting. The Parameter Lock control location is indicated in Operating Data Parameter 20 (Parameter Lock). Characters xxx after the parameter value (OPEN xxx, LOCKED xxx) indicate that the current control location is Keypad. To open the Parameter Lock, you must enter the correct combination. The combination for all ACS 501 with Option Pack units is 358. When viewing Parameter Lock, enter setting mode and set the xxx to 358. Press [ * ] to open the Parameter Lock. Refer to the ACS 500 Adjustable Frequency AC Drives 2 to 350 HP Programming Manual Including Application Macros, Chapter 3 Control Operations, for detailed setting instructions
4-8
Chapter 5 Option Pack Parameter Settings
This chapter lists and explains the Option Pack parameter settings. The following tables contain the ACS 501 with Option Pack parameter settings. You are most likely to change the parameter values indicated with an arrow ().
5-1
Opt. Pack Parameter Settings

START-UP DATA A LANGUAGE B APPLICATIONS C APPLIC. RESTORE D SUPPLY VOLTAGE E USER DISPLAY SCALE F MOTOR CURRENT -FLA G MOTOR POWER (kW) H MOTOR POWER FACTOR I MOTOR BASE FREQ. J MOTOR BASE R.P.M. K MOTOR NOM. VOLTAGE OPERATING DATA 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 OUTPUT SPEED MOTOR CURRENT % RATED TORQUE % RATED POWER DC BUS VOLTAGE OUTPUT VOLTAGE DRIVE TEMPERATURE CONTROL LOCATION KEYPAD REF 1 KEYPAD PI (REF 2) EXT REF 1 OR 2 EXTERNAL REF 1 EXTERNAL REF 2 RUN TIME KILOWATT HOURS LAST-RECD FAULT SECOND-RECD FAULT FIRST-RECD FAULT PARAMETER LOCK ENGLISH OPT. PACK NO 480/230/380 0 IN of drive PN of drive 0.83 60 1728 460/230/380 10.5 ANALOG INPUTS 10.5.1 MINIMUM AI1 10.5.2 MAXIMUM AI1 10.5.3 RC FILTER ON AI1 10.5.4 INVERT AI1 10.5.5 MINIMUM AI2 10.5.6 MAXIMUM AI2 10.5.7 RC FILTER ON AI2 10.5.8 INVERT AI2 10.6 RELAY OUTPUTS 10.6.1 RELAY RO1 OUTPUT 10.6.2 RELAY RO2 OUTPUT 10.6.3 RELAY RO3 OUTPUT 10.7 ANALOG OUTPUTS 10.7.1 ANALOG OUTPUT 1 10.7.2 SCALE AO1 10.7.3 MINIMUM AO1 10.7.4 RC FILTER ON AO1 10.7.5 INVERT AO1 10.7.6 ANALOG OUTPUT 2 10.7.7 SCALE AO2 10.7.8 MINIMUM AO2 10.7.9 RC FILTER ON AO2 10.7.10 INVERT AO2 0 V/0 mA 10 V/20 mA 0.1s NO 0 V/0 mA 10 V/20 mA 0.1s NO 20.5 CRIT FREQUENCIES 20.5.1 CRIT FREQ SELECT 20.5.2 CRIT FREQ 1 LOW 20.5.3 CRIT FREQ 1 HIGH 20.5.4 CRIT FREQ 2 LOW 20.5.5 CRIT FREQ 2 HIGH 20.5.6 CRIT FREQ 3 LOW 20.5.7 CRIT FREQ 3 HIGH 20.5.8 CRIT FREQ 4 LOW 20.5.9 CRIT FREQ 4 HIGH 20.5.10 CRIT FREQ 5 LOW 20.5.11 CRIT FREQ 5 HIGH 30 PROTECTION/INFORMAT 30.1 FAULT FUNCTION 30.1.1 SERIAL FAULT FUNC 30.1.2 AI <MIN FUNCTION 30.1.3 MOT TEMP FLT FUNC 30.1.4 MOTOR THERM TIME 30.1.5 MOTOR LOAD CURVE 30.1.6 ZERO SPEED LOAD 30.1.7 BREAK POINT 30.1.8 STALL FUNCTION 30.1.9 STALL CURRENT 30.1.10 STALL TIME/FREQ 30.1.11 UNDERLOAD FUNC 30.1.12 UNDERLOAD TIME 30.1.13 UNDERLOAD CURVE 30.2 AUTOMATIC RESET 30.2.1 NUMBER OF RESETS 30.2.2 TIME WINDOW 30.2.3 TIME BETW. RES ATT 30.2.4 OVERVOLTAGE 30.2.5 UNDERVOLTAGE 30.2.6 OVERCURRENT 30.2.7 AI SIGNAL <MIN OFF 0 Hz 0 Hz 0 Hz 0 Hz 0 Hz 0 Hz 0 Hz 0 Hz 0 Hz 0 Hz
READY RUN FAULT
EXTERNAL
OUT FREQ 100% 0 mA 2s NO OUT CURR 100% 0 mA 2s NO
REF 1 20.1 FREQ/CURRENT LIMITS 20.1.1 MINIMUM FREQUENCY 0 Hz 20.1.2 MAXIMUM FREQUENCY 60 Hz 20.1.3 FREQUENCY RANGE 0 120 Hz 20.1.4 CURRENT LIMIT 1.5 x IN 20.2 START/STOP 20.2.1 START FUNCTION 20.2.2 TORQUE BOOST CURR 20.2.3 STOP FUNCTION 20.2.4 BRAKE CHOPPER 20.2.5 DC HOLD 20.2.6 DC HOLD VOLTAGE 20.2.7 DC BRAKE VOLTAGE 20.2.8 DC BRAKE TIME
STOP NO FAULT 700 100% 40% 60 Hz WARNING 1.5 x IN 20s/25 Hz NO 600s 1
OPEN
10 CONTROL CONNECTIONS 10.1 START/STOP/DIRECTION 10.1.1 EXT 1 STRT/STP/DIR 10.1.2 EXT 2 STRT/STP/DIR 10.2 EX REFERENCE SELECT 10.2.1EXT 1/EXT 2 SELECT 10.2.2 EXTERNAL REF1 SEL 10.2.3 EXT REF1 MINIMUM 10.2.4 EXT REF1 MAXIMUM 10.2.5 EXTERNAL REF2 SEL 10.2.6 EXT REF2 MINIMUM 10.2.7 EXT REF2 MAXIMUM 10.3 PRESET SPEEDS 10.3.1 PRESET SPEED SEL 10.3.2 PRESET SPEED 1 10.3.3 PRESET SPEED 2 10.3.4 PRESET SPEED 3 10.4 SYSTEM CONTR INPUTS 10.4.1 RUN ENABLE 10.4.2 FAULT RESET SELECT 10.4.3 PARAM. LOCK SEL 10.4.4 EXTERNAL FAULT
DI1 DI6
FLYING 1.5 x IN COAST NO OFF 0.01 x VN 0.01 x VN 0s
5 30s 0 NO YES NO NO
DI2 AI2 0 Hz 60 Hz AI1 0 Hz 60 Hz
20.3 ACCEL/DECEL 20.3.1 ACC/DEC 1 0R 2 SEL NOT SEL 20.3.2 ACC/DEC RAMP SHAPE LINEAR 20.3.3 ACCEL TIME 1 30s 20.3.4 DECEL TIME 1 30s 20.3.5 ACCEL TIME 2 60s 20.3.6 DECEL TIME 2 60s 20.3.7 ACCEL REF2 TIME 0.1s 20.3.8 DECEL REF2 TIME 0.1s 20.4 MOTOR CONTROL 20.4.1 SWITCHING FREQ 20.4.2 MAX OUTPUT VOLTAGE 20.4.3 V/HZ RATIO 20.4.4 FIELD WEAK POINT 20.4.5 IR COMPENSATION 20.4.6 IR COMP VOLTAGE 20.4.7 IR COMP RANGE 20.4.8 SLIP COMPENSATION 20.4.9 NOMINAL SLIP 20.4.10 VOLTAGE LIMIT
30.3 SUPERVISION 30.3.1 OUTPUT FREQ 1 FUNC 30.3.2 OUTPUT FREQ 1 LIM 30.3.3 OUTPUT FREQ 2 FUNC 30.3.4 OUTPUT FREQ 2 LIM 30.3.5 CURRENT FUNCTION 30.3.6 CURRENT LIMIT 30.3.7 REF1 FUNCTION 30.3.8 REF1 LIMIT 30.3.9 REF2 FUNCTION 30.3.10 REF2 LIMIT 30.3.11 SUPERVIS MESSAGES 30.4 INFORMATION 30.4.11 CRI PROG VERSION 30.4.2 MC PROG VERSION 30.4.3 TEST DATE
NO 0 NO 0 NO 0 x IN NO 0 Hz NO 0% ON
DI3,4 5 Hz 10 Hz 15 Hz
DI5 NOT SEL OP DATA 20 NOT SEL
3 kHz 460 V SQUARED 60 Hz NO 0.01 x VN 0 Hz OFF 4% ON
(version) (version) (date)
= Typical parameter values to check during start-up. If needed, change values to meet the needs of your application. Complete parameter list provided in the ACS 500 Adjustable Frequency AC Drives 2 to 350 HP Programming Manual Including Application Macros, Appendix A.
5-2
ACS 501 with Option pack Users Manual
The most common Option Pack parameter settings are explained below. For a detailed explanation of all the parameter settings, refer to the ACS 500 Adjustable Frequency AC Drives 2 to 350 HP Programming Manual Including Application Macros, Chapter 3 Control Operations and Chapter 5 Parameters.
Start-up Data Parameters Operating Data Parameters

9 CONTROL LOCATION
For information on setting Start-Up Data Parameters, see Chapter 4 Start-Up Procedure in this manual.
This parameter allows you to select the location of the drive controls for start/ stop, speed reference, and rotation direction commands. Select: KEYPAD R1 to operate the drive from the Control Panel Keypad. EXTERNAL to operate the drive from an external control device connected to Terminal Block TB1, including HOA Switch, Speed Pot, External Start, Speed, etc. KEYPAD PI to use the Control Panel Keypad to change the reference for a PI controller if you are using a PI control.
Main 10 Control Connections

10.3 PRESET SPEEDS 2 PRESET SPEED 1
These parameter values can be altered while the ACS 501 with Option Pack is running. The available range of programmable preset speeds is 0 500 Hz. When in External Control mode, preset speeds override any other reference. Digital Input(s) selected through Parameter 10.3.1 (Preset Speed Sel) activate Preset Speeds. The available range of programmable preset speeds is 0 500 Hz. When in External Control mode, preset speeds override any other reference. Digital Input(s) selected through Parameter 10.3.1 (Preset Speed Sel) activate Preset Speeds. The available range of programmable preset speeds is 0 500 Hz. When in External Control mode, preset speeds override any other reference. Digital Input(s) selected through Parameter 10.3.1 (Preset Speed Sel) activate Preset Speeds.
3 PRESET SPEED 2
4 PRESET SPEED 3
5-3
10.5 ANALOG INPUTS 1 MINIMUM AI1
These parameter values can be altered while the ACS 501 with Option Pack is running. The available selections are 0V/0mA, 2V/4mA, and READ INPUT. This parameter sets the minimum value of the signal to be applied to AI1. This value will then correspond to zero speed. Typical minimum values are 0V/ 0mA or 2V/4mA. When input minimum is not 0 or 2 V for a voltage signal, or 0 or 4 mA for a current signal, the drive can read the minimum from this third display. While in Setting Mode at this third display, the ACS 501 will store the applied value in memory. Apply the minimum signal to the analog input and press [ * ]. This value then becomes the minimum. The range is 0 10 V and 0 20 mA. The ACS 501 with Option Pack has a living zero function which allows the protection and supervision circuits to detect a loss of signal. For this feature to be functional, the minimum input signal must be greater than 0.3 V/0.6 mA. When the minimum is set less than this level, the slash / between the volts and milliamps display will disappear, indicating the living zero is not active even if it has been programmed.
2 MAXIMUM AI1
The available selections are 10V/20mA and READ INPUT. When the maximum reference is less than 10 V or 20 mA, this parameter will set the maximum reference, so the drive will run at full speed when this reference is applied. If you select this parameter and apply the maximum reference, pressing [ * ] will store the applied reference and consider that value to be the maximum reference. These parameter values can be altered while the ACS 501 with Option Pack is running. The available selections are 0mA and 4mA. The minimum value of the Analog Output signal can be set to either 0 mA or 4 mA. The available selections are 0mA and 4mA. The minimum value of the Analog Output signal can be set to either 0 mA or 4 mA.
10.7 ANALOG OUTPUTS 3 MINIMUM AO1 8 MINIMUM AO2
Main 20 Drive Parameters

20.1 FREQ/CURRENT LIMITS 1 MINIMUM FREQUENCY 2 MAXIMUM FREQUENCY
These parameter values can be altered while the ACS 501 with Option Pack is running. The available range is 0 500 Hz. This parameter value represents the minimum output frequency. The available range is 0 500 Hz. This parameter value represents the maximum output frequency.
5-4
4 CURRENT LIMIT
The available range is 0.5 2.0 x IN Amps. This parameter setting is the output current limit the ACS 501 with Option Pack supplies to the motor. If the rated current of the motor is lower than the rated current of the ACS 501 with Option Pack, set the current limit in accordance with the motor rating in standard applications. Note: Current limitation time is not supervised. Too long a period of overcurrent may cause the ACS 501 with Option Pack to shut down due to overtemperature.
20.3 ACCEL/DECEL 3 ACCEL TIME 1
These parameter values can be altered while the ACS 501 with Option Pack is running. The available range is 0.1 1800s. This parameter represents the time required for the output frequency to change from minimum to maximum frequency. Regardless of the settings, the maximum acceleration/deceleration is 120 Hz/0.1s and the minimum is 120 Hz/1800s. The time required for the acceleration from zero to minimum frequency depends on the Accel Time (acceleration equals fmax -fmin/ acceleration time). Note: The ACS 501 with Option Pack incorporates a bus controller that prevents overcurrent and overvoltage trips caused by too quick acceleration and deceleration settings for a given system (by increasing the acceleration/deceleration). If a small number is entered for acceleration time in a system with high inertia, Parameter 20.1.4 (Current Limit) limits acceleration time. Conversely, if a small number is entered for deceleration time in such a system, the DC bus regulator limits deceleration time. In some cases, the motor will take a long time to stop. If a short deceleration time is critical to your application, add a dynamic braking device to your system. The maximum/minimum recommended acceleration/deceleration for the nominal size motor is 40 Hz in one second. If the motor rating is less than the maximum power of the ACS 501 with Option Pack, smaller settings can be used. If the reference signal changes at a rate slower than the acceleration or deceleration time, the output frequency change will follow the reference signal. If the reference signal changes faster than the acceleration or deceleration time, the output frequency change will be limited by the parameters.
4 DECEL TIME 1
The available range is 0.1 1800s. This parameter represents the time required for output frequency to change from maximum to minimum. Refer to Parameter 20.3.3 (Accel Time 1).
5-5
Main 30 Protection Parameters

30.2 AUTOMATIC RESET 4 OVERVOLTAGE 6 OVERCURRENT
If you select YES, the ACS 501 resumes operation when the DC bus voltage returns to normal level. If you select YES, the fault resets automatically and the ACS 501 resumes normal operation.
5-6
Index
Numerics
115 VAC auxiliary power 115 VAC start 3-12 3-11
D
DC bus capacitors Digital inputs Digital outputs Disconnect options door interlocked circuit breaker door interlocked switch Drive functions programming Drive parameters, main 20 Dry contact iv 3-10 3-11 2-6 2-6 2-6 1-2 1-2 5-4 3-11
A
ACCEL/DECEL Ambient temperature ANALOG INPUTS Analog inputs ANALOG OUTPUTS Analog outputs APPLIC. RESTORE APPLICATIONS Audience, intended AUTOMATIC RESET Auxiliary 24 VDC 5-5 3-2 5-4 3-10 5-4 3-10 4-2 4-2 1-1 5-6 3-10
E
Enclosure dimensions type types ESD warning External control 2-4, 3-4 2-2 2-4 iv 3-8, 4-6
B
Brake, control terminals Bypass options automatic manual manual with service switch 4-1 2-6 2-9 2-7 2-8
F
Fault tracing FREQ/CURRENT LIMITS Fuse sizing 4-4 5-4 2-6
C
Cautions, definition Circuit common Control connections, main10 Control identification Control interface card, ESD warning CONTROL LOCATION Control location external keypad pi keypad r1 Control locations Control nameplate Control options hand/off/auto hand/off/auto w/pot Control panel display keys Conventions used in this manual Cooling requirements iii 3-9 5-3 2-1 iv 5-3 5-3 5-3 5-3 3-8 2-1, 2-2 2-5 2-5 1-2 1-2 1-2 3-2
G
General information Group, definition 2-1 1-2
H
Heat sink Heater, sizes How to use this manual
3-2 2-9 1-1 I
Input wiring connections Inspection, initial Installation planning cooling environment mounting site power
3-6 3-4 3-1 3-1 3-4 3-3
I-1
Index
Installation, inspection Insulation resistance
4-1 3-7
K
Keypad control definition location tests 3-8 4-6 3-8 3-7, 4-1
L
LANGUAGE Liability, information 4-2 1-3
options 2-5 parameter settings 5-1 terminal block connections 3-9 Options bypass 2-2, 2-6, 2-7, 2-8 control 2-2 control switches 2-5 disconnect 2-2, 2-6 meters 2-2, 2-11 switches 2-2, 2-6 thermal motor overload relays 2-2, 2-9 Output wiring, connections 3-8
P M
Main 10, control connections Main 20, drive parameters Main 30, protection parameters Main, definition Manual, how to use Mechanical installation Meter options output ammeters output speed meter output voltmeter MOTOR BASE FREQUENCY MOTOR BASE R.P.M. Motor control card ESD warning MOTOR CURRENT -FLA MOTOR NOM. VOLTAGE MOTOR POWER MOTOR POWER FACTOR Motor rotation, direction 5-3 5-4 5-6 1-2 1-1 3-4 2-11 2-11 2-11 4-3 4-3 4-1 iv 4-3 4-4 4-3 4-3 4-5 Parameter lock Parameter, definition Parameters drive operating data option pack protection start-up data Password protection Potentiometer connections manual speed Power connections, tightening torque Pre-installation planning mounting mounting area requirements PRESET SPEEDS Press, definition Protection fire freeze smoke Protection parameters, main 30 Publications, related 4-8 1-2 5-4 5-3 4-6 5-6 4-6, 5-3 4-8 3-10 2-5 3-6 3-2 3-2 5-3 1-2 3-11 3-11 3-11 5-6 1-3
N
Notes, definition iii
O
Operating data parameters Opt. pack macro, parameter settings Option pack definition enclosure interior features functions illustration macro 5-3 5-2 2-3 2-4 2-3, 2-4 2-3, 2-4 2-3 4-6, 5-2 Relay outputs
R
3-11
S
Safety instructions general warning symbols Safety interlocks Safety precautions iii iii 3-11 4-1
I-2
Index
Space requirements Start-up data parameters applic restore applications language motor base frequency motor base r.p.m. motor current -fla motor nom. voltage motor power motor power factor supply voltage user display scale SUPPLY VOLTAGE
3-3 5-3 4-2 4-2 4-2 4-3 4-3 4-3 4-4 4-3 4-3 4-2 4-2 4-2
input lengths motor output power connections sizes
3-6 3-7 3-6 3-7, 3-8 3-6 3-3
T
TB1 Terminal block connections definition TB1 X50 Tests hi pot keypad control Meggar motor connected motor disconnected Trip curve Two-wire start 3-9 2-5, 3-9, 4-7 1-3 3-9 4-7 3-6 3-7, 4-1 3-6 4-5 4-4 2-9 3-11
U
USER DISPLAY SCALE
4-3
V
Voltage tolerance tests hi pot warning Meggar warning 3-6 3-6
W
Warnings, definition Warranty, information Wiring circuit common conduits control illustration iii 1-3 3-8, 3-9 3-7, 3-8 3-4, 3-8, 4-6, 4-7, 4-8 4-7, 4-8
I-3
Index
I-4
ASEA BROWN BOVERI
ABB Industrial Systems Inc. 16250 West Glendale Drive New Berlin, WI 53151 Telephone: (414) 785-3416 Fax: (414) 785-8525
ACS 501-08D EFFECTIVE 10/1/95 SUPERCEDES 9/1/94

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ACS 501

ACS 501 with Option Pack

ACS 501 with Option Pack Users Manual

General Safety Instructions

This warning symbol indicates an electrostatic discharge hazard.

ACS 501 with Option Pack Users Manual

Warnings, Cautions, and Notes

ACS 501 with Option Pack Users Manual

ACS 501 with Option Pack Users Manual

ACS 501 with Option Pack Users Manual

How To Use This Manual

ACS 501 with Option Pack Users Manual

Conventions Used In This Manual

Control Panel Keys

ACS 501 with Option Pack Users Manual

Warranty and Liability Information

ACS 501 with Option Pack Users Manual

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ACS 501 with Option Pack Users Manual

Chapter 2 Overview of the ACS 501 with Option Pack

General Information About the ACS 501

ACS 501 with Option Pack Users Manual

Chapter 2 Overview of the ACS 501 with Option Pack

ACS 501 with Option Pack Users Manual

Chapter 2 Overview of the ACS 501 with Option Pack

Option Pack Features and Functions

Speed Meter Normal/Test/Bypass Switch Hand/Off/Auto Switch

Manual Speed Pot

ACS 501 with Option Pack Users Manual

Chapter 2 Overview of the ACS 501 with Option Pack

Input Contactor Normal/Off/ Test Switch Terminal Board

ACS 501 with Option Pack Users Manual

Chapter 2 Overview of the ACS 501 with Option Pack

Hand/Off/Auto with Speed Potentiometer

ACS 501 with Option Pack Users Manual

Chapter 2 Overview of the ACS 501 with Option Pack

Input Line Reactor Bypass Options

These fuses are UL Listed components.

ACS 501 with Option Pack Users Manual

Chapter 2 Overview of the ACS 501 with Option Pack

ACS 501 with Option Pack Users Manual

Chapter 2 Overview of the ACS 501 with Option Pack

Manual Bypass with Service Switch

ACS 501 with Option Pack Users Manual

Chapter 2 Overview of the ACS 501 with Option Pack

Thermal Motor Overload Relays

ACS 501 with Option Pack Users Manual

Chapter 2 Overview of the ACS 501 with Option Pack

ACS 501 with Option Pack Users Manual

Chapter 2 Overview of the ACS 501 with Option Pack

83.4 86.9 87.0 92.9 93.0 100.0

Output Voltmeter Output Speed Meter

ACS 501 with Option Pack Users Manual

Chapter 2 Overview of the ACS 501 with Option Pack

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ACS 501 with Option Pack Users Manual

Chapter 3 Installation Instructions

ACS 501 with Option Pack Users Manual

Chapter 3 Installation Instructions