Variador PS200 - PDF

Goulds_ControlSolution_PS200_install_D502
PUMPSMART
CONTROL SOLUTIONS
PS200
Installation & Maintenance Guide
FOREWORD
This manual provides instructions for the Installation and Maintenance of the Goulds PS200 PumpSmart Process System. This manual must be read and understood before installation and start-up. For specific pump instructions, refer to the applicable centrifugal pump Installation, Operation and Maintenance Manual. The design, materials, and workmanship incorporated in the construction of Goulds Products makes them capable of giving troublefree service. The life and satisfactory service of any product, however, is enhanced and extended by correct application, proper installation, periodic inspection and careful maintenance. This instruction manual was prepared to assist operators in understanding the correct methods of installing and maintaining the PumpSmart PS200 AC Drive. Goulds shall not be liable for physical injury damage or delays caused by a failure to observe the instructions for Installation and Maintenance contained in this manual. Warranty is valid only when genuine Goulds parts are used. Use of the equipment on a service other than stated in the order could nullify the warranty, unless written approval is obtained in advance from ITT Industries - Goulds Pumps. Any modification of the original software or non-user accessible parameters could nullify the warranty, unless authorized in writing by ITT Industries - Goulds Pumps. Supervision by an authorized Goulds representative is recommended to assure proper installation. Start-up service is required by a Goulds authorized representative in order to validate the warranty on the PumpSmart System. For technical assistance and/or warranty issues contact your nearest ITT Industries - Goulds Representative or call 1-800-446-8537. Additional manuals can be obtained by contacting your ITT Industries Goulds Representative or by calling 1-800-446-8537. This manual explains: Safety Instructions Mechanical Installation Electrical Installation Product Information
PumpSmart AC Drives
Table of Contents
Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv Chapter 1 - Introduction General Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Delivery Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PumpSmart AC Drive Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ACS 601 Type Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PumpSmart AC Drive and Pump Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inquiries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PumpSmart Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chapter 2 Mechanical Installation General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Check The Installation Site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ACS 601 Installation Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ACS 601 Installation in a Cooling Air Duct . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation Procedure ACS 607 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chapter 3 Electrical Installation Insulation Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Disconnecting Means 601 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Disconnecting Means 607 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Input Line Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Motor Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Power Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Control Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Wiring Connections 601 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Wiring Connections 607 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 Slave Pump - Multipump Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 Installation of Optional Modules and DriveWindow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 Chapter 4 Installation Checklist Installation Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 PumpSmart Pre-Startup Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 2-1 2-1 2-2 2-3 2-4 1-1 1-1 1-1 1-2 1-3 1-3 1-4
Chapter 5 Local Control vs. External Control Local vs. External . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
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Chapter 6 - Maintenance Heatsink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Chapter 7 Optional Analog I/O Extension Module Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . The I/O Extension Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NAIO-03 Analogue I/O Extension Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Setting the Module Node Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mechanical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ACS600 Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NAIO-03 Analog I/O Extension Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Input Signal Type Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Appendix A PumpSmart Technical Data PumpSmart Ratings for NEMA 1(IP21/22) Enclosures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1 ACS 600 Altitude & Ambient Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3 ACS 601 Output Current Temperature Derating 380V, 480V, 690V . . . . . . . . . . . . . . . . . . . . . . . A-3 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-8 Power Connections R2-R6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-12 ACS 607 Power Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-12 Power and Ground Cable Terminations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-13 External Control Connection Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-14 PumpSmart Wiring Diagrams. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-16 Enclosures, Space Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-21 Cooling Air Flow Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-23 Dimensions and Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-24 ACS 607 Enclosure Size and Style . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-24 Dimensions and Weights (ACS 607) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-26 Input Power Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-27 Motor Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-27 Efficiency and Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-28 Ambient Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-28 External Control Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-29 Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-30 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-31 UL/CSA Markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-31 Fault Tolerance Matrix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-31 PumpSmart Minimum Instrumentation Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-32 Typical Instrument Mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-34 Instrumentaiton Location Requirements - Pipe Mounted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-36 Appendix B PumpSmart AC Drive Dimensional Drawings 7-1 7-1 7-1 7-1 7-2 7-5 7-5 7-5
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Appendix C IEC Installation IEC Installations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1 Power Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1 Cable Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2 Components Connected to Digital/Analog Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-4
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Safety Instructions
Overview
This chapter states the safety instructions which must be followed when installing, operating and servicing the Model PS200 PumpSmart AC drive. If neglected, physical injury and death may follow, or damage may occur to the AC drive, the motor and driven equipment. The material in this chapter must be studied before attempting any work on, or with, the unit. References to the AC drive you will see are: ACS 600 - general drive designation ACS 601 - wall mounted AC drive ACS 607 - floor standing AC drive
Warnings and Notes
This manual distinguishes two sorts of safety instructions. Warnings are used to inform of conditions which can, if proper steps are not taken, lead to a serious fault condition, physical injury and death. Notes are used when the reader is required to pay special attention or when there is additional information available on the subject. Notes are less crucial than Warnings, but should not be disregarded. Warnings are provided in the instruction manuals and on labels attached to the AC drive. Readers are informed of situations that can result in serious physical injury and/or serious damage to equipment with the following symbols: Dangerous Voltage Warning: warns of situations in which a high voltage can cause physical injury and/or damage equipment. The text next to this symbol describes ways to avoid the danger. General Warning: warns of situations which can cause physical injury and/or damage equipment by means other than electrical. The text next to this symbol describes ways to avoid the danger. Electrostatic Discharge Warning: warns of situations in which an electrostatic discharge can damage equipment. The text next to this symbol describes ways to avoid the danger.
Warnings
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Notes
Notes are provided in the instruction manuals to notify readers of the need for special attention or additional information available on the subject with the following symbols: CAUTION! Note: Caution aims to draw special attention to a particular issue. Note gives additional information or points out more information available on the subject.
PumpSmart Drives
Safety Instructions
Installation and Maintenance Safety
These safety instructions are intended for all work on the ACS 600. In addition to the instructions given below, there are more safety instructions on the first pages of the appropriate hardware manual. WARNING! All electrical installation and maintenance work on the ACS 600 should be carried out by qualified electricians. The ACS 600 and adjoining equipment must be grounded. Do not attempt any work on a powered ACS 600. After switching off the power, always allow the intermediate circuit capacitors 5 minutes to discharge before working on the drive, the motor or the motor cable. It is good practice to check (with a voltage indicating instrument) that the drive is in fact discharged before beginning work. The ACS 600 motor cable terminals are at a dangerously high voltage when power is applied, regardless of motor operation. The brake control terminals (UDC+, UDC-, R+ and R- terminals) carry a dangerous DC voltage (over 500V). There can be dangerous voltages inside the ACS 600 from external control circuits when the ACS 600 input power is shut off. Exercise appropriate care when working with the unit. Neglecting these instructions can cause physical injury and death. WARNING! The ACS 600 introduces electric motors, drive train mechanisms and driven machines to an extended operating range. The ACS 600 can be adjusted to operate the motor at speeds above and below the speed provided by connecting the motor directly to the power line. Before adjusting the drive and putting it into service, make sure that the motor and all driven equipment is suitable for operation throughout the speed range provided by the AC drive. WARNING! When the control location is not set to Local (L not shown in the status line of the display), the Stop key on the keypad will not stop the drive. To stop the drive using the keypad you must press the LOC/REM key and then the Stop key . WARNING! The printed circuit boards contain integrated circuits that are extremely sensitive to electrostatic discharge. Exercise appropriate care when working on the unit to avoid permanent damage to the circuits. Do not touch the boards unnecessarily. WARNING! There are automatic reset functions in the PS200. If selected, they reset the unit and resume operation after a fault. These functions should not be selected if other equipment is not compatible with this kind of operation, or dangerous situations can be caused by such action.
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Supply Connections
The ACS 601 does not include a disconnecting means. An input power disconnecting means must be installed between the AC power source and the ACS 601. The disconnecting means must conform to the applicable safety regulations. The disconnecting means must be locked in the open position during installation and maintenance work. The motor must not be controlled with the supply disconnecting means; instead, the and keys of the Control Panel or commands via the I/O board of the ACS 601 should be used. The maximum number of charging cycles of the d.c. capacitors of ACS 601 (i.e. power-ups by applying power) is five in ten minutes. WARNING! Never connect the line power to the ACS 600 output terminals U2, V2, or W2. If frequent bypassing is required, mechanically interlocked switches or contactors should be employed. Line voltage applied to the output can result in permanent damage to the unit. Operation outside the nominal input line voltage range should not be attempted, as overvoltages can result in permanent damage to the ACS 600. If an ACS 600 with the integrated EMC filter (code 0 in the type code for EMC Filters) is connected to an ungrounded power system or high resistance grounded power system (over 30 Ohms), the power line will be connected to ground potential through the EMC filter capacitors of the ACS 601. This may cause danger or damage the unit. Disconnect the EMC filter capacitors before connecting the ACS 601 to an ungrounded power system. For detailed instructions on how to do this, please contact Goulds Pumps.
Ground Fault Protective Function
The ACS 601 is equipped with an internal ground fault protective function to protect the unit against ground faults in the drive, the motor and the motor cable. This is not a personal safety or a fire protection feature. The ground fault protective function of the ACS 600 can be disabled by Parameter 24.25. The EMC filter of the ACS 601 includes capacitors connected between the power circuit and the chassis. These capacitors increase the ground leakage current from the AC line through the ground (PE) connection and may cause some ground fault current circuit breakers to trip.
Emergency Stop Devices
The person responsible for the overall design and operation of the driven process must make sure that the installation includes emergency stop devices and any other safety equipment that may be needed. Pressing the STOP key on the keypad of ACS 600 does not generate an emergency stop of the motor or separate the drive from dangerous potential. A Line Contactor with provisions for a remote
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power cut-off switch is available as a factory installed option for the ACS 607. Cutting off power to the drive allows the motor to coast to a stop.
Ground Connections
The ACS 600 and adjoining equipment must be properly grounded. The ACS 600 and the motor must be grounded at the installation site to ensure personnel safety in all circumstances and in addition to reduce electromagnetic emission and pick-up. Make sure that grounding conductors are adequately sized as required by safety regulations. In CE compliant installations and in other installations where EMC emissions must be minimized, 360 degree high frequency grounding of cable entries is done in order to suppress electromagnetic disturbances. In addition, power cable shields must be connected to the ground (PE) in order to meet safety regulations. Power cable shields are suitable for use as equipment grounding conductors only when the shield conductors are adequately sized as required by safety regulations. The ACS 600 ground terminals should not be connected in series in case of a multiple installation. Incorrect grounding can cause physical injury, death or equipment malfunction and increase electromagnetic interference.
Motor Connections
WARNING! Operation is not allowed if the motor nominal voltage is less than one half of the ACS 600 nominal input voltage, or the motor nominal current is less than 1/6 of the ACS 600 nominal output current. WARNING! Do not make any voltage tolerance or insulation resistance test (Hi-Pot or Megger) on any part of the ACS 600. Disconnect motor wires before making any tests of the motor or the cables between the drive and motor.
Motor Insulation Requirements
As with all AC drives employing the most modern IGBT invertor technology, the output waveform of the ACS 600 consists of a series of rectangular voltage pulses. Regardless of the output frequency, the voltage of the pulses is approximately 1.35 times the input line voltage with a very short rise time. The voltage of the pulses can be almost double at the motor terminals, depending on the properties of the cable between the drive and the motor. This in turn can cause additional stress to the motor insulation. The motor manufacturer should be consulted regarding the characteristics of the motor insulation system. Failure of the motor to
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Safety Instructions
fulfill the following requirements may shorten its life. The following table lists the insulation requirements for motors used with ACS 600 AC drives.
Motor Type ABB Motors (manufactured from beginning of 1998) Random-wound Motors Nominal AC Line Voltage VN < 500 V 525 V < VN 690 V Motor Insulation Requirement Standard insulation system Standard insulation and dv/dt filter or special insulation system Motor insulation system must withstand VPK = 1300 V. If motor insulation system withstands VPK = 1600 V and 0.2 s rise time, filter requirements vary with length of cable (controller to motor) as follows: Cable Length (controller to motor) 375 FT or less - No filter required 375-600 FT - Output reactor required Above 600 FT - dv/dt filter required Above 980 FT - Refer to Factory With a dv/dt filter at the output of the ACS 600, motor insulation system must withstand VPK = 1300 V. 500 V < VN 600 V 600 V < VN 690 V Motor insulation system must withstand VPK = 1600 V. A dv/dt filter must be used at the output of the ACS 600. Motor insulation system must withstand VPK = 1800 V. A dv/dt filter must be used at the output of the ACS 600. If motor insulation system withstands VPK = 2000 V and rise time 0.3 s, no dv/dt filter is needed.
VN 420 V 420 V < VN 500 V
Form-wound Motors
VN 690 V
Symbol VN VPK Rise time:
Definition nominal power line voltage peak line to line voltage at motor terminals Rise time is line to line voltage change rate at motor terminals (the interval during which the voltage changes from 10% to 90 % of the whole voltage range) VPK and t depend on cable length. Read the values of VPK and dv/dt from the diagrams below.
= 0.8 VPK/(dv/dt)
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Without Filter Below is a diagram of VPK and dv/dt as a function of cable length when no dv/dt filter is used.
5 4,5 4 3,5 3 2,5 2 1,5 1 0,5 0 0 50 100 150 200 250 300
VPK / VN
dv/dt / (kV/s)
(m)
500
1000 (feet)
Cable length
With dv/dt Filter

5 4,5 4 3,5 3 2,5 2 1,5 1 0,5 0 0
Below is a diagram of VPK and dv/dt as a function of cable length with dv/dt filter at the output of the ACS 600.
VPK / VN
dv/dt / (kV/s)
50
100
150
200
250
300 (m)
500
1000 (feet)
Cable length
Power Factor Correction Capacitors
Power factor correction capacitors and surge absorbers must not be connected between the drive and the motor. These devices are not designed to be used with AC drives, and will degrade motor control accuracy. They can cause permanent damage to the ACS 600 or themselves due to the rapid changes in the ACS 600 output voltage. If there are power factor correction capacitors in parallel with the ACS
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Safety Instructions
600 make sure that the capacitors and the ACS 600 are not charged simultaneously to avoid voltage surges which might damage the unit. Output Contactors If a contactor is used between the output of the ACS 600 and the motor with DTC control mode selected, the output voltage of the ACS 600 must be controlled to zero before the contactor is opened. Otherwise the contactor will be damaged. In scalar control the contactor can be opened with ACS 600 running. Varistors or RC networks (AC) or diodes (DC) should be used to protect against voltage transients generated by contactor coils. The protective components should be mounted as close as possible to the contactor coils. Protective components should not be installed at the NIOC board terminal block.
EMC
When used with inductive loads (relays, contactors, motors), the relay contacts of ACS 600 must be protected with varistors or RC networks (AC) or diodes (DC) against voltage transients. The protective components should not be installed at the NIOC board terminal block. Installing control devices (contactors or relays) or control cables other than those of the ACS 600 inside the drive enclosure is not acceptable. Note: If safety switches, contactors, connection boxes or similar equipment are installed between the drive and the motor, they should be installed in a metal enclosure in a way that the conduit or motor cable shielding runs consistently without breaks from the drive to the motor, so the emission level will be minimized.
Mechanical Installation
CAUTION! The ACS 601 weighs a considerable amount, and should not be handled by the front cover. The unit should only be placed on its back. Exercise appropriate care when maneuvering the unit to avoid damage and injury. Lifting the ACS 601 is much easier and safer with two people working together. CAUTION! Make sure that dust from drilling does not enter the ACS 600 when installing. Electrically conductive dust inside the unit may cause damage or lead to malfunction. CAUTION! Do not fasten the ACS 601 by riveting or welding. WARNING! The cooling air flows and space requirements must be fulfilled. Special attention must be paid to cooling if units are installed in confined spaces and user defined cabinets.
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Chapter 1 Introduction
General Overview
PumpSmart Model PS200 is an ITT Industries - Goulds Pumps product providing state of the art AC drive technology, with the unparalleled quality of ITT Goulds Pumps. This manual is primarily geared toward the AC drive installation. References to the AC drive you will see are: ACS 601 - Wall mounted AC drive ACS 607 - Floor standing AC drive Study this manual carefully before installing, starting, operating or servicing the drive. We expect that you have a basic knowledge of physical and electrical fundamentals, electrical wiring practices, electrical components and electrical schematic symbols.
Delivery Check
Check that there are no signs of damage. Before attempting installation and operation, check the information on the drive nameplate to verify that the unit is of the correct model.
PumpSmart AC Drive Checks

Drive Manufacturers Nameplate Each ACS 600 has a nameplate for identification purposes. See Figure 1-1. The nameplate data includes a type code and a serial number, which allow individual recognition of each unit. The ACS 600 Type Code contains information on the properties and configuration of the drive. The Type Code Chart explains the significance of each digit or character in the Type Code. ACS 600 drives are manufactured in several different chassis sizes that are designated as Frame R2, R3, etc. Drives of several different ratings are manufactured in the same frame. The ACS 600 rating tables on page A-1 in Appendix A list the Frame Size used for each Type Code. The Frame Size is not marked on the nameplate. The first digit of the serial number refers to the manufacturing plant. The next three digits refer to the units manufacturing year and week, respectively. The remaining digits complete the serial number so that there are no two units with the same serial number.
Type Code
Frame Size
Serial Number
PumpSmart AC Drives
1-1
U1 3-380...500V U2 3-0...U1 I1n/I1nsq 168/198A I2n/I2nsq 164/193A f1 48...63Hz f2 0...300Hz ACS60101405...
U1 3-380...480V U2 3-0...U1 I1hd/I1n 143/184A I2hd/I2n 141/180A f1 57...63Hz f2 0...300Hz ACS60101404...
ABB Industry Oy
Serno
*1983509999*
000C150001
IEC Ratings CE Marking FIIND Type Code
NEMA Ratings UL, cUL & CSA Markings USINY Type Code
Serial Number Bar Code Type Code continued
Figure 1-1. ACS 601 Nameplate
ACS 601 Type Code
The meaning of main selections of ACS 601 type code characters is given in the table below. Not all selections are available for all types. For further information, contact your ITT Industries - Goulds Pumps representative.
Character Meaning no. Example: ACS60701003000B1200901 1 Product Category A = AC Drive 2...3 Product Type CS = Standard, CC = Crane Drive, CP = MotionControl 4 Product Family 6 = ACS 600 5 Input Bridge 0 = 6-pulse rectifier, 2 = 12-pulse rectifier, 7 = Regenerative 4Q thyristor bridge 6 Construction 1 = Wall mounted, 4 = Module, 7 = Drives-MNS Cabinet 7...10 Power Rating (kVA) 11 Voltage Rating 2 = 280/230/240 VAC 4 = 380/400/415/440/460/480/500 VAC 5 = 380/400/415/440/460/480/500 VAC 6 = 525/550/575/600/660/690 VAC Option 1, Option 2, Option 3 Application Software x = Languages and Application Macro Options Control Panel 0 = None, 1 = CDP 312 Control Panel included, 4 = Customer I/O Terminal Block X2, 5 = 1 + 4 Refer to
Appendix A: Ratings
12...14 15
Appendix A: Application Programs
16
1-2
PumpSmart AC Drives
Character Meaning no. 17 Degree of Protection* 0 = IP 00 (chassis), A = IP 21, 2 = IP 22, 4 = IP 42, 5 = IP 54, 6 = IP 00 with Coated Boards, 7 = IP 22 with Coated Boards, 8 = IP 42 with Coated Boards 9 = IP 54 with Coated Boards B = IP 21 with Coated Boards 18 Line Input and Protection Options 19 Starter for Auxiliary Motor Fan 20 Filters 0 = CE with EMC Filters (not for 690V or 12-pulse rectifier) 3 = CE with output dv/dt Filters + EMC Filters (not for 690V) 5 = Output dv/dt Filters + no EMC Filters 8 = US Standard, US conduit: No CE, no EMC filters, 9 = CE Low Voltage and Machinery Directives; No EMC (ACS 607 only, secondary of all transformers 220 VAC) 21 Braking Chopper and Cabling Direction 0 = No Brake Chopper - Bottom Entry / Bottom Exit (BE/ BE 1 = Brake Chopper (BE / BE) 3 = Input Power Top Entry / Output Power Bottom Exit 4 = Input / Output Power Top Entry / Exit 5 = Option 1 and 3 6 = Option 1 and 4 22 Other Options 3 = NAMC-51 Board (PS200)
Refer to Appendix A: Enclosures
Appendix A: CE marking
Note: *IP21, 22 enclosures correspond to Nema 1. IP 54 enclosures correspond to Nema 12.
PumpSmart AC Drive and Pump Check Inquiries
The PumpSmart Model PS200 AC drive and pump should be checked to insure that the correct drive size and pump are being installed. Any inquiries about the product should be addressed to your ITT Industries - Goulds Pumps representative, quoting the type code and the serial number of the unit.
PumpSmart AC Drives
1-3
PumpSmart Nameplate
Each Model PS200 has a PumpSmart nameplate for identification purposes. See figure 1-2. The nameplate data includes an ITT serial number which allows individual recognition of each unit.
Figure 1-2
1-4
PumpSmart AC Drives
Chapter 2 Mechanical Installation
General
The mechanical installation chapter covers the following: General installation requirements. Specific requirements for the ACS 601 wall mounted drive and the ACS 607 floor mounted drive. The ACS 601 should be installed in an upright position with the cooling section mounted against a flat surface. The mounting surface should be as close to vertical as possible and of non-flammable material. Sufficient room around the ACS 601 is required to enable cooling air flow, service and maintenance. Refer to Enclosure space Requirements in Appendix A. Be sure to also observe all requirements of applicable safety regulations.
Check The Installation Site
Check the intended installation site to make sure that the environment is suitable. The service life and performance of the ACS 600 can be adversely affected if the drive is subjected to unsuitable environmental conditions. Complete environmental rating specifications are listed in Appendix A. If unsuitable conditions are found at the intended installation site, select a different location, improve the environment at the selected site, or provide additional protection for the ACS 600.
Installation Site Checklist
Check to make sure PumpSmart Model PS200 AC drive and pump are a set by referring to order documentation. For pump installation requirements, refer to the applicable centrifugal pump installation, operation and maintenance manual. IMPORTANT: If a check valve is installed in the pump discharge line, be sure that the process transmitter is installed downstream of the check valve. Do not install the process transmitter between the pump and check valve. Make sure that the ambient temperature is suitable for the type of enclosure provided and the output current required. (pages A-1 through A-5) Make sure that the installation site altitude is suitable for the output current required. (A-28) Make sure that the ambient air is sufficiently clean and dry or that the drive is adequately protected from contaminants. (A-28) Make sure that the enclosure selected is adequate to protect the
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2-1
drive considering site conditions regarding access by unauthorized persons, liquids that might be splashed, sprayed or fall on the enclosure, or any other foreign material that might get into the enclosure. Do not mount the drive on any surface with temperature exceeding the allowable air temperature. Do not mount the drive in direct sunlight. Make sure that the instrumentation enclosure and rating is suitable for the site conditions. Do not mount the drive where it will be subjected to excessive vibration. (A-28)
ACS 601 Installation Procedure
Appendix B contains detailed dimensional drawings showing the overall dimensions of the ACS 601 drives and the sizes and locations of the mounting bolt holes or slots. The drives have four mounting holes or slots as shown in Figure 2-1. CAUTION! Lift the ACS 601 by its chassis and not by its cover. (Frame R7 has lifting lugs to allow the use of a suitable lifting device). 1. Mark the locations of the mounting bolts by measuring to the dimensions shown in the drawings or by using the drive as a template. 2. Drill and tap or install appropriate anchors in the mounting surface. 3. Install the mounting bolts. 4. Position the ACS 601 onto the mounting bolts. 5. Tighten the bolts securely.
2-2
PumpSmart AC Drives
or (R7)
Air flow
Figure 2-1 Installing the ACS 601 on a wall.
ACS 601 Installation in a Cooling Air Duct
The ACS 601 design allows the unit to be recessed into a wall with the cooling section protruding into a special cooling air duct (frames R2 to R6). The cooling air grates in the bottom and the top of the unit must not be blocked by the wall or any other structure. Steps should be taken to enable service and maintenance access for the unit. Refer to page A-23 for cooling air flow requirements and heat dissipation data. The air in the cooling duct must meet the requirements stated on page A-28 for ambient air. If the air in the cooling duct is not clean the enclosure class of the ACS 601 must be IP 54 (NEMA 12). Note the power ratings of the IP 54 units given on page A-4. To install the ACS 601 in a cooling air duct, carry out the following steps: 1. See Appendix B Dimensional Drawings for dimensions of the opening in the duct. 2. Cut the opening. 3. Drill and tap or install appropriate anchors in the mounting bolt locations at the top and bottom of the opening. It may be necessary to install angle iron or similar stiffeners to provide mounting points of sufficient strength and thickness. 4. Frame R2 and R3: Remove the two screws at the lower front edge of the unit. Lift the front cover somewhat and disconnect the Control Panel cable from the board fitted on the inside of the cover. Remove
PumpSmart AC Drives
2-3
the front and top covers. 5. Frames R4 to R6: Remove the Control Panel. Remove the telephone connector. Remove the two screws at the lower front edge of the unit. Remove the front and top covers. 6. Follow the installation procedure in Figure 2-2.
Step 1
Max 3/8 Air flow out
Step 2
Step 3
Upper screws
Air flow in
Mounting flange
Lower screws first
Figure 2-2 Installation procedure of the ACS 601 in a cooling air duct.
Installation Procedure ACS 607
It is advisable to secure the cabinet to the floor with bolts through the holes at its base or with fastening hooks attached to its bottom front and back edges. This is especially important in installations subjected to vibration or other movement. 1. Check the intended installation site for sufficient room. Check that there is nothing on the floor to inhibit installation. See Appendix B ACS 607 Dimensional Drawings for cabinet details. Mark the locations for the mounting holes (and the cable duct opening). 2 Make mounting holes according to the dimensional drawings. Smooth cable duct edges if required. Install bolt anchors in the mounting holes. 3 Place the drive carefully onto the holes 4 Place bolts in the bolt anchors. 5. Tighten the bolts.
2-4
PumpSmart AC Drives
Chapter 3 Electrical Installation
WARNING! The electrical installation described in this chapter should only be carried out by a qualified electrician. The Safety Instructions on the first pages of this manual must be followed. Negligence of these instructions can cause injury or death. Note: The information presented in this chapter is primarily directed towards the North American market. For IEC installations, refer to Appendix C for additional information. For installations requiring CE compliance, refer to factory.
Insulation Checks
Before connecting the motor to the drive, check the insulation of the motor and the cable between the drive and the motor. WARNING! Do not make any voltage tolerance or insulation resistance test (Hi Pot or Megger) on any part of the ACS 600. A test (2500V rms, 50 Hz, 1 second) has been performed at the factory on every ACS 600 drive to verify the integrity of the insulation between the power circuitry and the chassis. To avoid damaging sensitive circuitry, this test is performed using a special procedure that can not easily be performed outside the factory. Use the following procedure to check the insulation of the motor and the cable between the drive and the motor. 1. Disconnect all sources of power from the drive and motor.
WARNING! Before proceeding with the insulation checks, make sure that the motor is disconnected from all sources of power including the drive and any bypass circuitry. 2 3 4. Check that the motor cable is disconnected from the ACS 600 output terminals U2, V2, and W2. Check that the motor cable is disconnected from the motor and remove bridging connections at the motor. Measure the insulation resistances of the motor between the phases and between each phase and Ground (PE). The voltage range of the resistance meter must be at least equal to the line voltage, but not higher than 1000V. The insulation resistance must be greater than 1 M.
PumpSmart AC Drives
3-1
5.
Measure the insulation resistance of the motor cable between the phases and between each phase and Ground (PE). The insulation resistance must be greater than 1 M.
Disconnecting Means 601
The ACS 601 does not include a disconnecting means. An input power disconnecting means must be installed between the AC power source and the ACS 601. The disconnecting means must conform to the applicable safety regulations. The disconnecting means must be locked in the open position during installation and maintenance work. The motor must not be controlled with the supply disconnecting means; instead, the and keys of the keypad or commands via the I/O board of the ACS 600 should be used. The maximum number of charging cycles of the d.c. capacitors of ACS 600 (i.e. power-ups by applying power) is five in ten minutes. The drive disconnecting means can serve as the motor disconnecting means if it complies with applicable safety regulations.
Disconnecting Means 607
ACS 607 units include a door interlocked fused disconnect. The disconnecting means must be locked to the open position during installation and maintenance work. The motor must not be controlled with the supply disconnecting means; instead, the and keys of the keypad or commands via the I/O board of the ACS 600 should be used. The maximum number of charging cycles of the d.c. capacitors of ACS 600 (i.e. power-ups by applying power) is five in ten minutes. The drive disconnecting means can serve as the motor disconnecting means if it complies with applicable safety regulations.
Input Line Fuses
Input line fuses are required to protect the input bridge in the ACS 601 in the event of an internal short circuit or ground fault. Fuses are not included in the drive and must be installed externally. The recommended ultrarapid fuses are listed in Appendix A. To ensure that adequate protection is maintained do not install slower types of fuses and do not allow blown fuses to be replaced with slower types. The ACS 607 includes a fused disconnect switch. Ther internal input fuse replacement is noted on the inside of the drive cabinet and in Appendix A of this manual. The fuses recommended for input bridge protection can be installed as drive and motor branch-circuit short-circuit and ground fault protection if they comply with applicable safety regulations.
Motor Overload Protection

3-2
The ACS 600 can provide overload protection for the motor by monitoring a thermostat or thermistor in the motor or by calculating the
PumpSmart AC Drives
motor temperature from measured operating data. The overload protection provided by the drive complies with the requirements of UL508c. Additional overload protection is not required unless more than one motor is connected to the drive or unless additional protection is required by applicable safety regulations.
Power Cables
The input power, motor and ground cables must be sized according to local regulations: 1. 2. The cable must carry the ACS 600 load current. 100 Amps and Below: All field wiring shall be copper conductor rated for a minimum of 140F (60C) and torqued to the values in Appendix A, subsection Cable Entries 601. 100 Amps and Above All field wiring and termination shall be copper conductor rated for a minimum of 167F (75C) and torqued to the values in Appendix A, subsection Cable Entries 607.
Cable Insulation Voltage Ratings
As a minimum requirement, cable insulation voltage ratings must conform to all applicable safety regulations. In addition, motor connecting cable insulation must accommodate the voltage peaks described under Motor Insulation Requirements on page viii of the Safety Instructions. For drives that are rated up to 500 V, cables that have a 600 VAC insulation rating are suitable for both input power and motor wiring. For drives that are rated over 500 V up to 600 V, cables that have a 600 VAC insulation rating are suitable for input power wiring. The motor wiring requires a higher voltage rating to accommodate the voltage peaks described under Motor Insulation Requirements on page vi of the Safety Instructions. As a general rule, the motor cable insulation should be rated for a minimum of 1000 V. For drives that are rated over 600 V up to 690 V, cables that have a 1000 VAC insulation rating are suitable for both input power and motor wiring.
Wiring Practices NOTE! When installing the ACS 600 wiring, it is important to carefully follow the wiring practice recommendations presented in the following paragraphs. Following these recommendations will ensure reliable long term operation of the ACS 600 drive. If these recommendations are not followed, the drive may experience various problems such as: Improper drive performance Nuisance shutdown trips
PumpSmart AC Drives
3-3
Damage to drive electronic circuits Incorrect installation practices can also cause malfunctions or damage to other equipment through electromagnetic interference (EMI) and noise injected into the grounding system. The drive warranty does not cover problems caused by improper installation.
When installing AC drive power wiring, wiring methods that provide shielding for the power cables reduce the possibility of electromagnetic interference (EMI). It is also important to ground the motor frame using a ground conductor connected to the grounding terminal in the drive. EMI reduction measures are most important for the motor wiring but are also applicable to the input power wiring. Any wiring method that is in conformance with applicable safety regulations is acceptable for input power wiring. Metallic conduit or armored cable must be used for motor wiring. Detailed conduit and armored cable wiring practice guidelines are provided below. Type MC continuous corrugated aluminum armor cable with symmetrical grounds is the best type of wiring to provide a good low impedance high frequency ground return path between the motor and the drive. This helps to prevent high frequency ground current from flowing in a potentially damaging path through the motor bearings and connected load bearings. Type MC continuous corrugated aluminum armor cable with symmetrical grounds is highly recommended for motor connections to drives. Conduit Metallic conduit must be used for motor wiring unless armored cable is used. Where conduits must be coupled together, the joint must be bridged with a ground conductor bonded to the conduit on each side of the joint. The conduits must also be bonded to the drive enclosure. Use separate conduits for input power, motor, brake resistors and control wiring. The recommended wiring configuration is shown on page 3-9. Do not run motor wiring from more than one drive in the same conduit. If metallic conduit is not used, type MC continuous corrugated aluminum armor cable with symmetrical grounds must be used for the motor cables. If type MC armor cables are used, the motor cables can be run in the same cable tray as other 480V or 600V power wiring. Control and signal cables must not be run in the same tray as power cables. Six conductor (3 phases and 3 grounds) type MC continuous corrugated aluminum armor cable with symmetrical grounds is available from the following suppliers. Trade names are in parentheses. Anixter Wire & Cable (Philsheath)
Armored Cable
3-4
PumpSmart AC Drives
BICC Cables Corp. (Philsheath) Rockbestos Co. (Gardex) Oaknite (CLX)
Control Cables
All control cables must be shielded. As a general rule, the control signal cable shield should be grounded directly in the ACS 600. The other end of the shield should be left unconnected. Twisting the signal wire with its return wire reduces disturbances caused by inductive coupling. Pairs should be twisted as close to terminals as possible. A double shielded twisted pair cable (Figure a, e.g. Belden 9729) must be used for analog signals. Employ one individually shielded pair for each signal. Do not use common return for different analog signals. A double shielded cable is the best alternative for low voltage digital signals but single shielded twisted multipair cable (Figure b) is also usable.
a A double shielded twisted pair cable
b A single shielded twisted multipair cable
The analog and digital input signals should be run in separate, shielded cables. Relay-controlled signals, providing their voltage does not exceed 48 V, can be run in the same cables as digital input signals. It is recommended that the relay-controlled signals be run as twisted pairs. Never mix 24 VDC and 115 / 230 VAC signals in the same cable. Control Panel Cable In remote use, the cable connecting the keypad to the ACS 600 must not exceed 3 meters (10 ft). The cable type tested and approved by ITT Industries - Goulds Pumps is provided in Control Panel option kits. For information refer to your ITT Industries Goulds Pumps Representative.
Wiring Connections 601

WARNING! This work should only be carried out by a qualified electrician. The Safety Instructions on the first pages of this manual must be followed. Negligence of these instructions can cause injury or
PumpSmart AC Drives
3-5
death. The input power and motor cables connect to the terminal block of the ACS 601 in the lower part of the frame. The control cables pass in front of the power terminals to the NIOC/NIOCP board. To connect the input power, motor and control cables carry out the following procedure. WARNING! Make sure that the ACS 600 is disconnected from the power network during installation. If the ACS 600 is already connected to the power, wait for 5 minutes after disconnecting power. Cover Removal Remove the cover as illustrated in Figure 3-1 on page 3-7 (Frames R2 and R3), Figure 3-2 on page 3-7 (Frames R4 to R6), or Figure 3-3 on page 3-8 (Frame R7). Attach conduits to the conduit entry plate at the bottom of the drive. Knockout sizes and locations are shown on pages B-9 and B-10 in Appendix B. Terminal locations are shown on the dimensioned drawings in Appendix B. Select locations for input power, motor, brake resistor and control wiring according to terminal locations and size requirements. Connect the input power, motor, brake resistor and ground wires first and then connect the control wiring. Refer to Figure 3-4 on page 3-9 for the recommended wiring configuration. See Appendix B - ACS 601 Dimensional Drawings to locate the terminals on each ACS 601 type. See Appendix A page A-16 through 20 for control connection details and multipump control wiring. Refer to the PS200 Programming manual for I/O programming information. General installation instructions are provided on page 3-14. For specific instructions, refer to the Installation and Start-Up Guide for the option module. Replace the cover as shown in Figure 3-6 on page 3-10.
Conduit Plate
Wiring Connections
Option Modules
Cover Replacement
3-6
PumpSmart AC Drives
1. Undo the two screws at the lower front edge of the unit. 2. Lift the lower edge of the cover to gain access to board A6. Disconnect the cable from connector X2. 3. Remove the cover. 4. After connecting the input power, motor and control cables, replace the front cover as shown in Figure 3-6 on page 3-10.)
Figure 3-1 Frames R2 and R3: Removal of the cover
1. 2. 3.
Remove the keypad. Remove the telephone connector. Remove the two screws at the lower front edge of the unit and remove the front cover by lifting it carefully from the bottom. After connecting the input power, motor and control wiring, replace the cover as shown in Figure 3-6 on page 3-10.
4.
Figure 3-2 Frames R4 to R6: removal of the cover
PumpSmart AC Drives
3-7
1. 2.
Loosen the screws of the cover. Lift the cover somewhat upwards to release it from the screws. Leave the cover hanging by its upper edge. Lift the lower edge of the cover to gain access to board A6. Disconnect the cable from connector X2. Remove the cover. After connecting the input power, motor and control cables, replace the front cover as shown in Figure 3-6 on page 3-10.
3. 4.
5. 6.
Figure 3-3 Frame R7: Removal of the cover
3-8
PumpSmart AC Drives
ACS 601 AC Drive
Signals
T1
T2
T3
Metallic Conduit
Figure 3-4 A view of the recommended wiring configuration.
In the R7 Frame, bolt connections are provided for connecting wires with ring lugs. Crimp ring lugs onto the phase conductors. Insulate the ends of the lugs using self-fusing (self-amalgamating) tape or shrink tubing. Figure 3-5 Frame R7: Ring Lugs
PumpSmart AC Drives
3-9
Frames R2 to R3
Frame R7
Connect the Control Panel cable to the connector X2, and replace the front cover. Frames R4 to R6 1. Replace the front cover. 2. Replace the telephone connector. 3. Attach the Control Panel by pushing it softly down onto the connector in the front cover hollow.
Figure 3-6 Replacing the front cover
Wiring Connections 607 WARNING! This work should only be carried out by a qualified
electrician. The Safety Instructions on the first pages of this manual must be followed. Negligence of these instructions can cause injury or death. ACS 607 The input power and motor cables connect to the ACS 607 in the left part of the cabinet. Input power, motor and control cable entry is from below or from above as specified at time of order and indicated by the Type Code. Refer to Appendix B for additional information and drawings showing cable entry and terminal locations. To connect the input power, motor and control cables, carry out the following procedure.
WARNING! Make sure that the ACS 607 is disconnected from the
power during installation. Wait for 5 minutes if the ACS 607 is already
3-10 PumpSmart AC Drives
connected to the mains after disconnecting mains power. Wiring Access 1. Open the cabinet door. 2. Open the hinged assembly plate to gain access to the input power and motor cable terminals. 3. Measure the voltage between each input terminal (U1, V1, W1) and ground with a multimeter (impedance at least 1 M) to ensure that the drive is discharged. Conduit Plate The External Filter Type Code 8 (20th digit of the Type Code) identifies drives equipped with blank conduit plates shown in the dimensional drawings in Appendix B. The following installation procedure applies to installations utilizing conduit. For IEC installation, refer to Appendix C. Attach conduits to the conduit entry plates at the top and/or bottom of the drive. Conduit plate sizes and locations and terminal locations are shown on the dimensional drawings in Appendix B. Terminal wire size capacities are listed on page A-13 in Appendix A. Select locations for input power, motor, brake resister and control conduits according to terminal locations and size requirements. Pull the wires and cables through the conduits into the enclosure.
PumpSmart AC Drives
3-11
Control Cables Metallic Conduit
L1
L2
L3 Gnd
ACx 607 AC Drive
X2 or 2TB Optional terminal block
ACx 604 AC Drive Module
In ACx 604 units, the NIOC/NIOCP board is located inside the drive module
dv/dt Filter
Metallic Conduit
T1
T2
T3
Figure 3-7 A view of the recommended wiring configuration.
3-12
PumpSmart AC Drives
Transformer Settings
ACS 607 units (except frame R7 units) include a transformers unit. The transformer is set to 415 V, 500 V or 690 V at the factory. Adjust the setting if it does not correspond to the supply voltage. To access the transformer remove the front cover of the drive unit with the logo. After adjusting the voltage put the plate back into its place.
F1 F2
T41
500V 480V 460V 440V 415V 400V 380V
Cabinets with the line contactor option include an internal auxiliary voltage transformer. Its input voltage is set to 415 V, 500 V or 690 V at the factory. Adjust the setting if it does not correspond to the supply voltage. The transformer is located in the upper right part of the cabinet, and is visible when the cabinet door is opened.
Keypad in Remote Use
Connect the keypad cable to terminal X19 of the NAMC-51 board.
PumpSmart AC Drives
3-13
Slave Pump
In multipump operation, constant slave mode, the PS200 unit can start and stop a fixed speed slave pump when needed during peak demand. Parameter 18.01, Relay RO3 Output, must be selected for start slave. Refer to page A-30 for Digital Relay Output specifications. The relay is located at terminal X-27 (refer to external control connections drawings in Appendix A) and can be configured for normally open or normally closed. Note that a starter must be provided for the slave pump. This section gives general installation instructions for DriveWindow PC tool and ACS 600 optional modules, such as fieldbus adapters and I/O extension modules. DriveWindow PC tool is an optional software tool which can be used for commissioning and configuring the PumpSmart drive. It can also provide realtime trending of analog signals. Connection examples are given at the end of the section. The module should be installed inside the unit on the location shown in the dimensional drawings (Appendix B). Option modules for the frame sizes R2 and R3 are installed outside the frequency converter. Follow the instructions given in the Mechanical Installation chapter of the module manual. The 24 V d.c. supply for one optional module is provided by the NIOC/ NIOCP board of the converter (NIOC: terminal X23, NIOCP: terminal X4). The location of the NIOC/NIOCP board is shown in the dimensional drawings (Appendix B). Optional modules are connected via a DDCS fiber optic link to the NAMC board or NDCO board (both mounted on top of the NIOC board). The terminals on the NDCO board to which the cables are connected are given in the table below. Channels CH0, CH1, CH2 and CH3 are on NDCO board.
Module Type Fieldbus Adapter Modules I/O Extension Modules Drive Window Channel CH0 CH1 CH3 Terminals V13, V14 V15, V16 V19, V20
Installation of Optional Modules and DriveWindow
Placement
Power Supply for the Module
Fiber Optic Link
Observe color codes when installing fiber optic cables. Blue connectors should go to blue terminals, and grey connectors to grey terminals. In case multiple modules are installed on the same channel, they must be connected in a ring.
3-14
PumpSmart AC Drives
Connection Examples
V25 V16 V15 NAMC
CH1 T R
I/O Extension Module
V26
NIOC
NDCO T R
RXD TXD
NIOC Terminal X23
The terminals for the power supply connection vary. Consult module manual.
Note: Refer to page 9-5 for connection of multiple extension modules
PumpSmart AC Drives
3-15
Fieldbus Module
3-16
PumpSmart AC Drives
DriveWindow ACS 600 NAMC

CH3 T R CH1 T R R
NIOC/ NIOCP
NDCO T R
R T
NDPC NDPA
PumpSmart AC Drives
3-17
Chapter 4 Installation Checklist
Installation Checklist
The PS200 mechanical and electrical installation should be checked before start-up. It is advisable to go through the checklist below together with another person. Study carefully the Safety Instructions on the first pages of this manual before attempting any work on, or with, the unit.
MECHANICAL INSTALLATION Check that the ambient operating conditions are suitable (see Appendix A: environmental limits, cooling air flow requirements, free space requirements). Check that the unit is mounted properly on a vertical non-flammable wall (see Chapter 2 Mechanical Installation). Check that cooling air flows freely. Check the applicability of the motor and the driven equipment (see Appendix A: Motor Connection). ELECTRICAL INSTALLATION (see Chapter 3 Electrical Installation) If the ACS 600 is connected to an ungrounded power system or a high resistance grounded power system (over 30 Ohms), check that the EMC filter capacitors are disconnected. Check that the drive is grounded properly. Check that the input voltage matches the drive nominal input voltage. Check that input power connections at U1, V1 and W1 are OK. Check that appropriate input line fuses are installed. Check that motor connections at U2, V2 and W2 are OK. Check motor cable routing. Check that there are no power factor compensation capacitors connected between the drive and the motor. Check that control connections inside the drive are OK. Check that there are no tools or other foreign objects inside the drive. With bypass connection, check that input line voltage cannot be applied to the output of the ACS 600.
PumpSmart AC Drives
4-1
The drive must be connected to the motor to operate.
When the drive is connected to the motor and started for the first time, the drive identifies specific motor detail. For a mathematical motor model. The motor model is calculated by magnetizing the motor for 20 to 60 seconds at zero speed. This is called a First Start ID Run. If the motor is changed in the future, a First Start ID Run must be performed to maintain the accuracy of the PumpSmart Control.
PumpStart Pre-Startup Checklist
Check that the instrumentation is wired per the instrumentation wiring diagrams. Refer to Appendix A. Make sure that the instrumentation enclosure and rating is suitable for the service. Check that all PS200 programming selections have been made. Refer to Programming Manual for PS200. Check for proper location and mounting of instrumentation; refer to contract drawings. If installing the suction and discharge transmitters in piping not supplied by ITT Goulds check that the transmitters are properly located and oriented as shown in Appendix A. The improper location of increasers, reducers and/or insufficient straight pipe diameters before and after pressure transmitters or flow meters may effect readings. Refer to the pump installation manual and Hydraulic Institute procedures for good piping practice. Check that the system static head will not cause the pump to deadhead at the minimum speed setting. The minimum speed setting can be adjusted as required. Refer to the PS200 Programming Manual. Enter the setpoints via the keypad, AI1 or DCS for the control mode being used (flow, pressure, speed, level and temperature). If a 4-20 ma setpoint signal is connected to AI1 a 500 ohm resistor across the AI1 input is required to convert the ma signal to voltage. Refer to the PumpSmart wiring diagram. Prior to startup, check the motor rotation with the pump coupling disconnected. Note if the unit is already coupled, an alternate method of checking motor rotation is given in the PS200 Programming and Operation Manual which does not require uncoupling of the pump and motor. Refer to the Pump Installation, Operation and Maintenance Manual for correct rotation. If the motor rotation is incorrect the positions of two leads must be changed either at the drive (U2, V2, W2) or at the motor (T1,T2,T3). Note, when the unit is first started PumpSmart will automatically perform an ID run. This is a one-time process that characterizes the motor at zero speed. The process normally takes 20-60 seconds. Prior to startup, verify that the instrument readings are being
4-2
PumpSmart AC Drives
properly measured by Pumpsmart. Refer to the appropriate parameters in the PS200 Programming Manual (Group 2 - Actual Signals). Once the unit is started, check setpoint for proper operation. Note if changing macro selection (speed control, single pump or multipump) the PS200 must be shut down.
PumpSmart AC Drives
4-3
Chapter 5 Local Control vs. External Control
Local Control vs. External Control
The PS200 can be controlled (i.e. reference and Start/Stop commands can be given) from a distributive control system (DCS) or from the Local control location, Control Panel Keypad. The selection between Local control and External control can be done with the LOC REM key on the Control Panel keypad.
Local Control
The control commands are given from the Control Panel keypad when PS200 is in Local control. This is indicated by L (Local) on the Control Panel display.
1 L ->1242 rpm
External Control
When the PS200 is in External (Remote) control, the commands are given through a fieldbus adapter. Start-Stop commands must also be given in External (Remote) control via 2 wire or 3 wire start-stop. For installation and operating instructions of fieldbus communication adapters, refer to the specific manual applicable to the communication protocol being used. External control is indicated by a blank character or an R on the Control Panel display.
1 ->1242 rpm
1 R ->1242 rpm
External Control through a (fieldbus adapter) communication module
External Control by External Source (Start/Stop command via 2 wire or 3 wire start-stop)
PumpSmart AC Drives
5-1
Chapter 6 Maintenance
The PS200 requires minimum maintenance. WARNING! The Safety Instructions on the first pages of this manual must be followed.
Heatsink
The heatsink fins pick up dust from the cooling air. The PS200 can run into overtemperature Warnings and Faults if the heatsink is not cleaned regularly. In a normal environment, the heatsink should be checked and cleaned annually. The dust should be removed gently with a soft brush if the cleaning is carried out in the same room where the unit is normally operated. Compressed air should not be used for cleaning unless the installation can be taken apart and the cleaning is carried out in another room (or outdoors). Fan rotation should be prevented (in order to prevent bearing wear) when using compressed air for heatsink cleaning.
Fan
The cooling fan lifespan of ACS 601 units is about 60,000 hours and 30,000 hours for an ACS 607. The actual lifespan depends on the AC drive usage and ambient temperature. Fan failure can be predicted by the increasing noise from fan bearings and the gradual rise in the heatsink temperature in spite of heatsink cleaning. If the drive is operated in a critical part of a process, fan replacement is recommended once these symptoms start appearing. The fan can be withdrawn by removing the bottom of the frame. Replacement fans are available from ABB. Do not attempt operation with other than ABB specified spare parts.
Capacitors
The ACS 600 intermediate circuit employs several electrolytic capacitors. Their lifespan is approximately 100,000 hours, but dependent on the drive loading and the ambient temperature. Capacitor life can be prolonged by lowering the ambient temperature. It is not possible to predict capacitor failure. Capacitor failure is usually followed by an input line fuse failure or a Fault trip. Contact ABB if capacitor failure is suspected. Replacements are available from ABB. Do not attempt operation with other than ABB specified spare parts. Reforming For more information on reforming (re-aging) spare part capacitors, contact Technical Support.
PumpSmart AC Drives
6-1
Chapter 7 Optional Analog I/O Extension Module
Overview
This chapter contains a description of the optional Analog I/O Extension Module. The Analog I/O Extension Module is only required when optional vibration transmitter #2 is specified or more than two analog outputs are required. The Analog I/O Extension Module can also be furnished as a field repairable kit. The Analog I/O Extension Module is connected to the AC Drive via an optical DDCS-protocol communication link. The module, together with the NIOC Standard I/O Board, is connected to Channel CH1 of the NDCO Board. Refer to page 3-15. Each device on the DDCS link has an individual node number. The modules are numbered by setting the DIP switches located inside the module enclosure.
The I/O Extension Link
NAIO-03 Analog I/O Extension Module
The Analog I/O Extension Module (NAIO) offers two bipolar current (0(4) to 20 mA) or voltage (0(2) to 10 V, or 0 to 2 V) inputs and two unipolar current (0(4) to 20 mA) outputs. The signal resolution (12 bits) is better than that of the standard analog I/O. The Analog I/O Extension Module may be supplied as a field installation kit or installed inside the PumpSmart Model PS200 AC Drive. On drive frames R2 and R3 the module must be mounted outside the drive.
Delivery Check for Field Installation Kit
The option package contains: NAIO-03 module three pairs of fibre optic cables (120/370/2000 mm) mounting rail (DIN 50022, 35 7.5 mm, length 45 mm) This manual, the NTAC-0x/NDIO-0x/NAIO-0x Installation and Start-up Guide.
Setting the Module Node Number
The module must be given a node number. DIP switch 1 and 3 must be in the ON position. All other DIP switches must be off. The node number is set by adjusting the DIP switches located under the top
PumpSmart AC Drives
7-1
lid of the module casing (see figure 7-1 below). The switch settings for the module is shown below.
Figure 7-1 Setting the module node number.
Note: The new settings take effect only the next time the module is powered up.
Mechanical Installation
Depending on the drive, the module(s) can be installed either inside or outside the drive housing or cabinet. See Chapter 3, Electrical Installation page 3-14, for module placement options. Choose the location for the module. Note the following: The cabling instructions (given later in this chapter for each module type) must be followed. Also, the length of the fibre optic cables included in the option package may restrict the distance between the module and the drive. Observe the free space requirements for the module (min. 10 mm
Mounting Outside the Drive
7-2
PumpSmart AC Drives
from adjoining equipment or wall) and the drive (see the drive documentation). The ambient conditions must be taken into account (see Appendix A). The degree of protection of the module is IP 20. Module earth is connected to the mounting rail by means of an earthing clip (see Figure below). The mounting rail onto which the module is to be mounted must be earthed to a noiseless earth. If the rail is not mounted on a properly earthed base, a separate earthing conductor must be used. The conductor must be as short as possible and the cross-sectional area must be 6 mm2 at least. Note: No solid copper conductor may be used (stranded wire allowed only). Mounting instructions: 1. Switch off all dangerous voltages in the enclosure that the module is to be mounted in. 2. Fasten the rail and ensure proper earthing as described above. 3. Push the module onto the rail. The module can be released by pulling the locking spring with a screwdriver. Earthing Clip
Figure 7-1Mounting and removing the module.
PumpSmart AC Drives
7-3
Mounting Inside the Drive
The work inside the drive should be carried out by a qualified electrician only.
WARNING! Pay attention to the slowly discharging voltage of the capacitor bank and the voltages that are connected from external control circuits to the inputs and outputs of the drive.
WARNING! Do not touch the printed circuit boards. The integrated circuits are extremely sensitive to electrostatic discharge. Mounting instructions: 1. Stop the drive. 2. Switch off the power supply of the drive and all dangerous voltages connected to the inputs and outputs. 3. Wait for five minutes to ensure that the capacitors in the intermediate circuit have discharged. 4. Remove the front cover of the drive. 5. Ensure that the mains cable, motor cable and capacitor bank (UDC+ and UDC) are not powered. 6. Locate the position for the module (see Chapter 3, Electrical Installation, page 3-14). Fasten the mounting rail to its place if not already installed. Observe the free space requirements for the module (min. 10 mm from adjoining equipment/wall). 7. Push the module onto the rail. The module can be released by pulling the locking spring with a screwdriver (see Figure 7-1).
7-4
PumpSmart AC Drives
ACS 600 Connection

General The modules are connected to the drive (NAMC/NDCO board) using the fibre optic cables included in the module package. Observe the connector color coding: blue connectors should go to blue receivers (RXD), grey (or black) connectors to grey transmitters (TXD). Multiple modules on the same channel are connected in a ring. The fibre optic cables must be handled with care. The maximum longterm tensile load is 1 N and the minimum short-term bend radius is 25 mm. The ends of the fibre must not be touched as optical fibres are sensitive to dirt. Grommets should be used at cable lead-throughs. Terminals The terminals which the NAIO-03 module is connected to are given in the table below.
Application Program
PS200
Module
NAIO-03
Board
NDCO
Channel
CH1
Terminals
V15, V16
Refer to page 3-15 I/O Extension Module Connections.
NAIO-03 Analog I/O Extension Module

Mode Selection The operating mode of the analog inputs are unipolar mode only. In unipolar mode, the analog inputs can handle positive signals only. The resolution of the A/D conversion is 12 data bits. The PumpSmart Drive must be programmed to recognize the analog input module. Drive parameter 30.02 (if applicable) must be programmed to YES. Note: New settings take effect after the AC drive has input power cycled off and on.
Input Signal Type Selection
Each input can be used with a current or voltage signal. The selection is made with a DIP switch located behind the top lid of the NAIO module casing (see Figure 9-1). The switch settings must be set for 1 and 3 in the ON position (current signal) since the vibration transmitter output is 4-20 mA.
DIP Switch Settings Input Signal Type AI1 AI2
Current signal 0(4) 20 mA
ON DIP 1 2 3 4
ON DIP 1 2 3 4
PumpSmart AC Drives
7-5
Voltage signal 0(2) 10 V
ON DIP 1 2 3 4
ON DIP 1 2 3 4
Voltage signal 02V
ON DIP 1 2 3 4
ON DIP 1 2 3 4
Figure 7-1 Analog input type selection.
Note: Independent of the selection of the signal type, the values of the analog inputs are displayed in mA on the PS200 Control Panel Keypad; e.g. 10 V will be displayed as 20 mA. This must be taken into account when scaling the signals or reading the actual value of the analog inputs AI2 and AI3.
7-6
PumpSmart AC Drives
Terminal Designations
X2 1 2 3 Marking AO1+ AO1AO2+ AO2SHF SHF SHF SHF Cable screen AC earthing (via an RC filter). For connection of the cable screens Description Current Output 1 Current Output 2 Analogue Analogue Input 1 Input 2
Current signal 0(4) 20 mA Rload 700 Isolated from power supply and from earth
X2 8 7 6 5 4 3 2 1
4 5 6
SHF
SHF
SHF
SHF AO2- AO2+ AO1- AO1+
X2
7
RXD
NAIO-03
ANALOGUE I/O EXTENSION
TXD
X1 1
Marking +24V
Description
X1
+24V 0V SHF SHF AI2AI2+ AI1AI1+
Power supply for the module (24 V d.c. 10%, 160 mA) 2 3 0V SHF SHF AI2AI2+ AI1AI1+ Cable screen AC earthing (via an RC filter). For connection of the cable screens
1 2 3 4 5 6 7 8 X1
4 5 6 7 8
Current signal 0(4) 20 mA Rin = 100 Isolated from power supply and from earth
Voltage signal 0(2) 10 V or 0 2 V Rin = 200 k Isolated from power supply and from earth
Figure 7-1 NAIO-03 terminal designations. The NAIO module analog input assignments for the PS200 are as follows:
NAIO-03 Module 1 Optional Vib#2 AI1 not used AI2
PumpSmart AC Drives
7-7
NAIO-03 X1 Transducer 1
AI1+ AI1SHF AI2+ AI2-
X2
AO1+ AO1SHF AO2+ AO2SHF
P T
*
Indicator 1
Transducer 2 *
Indicator 2
SHF
*If the transducers/indicators are located far away from each other, earth the screen at one unit through a capacitor (e.g. 10 nF/400 V) to avoid earth current flow through the NAIO-03.
Note: X1 and X2 have separate RC filters as pictured above, i.e. the SHF terminals on one terminal block are connected together, then to earth through an RC filter.
Note: Do not route the signal cables parallel to power cables. Programming The communication between the module and the drive is activated by a drive parameter 30.02. Note: The new settings take effect only the next time the module is powered up. NAIO Module Replacement An NAIO-03 can be used to replace a faulty NAIO-01/02.
7-8
PumpSmart AC Drives
Appendix A PumpSmart AC Drives Technical Data
PumpSmart Ratings for NEMA1 (IP21/22) Enclosures
Below are the PumpSmart ratings for ACS 601 with 50 Hz and 60 Hz supplies. Note: IP21/22 enclosures are equivalent to Nema1. IP 54 enclosure is equivalent to Nema 12.
Normal Use Duty Cycle 1/10 min I2 N

9/10min
ACS 601 Type
I2Nmax
1/10min
SN [kVA] 3 5 6 9 11 16 20 25 30 40 50 60 70 80 100 120 150 200
PN [kW] 1.1 1.5 2.2 3.7 5.5 7.5 11 15 18.5 22 30 37 45 55 75 90 110 150 4 5.5 7.5 11 15 18.5 22 30 37 45 55 75 90 110 90 110 132 160 200 250
PN [HP] 1.5 2 3 5 7.5 10 15 20 25 30 40 50 60 75 100 125 150 200 5 7.5 10 15 20 25 30 40 50 60 75 100 125 150 125 150 150 200 250 300/350
[A] Three-phase supply voltage 240 V ACS 601-0003-2 ACS 601-0005-2 ACS 601-0006-2 ACS 601-0009-2 ACS 601-0011-2 ACS 601-0016-2 ACS 601-0020-2 ACS 601-0025-2 ACS 601-0030-2 ACS 601-0040-2 ACS 601-0050-2 ACS 601-0060-2 ACS 601-0070-2 ACS 601-0080-2 ACS 601-0100-2 ACS 604-0125-2 ACS 604-0150-2 ACS 604-0200-2 7.8 11 15 18 25 32 48 60 75 88 114 143 178 211 248 300 365 460
[A] 8.6 12.1 16.5 19.8 28 35 53 66 83 97 125 157 187 232 300 348 435 528
Three-phase supply voltage 380 V, 400 V, 415 V, 440 V, 460 V, 480 V or 500 V ACS 601-0006-4 7.6 8.4 5 ACS 601-0009-4 11 12 7.5 ACS 601-0011-4 15 17 10 ACS 601-0016-4 21 23 15 ACS 601-0020-4 27 30 20 ACS 601-0025-4 34 37 25 ACS 601-0030-4 41 45 30 ACS 601-0040-4 52 57 40 ACS 601-0050-4 65 72 50 ACS 601-0060-4 77 85 60 ACS 601-0070-4 96 106 75 ACS 601-0100-4 124 136 100 ACS 601-0120-4 156 172 125 ACS 601-0140-4 180 198 150 Three-phase supply voltage 380 V, 400 V, 415 V, 440 V, 460 V, 480 V or 500 V ACS 604/607-0120-4 156 172 125 ACS 604/607-0140-4 180 198 150 ACS 604/607-0170-4 216 238 150 ACS 604/607-0210-4 260 286 200 ACS 604/607-0260-4 316 348 250 ACS 604/607-0320-4 414 455 320
PumpSmart AC Drives
A-1
ACS 604/607-0400-4 ACx 604/607-0490-5 ACx 604/607-0610-5 ACx 604/607-0760-5
480 570 694 874
528 627 764 961
400 490 610 760
315 400 500 630 5.5 7.5 11 15 18.5 22 30 37 45 55 75 90 75 90 110 132 160 200 250 315 400 500 630
400 500 600 700 7.5 10 15 20 25 30 40 50 60 75 100 125 100 125 150 150 200 250 300 350 450 500 700
Three-phase supply voltage 525 V, 550 V, 575 V, 600 V, 660 V or 690 V ACS 601-0009-6 7.6 11 9 ACS 601-0011-6 11 12 11 ACS 601-0016-6 15 17 16 ACS 601-0020-6 20 22 20 ACS 601-0025-6 25 28 25 ACS 601-0030-6 28 31 30 ACS 601-0040-6 36 40 40 ACS 601-0050-6 44 48 50 ACS 601-0060-6 52 57 60 ACS 601-0070-6 65 72 70 ACS 601-0100-6 88 97 100 ACS 601-0120-6 105 116 120 Three-phase supply voltage 525 V, 550 V, 575 V, 600 V, 660 V or 690 V ACS 604/607-0100-6 88 97 100 ACS 604/607-0120-6 105 116 120 ACS 604/607-0140-6 127 140 140 ACS 604/607-0170-6 150 165 170 ACS 604/607-0210-6 179 197 210 ACS 604/607-0260-6 225 248 260 ACx 604/607-0320-6 265 292 320 ACx 604/607-0400-6 351 386 400 ACx 604/607-0490-6 428 470 490 ACx 604/607-0610-6 504 555 610 ACx 604/607-0760-6 667 734 760
Current ratings are for operation up to 1000m (3300 ft) altitude and 40C(104F) ambient temperature (35C/95F for models ACS 601-0025-2, ACS 601-0050-2 and ACS 601-0070-2 in IP54 enclosures). For high temperature and altitude derating, see pages A-2 to A-page 8. The current ratings are the same regardless of the supply voltage within one voltage range. The rated current of the ACS 60x must be higher than or equal to the rated motor current to achieve the rated motor power given in the table . Note 1: The maximum allowed motor shaft power is limited to 1.5 Phd. If the limit is exceeded, the motor torque and the I hdmax 2 s current is automatically restricted. The function protects the input bridge of the ACS 600 against overload. Note 2: The load capacity (current and power) decreases if the installation site altitude exceeds 1000 meters (3300 ft.), or if the ambient temperature exceeds 40 C (104 F(35 C/95 F for ACS 601-0120-03 units).
A-2
PumpSmart AC Drives
Normal use (10 % overload capacity): I2N rated RMS output current I2Nmax short term rms overload current (allowed for one minute every 10 minutes). SN rated apparent output power PN typical motor power. The power ratings in kW apply to most IEC 34 motors. The power ratings in HP apply to most four pole NEMA rated motors.
ACS 600 Altitude & Ambient Derates
The ACS 600 product is designed for a maximum ambient temperature and altitude for proper operation. The maximum ambient may change depending upon: If an ACS 601 is supplied in an IP21/22 enclosure versus IP54. IP21/22 are always 40 C (104 F). IP54 ratings are derated depending upon drive power rating. If an ACS 601 is to be applied at an altitude of 3300 feet or below and an ambient from 40 C (104 F) to 50 C (122 F), the ACS 600 will be derated. The ACS 601 derate depends upon power rating and enclosure protection (IP21/22 versus IP54) There is no current derate for an IP54 design on an ACS 607 at or below 40 C (104 F). The ACS 607 ambient derate from 40 C (104 F) to 50 C (122 F) is 1.5% of the drives current rating per 1 C (1.8 F). Altitude deration Sites above 1000 meters (3300 ft.) above sea level, the maximum power is derated by 1% for every 100 meters (330 ft.). If the installation site is above 2000 meters, please contact ITT Goulds Pumps. The following sections are specific derating information for the ACS 601 230 VAC, 380-690 VAC.
ACS 601 Output Current Temperature Derating 380V, 480V, 690V
The output current is calculated by multiplying the current given in the rating table by the derating factor. Temperature derating factor for degree of protection IP 21/22: General rule: Above +40 C (104 F), the rated output current is decreased 3.5% for every additional 1 C up to +50 C (1.94% for every additional 1 F up to 122 F). Example 1. If the ambient temperature is 50 C the derating factor is 100% - 3.5 % 10 C = 65% or 0.65. The output current is then 0.65 I2N or C I2hd.
PumpSmart AC Drives
A-3
Derating factor for ACS 600 in Pump and Fan Use (INsq rating): Above +40 C (104 F) (+35 C/95 F for ACS 601-120-03 units), the rated output current is decreased 5 % for every additional 1 C up to +50 C (2.78% for every additional 1 F up to 122 F). Derating factor for ACS 601 with degree of protection IP 54: From +25 C (77F) to +40 C (104 F), the output current is calculated using the table below. Above +40 C (104 F), the output current is decreased 3.5 % for every additional 1 C up to +50 C (1.94% for every additinoal 1 F up to 122 F). Example 1. If the ambient temperature is 38 C, the derating factor for ACS 601-0006-3 is 95 % or 0.95 (Curve 2). The output current is then 0.95 I2N or I2hd. Example 2. If the ambient temperature is 122 F, the output current for ACS 601-0006-3 is first calculated at 104 F (derating factor 92 % or 0.92 from Curve 2) and the result is multiplied by factor 0.65 (See Example 1 (IP 21/22)). The output current is then 0.92 0.65 I2N or 0.92 0.65 I2hd. ACS 601 Output Current Ratings for IP54 (Nema 12) Enclosures Output current for ACS 601 with degree of protection IP 54 and with ambient temperature from 25 C to 40 C is presented in the diagram below. I2N total rms output current for normal use, I2hd total rms output current for heavy-duty use, t ambient temperature.
380V, 480V, 690V
A-4
PumpSmart AC Drives
% of I2N and I2hd 100 95 90 85 80 75 70 65 60 24 77 26 28 30 86 32 1 2
3 4 5
34 95
36
38
40 C 104 F
Curve 1 (100 % no derating) ACS 601-0005-3 ACS 601-0006-4 ACS 601-0009-6 ACS 601-0011-6 ACS 601-0100-6 ACS 601-0120-6
Curve 2 ACS 601-0006-3 ACS 601-0009-4 ACS 601-0025-4 ACS 601-0070-4 ACS 601-0016-6
Curve 3 ACS 601-0011-3 ACS 601-0020-3 ACS 601-0025-3 ACS 601-0030-3 ACS 601-0060-3 ACS 601-0016-4 ACS 601-0030-4 ACS 601-0040-4 ACS 601-0020-6 ACS 601-0025-6 ACS 601-0030-6 ACS 601-0060-6
Curve 4 ACS 601-0009-3 ACS 601-0040-3 ACS 601-0050-3 ACS 601-0011-4 ACS 601-0050-4 ACS 601-0060-4 ACS 601-0040-6 ACS 601-0050-6
Curve 5 ACS 601-0016-3 ACS 601-0070-3 ACS 601-0020-4 ACS 601-0100-4 ACS 601-0070-6
230 VAC ACS 600 Output Current Derating For High Ambient Temperature
When the ambient temperature of the air around the drive exceeds the rated temperature, the rated output current is decreased by some percentage of the normal current rating for every degree above the rated temperature. The output current is calculated by multiplying the I2N current given in the rating table by a derating factor determined from the derating curves. The derating factor is determined by the ambient temperature, the type of enclosure and the duty classification. For IP 21/22 enclosures with Normal Use, apply Curve 1 to I2N except for model ACS 601-0100-2, apply curve 2 to I2N. For IP 21/22 enclosures with Heavy Duty Use, apply the I 2HD current given in the rating table. No derating is required. For IP 54 enclosures with Normal Use, apply Curve 1 to I2N except for models ACS 601-0025-2, ACS 601-0050-2 and ACS 601-0070-2, apply curve 2 to I2N. For IP 54 enclosures with Heavy Duty Use, determine the derated current for Normal Use by multiplying I2N by the derating factor using
PumpSmart AC Drives
A-5
the curve selected from the following table. Compare the derated current for Normal Use with the I2HD current given in the rating table. and use the lower of the two current ratings. Example 1: ACS 601-0030-2 is to be derated for operation at 50C with Normal Duty Use and an IP 21/22 enclosure. The I2N current listed in the rating table is 75A. From curve 1, the derating factor is 85%. The derated current is 85% of 75A or 63.8A (75 X 0.85). Example 2: ACS 601-0025-2 is to be derated for operation at 40C with Normal Duty Use and an IP 54 enclosure. The I2N current listed in the rating table is 60A. From curve 2, the derating factor is 92%. The derated current is 92% of 60A or 55.2A (60 X 0.92). Example 3: The ACS 601-0025-2 described in Example 2 is to be rated for Heavy Duty Use. From Example 2, the derated current for Normal Use is 55.2A. From the rating table, the I2HD current is 48A. The lower of these two current ratings is the 48A I2HD rating therefore, the I2HD rating applies. Example 4: ACS 601-0070-2 is to be derated for operation at 50C with Heavy Duty Duty Use and an IP 54 enclosure. The I2N current listed in the rating table is 178A. From curve 2, the derating factor is 78%. The derated current for Normal Use is 78% of 178A or 138.8A (178 X 0.78). The I2HD current listed in the rating table is 143A. Since the derated current for Normal Use is less than the I2HD current, the 138.8A derated current for Normal Use is the rating that applies. Output Current Derating Factors for High Ambient Temperature (Percent of I2N or I2Nsq)
100% 95% 90% 85% 80% 2 75% 70% 65% 60% 55% 50% 77 25 86 30 95 35 104 40 113 45 122 F 50 C Curve No. 1
Ambient Temperature
A-6
PumpSmart AC Drives
Output Current Derating For High Altitude
When the altitude of the installation site exceeds 1000 m (3300 ft.) above sea level, the rated output current for Normal Use is decreased by 1% for every additional 100 m (300 ft.). If the installation site is higher than 2000 m (6600 ft.) above sea level, please contact ITT Industries Goulds Pumps for further information. For Heavy Duty Use, apply the I2HD current given in the rating table up to 2000 m (6600 ft.). No derating is required. The output current is calculated by multiplying the I2N current given in the rating table by the derating factor determined from the derating curve. Output Current Derating Factors for High Altitude (Percent of I2N)
100%
98%
96%
94%
92%
90% 88% 3300 1000
4900 1500 Altitude
6600 Feet 2000 Meters
PumpSmart AC Drives
A-7
Temperature Derating For High Altitude
When the altitude of the installation site exceeds 1000 m (3300 ft.) above sea level, the rated ambient temperature can be decreased as an alternative to decreasing the rated output current. Use curve 2 for models ACx 601-0025-2, ACx 601-0050-2 and ACx 601-0070-2 when they are in IP54 enclosures. Ambient Temperature Derating for High Altitude
40 C 39 C 38 C 37 C 36 C 96 F 35 C 34 C 33 C 32 C 31 C 30 C 3300 1000 2 94 F 92 F 90 F 88 F 86 F 6600 Ft 2000 M 1 102 F 100 F 98 F 104 F
4900 1500
Fuses
Recommended input fuse ratings of the ACS 601/4 are below. A minimum rated current in amperes, A2s maximum I2t value, V rated voltage in volts. Only ultra rapid fuses guarantee proper protection for the rectifier semiconductors.
A-8
PumpSmart AC Drives
Fuses ACS 601 Type A ACS 601-0003-2 ACS 601-0005-2 ACS 601-0005-3 ACS 601-0006-4 ACS 601-0006-5 ACS 601-0006-3 ACS 601-0009-4 ACS 601-0009-5 ACS 601-0006-2 ACS 601-0009-3 ACS 601-0011-4 ACS 601-0011-5 ACS 601-0009-2 ACS 601-0011-3 ACS 601-0016-4 ACS 601-0016-5 ACS 601-0011-2 ACS 601-0016-3 ACS 601-0020-4 ACS 601-0020-5 ACS 601-0016-2 ACS 601-0020-3 ACS 601-0025-4 ACS 601-0025-5 ACS 601-0030-2 ACS 601-0025-3 ACS 601-0030-4 ACS 601-0030-5 ACS 601-0020-2 ACS 601-0030-3 ACS 601-0040-3 ACS 601-0040-4 ACS 601-0040-5 ACS 601-0050-5 ACS 601-0025-2 ACS 601-0030-2 ACS 601-0050-3 ACS 601-0050-4 ACS 601-0060-5 ACS 601-0040-2 ACS 601-0060-3 ACS 601-0070-5 ACS 601-0050-2 ACS 601-0060-4 ACS 601-0070-3 ACS 601-0070-4 ACS 601-0100-4 ACS 601-0100-5 16 A 2s 48 V 660 Manufacturer Bussmann Type DIN 43620 170M1559 Size 000 Type DIN 43653 170M1359 Size 000/80
16
48
660
Bussmann
170M1559
000
170M1359
000/80
25
130
660
Bussmann
170M1561
000
170M1361
000/80
32
270
660
Bussmann
170M1562
000
170M1362
000/80
40
460
660
Bussmann
170M1563
000
170M1363
000/80
50
770
660
Bussmann
170M1564
000
170M1364
000/80
63
1450
660
Bussmann
170M1565
000
170M1365
000/80
80
1250
660
Bussmann
170M3811
170M3011
1/80
125
3700
660
Bussmann
170M3813
170M3013
1/80
160
7500
660
Bussmann
170M3814
170M3014
1/80
200
28000
660
Bussmann
170M1570
000
170M1370
000/80
PumpSmart AC Drives
A-9
Fuses ACS 601 Type A ACS 601-0060-2 ACS 601-0070-2 ACS 601-0080-2 ACS 601-0100-2 ACS 601-0100-3 ACS 601-0120-3 ACS 601-0120-4 ACS 601-0120-5 ACS 601-0140-4 ACS 601-0140-5 ACS 60x-0210-4 ACS 604-0125-2 ACS 604-0150-2 ACS 604-0200-2 ACS 60x-0210-3 ACS 60x-0260-4 ACx 60x-0210-3 ACx 60x-0400-3 ACx 60x-0490-5 ACx 60x-0260-3 ACx 60x-0320-4 ACx 60x-0490-3 ACx 60x-0610-5 ACx 60x-0320-3 ACx 60x-0400-4 ACx 60x-0610-3 ACx 60x-0760-5 ACS 601-0009-6 ACS 601-0011-6 ACS 601-0016-6 ACS 601-0020-6 ACS 601-0025-6 ACS 601-0030-6 ACS 601-0040-6 ACS 601-0050-6 ACS 601-0060-6 ACS 601-0070-6 ACS 601-0100-6 ACS 601-0120-6 ACS 60x-0100-6 ACS 60x-0120-6 ACS 60x-0140-6 ACS 60x-0170-6 ACS 60x-0210-6 ACS 60x-0260-6 ACx 60x-0320-6 ACx 60x-0400-6 400 A2s 105000 V 660 Manufacturer Bussmann Type DIN 43620 170M3819 Size 1 Type DIN 43653 170M3019 Size 1/80
550 700
190000 405000
660 660
Bussmann Bussmann
170M5811 170M5813
2 2
170M5011 170M5013
2 2
700
405000
660
Bussmann
170M5813
170M5013
800
465000
660
Bussmann
170M6812
170M6012
16 16 16 25 40 50 50 63 100 100 125 200 125 200 250 315 400 550
48 48 48 130 460 770 770 1450 4650 4650 8500 28000 3700 15000 28500 46500 105000 190000
660 660 660 660 660 660 660 660 660 660 660 660 660 660 660 660 660 660
Bussmann Bussmann Bussmann Bussmann Bussmann Bussmann Bussmann Bussmann Bussmann Bussmann Bussmann Bussmann Bussmann Bussmann Bussmann Bussmann Bussmann Bussmann
170M1559 170M1559 170M1559 170M1561 170M1563 170M1564 170M1564 170M1565 170M1567 170M1567 170M1568 170M1570 170M1568 170M1570 170M3816 170M3817 170M3819 170M5811
000 000 000 000 000 000 000 000 000 000 000 000 000 000 1 1 1 2
170M1359 170M1359 170M1359 170M1361 170M1363 170M1364 170M1364 170M1365 170M1367 170M1367 170M1368 170M1370 170M1368 170M1370 170M3016 170M3017 170M3019 170M5011
000/80 000/80 000/80 000/80 000/80 000/80 000/80 000/80 000/80 000/80 000/80 000/80 000 000 1 1 1 2
A-10
PumpSmart AC Drives
Fuses ACS 601 Type A ACx 60x-0490-6 ACx 60x-0610-6 ACx 60x-0760-6 400 550 A 2s 105000 190000 V 660 660 Manufacturer Bussmann Bussmann Type DIN 43620 170M3819 170M5811 Size 1 2 Type DIN 43653 170M3019 170M5011 Size 1 2
Note: Fuses from other manufacturers can be used if they meet the ratings given in the table. Only ultra rapid fuses guarantee the proper protection for the rectifier semiconductors. The fuses recommended in the table are UL recognized.
The fuse table lists the smallest recommended fuse available from Bussman for each drive model. These are not necessarily the fuses that were provided with your drive. The information provided is for purchasers of 604 modules. The smallest fuse sizes were listed to allow the most compact ACS 604 installation. The following table lists the required fuse sizes for an ACS 607 with UL approval. These fuses are necessary to maintain your units UL approval rating. A label has been placed inside your drives enclosure door listing the replacement fuse sizes required to maintain UL approval.
ABB 604/607 Types Manufacturer Type DIN 43653 Fuse (Hook and Slot Style) Model Number 170M1370 170M3169 170M3169 170M5161 170M5163 170M5013 170M6012 170M5813* 170M6812* 170M3819 170M5811
ACS 607-0120-4/0100-6 ACS 607-0140-4/0120-6 ACS 607-0140-3/0170-4/0170-5/0140-6 ACS 607-0170-3/0210-4/0210-5/0170-6 ACS 607-0210-3/0260-4/0260-5/0210-6 ACS 607-0260-3/0320-4/0320-5/0260-6 ACS 607-0320-3/0400-4/0400-5/0320-6 ACS 607-0400-3/0490-3/0490-5/0610-5 ACS 607-0610-3/0760-5 ACS 607-0490-6 ACS 607-0610-6/0760-6
Bussman Bussman Bussman Bussman Bussman Bussman Bussman Bussman Bussman Bussman Bussman
Note: Fuses designated with an * are Type DIN 43620 Stap-In Style fuses, NOT Type DIN 43653 Hook and Slot Style fuses.
PumpSmart AC Drives
A-11
Power Connections R2-R6
Power and motor cable terminal sizes and tightening torques for the ACS601 with cable diameters accepted by the rubber glands are given below..
U1,V1,W1 / U2,V2,W2 ACS 600 Type Maximum WIre Size Tightening Torque Ground (PE) Maximum WIre Size
ACS 601-0003-2/0005-2/0006-4 ACS 601-0006-2/0009-4 ACS 601-0009-2/0011-4 ACS 601-0009-6/0011-6 ACS 601-0011-2/0016-4/0016-6 ACS 601-0016-2/0020-4/0020-6 ACS 601-0020-2/0025-4/0025-6 ACS 601-0025-2/0030-4/0030-6 ACS 601-0040-4/0040-6 ACS 601-0050-4/0050-6 ACS 601-0060-4 ACS 601-0030-2 ACS 601-0040-2 ACS 601-0050-2 ACS 601-0060-2 ACS 601-0070-2 ACS 601-0080-2 ACS 601-0100-2 ACS 601-0070-4/0060-6 ACS 601-0100-4/0070-6 ACS 601-0120-4/0100-6 ACS 601-0140-4/0120-6
1)The terminals are 10mm (13/32) bolts for attaching ring lugs (lugs not furnished). 2)For conduit plate drawings, see pages B-9 and B-10.
#10 AWG
#10 AWG
#8 AWG
13-18 lb.-in.
#8 AWG
#6 AWG
Cu
#6 AWG
#2 AWG AI #1 AWG
5.9 lb.-ft.
#2 AWG
#0 AWG
5.9 lb.-ft.
#2 AWG
95 mm2 #000 AWG

1)
8.9 lb.-ft.
22 lb.-ft.
#00 AWG
#00 AWG
1)
22 lb.-ft.
#00 AWG
ACS 607 Power Connections
The PumpSmart AC drive has been supplied with the following power connections. The installer of the equipment will require NEMA single hole or short shaft 2 hole lugs for termination as shown below.
Frame Size R7 R8 Input Connection 1) NEMA Single Hole 2) NEMA 2 Hole Output Connection 2) NEMA 2 Hole 2) NEMA 2 Hole
Note: The R7 Input is being connected directly to the input disconnect ony one wire
per phase. All landing points for short shaft NEMA 2 holes lugs are to bus bar.
A-12
PumpSmart AC Drives
A lug may be landed on the front and back of the bus bar . Input Power Terminals / Motor Terminals
ACx 600 Type T Grounding Ground PE Grounding Terminals T Lbs-ft/ Nm
Cabinet (Frame)
Lbs-ft/Nm
ACx 607-0100-3/0120-4/0100-6 ACx 607-0120-3/0140-4/0120-6 ACx 607-0140-3/0170-4/0140-6 ACx 607-0170-3/0210-4/0170-6 ACx 607-0210-3/0260-4/0210-6 ACx 607-00260-6 ACx 607-0260-3/0320-4/0320-6 ACx 607-0320-3/0400-4/0400-6 ACx 607-0400-3/0490-5/0490-6 ACx 607-0490-3/0610-5/0610-6 ACx 607-0610-3/0760-5/0760-6
22/30 22 33/44 33/44 33/44 33/44 33/44 33/44 41/55 41/55 41/55
M12 M12 M12 M12 M12 M12 M12 M12 M10 (2x2 pcs) M10 (2x2 pcs) M10 (2x2 pcs)
22/30 22/30 22/30 22/30 22/30 22/30 22/30 22/30 26/35 26/35 26/35
MNS (R7) MNS (R8)
MNS (R9)
MNS (2xR8) MNS (2xR9)
Power and Ground Cable Terminations
All ACS 607 input and output connections require the customer to provide their own cable lugs for connection to the drive. You may use a single hole ABB Controls lug or a UL/UR approved equivalent lug from the vendor of your choice.
Manufacturer ABB Control ABB Control ABB Control ABB Control ABB Control ABB Control ABB Control ABB Control ABB Control ABB Control Model Number OZXA-25 OZXA-26 OZXA-26 OZXA-26 OZXA-26 OZXA-27 OZXA-27 OZXA-27 OZXA-27 OZXA-27 Recommended Wire Size* 6AWG-300kcmil 2AWG-600kcmil 2AWG-600kcmil 2AWG-600kcmil 2AWG-600kcmil (2) 2AWG-600kcmil (2) 2AWG-600kcmil (2) 2AWG-600kcmil (2) 2AWG-600kcmil (2) 2AWG-600kcmil
ABB 604/607 Types ACS 607-0100-3/0120-4/0120-5/0100-6 ACS 607-0120-3/0140-4/0140-5/0120-6 ACS 607-0140-3/0170-4/0170-5/0140-6 ACS 607-0170-3/0210-4/0210-5/0170-6 ACS 607-0210-3/0260-4/0260-5/0210-6 ACS 607-0260-3/0320-4/0320-5/0260-6 ACS 607-0320-3/0400-4/0400-5/0320-6 ACS 607-0400-3/0490-5/0490-6 ACS 607-0490-3/0610-5/0610-6 ACS 607-0610-3/0760-5/0760-6
*If larger or smaller wire is necessary, use a UL/UR approved equivalent lug.
PumpSmart AC Drives
A-13
External Control Connection Diagrams
External control connections of PumpSmart equipped with PumpSmart Application Program are shown below. External control wiring is connected either directly to terminals on the NIOC board on the ACS 601 or ACS 607 or through an optional terminal block (not shown) on the ACS 607. If an optional I/O terminal block is furnished, the control panel code (16th digit) of the ACS 600 type code will contain a 4 or 5. If the optional I/O terminal block is not furnished, the control panel code (16th digit in type code) of the ACS 600 type code is 1. Refer to Chapter 1 for the PumpSmart type code description. When making the external control connections be sure to carefully compare the terminal configuration found in the drive with diagrams below to be sure that the correct diagram is used. For applications with a combination of PumpSmart powered transmitter(s) and an externally powered flowmeter, refer to the appropriate drawing. For externally powered transmitters, the corresponding ground jumper shown in the wiring diagram for PumpSmart powered transmitters is omitted.
Drawing No. CO6928A CO6929A CO6927A CO6930A B04721A When Used All Transmitters powered by PumpSmart. AI1 and/or AI2 powered externally, vibration transmitter powered by PumpSmart. Use for speed control only. Optional NAIO-03 analog module for vibration transmitter #2 and/or analog outputs 3 and 4. DDCS link for multipump Control.
Multipump Applications with Secondary Protect
When using the SECONDARY PROTECT feature in multipump applications terminal X22-4 (digital input 4) is programmed to be closed under normal operation. For multipump applications with a direct connected single suction source, the pressure or flow switch must be powered externally and wired to a junction box having a normally open relay. Separate relay contacts must be provided and wired to each PS200 unit. This will prevent lag pumps from turning-on in case of a dry run or no flow fault. For multipump applications having multiple suction sources each PS200 unit must have its own pressure or flow switch for dry run or no flow protection.
Multicontrol Mode with One Process Transmitter
Multipump applications in multicontrol mode (parameter 22.01) may alternatively use just one process transmitter (e.g., flowmeter or pressure transmitter) for multicontrol of other PS200 units. In this arrangement the process transmitter is wired to terminals X21-5 and X21-6 (AI2) on the Master PS200 Unit and then wired in series to the aforementioned terminals on all other PS200 units. However, this
A-14
PumpSmart AC Drives
arrangement will not provide the PUMP PROTECT feature on the PS200 units. It is recommended that the SECONDARY PROTECT feature be used. Note: This cannot be done in synchronous control mode. Important: the process transmitter must be installed in a common header and must be on the downstream side of the check valve if furnished.
PumpSmart AC Drives
A-15
Appendix A - PumpSmart AC Drives Technical Data
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A-16
PumpSmart AC Drives
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A-18
PumpSmart AC Drives
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A-19
INTENTIONALLY LEFT BLANK
A-20
PumpSmart AC Drives
Enclosures, Space Requirements

ACS 600 Type 601 607 Enclosure
The cabinets, degrees of protection and free space requirements of ACS 600 types are given below.
Degree of Protection 2) Nema1/Nema12 Nema1/Nema12 Space above 12in 8 Space below 12in 0 Space on left/right 2/2in 0 Space in front/ back 0.8/0in 8/0
wall-mounted metal frame Drives-MNS cabinet
PS200 Floor Standing Drive (ACS 607) Space requirement for the door opening 700 mm (27.6 in.) (2 x R8 and 2 x R9) 800 mm (31.5 in.) (R7, R8 and R9)
Heat DIssipation Requirements
ACS 601 drives are self-cooled. The table below gives the heat dissipated into the hot air exhausted from the drives. If the drives are installed in a confined space, the heat must be removed from the area by ventilation or air conditioning equipment.
380 VAC / 480 VAC / 600 VAC

Heat Dissipation ACS 601 Type Watts ACS 601-0005 ACS 601-0006 ACS 601-0009 ACS 601-0011 ACS 601-0016 ACS 601-0020 ACS 601-0025 ACS 601-0030 ACS 601-0040 ACS 601-0050 ACS 601-0060 ACS 601-0070 ACS 601-0100 ACS 601-0120 ACS 601-0140 150 180 270 330 480 600 750 900 1200 1500 1800 2100 3000 3600 4200 BTU/Hr 512 615 922 1130 1640 2050 2560 3070 4100 5120 6150 7170 10200 12300 14300
ACS 601 Type Code 230 VAC ACS 601-0003-2 ACS 601-0005-2 ACS 601-0006-2 ACS 601-0009-2 ACS 601-0011-2 ACS 601-0016-2 ACS 601-0020-2 ACS 601-0025-2 ACS 601-0030-2 ACS 601-0040-2 ACS 601-0050-2 ACS 601-0060-2 ACS 601-0070-2 ACS 601-0080-2 ACS 601-0100-2 ACS 604-0125-2 ACS 604-0150-2 ACS 604-0200-2
Heat Dissipation Watts 112 156 182 217 370 540 620 1000 1120 1480 1880 2185 2950 3200 4300 6300 7800 9600 BTU/Hr 380 530 620 740 1265 1840 2120 3400 3800 5100 6400 7500 10100 10900 14700 21500 26600 32800
PumpSmart AC Drives
A-21
Heat DIssipation Requirements ACS 607 drives are self-cooled. The table below gives the heat dissipated into the hot air exhausted from the drives. If the drives are installed in a confined space, the heat must be removed from the area by ventilation or air conditioning equipment.
Heat Dissipation ACS 607 Type Watts ACS 607-0100 ACS 607-0120 ACS 607-0140 ACS 607-0170 ACS 607-0210 ACS 607-0260 ACS 607-0320 ACS 607-0400 ACS 607-0490 ACS 607-0610 ACx607-0760 3000 3600 4200 5100 6300 7800 9600 12000 14700 18300 22800 BTU/Hr 10200 12300 14300 17400 21500 26600 32800 40900 50200 62400 77800
A-22
PumpSmart AC Drives
Cooling Air Flow Requirements
Cooling air flow requirements are given below.
380 VAC / 480 VAC / 600 VAC 230 VAC

ACS 600 Type Code ACS 601-0003-2 ACS 601-0005-2 ACS 601-0006-2 ACS 601-0009-2 ACS 601-0011-2 ACS 601-0016-2 ACS 601-0020-2 ACS 601-0025-2 ACS 601-0030-2 ACS 601-0040-2 ACS 601-0050-2 ACS 601-0060-2 ACS 601-0070-2 ACS 601-0080-2 ACS 601-0100-2 ACS 604-0125-2 ACS 604-0150-2 ACS 604-0200-2 Flow m 3/h 40 40 50 60 150 150 260 280 300 300 350 500 550 660 700 1640 1840 1840 Flow ft3/h 25 25 30 35 90 90 155 165 175 175 210 295 325 390 410 965 1085 1085 ACS 607 ACS 607-0100-3/0120-4/0100-6 ACS 607-0120-3/0140-4/0120-6 ACS 607-0140-3/0170-4/0140-6/0170-6 ACS 607-0170-3/0210-4/0210-6 ACS 607-0210-3/0260-4/0260-6 ACS 607-0260-3/0320-4/0320-6 ACS 607-0320-3/0400-4/0400-6 ACS 607-0400-3/0490-5/0490-6 ACS 607-0490-3/0610-5/0610-6 ACS 607-0610-3/0760-5/0760-6 ACS 601 ACS 601-0005-3/0006-4 ACS 601-0006-3/0009-4 ACS 601-0009-3/0011-4 ACS 601-0011-3/0016-4/0009-6/0011-6 ACS 601-0016-3/0020-4/0016-6/0020-6 ACS 601-0020-3/0025-4/0025-6 ACS 601-0025-3/0030-4/0030-6 ACS 601-0030-3/0040-4/0040-6 ACS 601-0040-3/0050-4/0050-6 ACS 601-0050-3/0060-4 ACS 601-0060-3/0070-4/0060-6 ACS 601-0070-3/0100-4/0070-6 ACS 601-0100-3/0120-4/0100-6 ACS 601-0120-3/0140-4/0120-6 Flow m3 /h 40 40 40 60 60 70 100 260 260 260 280 280 660 660 Flow m3/h 660 660 1640 1640 1640 1840 1840 3580 3980 3980 Flow ft3/h 25 25 25 35 35 40 60 155 155 155 165 165 390 390 ft3 /hr 390 390 1000 1000 1000 1100 1100 2100 2300 2300
Cooling Air Duct

Degree of protection
Heat dissipations and cooling air flows of ACS 601 in a cooling air duct installation are below.
Heat Dissipation Degree of protection Cooling Air Flow Out
Heatsink IP 22 85 % of ACS 600 losses 90 % of ACS 600 losses
Front Section 15 % of ACS 600 losses 10 % of ACS 600 losses IP 22
Heatsink 80 % of air flow
Front Section 20 % of air flow
IP 54
IP 54
100 % of air flow
0 % of air flow
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A-23
Dimensions and Weights

Dimensions and weights of the wall-mounted ACS/ACC/ACP 601 units are given below.
ACS 601 Type ACS 601-0003-2 ACS 601-0005-2 ACS 601-0006-2 ACS 601-0009-2
ACS 600
Height mm/in 420/16.5
Width mm/in 220/8.7 220/8.7 220/8.7 220/8.7 260/10.2 260/10.2 306/12.0 306/12.0 306/12.0 306/12.0 306/12.0 306/12.0 306/12.0 480/18.9 480/18.9
Depth mm/in 292/11.5 292/11.5 292/11.5 292/11.5 298/11/7 298/11.7 310/12.2 310/12.2 360/14.2 360/14.2 360/14.2 432/17.0 432/17.0 428/16.9 428/16.9
Weight kg/lb 14/31 14/31 14/31 14/31 17.5/39 17.5/39 25/55 25/55 35/77 35/77 35/77 50/110 50/110 88/194 88/194
0005-3 0006-3 0009-3 0011-3 0016-3 0020-3 0025-3 0030-3 0040-3 0050-3 0060-3 0070-3 0100-3 0120-3
0006-4 0009-4 0011-4 0016-4 0020-4 0025-4 0030-4 0040-4 0050-4 0060-4 0070-4 0100-4 0120-4 0140-4 0060-6 0070-6 0100-6 0120-6 0009-6/0011-6 0016-6/0020-6 0025-6 0030-6 0040-6 0050-6
420/16.5 420/16.5 420/16.5 420/16.5 420/16.5 526/20.7 526/20.7 715/27.8 715/27.8 715/27.8 715/27.8 715 860/33.9 860/33.9
ACS 601-0011-2 ACS 601-0016-2

AC T PA R FU N C D R I VE
E N T E R
ACS 601-0020-2 ACS 601-0025-2 ACS 601-0030-2 ACS 601-0040-2 ACS 601-0050-2 ACS 601-0060-2 ACS 601-0070-2 ACS 601-0080-2 ACS 601-0100-2
L O C
R ES E T
REF
REM
ACS 607 Enclosure Size and Style
The ACS 607 enclosure size and style is determined by the following product and option selection items as indicated by the Type Code. The ACS 600 Type Codes are explained in detail in Chapter 1.
Product and Option Selection Item Power Rating Voltage Rating Enclosure degree of protection (IP No.) EMC (RFI) Filters Braking chopper and cabling direction Type Code Character No. 7 - 10 11 17 20 21
The dimension and weight table on the following page lists power and voltage rating type codes and provides dimensions for each listing. The Height column contains two sets of figures, one for the (Nema 1) IP 21 / IP 22 / IP 42 version and one for the (Nema 12) IP 54 version. Several columns are provided to show the enclosure widths for the various combinations of EMC filter and braking options. The letters A), B) etc. included in the width columns indicate the applicable dimension drawings in Appendix B as listed in the table notes below.
A-24
PumpSmart AC Drives
Notes for the ACS 607 Dimension Table

Notes: Applicable Dimension Drawings in 1) Appendix B: Height of the Nema 1 version. A) 3AFE 61417184 - See Appendix B 2) Height of the Nema 12 filtered B) and ventilated version. 3AFE 61417206 - Refer to Factory 3) Weight of the (Nema 1) IP 21 / IP C) 3AFE 61417214 - Refer to Factory D) 3AFE 61477390 - Refer to Factory 22 / IP 42 version 4) Weight of the 690 V unit with dv/ E) 3AFE 61417222 - Refer to Factory F) 3AFE 61477381 - Refer to Factory dt filter G) Refer to factory
PumpSmart AC Drives
A-25
A-26
Width mm (in) with: Frame Size EMC Filter Braking Chopper 830 A) (32.7) 644 (25.35) 644 (25.35) 644 (25.35) 644 (25.35) 1630 D) (64.2) 1930 F) (76) 1630 D) (64.2) 1630 D) (64.2) 1630 D) (64.2) 1530 E) (60.2) G) 2930 G) (115.4) 2930 G) (115.4) G) G) G) 1630 D) (64.2) G) G) G) 1930 F) (76) 1930 F) (76) 1930 F) (76) 1930 F) (76) G) G) G) 644 (25.35) 644 (25.35) 644 (25.35) 644 (25.35) 644 (25.35) 644 (25.35) 644 (25.35) 644 (25.35) 644 (25.35) 830 A) (32.7) 1230 C) (48.4) 1230 C) (48.4) 1230 C) (48.4) 1230 C) (48.4) 1230 C) (48.4) 1230 C) (48.4) 1230 C) (48.4) 1230 C) (48.4) 2930 G) (115.4) 1530 E) (60.2) 1530 E) (60.2) 1530 E) (60.2) 1530 E) (60.2) 1630 D) (64.2) 1230 C) (48.4) 1630 D) (64.2) 1530 E) (60.2) 1630 D) (64.2) 1930 F) (76) 1230 C) (48.4) 1630 D) (64.2) 1630 D) (64.2) 1230 C) (48.4) 830 A) (32.7) 1630 D) (64.2) 1230 C) (48.4) 830 A) (32.7) 1630 D) (64.2) Height 1) mm (in) No EMC Filter or Braking Depth mm (in) 830 A) (32.7) 830 A) (32.7) 830 A) (32.7) 830 A) (32.7) 830 A) (32.7) 830 A) (32.7) 830 A) (32.7) 830 A) (32.7) 830 A) (32.7) 830 A) (32.7) 2130 G) (83.9) G) G) 2130 G) (83.9) 2130 G) (83.9) 1230 B) (48.4) 1230 B) (48.4) 1230 B) (48.4) 1230 B) (48.4) 1230 B) (48.4) 1230 B) (48.4) 1230 B) (48.4) 1230 B) (48.4) 830 A) (32.7) 830 A) (32.7) 275/3004) (605)/(660) 275/3004) (605)/(660) 340/3904) (748)/(858) 345/3904) (749)/(858) 345/3904) (749)/(858) 345/3904) (749)/(858) 370 (814) 370 (814) 375/4354) (825)/(957) 375/4354) (825)/(957) 710 (1562) 870 (1914) 870 (1914) Braking Chopper and Resistors EMC Filter and Braking Chopper EMC Filter, Braking Chopper & Resistors Weight 3) kg (lbs) R7 R7 R8 R8 R8 R8 R9 R9 R9 R9 2xR8 2xR9 2xR9 2065/2215 (81.3)/(87.2) 2065/2215 (81.3)/(87.2) 2065/2215 (81.3)/(87.2) 20781)/23162) (81.8)/(91.2) 20781)/23162) (81.8)/(91.2) 20781)/23162) (81.8)/(91.2) 20781)/23162) (81.8)/(91.2) 20781)/23162) (81.8)/(91.2) 20781)/23162) (81.8)/(91.2) 20781)/23162) (81.8)/(91.2) 20781)/23162) (81.8)/(91.2) 20781)/23162) (81.8)/(91.2) 20781)/23162) (81.8)/(91.2)
Dimensions and Weights (ACS 607)
ACS 607 Type Code
0100-3 0120-4 0100-6
0120-3 0140-4 0120-6
0140-3 0170-4 0140-6 0170-6
0170-3
0210-4 0210-6
0210-3 0260-4 0260-6
0260-3
0320-3
0320-4 0320-6
0400-4 0400-6
0400-3 0490-5 0490-6
0490-3 0610-5 0610-6
0610-3 0760-5 0760-6
1)
PumpSmart AC Drives
2)
Height of the Nema 1 version. Height of the Nema 12 filtered and ventilated version.
Input Power Connection
Voltage (U1): 208/230/240 VAC 3-phase 10 % for 230 VAC units 380/400/415 VAC 3-phase 10 % for 400 VAC units 380/400/415/440/460/480/500 VAC 3-phase 10 % for 500 VAC units 525/550/575/600/660 VAC 3-phase 10 % for 690 VAC units 690 VAC 3-phase 5 % for ACS 607 units Short Circuit Capability: The rated short time withstand current of ACS 600 is 50 kA 1s. Frequency: 48 to 63 Hz, maximum rate of change 17 %/s Imbalance: Max. 3 % of nominal phase to phase input voltage Fundamental Power Factor (cos 1): 0.97 (at nominal load)
Motor Connection
Voltage (U2): 0 to U1, 3-phase symmetrical Frequency: DTC mode: 0 to 3.2 fFWP . Maximum frequency 300 Hz.
fFWP = UNmains UNmotor fNmotor
fFWP: Frequency at field weakening point; UNmains: Mains voltage; UNmotor: Rated motor voltage; fNmotor: Rated motor frequency
Scalar Control mode: 0 to 300 Hz With du/dt Filter (DTC) : 0 to 120 Hz Frequency Resolution: 0.01 Hz Continuous Current: 1.0 I2N (normal use) Short Term Overload Capacity (1 min/10 min): I2Nmax = 1.1 I2N Peak Overload Capacity (2 s/15 s): 1.5 I2N (400 and 500 VAC units) Power Limit: 1.5 Phd Overcurrent Trip: 2.4 I2N Field Weakening Point: 8 to 300 Hz Switching Frequency: 3 kHz (average). In 690 V units 2 kHz (average). Refer to external control connection drawings A-16 through A-20 Maximum Recommended Motor Cable Length: 300 m (980 ft.). This is the cumulative length in case of parallel connected motors. For 460V motors an output reactor is required for cable lengths >375 FT and a dv/dt filter is required if cable length exceeds 600 FT. For 575V
PumpSmart AC Drives
A-27
motors, a dv/dt filter is always required. Bearings of motors larger than 90 kW (125 Hp): Insulated bearing at non-driven end is recommended.
Efficiency and Cooling
Efficiency: Approximately 98 % at nominal power level Cooling Method: Internal fan, flow direction from the bottom to the top
Ambient Conditions
ACS 600 Installation Site Altitude Air Temperature
ACS 600 AC drives are to be used in a heated, indoor controlled environment as specified below.
Storage in the protective package Transportation in the protective package -
Operation installed for stationary use Nominal output power at 0 to 1000 m (3300) above sea level. 1) 0 to +40 C (32 to 104 F) 2) (IP 21/22 and ACS 607 with IP 54) 0 to +25 C (32 to 77 F) 2) (ACS 601 with IP 54) 5 to 95 %
-40 to +70 C -40 to +158 F
-40 to +70 C -40 to +158 F
Relative Humidity
Max. 95 %
Max. 95 %
No condensation allowed. Maximum allowed relative humidity is 60 % in the presence of corrosive gases. Contamination Levels (IEC 721-3-3) No conductive dust allowed. Boards without coating: Chemical gases: Class 3C2 Solid particles: Class 3S2 Boards with coating: Chemical gases: Class 3C3 Solid particles: Class 3S2 Atmospheric Pressure Vibration (IEC 68-2-6) Shock (IEC 68-2-29) Free Fall 70 to 106 kPa 0.7 to 1.05 atmospheres Max. 0.3 mm (0.01 in) (2 to 9 Hz), max. 1 m/s2 (3.3 ft/s2)(9 to 200 Hz) sinusoidal Not allowed Not allowed Boards without coating: Chemical gases: Class 1C2 Solid particles: Class 1S3 Boards with coating: Chemical gases: Class 1C2 Solid particles: Class 1S3 70 to 106 kPa 0.7 to 1.05 atmospheres Max. 1.5 mm (0.06 in) (2 to 9 Hz), max. 5 m/s2 (16.4 ft/s2) (9 to 200 Hz) sinusoidal Max. 100 m/s2, 11 ms (330 ft/s2) 250 mm (10in) (weight under 100 kg) (220 lbs) 100 mm (4 in)(weight over 100 kg) (220 lbs) Boards without coating: Chemical gases: Class 2C2 Solid particles: Class 2S2 Boards with coating: Chemical gases: Class 2C2 Solid particles: Class 2S2 60 to 106 kPa 0.6 to 1.05 atmospheres Max. 3.5 mm (0.14 in) (2 to 9 Hz), max. 15 m/s2 49.2 ft/s2) (9 to 200 Hz) sinusoidal Max. 100 m/s2, 11 ms (330 ft/s2) 250 mm (10in) (weight under 100 kg) (220 lbs) 100 mm (4 in)(weight over 100 kg) (220 lbs)
1)
At sites over 1000 m (3300 ft) above sea level, the maximum output current is derated 1 % for every additional 100 m (330 ft). If the installation site is higher than 2000 m (6600 ft) above sea level, please contact your local ABB distributor or office for further information.
2)
See subsection Output Current Temperature Derating , page A-3.
A-28
PumpSmart AC Drives
External Control Connections
Data of the external control connection boards of the ACS 600 product family are given below.
ACS 600 NIOC-01 Board Analog Inputs The advantage of the differential analog input is that the ground potential of the device or transmitter sending an analog signal can differ up to 15 V from the ground potential of the ACS 600 chassis without disturbing the signal. Differential input also efficiently attenuates common mode disturbances coupled to control cables. Constant Voltage Output ACS 600: Two Programmable Differential Current Inputs: 0 (4) to 20 mA, Rin = 100 ACS 600: One Programmable Differential Voltage Input: ACS 600: 0 (2) to 10 V, Rin > 200 k ; ACP 600: 0 to 10 V, Rin > 200 k Common Mode Voltage: 15 VDC, max. Common Mode Rejection Ratio: > 60 dB at 50 Hz Resolution: 0.1 % (10 bit) Inaccuracy: 0.5 % (Full Scale Range) at 25 C (77 F). Temperature Coefficient: 100 ppm/C (56 ppm/ F), max. Input Updating Time: 12 ms (ACS 600), 44 ms (ACC 600), 1 ms (ACP 600)
Voltage: 10 VDC 0.5 % (Full Scale Range) at 25 C (77 F). Temperature Coefficient: 100 ppm/C (56 ppm/ F), max. Maximum Load: 10 mA Applicable Potentiometer: 1 k to 10 k Voltage: 24 VDC 10 %, Short circuit proof Maximum Current: 250 mA (130 mA with NLMD-01 option) ACS 600: Two Programmable Current Outputs: 0 (4) to 20 mA, RL < 700 Resolution: 0.1 % (10 bit) Inaccuracy: 1 % (Full Scale Range) at 25 C. Temperature Coefficient: 200 ppm/C (110 ppm/ F), max. Output Updating Time: 24 or 100 ms (ACS 600), 44 ms (ACC 600), 8 ms (ACP 600)
Auxiliary Power Output Analog Outputs
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A-29
ACS 600 NIOC-01 Board Digital Inputs ACS 600: Six Programmable Digital Inputs (Common Ground): 24 VDC, -15 % to +20 % Logical Thresholds: < 8 VDC > 12 VDC 1 0,
Input Current: DI1 to DI 5: 10 mA, DI6: 5 mA Filtering Time Constant: 1 ms Thermistor Input: 5 mA, < 1.5 k 1 (normal temperature), > 4 k 0 (high temperature), Open Circuit 0 (high temperature) Internal Supply For Digital Inputs (+24 VDC): Short circuit proof, group isolated Isolation Test Voltage: 500 VAC, 1 minute Input Updating Time: 12 ms (ACS 600), 44 ms (ACC 600), 4 ms (ACP 600) An external 24 VDC supply can be used instead of the internal supply. Digital Outputs Relay Outputs Three Programmable Relay Outputs Switching Capacity: 8 A at 24 VDC or 250 VAC, 0.4 A at 120 VDC Maximum Continuous Current: 2 A rms Contact Material: Silver Cadmium Oxide (AgCdO) Isolation Test Voltage: 4 kVAC, 1 minute Output Updating Time: 100 ms (ACS 600), 44 ms (ACC 600), 8 ms (ACP 600) Protocol: DDCS (ABB Distributed Drives Communication System)
DDCS Fiber Optic Link
Refer to the external control connections drawings (A-16 through A-20) for NIOC Board assignments.
Materials
Enclosure (ACS 601) PS (polystyrene) 3 mm (0.12 in) hot-dip zinc coated steel sheet 1.5 to 2 mm(0.06 to 0.08 in) painted with epoxy polyester powder paint anodized aluminium profile (R2 to R6) Package (ACS 601) corrugated board (frames R2 to R5 and option modules), plywood (R6). Plastic covering of the package: PE-LD, bands PP or steel. Thickness of Coating 60 m Color NCS 1502-Y (RAL 90021 / PMS 420 C) NCS 8502-Y (RAL 9004 / PMS 426 C) semigloss black ES 900
A-30
PumpSmart AC Drives
Disposal
ACS 600 contains raw materials that should be recycled, thus preserving energy and natural resources. Package materials of ACS 600 units and options are environmentally compatible and recyclable. All metal parts can be recycled. The plastic parts can either be recycled or burned under controlled circumstances, according to local regulations. If recycling is not feasible, all parts excluding electrolytic capacitors can be landfilled. The DC capacitors of the unit contain electrolyte which is classified as hazardous waste. (Location of the electrolytic capacitors is shown on a sticker in the back of the front cover, C11 to C13.) They must be removed and handled according to local regulations. For further information on environmental aspects, please contact your local ABB distributor.
UL/CSA Markings
The UL/ULC/CSA markings of the ACS 600 drives are listed below (x). ACS 600 Type ACS 601 (IP 22) 400 V, 500 V and 6001) V ranges ACS 601 (IP 54) ACS 604 frame sizes R7 to R9 400 V, 500 V and 6001) V ranges ACS 604 600 V parallel connected units 1) the approval is valid up to 600 V UL x x x pending UL C x x x pending CSA x pending x pending
UL
ACS 600 is suitable for use in a circuit capable of delivering not more than 65 kA rms symmetrical amperes at 480 V maximum (500 V units), and at 600 V maximum (690 V units). PumpSmart AC Drives are to be used in a heated indoor controlled environment. See subsection Ambient and Altitude Derates of Appendix A in this manual for specific limits. Note that it is possible to provide PumpSmart in an enclosure appropriate for outdoor installations. It would be an engineered solution. Please contact your ITT Industries Goulds Pumps representative for information.
Fault Tolerance
A fault tolerance matrix is shown on page A-32. This matrix shows standard and optional fault protection for each control mode.
PumpSmart AC Drives
A-31
PS200 Fault Tolerance Matrix

Fault Conditon Pump Protect Control - Loss of Suction (Dry Running) Pump Protect Control - Excessive Runout Flow (Cavitation) Secondary Protect Control - No Flow/ Dry Run/Low Level Protection (Flow Switch/Pressure Switch or Level Switch Required) Shutoff Protection High Vibration - Bearing Housing (Vibration Transmitter Required) Transmitter Failure Keypad Failure Motor Phase Loss Earth Fault Over Current Over Torque Over Voltage Under Voltage Over Temp - VFD Over Temp - Motor Speed Control N/A N/A Optional Pressure Standard Standard Optional See Note 2 Flow Standard Standard Level or Temperature Control See Note 1 See Note 1
Optional Optional See Note 2
Optional See Note 3 Optional Standard Standard Standard Standard Standard Standard Standard Standard Standard Standard
Standard Optional Standard Standard Standard Standard Standard Standard Standard Standard Standard Standard
1. Due to slow system response for level and temperature applications an optional flow switch is required for this protection. 2. An optional flow switch, pressure switch or level switch is desirable in single pump applications where the Pump Protect Control Delay is set long. A flow switch will protect against dry running or no flow conditions, a pressure switch will protect against dry run or low suction conditions and a level switch will protect against low tank level conditions. For multipump systems with common header an optional pressure switch or flow switch is required to protect against loss of suction. For multipump systems with individual suction sources an optional pressure switch or flow switch is required for each suction line to prevent dry running. 3. An optional flow switch (Secondary Protect) is required for this protection. For multipump applications a flow switch is required for each pump to enable this protection.
PumpSmart Minimum Instrumentation Specifications
Available PS200 Instruments: Pressure Transmitter Differential Pressure Transmitter (required when differential pressure type external flowmeters are used).
A-32
PumpSmart AC Drives
Process temperature transmitter Flowmeter: - Differential pressure type external flowmeter (orifice plate, venturi etc.) - Direct reading external flowmeter (magmeter,vortex, coriolis etc.) Level Transmitter (level control applications only) Minimum Specifications: 4-20 mA output Overall accuracy: +/- 0.5% full scale Stability: +/- 0.2% full scale Supply Voltage: 24 VDC (if powered by PumpSmart) Response Time: - 100 Milliseconds minimum for pressure and differential pressure transmitters. - 200 Milliseconds recommended for direct external flowmeters. - 500 Milliseconds minimum for temperature transmitters. NOTE: Flowmeters having response times of up to 1 second are permissible for use on the PS200. However, system response to a setpoint change may increase by a factor of 2 to 2.5. System response from startup to setpoint may increase by a factor of three. Pressure transmitters must be gage type pressure transmitters.
PumpSmart AC Drives
A-33
Typical Instrument Mountings

Note: If a check valve is installed in the pump discharge line, be sure that the process transmitter is installed downstream of the check valve. Do not install the process transmitter between the pump and check valve.
Pump Mounted Instrumentation*
Spool Piece Mounted Instrumentation with Diaphragm Seals* *The PS200 requires only one instrument to operate. Certain PS200 features such as offsets and variable setpoint (refer to PS200 Programming Manual) require a second transmitter.
A-34
PumpSmart AC Drives
Typical Instrument Mountings
* The PS200 requires only one instrument to operate. Certain PS200 features such as offsets and variable setpoint (refer to PS200 Programming Manual) require a second transmitter.
PumpSmart AC Drives
A-35
A-36
PumpSmart AC Drives
PumpSmart AC Drives
A-37
Appendix B PumpSmart AC Drives Dimensional Drawings
The following drawing package is effective from 5/10/98.
Gland Plate Holes (IEC Units)

Frame Hole R2 ACS 601-0005-3 ACS 601-0006-3 ACS 601-0009-3 ACS 601-0006-5/-4 ACS 601-0009-5/-4 ACS 601-0011-5/-4 mm SIGN IN/OUT BR 23 29 29 23 ACS ACS ACS ACS ACS R3 601-0009-6 601-0011-3/-6 601-0016-3 601-0016-5/-6/-4 601-0020-5/-6/-4 ACS ACS ACS ACS R4 601-0020-3 601-0025-3/-6 601-0025-5/-4 601-0030-5/-6/-4 R5 ACS 601-0030-3 ACS 601-0040-3/-4 ACS 601-0050-3/-4 ACS 601-0040-5/-6 ACS 601-0050-5/-6 ACS 601-0060-5/-4 mm 29 37 37 23 ACS ACS ACS ACS R6 601-0060-3/-6 601-0070-3/-4 601-0070-5/-6 601-0100-5/-4 ACS ACS ACS ACS R7 601-0100-3/-6 601-0120-3/-4 601-0120-5/-6 601-0140-5/-4
mm 23 29 29 23
mm 29 37 29 23
mm 29 48 37 23
mm 29 60 60 29
PumpSmart AC Drives
B-1
Frame R2
TYPE (ACS = ACS/ACC/ACP) ACS 601-0005-3 ACS 601-0006-3 ACS 601-0009-3 ACS 601-0006-5/-4 ACS 601-0009-5/-4 ACS 601-0011-5/-4 WEIGHT 14 kg 14 kg 14 kg 14 kg 14 kg 14 kg
Air out
Air out
Main air out
Air in
Flange mounting
Wall mounting
Air in
B-2
PumpSmart AC Drives
Frame R2 Flange Mounting
PumpSmart AC Drives
B-3
Frame R3
TYPE (ACS = ACS/ACC/ACP) ACS 601-0011-3 ACS 601-0016-3 ACS 601-0016-5/-4 ACS 601-0020-5/-4 ACS 601-0009-6/0011-6 ACS 601-0009-6/0020-6
WEIGHT 17.5 kg 17.5 kg 17.5 kg 17.5 kg 17.5 kg 17.5 kg
Bottom view
Air out
Air out
Air out
Flange mounting
Wall mounting
Air in
Air in
B-4
PumpSmart AC Drives
Frame R4
TYPE (ACS = ACS/ACC/ACP) ACS 601-0020-3 ACS 601-0025-3 ACS 601-0025-5/-4 ACS 601-0030-5/-4 ACS 601-0025-6 ACS 601-0030-6 WEIGHT 25 kg 25 kg 25 kg 25 kg 25 kg 25 kg
PumpSmart AC Drives
B-5
Frame R5/R6 Flange Mounting
B-6
PumpSmart AC Drives
Frame R5/R6
TYPE (ACS = ACS/ACC/ACP) ACS 601-0030...0050-3 ACS 601-0040...0060-5/-4 ACS 601-0040-6/-0060-6 ACS 601-0060...0070-3/-4 ACS 601-0070...0100-5/-4 ACS 601-0060-6/-0070-6 WEIGHT 35 kg 35 kg 35 kg 50 kg 50 kg 50 kg L1 190.5 190.5 190.5 262.5 262.5 262.5
PumpSmart AC Drives
B-7
Frame R7
TYPE (ACS = ACS/ACC/ACP) ACS 601-0100-3/-6 ACS 601-0120-3/-4 ACS 601-0120-5/-6 ACS 601-0140-5/-4 WEIGHT 88 kg 88 kg 88 kg 88 kg
B-8
PumpSmart AC Drives
Conduit Plates (USA Version)
The following figures show the conduit plate (bottom view) of the different size ACS 600 units: At least three separate rigid metallic conduits must be used; one each for input power, output power, and control wires. Additionally, a separate conduit must be used for dynamic braking device, if used.
R2
3/4 1/2 1/2 1/2
R3
3/4 3/4 1/2 3/4
R4
3/4
3/4
3/4
3/4
Conduit Entry Plates, R2 - R4 USA Version
PumpSmart AC Drives
B-9
R5
3/4
1-1/4
1-1/4
1-1/4
R6
3/4
1-1/4
1-1/2
1-1/2
R7
2-1/2
2-1/2
2-1/2
Conduit Entry Plates, R5- R7 USA Version
B-10
PumpSmart AC Drives
PumpSmart AC Drives
B-11
B-12
PumpSmart AC Drives
ACS 607 Dimension Drawing R7-R9 Drawing 3AFE61417184
PumpSmart AC Drives
B-13
ACS 607 R7 Cable Connections, Top Entry/Top Exit - Drwg 3AFE 61477543
B-14
PumpSmart AC Drives
ACS 607 R8-R9 Cable Connections Top Entry/Exit Drwg 3AFE 61477497
PumpSmart AC Drives
B-15
Appendix C IEC Installation
IEC Installations
This appendix is a supplement to Chapter 3 Electrical Installation. It contains additional information to be used in IEC installations. For installations requiring CE compliance, refer to ITT Industries Goulds Pumps. For ACS 601 frame size R5 and larger or larger 30 kW motors symmetrical shielded motor cable must be used (figure below). A fourconductor system can be used up to frame size R4 with up to 30 kW motors, but shielded symmetrical motor cable is recommended. A four-conductor system is allowed for power cabling, but shielded symmetrical cable is recommended. To operate as a protective conductor, the shield conductivity must be at least 50 % of the conductivity of the phase lead. Compared to a four-conductor system, the use of symmetrical shielded cable reduces electromagnetic emission of the whole drive system as well as motor bearing currents and wear. The motor cable and its PE pigtail should be kept as short as possible in order to reduce electromagnetic emission as well as capacitive current.
Power Cables
Alternative Power Cable Types
Power cable types that can be used with ACS 600 are represented below.
Recommended Symmetrical shielded cable: three phase conductors and a concentric or otherwise symmetrically constructed PE conductor, and a shield PE conductor and shield Shield A separate PE conductor is required if the conductivity of the cable shield is < 50 % of the conductivity of the phase conductor. Shield
PE
PE
A four-conductor system: three phase conductors and a protective conductor.
PE
Shield
Not allowed for motor cables
Not allowed for motor cables larger than 10 mm2 (motors > 30 kW).
PumpSmart AC Drives
C-1
Motor Cable Shield
To effectively supress radiated and conducted radio-frequency emissions, the shield conductivity must be at least 1/10 of the phase conductor conductivity. One way of evaluating the effectiveness of the shield is the shield inductance, which must be low and only slightly dependent on the frequency. These requirements are easily met with a copper or aluminium shield. The minimum requirement of the motor cable shield of the ACS 600 is shown below. It consists of a concentric layer of copper wires with an open helix of copper tape. The better and tighter the shield is, the lower is the emission level and the bearing currents.
Copper wire screen Helix of copper tape Inner insulation
Insulation jacket
Cable core
Cable Routing
The motor cable should be installed away from other cable routes. Motor cables of several drives can be run in parallel installed next to each other. It is recommended that the motor cable, power cable and control cables be installed on separate trays (minimum distance 500 mm (20)). Long parallel runs of motor cable with other cables should be avoided in order to decrease electromagnetic interference caused by the rapid changes in the frequency converter output voltage. Where control cables must cross power cables make sure they are arranged at an angle as near to 90 degrees as possible. Extra cables should not be run through the ACS 600. The cable trays have good electrical bonding to each other and to the grounding electrodes. Aluminium tray systems can be used to improve local equalizing of potential. Below is a diagram of cable routing.
ACS 600
ACT
PAR
FUNC
DRIVE
ENTER
LOC R E M
RESET
REF
Power cable 90
min 300 mm (12)
Motor cable min 500 mm (20)
Control cables
C-2
PumpSmart AC Drives
Cable Connections
Recommended earthing, mains and motor cable connections are presented below. See Appendix B Dimensional Drawings to locate the terminals
1) Alternative to earthing of the ACS 601 and the motor through the cable screen. Note: Connecting the fourth conductor of the motor cable at the motor end increases bearing currents, thus causing extra wear. 2) Used if the conductivity of the cable screen is < 50 % of the conductivity of the phase conductor.
Earth the other end of the mains cable at the distribution board. For minimum radio frequency interference (RFI) at the motor end, earth the cable screen 360 degrees at the lead-through of the motor terminal box or earth the cable by twisting the screen (flattened width > 1/5 length).
Earthing, Power, and Motor Cable Connections
1.
Lead the power cable through the INPUT cable entry, and the motor cable through the OUTPUT entry into the unit. Frame R7: Remove the rubber grommets from the INPUT and OUTPUT entries and cut them to adequate diameter for the power and the motor cable. To ensure proper sealing cut along the diameter marking which corresponds to the cable diameter.
2. Connect the phase conductors of the power cable to the U1, V1 and W1 terminals and the phase conductors of the motor cable to the U2, V2 and W2 terminals. 3. Connect the twisted screen of the power cable to the grounding terminal. Perform the same with the motor cable screen. Connect the additional PE conductors (if present) of the power and motor cables to the grounding terminal. Connect the separate PE conductor (if used) to the grounding terminal. Control Cable Connections 1. Lead the cable inside the unit through the SIGN entry.
Connect the conductor in appropriate terminal at the NIOC/NIOCP board (A2, refer Appendix A and Firmware Manual) and tighten screw to secure connection. Connect the twisted screen (grounding wires) to
PumpSmart AC Drives
C-3
the grounding rail
next to the NIOC/NIOCP board.
Components Connected to Digital/ Analog Inputs
WARNING! IEC 664 requires double or reinforced insulation between live parts and the surface of accessible parts of electrical equipment which are either non-conductive or conductive but not connected to the ground (PE). To fulfil this requirement, the connection of a thermistor (and other similar components) to the digital inputs of ACS 600 can be implemented in three alternate ways: 1. There is double or reinforced insulation between the thermistor and live parts of the motor. 2. Circuits connected to all digital and analog inputs of the ACS 600 are protected against contact, and insulated with basic insulation (the same voltage level as the converter main circuit) from other low voltage circuits. 3. An external thermistor relay is used. The insulation of the relay must be rated for the same voltage level as the converter main circuit.
C-4
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APPLICATION FLEXIBILITY
Cooling Water Transfer & Loading Paper Stock Reboiler & Bottoms Pumps
Pressure or Temp Control Multi-Pump Sequencing Auto Load Sharing Eliminate Control Valves
Flow Control Auto Shut Off No Dry Run/Cavitation Total Protection for Mag Drive Pumps
Fan, Broke, Liquor, Digester Control Level, Pressure, Flow Improved Headbox Control
Increase Drain Down Control Suction Level Control Cavitation Eliminate Control Valves
Municipal Wastewater
Filtration
Slurry Pumps
Boiler Feed
Handle Wide Load Swings Multi-Pump Control Remote Diagnostics Reduce HP Requirements
Maintain Constant Flow as Filters Clog Fewer Filter Changes No Flow Protection
Control Pump Output Run Slower Run in Pump Sweet Spot Reduce Pump Wear
Level Control Reduce Recirculation Eliminate Valves Reduce Horsepower
OTHER PRODUCTS FROM PUMPSMART CONTROL SOLUTIONS PS100

2-30HP Motor Mount Nema 4 Easy to Install Pump Protection
PS300
3-800 HP Advanced Protection Engineered Solution
PS300C
Programmable Controller with PS300 Features Controls Any HP VFD Control Any Brand of VFD
Visit our website at www.gouldspumps.com or www.pumpsmart.net
Form IOMPS200 5/02
copyright 2002 Goulds Pumps, Incorporated, A subsidiary of ITT Industries, Inc.

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What are some of the main components and features of the PumpSmart control system?

What are some of the main components and features of the PumpSmart control system?

What are some recommended applications for using the PumpSmart control system?

What are some recommended applications for using the PumpSmart control system?

Goulds_ControlSolution_PS200_install_D502

Installation & Maintenance Guide

Warnings and Notes

Installation and Maintenance Safety

Ground Fault Protective Function

Emergency Stop Devices

Motor Insulation Requirements

VN 420 V 420 V < VN 500 V

Symbol VN VPK Rise time:

With dv/dt Filter

Power Factor Correction Capacitors

PumpSmart AC Drive Checks

U1 3-380...500V U2 3-0...U1 I1n/I1nsq 168/198A I2n/I2nsq 164/193A f1 48...63Hz f2 0...300Hz ACS60101405...

U1 3-380...480V U2 3-0...U1 I1hd/I1n 143/184A I2hd/I2n 141/180A f1 57...63Hz f2 0...300Hz ACS60101404...

IEC Ratings CE Marking FIIND Type Code

Serial Number Bar Code Type Code continued

Figure 1-1. ACS 601 Nameplate

ACS 601 Type Code

Appendix A: Application Programs

Refer to Appendix A: Enclosures

Note: *IP21, 22 enclosures correspond to Nema 1. IP 54 enclosures correspond to Nema 12.

PumpSmart AC Drive and Pump Check Inquiries

Chapter 2 Mechanical Installation

Check The Installation Site

Installation Site Checklist

Chapter 2 Mechanical Installation

ACS 601 Installation Procedure

Chapter 2 Mechanical Installation

Figure 2-1 Installing the ACS 601 on a wall.

ACS 601 Installation in a Cooling Air Duct

Chapter 2 Mechanical Installation

Lower screws first

Installation Procedure ACS 607

Chapter 3 Electrical Installation

Chapter 3 Electrical Installation

Disconnecting Means 601

Disconnecting Means 607

Input Line Fuses

Motor Overload Protection

Chapter 3 Electrical Installation

Cable Insulation Voltage Ratings

Chapter 3 Electrical Installation

Chapter 3 Electrical Installation

BICC Cables Corp. (Philsheath) Rockbestos Co. (Gardex) Oaknite (CLX)

a A double shielded twisted pair cable

b A single shielded twisted multipair cable

Wiring Connections 601

Chapter 3 Electrical Installation

Chapter 3 Electrical Installation

Figure 3-1 Frames R2 and R3: Removal of the cover

Figure 3-2 Frames R4 to R6: removal of the cover

Chapter 3 Electrical Installation

Figure 3-3 Frame R7: Removal of the cover

Chapter 3 Electrical Installation

ACS 601 AC Drive