ABB ACS800 Series Firmware Manual

Center winder/unwind control program

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Firmware manual (340 pages)

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Summary of Contents for ABB ACS800 Series

Page 1 ACS800 Firmware Manual Center Winder/Unwind Control Program...
Page 5: Table Of Contents
Providing feedback on ABB Drives manuals ........
Page 6 Program features Chapter overview ............. . 23 Local control vs.
Page 7 Diagnostics ..............36 Speed control performance figures .
Page 8 Master/Follower General ..............49 Checklist for a quick start-up .
Page 9 33 INFORMATION ............. 97 35 MTR TEMP MEAS .
Page 10 Table 5 Main Status Word (Actual Signal 02.26) ......151 Table 6 Auxiliary Status Word 4 (Actual Signal 02.28) ......152 Table 7 Auxiliary Status Word (Actual Signal 02.27).
Page 11 Figure B-6 SPD/TQ Chain 2 ..........200 Table of Contents...
Page 12 viii Table of Contents...
Page 13: Introduction To The Manual
Introduction to the manual Chapter overview The chapter includes a description of the contents of the manual. In addition it contains information about the compatibility, safety, intended audience, and related publications. Compatibility The manual is compatible with ACS800 Center Winder/Unwind Control Program (Version BJXR3300 and above).
Page 14: Product And Service Inquiries
Product and service inquiries Address any inquiries about the product to your local ABB representative, quoting the type code and serial number of the unit in question. A listing of ABB sales, support and service contacts can be found by navigating to www.abb.com/drives...
Page 15: Start-Up
Start-up Chapter overview The chapter instructs how to: • complete the initial start-up. • perform an identification run (ID Run) for the drive. How to start-up SAFETY The start-up may only be carried out by a qualified electrician. The safety instructions must be followed during the start-up procedure. See the appropriate hardware manual for safety instructions.
Page 16 Enter the motor data from the motor nameplate: Note: Set the motor data to exactly the same value as on the motor nameplate. ABB Motors For example, if the motor motor M2AA 200 MLA 4 nominal speed is 1440 rpm...
Page 17 -motor nominal power -> 0.0 rpm 99 START-UP DATA … Range: 0 9000 kW 09 MOTOR NOM POWER When the motor data has been entered, a warning appears. It -> 0.0 rpm ** WARNING ** indicates that the motor parameters have been set, and the drive is ID MAGN REQ ready to start the motor identification (ID magnetization or ID Run).
Page 18 SPEED LIMITS AND ACCELERATION/DECELERATION TIMES Set the minimum speed. L-> 0.0 rpm 20 LIMITS 01 MINIMUM SPEED Set the maximum speed. L-> 0.0 rpm 20 LIMITS 02 MAXIMUM SPEED Set the acceleration time 1. L-> 0.0 rpm 22 ACCEL/DECEL 02 ACCELER TIME 1 Set the deceleration time 1.
Page 19: How To Perform The Id Run
How to perform the ID Run For this application, the Standard ID Run must be performed. Uncouple the motor from the spool if possible. If the motor cannot be uncoupled from the spool, ensure the spool is at core. Note: DIIL must be made and 16.01 RUN ENABLE must be set to “Yes”...
Page 20 In general it is recommended not to press any control panel keys during the ID run. However: • The Motor ID Run can be stopped at any time by pressing the control panel stop key ( • After the ID Run is started with the start key ( ), it is possible to monitor the actual values by first pressing the ACT key and then a double-arrow key ( Start-up...
Page 21: Control Panel
The chapter describes how to control, monitor and change the settings of the drive using the control panel CDP 312R. The same control panel is used with all ACS800 series drives, so the instructions given apply to all ACS800 types. The display examples shown are based on the Standard Control Program;...
Page 22: Panel Operation Mode Keys And Displays
Panel operation mode keys and displays The figure below shows the mode selection keys of the panel, and the basic operations and displays in each mode. Actual Signal Display Mode Act. signal / Status row 1 L -> 1242.0 rpm I Fault history selection FREQ 45.00 Hz...
Page 23: Drive Control With The Panel
Drive control with the panel The user can control the drive with the panel as follows: • start, stop, and change direction of the motor • give the motor speed reference or torque reference • reset the fault and warning messages •...
Page 24: How To Set Speed Reference
How to set speed reference Step Action Press Key Display To show the status row. ->1242.0 rpm FREQ 45.00 Hz CURRENT 80.00 A FUNC POWER 75.00 % To switch to local control. 1 L ->1242.0 rpm FREQ 45.00 Hz (Only if the drive is not under local CURRENT 80.00 A control, i.e.
Page 25: Actual Signal Display Mode
Actual signal display mode In the Actual Signal Display Mode, the user can: • show three actual signals on the display at a time • select the actual signals to display • view the fault history • reset the fault history. The panel enters the Actual Signal Display Mode when the user presses the ACT key, or does not press any key within one minute.
Page 26: How To Display The Full Name Of The Actual Signals
How to display the full name of the actual signals Step Action Press Key Display To display the full name of the three Hold 1 L -> 1242.0 rpm I actual signals. FREQUENCY CURRENT POWER To return to the Actual Signal Display Release 1 L ->...
Page 27: How To Display And Reset An Active Fault
How to display and reset an active fault The table below includes the step-by-step instructions. WARNING! If an external source for start command is selected and it is ON, the drive will start immediately after fault reset. If the cause of the fault has not been removed, the drive will trip again.
Page 28: Parameter Mode
Parameter mode In the Parameter Mode, the user can: • view the parameter values • change the parameter settings. The panel enters the Parameter Mode when the user presses the PAR key. How to select a parameter and change the value Step Action Press Key...
Page 29: How To Adjust A Source Selection (Pointer) Parameter
How to adjust a source selection (pointer) parameter Most parameters define values that are used directly in the drive application program. Source selection (pointer) parameters are exceptions: They point to the value of another parameter. The parameter setting procedure differs somewhat from that of the other parameters.
Page 30: Function Mode
The parameter groups 98, 99 and the results of the motor identification are not included as default. The restriction prevents downloading of unfit motor data. In special cases it is, however, possible to download all. For more information, please contact your local ABB representative. Control panel...
Page 31: How To Download Data From The Panel To A Drive
How to download data from the panel to a drive Consider the notes in section How to copy data from a drive to the panel above. Step Action Press Key Display Connect the panel containing the uploaded data to the drive. Ensure the drive is in local control (L 1 L ->...
Page 32: Drive Selection Mode
Drive selection mode In normal use the features available in the Drive Selection Mode are not needed; the features are reserved for applications where several drives are connected to one panel link. (For more information, see Installation and Start-up Guide for the Panel Bus Connection Interface Module, NBCI, Code: 3AFY58919748).
Page 33: Reading And Entering Packed Boolean Values On The Display
Reading and entering packed boolean values on the display Some actual values and parameters are packed boolean, i.e. each individual bit has a defined meaning (explained at the corresponding signal or parameter). On the control panel, packed boolean values are read and entered in hexadecimal format. In this example, bits 1, 3 and 4 of the packed boolean value are ON: Bit 15 Bit 0...
Page 34 Control panel...
Page 35: Program Features
Program features Chapter overview The chapter describes program features. For each feature, there is a list of related user settings, actual signals, and fault and warning messages. Local control vs. external control The drive can receive start, stop and direction commands and reference values from the control panel or through digital and analog inputs.
Page 36: External Control
External control When the drive is in external control, the commands are given through the control terminal block on the standard I/O board (digital and analog inputs), optional I/O extension modules and/or CH0 Fieldbus Adapter. In addition, it is also possible to set the control panel as the source for the external control.
Page 37: Block Diagram: Start, Stop, Direction Source For Ext1
Block diagram: start, stop, direction source for EXT1 The figure below shows the parameters that select the interface for start, stop, and direction for external control location EXT1. Select DI1 / Std IO DI1, DI2 DI2 / Std IO EXT1 XT DI1 Start/stop I/O Extensions...
Page 38: Reference Types And Processing
Reference types and processing It is possible to scale the external reference so that the signal maximum value corresponds to a speed other than the maximum speed limit. Settings Parameter Additional Information Group 11 REFERENCE SELECT External reference source, type and scaling Group 20 LIMITS Operating limits...
Page 39: Programmable Analog Inputs
Programmable analog inputs The drive has three programmable analog inputs: one voltage input (0/2…10 V) and two current inputs (0/4…20 mA). Two extra inputs are available if an optional Analog I/O Extension Module is used. Each input can be inverted and filtered, and the maximum and minimum values can be adjusted.
Page 40: Programmable Analog Outputs
Programmable analog outputs Two programmable current outputs are available as standard, and two outputs can be added by using an optional Analog I/O Extension Module. Analog output signals can be inverted and filtered. The analog output signals can be proportional to motor speed, process speed (scaled motor speed), output frequency, output current, motor torque, motor power, etc.
Page 41: Programmable Digital Inputs
Programmable digital inputs The drive has six programmable digital inputs as a standard. Six extra inputs are available if the optional Digital I/O Extension Modules are used. Update cycles in the Control Program Input Cycle DI / standard 50 ms DI / extension 50 ms Settings...
Page 42: Programmable Relay Outputs
Programmable relay outputs On the standard I/O board there are three programmable relay outputs. Six outputs can be added by using the optional Digital I/O Extension Modules. With parameter setting it is possible to choose which information to indicate through the relay output: ready, running, fault, warning, motor stall, etc.
Page 43: Actual Signals
Actual signals Several actual signals are available: • Drive output frequency, current, voltage and power • Motor speed and torque • Supply voltage and intermediate circuit DC voltage • Reference values • Drive temperature • Operating time counter (h), kWh counter •...
Page 44: Motor Identification
Motor identification The performance of Direct Torque Control is based on an accurate motor model determined during the motor start-up. A motor identification magnetization is automatically done the first time the start command is given. During this first start-up, the motor is magnetized at zero speed for several seconds to allow the motor model to be created.
Page 45: Automatic Start
Automatic Start Since the drive can detect the state of the motor within a few milliseconds, starting is immediate under all conditions. There is no restart delay, e.g. the starting of turbining pumps or windmilling fans is easy. Settings Parameter 21.01 DC Magnetizing When DC Magnetizing is activated, the drive automatically magnetizes the motor...
Page 46: Flux Braking
Flux Braking The drive can provide greater deceleration by raising the level of magnetization in the motor. By increasing the motor flux, the energy generated by the motor during braking can be converted to motor thermal energy. This feature is useful in motor power ranges below 15 kW.
Page 47: Flux Optimization
Flux Optimization Flux Optimization reduces the total energy consumption and motor noise level when the drive operates below the nominal load. The total efficiency (motor and the drive) can be improved by 1% to 10%, depending on the load torque and speed. Settings Parameter 26.01...
Page 48: Speed Controller Tuning
Speed controller tuning During the motor identification, the drive speed controller is automatically tuned. It is, however, possible to manually adjust the controller gain, integration time and derivation time, or let the drive perform a separate speed controller Autotune Run. In Autotune Run, the speed controller is tuned based on the load and inertia of the motor and the machine.
Page 49: Speed Control Performance Figures
Speed control performance figures The table below shows typical performance figures for speed control when Direct Torque Control is used. load Speed Control No Pulse Encoder With Pulse Encoder Static speed + 0.1 to 0.5% + 0.01% error, % of n (10% of nominal slip) t (s) Dynamic speed...
Page 50: Programmable Protection Functions
Programmable protection functions Motor Thermal Protection The motor can be protected against overheating by activating the Motor Thermal Protection function and by selecting one of the motor thermal protection modes available. The Motor Thermal Protection modes are based either on a motor temperature thermal model or on an overtemperature indication from a motor thermistor.
Page 51: Settings
Settings Parameters 30.04…30.09. Note: It is also possible to use the motor temperature measurement function. See subsection Motor temperature measurement through the standard I/O on page Motor temperature measurement through the analog I/O extension on page 46. Stall Protection The drive protects the motor in a stall situation. It is possible to adjust the supervision limits (torque, frequency, time) and choose how the drive reacts to a motor stall condition (warning indication / fault indication and stop the drive / no reaction).
Page 52: Ground Fault Protection
Ground Fault Protection The Ground Fault Protection detects ground faults in the motor or motor cable.The protection is based on sum current measurement. • A ground fault in the line supply does not activate the protection. • In a grounded supply, the protection activates in 200 microseconds. •...
Page 53: Preprogrammed Faults
Preprogrammed Faults Overcurrent The overcurrent trip limit for the drive is 1.65…2.17 × I depending on the drive type. DC overvoltage The DC overvoltage trip limit is 1.3 ·U , where U is the maximum value of the 1max 1max supply voltage range.
Page 54: Settings
simulates the normal temperature changes in the module depending on the load. The drive generates a warning when the temperature exceeds the limit, and trips when the temperature exceeds the limit by 6 Note: The monitoring is available only for ACS800-U2, -U4 and -U7, frame size R7 and R8 with Standard Control Program version BJXX3600 (and later versions).
Page 55: Overfrequency
Overfrequency If the drive output frequency exceeds the preset level, the drive is stopped and a fault indication is given. The preset level is 50 Hz over the operating range absolute maximum speed limit (Direct Torque Control mode active) or frequency limit (Scalar Control active).
Page 56: Motor Temperature Measurement Through The Standard I/O
Motor temperature measurement through the standard I/O The figure below shows the temperature measurement options of one motor when the RMIO is used as the connection interface. RMIO board One sensor Motor AI1+ AI1- AO1+ AO1- 10 nF (>630 VAC) The minimum voltage of the capacitor must be 630 VAC...
Page 57: Settings
Settings Parameter Additional Information 15.01 Analog output in a motor 1 temperature measurement 35.01…35.03 Motor 1 temperature measurement settings Other Parameters 13.01…13.05 (AI1 processing) and 15.03…15.05 (AO1 processing) are not effective. At the motor end the cable shield should be grounded through a 10 nF capacitor. If this is not possible, the shield is to be left unconnected.
Page 58: Motor Temperature Measurement Through The Analog I/O Extension
Motor temperature measurement through the analog I/O extension The figure below shows the temperature measurement options of one motor when an optional Analog I/O Extension Module is used. RAIO or NAIO module One sensor AI1+ Motor AI1- AO1+ AO1- 10 nF (>630 VAC) SHLD The minimum voltage...
Page 59: Settings
Settings Parameter Additional Information 35.01…35.03 Motor 1 temperature measurement 98.12 Activation of optional analog I/O Other Parameters 13.16…13.20 15.11…15.15 are not effective. At the motor end the cable shield should be grounded through a 10 nF capacitor. If this is not possible, the shield is to be left unconnected.
Page 60: Adaptive Programming Using The Function Blocks
Adaptive Programming using the function blocks Conventionally, the user can control the operation of the drive by parameters. Each parameter has a fixed set of choices or a setting range. The parameters make the programming easy, but the choices are limited. The user cannot customize the operation any further.
Page 61: General
Master/Follower General The Master/Follower function is designed for applications in which the system is run by several ACS800 drives and the motor shafts are coupled to each other via gearing, chain, belt etc. Thanks to the Master/Follower function, the load can be evenly distributed between the drives.
Page 62: Checklist For A Quick Start-Up
Checklist for a quick start-up • A checklist for the Master/Follower function is given below. • Switch off the power supplies of the drives. Wait for five minutes to ensure that the intermediate circuits are discharged. • Install RDCO communication boards onto the RMIO boards of all drives to be used in Master/Follower communication (if not already installed).
Page 63: Installation
The ring configuration can be used in most applications. A parallel connection can also be implemented by using a branching unit. (For more information, contact your local ABB representative.) Handle the fibre optic cables with care. Do not touch the ends with bare hands, as fibre optic cables are extremely sensitive to dirt.
Page 64: Master/Follower Link Specification
Master/Follower link specification Size of the Link: One Master and max. 10 Follower stations. If more than 10 followers are required, an ABB representative should be consulted. Transmission medium: Fibre Optic Cable. • Construction: Plastic core, diameter 1 mm, sheathed with plastic jacket •...
Page 65: Application Macros
Application macros Chapter overview This chapter describes the intended use, operation and the default control connections of the standard application macros. Overview of macros Application macros are preprogrammed parameter sets. While starting up the drive, the user can select one of the macros with parameter 99.02. There are five standard macros and two user macros.
Page 66 The drive is speed controlled and uses the dancer position feedback to regulate the web tension to the midpoint. To properly operate in this mode the following parameters must be set up: 62.05 RANGE ADJUST 62.06 TRIM REG REL TO 62.09 DANCER CTL ENABLE - must be active for the PI regulator to operate 62.11...
Page 67: Default Control Connections
Default control connections The figure below shows the external control connections for the Dancer macro(s). The markings of the terminals on the RMIO board are visible. VREF Reference voltage -10 VDC 1 kOhm < R < 10 kOhm VREF Speed Reference 0(2)…10 V 1kOhm <...
Page 68: Tension Macro
Tension macro The purpose of tension regulation is to control the surface web tension as material is wound or unwound. This is achieved by using loadcell tension feedback. Differences between the tension setpoint and the loadcell feedback allow the tension PI regulator to develop the error correction needed to maintain tension by trimming either speed or torque of the driven section.
Page 69: Open Lp Torq
OPEN LP TORQ The drive is torque controlled with no tension trim. To properly operate in this mode the following parameters must be set up: 60.02 GEAR RATIO 63.09 TENSION CTL ENABLE - must be active to run in torque mode 63.10 TENSION SETPOINT 63.12...
Page 70: Default Control Connections
Default control connections The figure below shows the external control connections for the Tension macro(s). The markings of the terminals on the RMIO board are visible. VREF Reference voltage -10 VDC 1 kOhm < R < 10 kOhm VREF Speed Reference 0(2)…10 V 1 kOhm <...
Page 71: Lead-Winder Macro
Lead-Winder macro The Lead macro is designed for a machine where it is necessary for the Winder to be the “Machine Master.” An Inspection machine is one example where this macro would be useful. This macro has no web tension control. The basic principle of this macro is that the speed reference is set via the keypad or AI and, upon receiving a start command, the drive ramps up to this speed.
Page 72: Default Control Connections
Default control connections The figure below shows the external control connections for the Lead-Winder macro. The markings of the terminals on the RMIO board are visible. VREF Reference voltage -10 VDC 1 kOhm < R < 10 kOhm VREF Speed Reference 0(2)…10V 1 kOhm <...
Page 73: Torque Follower Macro
Torque Follower macro The Torque Follower macro selection allows for a one step set up to enable a torque follower of a torque master winder/unwind drive. In this mode, the follower motor must be mechanically coupled to the master motor. The follower(s) drive(s) is connected to the master drive through a fiber optic connection on CH2 on the RDCO board.
Page 74: User Macros
User macros In addition to the standard application macros, it is possible to create two user macros. The User macro allows the user to save the parameter settings including Group 99, and the results of the motor identification into the permanent memory, and recall the data at a later time.
Page 75: Actual Signals And Parameters
Actual signals and parameters Chapter overview The chapter describes the actual signals and parameters. The fieldbus equivalent value is given for each signal/parameter. More data is given in chapter Additional data: actual signals and parameters. Terms and abbreviations The table defines the terms and abbreviations used in the parameter and actual signal tables.
Page 76: Actual Signals
Name/Value Description FbEq 01 ACTUAL SIGNALS Basic signals for monitoring of the drive. 01.02 MOTOR SPEED FILT Calculated motor speed in rpm. 100% corresponds to 11.05 200 = 1% REF1 MAXIMUM. 01.03 FREQUENCY Calculated output frequency. 100 = 1 Hz 01.04 CURRENT Measured motor current.
Page 77 Name/Value Description FbEq 02.02 SPEED REF 3 Ramped and shaped speed reference. 100% corresponds to 11.05 200 = 1% EXT REF1 MAXIMUM. 02.03 SPEED REF 4 Sum of 02.02 SPEED REF 3 and 25.03 SPEED CORRECTION. 200 = 1% 100% corresponds to 11.05 EXT REF1 MAXIMUM.
Page 78: Actual Signals
Name/Value Description FbEq 02.37 2. LATEST WARNING Fieldbus code of the 2nd latest warning. 1 = 1 02.38 3. LATEST WARNING Fieldbus code of the 3rd latest warning. 1 = 1 02.39 4. LATEST WARNING Fieldbus code of the 4th latest warning. 1 = 1 02.40 5.
Page 79: Actual Signals
Name/Value Description FbEq 06.04 DATASET 3 WORD 1 A 16-bit data word. Dancer / Tension setpoint (see 62.10 DANCER 1 = 1 LOAD SETPT and 63.10 TENSION SETPOINT). 06.05 DATASET 3 WORD 2 A 16-bit data word. Taper reference (see 62.12 TAPER REF SELECT 1 = 1...
Page 80: Reference Select
Name/Value Description FbEq See selection DI2. See selection DI2. See selection DI2. See selection DI2. See selection DI2. DI10 See selection DI2. DI11 See selection DI2. DI12 See selection DI2. Direction will reverse if the speed reference is negative; 11.03 EXT1 REF SELECT must be “AI5”.
Page 81 Name/Value Description FbEq MASTER DRV Follows the speed reference of the master drive. MSTR PSEUDO Follows 03.16 PSEUDO SPD OUT of the master drive. PARAM 11.12 Source selected by 11.12 EXT 1 REF PTR. 11.04 EXT1 REF MINIMUM Defines the minimum value for external reference 1 (absolute value). Corresponds to the minimum setting of the used source signal.
Page 82: Constant Speeds
Name/Value Description FbEq 11.05 EXT1 REF MAXIMUM The factor Speed Share (Speed Multiplier) is used to scale the line (Continued) speed reference input to the rpm reference of the drive. 1. If Group 61 is being utilized, ensure that 61.01 SPD MTCH REF SEL is set to “NOT SEL”.
Page 83 Name/Value Description FbEq Digital input DI3 = 1 selects 12.02 CONST SPD 1. DI3, DI4 Digital input DI3 = 1 selects 12.02 CONST SPD 1. Digital input DI4 = 1 selects 12.03 CONST SPD 2. See selection DI3. DI5, DI6 See selection DI3, DI4.
Page 84: Analog Inputs
Name/Value Description FbEq See selection DI2. See selection DI2. See selection DI2. See selection DI2. See selection DI2. DI10 See selection DI2. DI11 See selection DI2. DI12 See selection DI2. FIELDBUS See selection DI2. Instead of a digital input, the selection comes from 06.01 DATASET 1 WORD 1 bit 09.
Page 85 Name/Value Description FbEq 13.03 SCALE AI1 Scales analog input AI1. Example: The effect on speed reference 10 V 1500 rpm REF1 when: 11.05 EXT REF MAXIMUM = 1500 rpm - Actual AI1 value = 4 V (40% of the full scale value) - 13.03 SCALE AI = 100% 600 rpm...
Page 86: Relay Outputs
Name/Value Description FbEq 13.16 MINIMUM AI5 Defines the minimum value for analog input AI5. When used as a reference, the value corresponds to the reference minimum setting. Example: If AI5 is selected as the source for external reference 1, this value corresponds to the value of 11.04 EXT1 REF MINIMUM.
Page 87: Analog Outputs
Name/Value Description FbEq 14.11 RO3 TON DELAY 14.03 RO1 TON DELAY. 1 = 1 s 14.12 RO3 TOFF DELAY 14.04 RO1 TOFF DELAY. 1 = 1 s 14.13 RO4 POINTER 14.01 RO1 POINTER. 14.15 RO5 POINTER 14.01 RO1 POINTER. 14.17 RO6 POINTER 14.01 RO1 POINTER.
Page 88: Sys Ctrl Inputs
Name/Value Description FbEq 16 SYS CTRL INPUTS Run enable, parameter lock, etc. 16.01 RUN ENABLE Sets the run enable signal on, or selects a source for the external run enable signal. If no run enable signal is on, the drive will not start or stops if it is running.
Page 89 Name/Value Description FbEq FIELDBUS See selection DI2. Instead of a digital input, the selection comes from 06.01 DATASET 1 WORD 1 bit 07 See chapter Fieldbus control. MASTER DRV The reset signal comes from the master drive. The master drive must be stopped (not in RUN).
Page 90: Limits
Name/Value Description FbEq 20 LIMITS Drive operation limits. 20.01 MINIMUM SPEED Defines the allowed minimum speed. WARNING! The limit is linked to the motor nominal speed setting i.e. 99.08 MOTOR NOM SPEED. If 99.08 is changed, the default speed limit will also change. -18000 / (no.
Page 91 Name/Value Description FbEq FREQUENCY Maximum frequency limit 100 = 1 Hz MIN…300.00 Hz 20.10 MINIMUM TORQUE Minimum negative output torque as a percentage of the motor nominal torque. -600.0…0.0% Setting range. 100 = 1% 20.11 P MOTORING LIM Defines the allowed maximum power fed by the inverter to the motor. 0.0…600.0% Maximum motoring power limit in percent of the motor nominal power 100 = 1% 20.12 P GENERATING LIM...
Page 92: Start/Stop
Name/Value Description FbEq See selection DI1. See selection DI1. See selection DI1. DI10 See selection DI1. DI11 See selection DI1. DI12 See selection DI1. Analog input AI1. See 20.20 MIN AI SCALE on how the signal is converted to a torque limit. See selection AI1.
Page 93 Name/Value Description FbEq 21.01 START FUNCTION Selects the motor starting method. See also section Automatic Start on page 33. AUTO Automatic start guarantees optimal motor start in most cases. It includes the flying start function (starting to a rotating machine) and the automatic restart function (stopped motor can be restarted immediately without waiting the motor flux to die away).
Page 94 Name/Value Description FbEq 21.04 DC HOLD Activates/deactivates the DC hold function. When both the reference and the speed drop below 21.05, DC HOLD SPEED the drive will stop generating sinusoidal current and start to inject DC into the motor. The current is set by 21.06 DC HOLD CURR.
Page 95: Accel/Decel
Name/Value Description FbEq 21.10 ZERO SPEED DELAY Defines the delay for zero speed delay function. The function is useful in applications where a smooth and quick restarting is essential. During the delay the drive knows accurately the rotor position. No Zero Speed Delay With Zero Speed Delay Speed Controller remains live.
Page 96 Name/Value Description FbEq 22.02 ACCEL TIME 1 Defines the acceleration time 1 i.e. the time required for the speed to change from zero to the maximum speed. - If the speed reference increases faster than the set acceleration rate, the motor speed will follow the acceleration rate. - If the speed reference increases slower than the set acceleration rate, the motor speed will follow the reference signal.
Page 97: Speed Control
The emergency stop command can be given through a fieldbus or an Emergency Stop module (optional). Consult the local ABB representative for more information on the optional module and the related settings of the Standard Control Program.
Page 98 Name/Value Description FbEq 23.02 INTEGRATION TIME Defines an integration time for the speed controller. The integration time defines the rate at which the controller output changes when the error value is constant. The shorter the integration time, the faster the continuous error value is corrected.
Page 99 Name/Value Description FbEq 23.04 ACC COMPENSATION Defines the derivation time for acceleration compensation. In order to compensate inertia during acceleration a derivative of the reference is added to the output of the speed controller. The principle of a derivative action is described for 23.03 DERIVATION TIME.
Page 100 Name/Value Description FbEq 23.11 P-GAIN MIN The proportional gain setting when the speed controller output is zero. Note: Visible only after entering proper code in 16.03 PASS CODE. 0…100 Setting range. 1 = 1 23.12 P-GAIN WEAKPOINT The output level of the speed controller where the gain is set to 23.01 GAIN.
Page 101: Torq Ref Ctrl
Name/Value Description FbEq 100…500% Setting range. 1 = 1% 23.18 TIS VAL MIN FREQ The relative gain percentage of the TIS value at the speed defined by 23.15 KPS TIS MIN FREQ. Note: Visible only after entering proper code in 16.03 PASS CODE.
Page 102: Flux Control
Name/Value Description FbEq 26 FLUX CONTROL Flux control variables. Improves the stability of a system by decreasing the amount of electrical motor flux when low torque requirements are present. 26.01 FLUX OPTIMIZATION Activates/deactivates the flux optimization function. See Flux Optimization on page 35.
Page 103: Fault Functions
Name/Value Description FbEq 27.05 MAX CONT BR POWER Defines the maximum continuous braking power which will raise the resistor temperature to the maximum allowed value. The value is used in the overload protection. See 27.02 BR OVERLOAD FUNC. 0.01…10000.00 kW Power.
Page 104 Name/Value Description FbEq The protection is based on the calculated motor thermal model. The following assumptions are used in the calculation: - The motor is at the estimated temperature (value of 01.37 MOTOR TEMP EST saved at power switch off) when the power is switched on.
Page 105 Name/Value Description FbEq THERMISTOR Motor thermal protection is activated through digital input DI6. A motor thermistor, or a break contact of a thermistor relay, must be connected to digital input DI6. The drive reads the DI6 states as follows: DI6 Status (Thermistor Resistance) Temperature 1 (0…1.5 kOhm) Normal...
Page 106 Name/Value Description FbEq 30.06 MOTOR THERM TIME Defines the thermal time constant for the user-defined thermal model (see selection USER MODE of 30.05 MOTOR THERM P MODE). Motor Load 100% Temperature 100% Motor thermal time constant 256.0…9999.8 s Time constant 1 = 1 s 30.07 MOTOR LOAD CURVE Defines the load curve together with...
Page 107 Name/Value Description FbEq 30.10 STALL FUNCTION Selects how the drive reacts to a motor stall condition. The protection wakes up if: - the drive is at stall limit (defined by 20.03 MAXIMUM CURRENT, 20.13 MIN TORQ SEL and 20.14 MAX TORQ SEL) - the output frequency is below the level set by 30.11 STALL FREQ HI...
Page 108: Supervision
Name/Value Description FbEq 30.15 UNDERLOAD CURVE Selects the load curve for the underload function. 30.13 UNDERLOAD FUNC. = Motor torque = Nominal motor torque ƒ = Nominal motor frequency 2.4 * ƒ ƒ 1…5 Number of the load curve 1 = 1 30.16 MOTOR PHASE LOSS Activates the motor phase loss supervision function.
Page 109: Information
Name/Value Description FbEq ABS LOW LIM Supervision wakes up if the value is below the set limit. The limit is supervised in both rotating directions. The figure below illustrates the principle. speed/rpm ABS LOW LIMIT -ABS LOW LIMIT 32.02 SPEED1 LIMIT Defines the speed supervision limit.
Page 110: Mtr Temp Meas
Name/Value Description FbEq 35 MTR TEMP MEAS Motor temperature measurement. See sections Motor temperature measurement through the standard I/O on page Motor temperature measurement through the analog I/O extensionon page 35.01 MTR1 TEMP SEL Activates the motor 1 temperature measurement function and selects the sensor type.
Page 111: Pulse Encoder
Name/Value Description FbEq 35.07 MTR MODEL COMP Selects whether measured motor 1 temperature is used in the motor model compensation. The function is inactive. The temperature is used in the motor model compensation. 65535 Note: Selection is possible only when Pt100 sensor(s) are used. 50 PULSE ENCODER Encoder connection.
Page 112: Fieldbus Data
Name/Value Description FbEq 50.08 ENC CABLE CHECK Selects the drive operation when encoder signal is missing. Note: Monitoring is only for RTAC-03. For more information, see RTAC-03 Pulse Encoder Interface Module User’s Manual [3AFE68650500 (English)]. No action. WARNING Drive generates warning ENC CABLE. FAULT Drive trips on fault ENC CABLE.
Page 113: Core Speed Match
Name/Value Description FbEq 60.04 WEB LOSS DELAY Time after detection occurs before a digital output (03.15 PACK STATUS BITS bit 00) is set. See chapter Fieldbus control. Web Loss is calculated three different ways: DANCER CONTROL Trip occurs if Dancer moves to its maximum position signifying loss of tension on the web.
Page 114: Dancer Controls
Name/Value Description FbEq Analog input AI1 (voltage). Analog input AI2 (current). Analog input AI3 (current). Analog input AI5 (voltage or current). Analog input AI6 (voltage or current). FIELDBUS 06.06 DATASET 3 WORD 3. See chapter Fieldbus control. DI3, DI4 Digital inputs DI3 and DI4 are used as a digital pot. FBUS b4,5 06.03 DATASET 1 WORD 3 bits 04 and 05 are used as a digital pot.
Page 115 Name/Value Description FbEq 62.04 ZERO INTEG TIME Selects the activation source for forcing the integral part of the PI controller compensation to be zero. The PI controller will become just a P controller. NOT SEL Function not selected. Digital input DI2 = 1 forces the integration time to zero. See selection DI2.
Page 116 Name/Value Description FbEq 62.08 REV REG OUT This is set to a default value by the program, depending on the macro selected. If the PI regulator is adjusting the speed in the wrong direction it can be reversed here. See 60.05 WINDING MODE for expected machine orientation...
Page 117 Name/Value Description FbEq 62.10 DANCER LOAD SETPT This parameter is only used if the drive is used to control the dancer loading. If the drive is not controlling the dancer loading (03.04 DANCER LOAD REF is not sent to an AO) then this parameter can be ignored.
Page 118 Name/Value Description FbEq 62.13 MAX TAPER/% TAPER This parameter is only used if the drive is used to control the dancer loading. If the drive is not controlling the dancer loading (03.04 DANCER LOAD REF is not sent to an AO) then this parameter can be ignored.
Page 119 Name/Value Description FbEq 62.27 STALL ENABLE This parameter is only used if the drive is used to control the dancer loading. If the drive is not controlling the dancer loading (03.04 DANCER LOAD REF is not sent to an AO) then this parameter can be ignored.
Page 120: Tension Controls
Name/Value Description FbEq 63 TENSION CONTROLS Tension control and PI regulator setup. Note: This group is hidden unless a Tension macro is selected. 63.01 P-GAIN 1 MIN This parameter sets the immediate reaction step of the PI regulator. 63.01 P-GAIN 1 MIN sets the gain at 65.01 MIN CORE DIAMETER;...
Page 121 Name/Value Description FbEq 63.05 RANGE ADJUST Determines the amount of speed correction the PI regulator is allowed to add. The value entered is scaled to 63.06 TRIM REG REL TO. Example: If 63.05 RANGE ADJUST = 5% 63.06 TRIM REG REL TO = “SPD REF MAX” 11.05 EXT1 REF MAX = 1800 rpm 03.09...
Page 122 Name/Value Description FbEq 63.09 TENSION CTL ENABL Set to “ENABLE” if this is a single position machine and there are no requirements to ever RUN without tension control. Set to a DI or FBA option if this is a turret or if there are some instances where the tension regulation should be ignored in RUN mode.
Page 123 Name/Value Description FbEq 63.11 TENSION FDBK INPUT Set to the AI that the tension feedback device is wired into. The feedback device should be set up to provide zero output (approx. 0…0.3 VDC) at zero tension and full output (approx. 9.7…10 VDC) at maximum tension.
Page 124 Name/Value Description FbEq 63.15 TENSION MODE Selecting “CLOSE LP SPD” mode means the drive operates as a speed controller with the output of the tension PI regulator adjusting the speed. Depending on the status of 63.16 MODE TRANSITION, the drive can also be switched to a torque controlled drive with no trim function.
Page 125 Name/Value Description FbEq FBA (NO TRM) See selection DI1 (NO TRM). Instead of a digital input, the command comes from 06.03 DATASET 1 WORD 3 bit 02. See chapter Fieldbus control. 63.17 STATIC FRICTION This is the mechanical friction of the section. This parameter must be adjusted if torque control is to be used at any time.
Page 126 Name/Value Description FbEq 63.18 LINEAR FRIC @ 20% Linear friction is an additional friction loss component as a function of speed. To account for varying loss at different speeds, there are 5 different offsets that can be entered; each one accounting for the offset needed at the percentage of 20.02 MAXIMUM SPEED.
Page 127 Name/Value Description FbEq 63.21 LINEAR FRIC @ 80% 63.18 INEAR FRIC @ 20%. -1000.0…1000.0 Nm Setting range. 10 = 1 Nm -1000.0…1000.0 lbft 10 = 1 lbft 63.22 LINEAR FRIC @ MAX 63.18 INEAR FRIC @ 20%. -1000.0…1000.0 Nm Setting range. 10 = 1 Nm -1000.0…1000.0 lbft 10 = 1 lbft...
Page 128: Inertia Control
Name/Value Description FbEq 0.0…22.0% Setting range. 10 = 1% 63.30 STALL P-GAIN Proportional gain of the dancer PI regulator when in stall mode. 0.01…1000.00 K Setting range. 100 = 1 K 63.31 STALL INTEG Integration time of the dancer PI regulator when in stall mode. 10…10000 ms Setting range 1 = 1 ms...
Page 129 Name/Value Description FbEq 64.09 MOTOR INERTIA Inertia of the motor. May be obtained from the motor manufacturer or see appendix Motor Rotor Inertia for typical values. 0.01…1000.00 kg/m Setting range. 100 = 0.01…1000.00 lb/ft 1 kg/m 100 = 1 lb/ft 64.10 GEARING INERTIA Inertia of the gearing.
Page 130: Dia Calc Control
Name/Value Description FbEq 65 DIA CALC CONTROL There are three methods used to calculate the actual diameter of the roll; selected by 65.14 CALC DIA USING. Method 1 uses an AI from an ultrasonic sensor. Method 2 is the internal calculator used when the Tension or Dancer macro is selected.
Page 131 Name/Value Description FbEq 65.01 MIN CORE DIAMETER Set to the minimum core diameter that will be used on the machine. Example: The machine uses three different cores to run varying grades of material. The cores are 4" (100 mm), 6" (150 mm), and 8" (200 mm).
Page 132 Name/Value Description FbEq 65.07 WEB THICKNESS Set to a value larger than the thickest material that will be run through the machine. If the value entered is too small, the calculator can not keep up with the actual rate of change on the machine. For a wire winding application enter a value equivalent to the wire's diameter divided by the number of turns needed to complete one full width of the spool.
Page 133 Name/Value Description FbEq See selection DI2. See selection DI2. See selection DI2. See selection DI2. See selection DI2. See selection DI2. DI10 See selection DI2. DI11 See selection DI2. DI12 See selection DI2. FIELDBUS See selection DI2. Instead of a digital input, the command comes from 06.03 DATASET 1 WORD 3 bit 10.
Page 134: Torque Mem Ctrl
Name/Value Description FbEq Uses a sensor on analog input AI6 (voltage or current). 65.22 DIA HOLD PTR This parameter defines the source to hold the diameter calculation. An input of binary 1 will hold the calculation. -255.255.31…+255.255.31 Parameter index or a constant value. See 10.05 EXT1 STRT PTR for / C.-32768 …C.32767...
Page 135 Name/Value Description FbEq PARAM 66.07 Source selected by 66.07 TORQ MEM SMPL PTR. 66.02 TORQUE MEM ENABLE Selects the activation signal source to use the memorized torque as the torque reference. NOT SEL Torque memory is not used. Digital input DI2 = 1 selects the memorized torque as the torque reference.
Page 136: Lead Ctrl
The setting needs to be changed when a master station is connected to channel 0 and it does not automatically change the address of the slave. Examples of such masters are an ABB Advant Controller or another drive. 0…254 Address.
Page 137: Adapt Prog Ctrl
Name/Value Description FbEq 0…20000 Setting range. 1 = 1 70.08 MASTER SIGNAL 2 Signal pointer for high speed dataset communications to followers as Reference 1 (speed reference). 0…20000 Setting range. 1 = 1 70.09 MASTER SIGNAL 3 Signal pointer for high speed dataset communications to followers as Reference 2 (torque reference).
Page 138 Name/Value Description FbEq PUSH Shifts the block in location defined by 83.03 EDIT BLOCK and the following blocks one location up. A new block can be placed in the emptied location by programming the Block Parameter Set as usual. Example: A new block needs to be placed in between the current block number four (parameters 84.20…84.25) and five (parameters 84.25…84.29).
Page 139: Adaptive Program
Name/Value Description FbEq 0… Passcode. The setting restores to 0 after the protection is activated/ 1 = 1 inactivated. Note: When activating, write down the passcode and store it in a safe place. 84 ADAPTIVE PROGRAM - selections of the function blocks and their input connections. - diagnostics For more information, see Adaptive Program Application Guide (code: 3AFE64527274 [English]).
Page 140: User Constants
Name/Value Description FbEq TOFF TRIGG WR-I W-PB 84.06 INPUT1 Selects the source for input I1 of Block Parameter Set 1. -255.255.31…+255.255.31 Parameter index or a constant value: / C.-32768…C.32767 - Parameter pointer: Inversion, group, index and bit fields. The bit number is effective only for blocks handling boolean inputs.
Page 141: Dataset Input Sel
Name/Value Description FbEq 85.08 CONSTANT8 Sets a constant for the Adaptive Program. -8388608 to 8388607 Integer value. 1 = 1 85.09 CONSTANT9 Sets a constant for the Adaptive Program. -8388608 to 8388607 Integer value. 1 = 1 85.10 CONSTANT10 Sets a constant for the Adaptive Program. -8388608 to 8388607 Integer value.
Page 142: Dataset Output Sel
Name/Value Description FbEq 0…10000 Setting range. 1 = 1 90.09 DATA 5 WORD 3 Pointer for the parameter to which the value of the fieldbus is written. 0…10000 Setting range. 1 = 1 92 DATASET OUTPUT SEL Addresses of the parameters that are to be sent over the fieldbus. Refer to the Table 2 on page...
Page 143 Name/Value Description FbEq 95.06 LCU Q POW REF Defines the reference value for the line-side converter reactive power generation. Line-side converter can generate reactive power to the supply network. This reference is written into line-side converter unit 24.02 Q POWER REF2. For more information, see IGBT Supply Control Program 7.x Firmware manual [3AFE68315735 (English)].
Page 144: Option Modules
CH0 on the RDCO board. See also group FIELDBUS DATA. ADVANT The drive communicates with an ABB Advant OCS system via CH0 on the RDCO board (optional). See also group 70 DDCS CONTROL. Actual signals and parameters...
Page 145 Name/Value Description FbEq STD MODBUS The drive communicates with a Modbus controller via the Modbus Adapter Module (RMBA) in option slot 1 of the drive. See also group 52 STANDARD MODBUS. 98.03 DI/O EXT MODULE 1 Activates the communication to the digital I/O extension module 1 (optional) and defines the type and connection interface of the module.
Page 146 Name/Value Description FbEq 98.06 AI/O EXT MODULE Activates the communication to an optional Analog I/O Extension Module. Note: Before setting the drive parameters, ensure the module hardware settings are OK: - The module node number is set to 5. - The input signal type selections matches the actual signals (mA/V). - The operation mode selection matches the applied input signals (unipolar/bipolar).
Page 147 Name/Value Description FbEq 98.12 AI/O MOTOR TEMP Activates the communication to the analogue I/O extension module and reserves the module for the use of the motor temperature measurement function. The parameter also defines the type and connection interface of the module. For more information on the temperature measurement function, see group 35 MTR TEMP...
Page 148: Start-Up Data
Name/Value Description FbEq RAIO-DDCS Communication active. Module type: RAIO. Connection interface: Optional I/O module adapter (AIMA) that communicates with the drive through a fibre optic DDCS link. Note: Set the module node number to 9. For directions, see User’s Manual for RAIO Module (Code: 3AFE64484567 [English]). 98.13 AI/O EXT AI1 FUNC This parameter defines the configuration for external analog input AI1.
Page 149 Name/Value Description FbEq USER 1 LOAD User 1 macro loaded into use. Before loading, check that the saved parameter settings and the motor model are suitable for the application. USER 1 SAVE Save User 1 macro. Stores the current parameter settings and the motor model.
Page 150 Name/Value Description FbEq 99.10 MOTOR ID RUN Selects the type of the motor identification. During the identification, the drive will identify the characteristics of the motor for optimum motor control. The ID Run Procedure is described in chapter Start-up. Note: The ID Run (STANDARD) should be selected. No ID Run.
Page 151: Fieldbus Control
Fieldbus control Chapter overview The chapter describes how the drive can be controlled by external devices over a communication network. System overview The drive can be connected to an external control system – usually a fieldbus controller – via an adapter module. The drive can be set to receive all of its control information through the external control interface, or the control can be distributed between the external control interface and other available sources, for example digital and analog inputs.
Page 152: Redundant Fieldbus Control
Redundant fieldbus control It is possible to connect two fieldbuses to the drive with the following adapter configuration: • Type Rxxx fieldbus adapter module (not RMBA-01) is installed in drive slot 1. • RMBA-01 Modbus Adapter module is installed in drive slot 2. E.g.
Page 153: Setting Up Communication Through A Fieldbus Adapter Module
Setting up communication through a fieldbus adapter module Fieldbus adapters for several communication protocols are available (e.g. PROFIBUS and Modbus). Rxxx type fieldbus adapter modules are mounted in expansion slot 1 of the drive. Nxxx type fieldbus adapter modules are connected to channel CH0 of the RDCO module.
Page 154 Parameter Alternative Setting for Function/Information Settings Fieldbus Control 51.30 FILE xyz (binary – Displays the fieldbus adapter module CONFIG REV* coded decimal) configuration file revision stored in the memory of the drive. x = major revision number; y = minor revision number; z = correction number.
Page 155: Setting Up Communication Through The Standard Modbus Link
Setting up communication through the Standard Modbus Link An RMBA-01 Modbus Adapter installed in slot 1 or 2 of the drive forms an interface called the Standard Modbus Link. The Standard Modbus Link can be used for external control of the drive by a Modbus controller (RTU protocol only). Before configuring the drive for Modbus control, the adapter module must be mechanically and electrically installed according to the instructions given in the hardware manual of the drive, and the module manual.
Page 156: Modbus Addressing
Modbus addressing In the Modbus controller memory, the Control Word, the Status Word, the references, and the actual values are mapped as follows: Data from Fieldbus Controller to Drive Data from Drive to Fieldbus Controller Address Contents Address Contents 40001 Control Word 40004 Status Word...
Page 157: Setting Up Communication Through Advant Controller
For more information, see AC 800M Controller Hardware Manual [3BSE027941 (English)], AC 800M/C Communication, Protocols and Design Manual [3BSE028811 (English),] ABB Industrial Systems, Västerås, Sweden. AC 80 Advant Controller Optical ModuleBus connection TB811 (5 MBd) or TB810 (10 MBd) Optical ModuleBus Port Interface required. See table below.
Page 158 Table 1 Setting up communication Parameter Alternative Setting for Control through Function/Information Settings COMMUNICATION INITIALIZATION 98.02 ADVANT Initializes communication FIELDBUS between drive (fibre optic ADVANT channel CH0) and Advant STD MODBUS controller. The transmission speed is 4 Mbit/s. 70.01 0…254 AC 800M ModuleBus 1…125 Defines the node address for...
Page 159: The Fieldbus Control Interface
The fieldbus control interface The communication between a fieldbus system and the drive employs data sets. One data set (abbreviated DS) consists of three 16-bit words called data words (DW). The Winder Program supports the use of six data sets, three in each direction. Table 2 Default connections for the cyclical fieldbus communication.
Page 160: The Control Word And The Status Word
The Control Word and the Status Word The Control Word (CW) is the principal means of controlling the drive from a fieldbus system. It is effective when the active control location is set to FIELDBUS. The Control Word is sent by the fieldbus controller to the drive. The drive switches between its states according to the bit-coded instructions of the Control Word.
Page 161: Communication Profiles
Communication profiles The ACS800 Winder supports one communication profile based on CSA 2.8/3.0 communication profile. Table 3 DataSet 1 Word 1 - Fieldbus Main Cmd Wd (Actual Signal 06.01) Name Description DRIVE ENABLE See chapter Actual signals and parameters, parameter 16.01. USER 2 MACRO SEL See chapter Actual signals and...
Page 162 Table 4 DataSet 1 Word 3 - Fieldbus Aux Cmd Wd (Actual Signal 06.03) Name Description DANCER/TENSION See chapter Actual signals and parameters, parameter 62.09 ENABLE and 63.09. DANCER/TENSION WEB2 See chapter Actual signals and parameters, parameter 62.23 and 63.23. MODE TRANSITION See chapter Actual signals and...
Page 163 Table 5 Main Status Word (Actual Signal 02.26) Name Value STATE/Description RDY_ON READY TO SWITCH ON. NOT READY TO SWITCH ON. RDY_RUN READY TO OPERATE. OFF1 ACTIVE. RDY_REF OPERATION ENABLED. OPERATION INHIBITED. TRIPPED FAULT. No fault. OFF_2_STA OFF2 inactive. OFF2 ACTIVE. OFF_3_STA OFF3 inactive.
Page 164 Table 6 Auxiliary Status Word 4 (Actual Signal 02.28) Name Description SPEED 1 LIM Output speed has exceeded or fallen below supervision limit 1. See group SUPERVISION. Reserved Reserved REF 1 LIM Reference 1 has exceeded or fallen below the set supervision limit. See group SUPERVISION.
Page 165 Table 8 Pack Status Bits (Actual Signal 03.15) Name Description WEB LOSS DETECTED A web loss has been detected. See chapter Actual signals parameters, parameters 60.03 and 60.04. AT CORE DIAMETER The calculated diameter equals the core diameter. See chapter Actual signals and parameters, parameter 65.01.
Page 166 Table 9 Alarm Word 1 (Actual Signal 02.15). Name Description START INHIBIT For the possible causes and remedies, see chapter Fault tracing. Reserved THERMISTOR For the possible causes and remedies, see chapter Fault tracing. MOTOR TEMP ACx 800 TEMP ENCODER ERR T MEAS ALM 7 …11 Reserved...
Page 167 Table 11 Alarm Word 3 (Actual Signal 02.17) Name Description Reserved MOTOR 1 TEMP For the possible causes and remedies, see chapter Fault tracing. MOTOR 2 TEMP BRAKE ACKN SLEEP MODE 5…15 Reserved Table 12 Fault Word 1 (Actual Signal 02.18). Name Description SHORT CIRC...
Page 168 Table 13 Fault Word 2 (Actual Signal 02.19). Name Description SUPPLY PHASE For the possible causes and remedies, see chapter Fault tracing. NO MOT DATA DC UNDERVOLT Reserved RUN DISABLED For the possible causes and remedies, see chapter Fault tracing. ENCODER FLT I/O COMM AMBIENT TEMP...
Page 169 Table 15 System Fault Word (Actual Signal 02.21). Name Description FLT (F1_7) Factory default parameter file error. USER MACRO User Macro file error. FLT (F1_4) FPROM operating error. FLT (F1_5) FPROM data error. FLT (F2_12) Internal time level 2 overflow. FLT (F2_13) Internal time level 3 overflow.
Page 170 The FAULTED INT INFO Word includes information on the location of faults PPCC LINK, OVERCURRENT, EARTH FAULT, SHORT CIRCUIT, ACS800 TEMP, TEMP DIF and POWERF INV (see 02.18 FAULT WORD 1, 02.19 FAULT WORD 2, and chapter Fault tracing). Table 16 INT Fault Info Word (Actual Signal 02.22). Name Description INT 1 FLT...
Page 171 Table 17 Limit Word 1 (Actual Signal 02.23). Name Active Limit TORQ MOTOR LIM Pull-out limit. SPD_TOR_MIN_LIM Speed control torque min. limit. SPD_TOR_MAX_LIM Speed control torque max. limit. TORQ_USER_CUR_LIM User-defined current limit. TORQ_INV_CUR_LIM Internal current limit. TORQ_MIN_LIM Any torque min. limit. TORQ_MAX_LIM Any torque max.
Page 172 The LIMIT WORD INV Word includes faults and warnings, which occur when the output current limit of the drive is exceeded. The current limit protects the drive in various cases, e.g. integrator overload, high IGBT temperature etc. Table 19 Limit Word Inv (Actual Signal 02.41) Name Description INTEGRAT 200...
Page 173: Fault Tracing
A warning or fault message on the panel display indicates abnormal drive status. Most warning and fault causes can be identified and corrected using this information. If not, an ABB representative should be contacted. If the drive is operated with the control panel detached, the red LED in the panel mounting platform indicates the fault condition.
Page 174: Warning Messages Generated By The Drive
Warning messages generated by the drive Warning Cause What to Do Drive IGBT temperature is excessive. Fault trip Check ambient conditions. ACS800 TEMP limit is 100%. (4210) Check air flow and fan operation. 02.15 AW 1 bit 04 Check heatsink fins for dust pick-up. Check motor power against unit power.
Page 175 (2...12) refers to 30.17) If no earth fault can be detected, contact your inverter module number. local ABB representative. DC BUS LIM Drive limits torque due to too high or too low Informative alarm intermediate circuit DC voltage.
Page 176 Warning Cause What to Do ID RUN Motor identification Run is on. Wait until drive indicates that motor identification Run is completed. (FF35) ID RUN SEL Motor Identification Run is selected, and drive Press Start key to start Identification Run. is ready to start ID Run.
Page 177 Warning Cause What to Do MOD CHOKE T Overtemperature in choke of liquid cooled R8i Check inverter fan. inverter module. (FF89) Check ambient temperature. 02.17 AW 3 bit 13 Check liquid cooling system. MOT CUR LIM Drive limits motor current according to current Reduce load or increase ramp time.
Page 178 Warning Cause What to Do POINTER ERROR Source selection (pointer) parameter points to Check source selection (pointer) parameter non existing parameter index. settings. (FFD0) ->POWEROFF! Inverter type (e.g. sr0025_3) has been Switch control board power off to validate changed. Inverter type is usually changed at inverter type change.
Page 179: Warning Messages Generated By The Control Panel
Download function of panel has failed. No data Make sure panel is in local mode. FAILED has been copied from panel to drive. Retry (there might be interference on link). Contact ABB representative. DRIVE IS Downloading is not possible while motor is Stop motor. Perform downloading. RUNNING running.
Page 180: Fault Messages Generated By The Drive
Fault messages generated by the drive Fault Cause What to Do Drive IGBT temperature is excessive. Fault trip Check ambient conditions. ACS800 TEMP limit is 100%. (4210) Check air flow and fan operation. 02.18 FW 1 bit 03 Check heatsink fins for dust pick-up. Check motor power against unit power.
Page 181 (1...12) refers to 30.17) If no earth fault can be detected, contact your inverter module number. local ABB representative. DC HIGH RUSH Drive supply voltage is excessive. When Check supply voltage level, drive rated voltage supply voltage is over 124% of unit voltage and allowed voltage range of drive.
Page 182 Fault Function 30.17) If no ground fault can be detected, contact your local ABB representative. ID RUN FAIL Motor ID Run is not completed successfully. Check maximum speed (parameter 20.02). It should be at least 80% of motor nominal speed (FF84) (parameter 99.08).
Page 183 Fault Cause What to Do INV OVERTEMP Converter module temperature is excessive. Check ambient temperature. If it exceeds 40 °C, ensure that load current does not (4290) exceed derated load capacity of drive. See appropriate hardware manual. Check that ambient temperature setting is correct (parameter 95.10).
Page 184 Fault Cause What to Do MOTOR TEMP Motor temperature is too high (or appears to be Check motor ratings and load. too high) due to excessive load, insufficient (4310) Check start-up data. motor power, inadequate cooling or incorrect 02.18FW 1 bit 06 Check Fault Function parameters.
Page 185 Short-circuit in motor cable(s) or motor Check motor and motor cable. Check there are no power factor correction (2340) capacitors or surge absorbers in motor cable. 02.18 FW 1 bit 00 Output bridge of converter unit is faulty. Contact ABB representative. Fault tracing...
Page 186 Fault Cause What to Do SLOT OVERLAP Two option modules have same connection Check connection interface selections in group interface selection. 98 OPTION MODULES. (FF8A) START INHIBI Optional start inhibit hardware logic is Check start inhibit circuit (AGPS board). activated. (FF7A) SUPPLY PHASE Intermediate circuit DC voltage is oscillating...
Page 187: Additional Data: Actual Signals And Parameters
Additional data: actual signals and parameters Chapter overview This chapter lists the actual signal and parameter lists with some additional data. For the descriptions, see chapter Actual signals and parameters. Terms and abbreviations Term Definition Parameter address for the fieldbus communication through a Profibus link (Add 4000 in FMS Mode).
Page 188: Actual Signals
Actual signals Index Name Short Name FbEq Unit Range ACTUAL SIGNALS 01.02 MOTOR SPEED FILT SPEED 200 = 1% 01.03 FREQUENCY FREQ 1 = 1 Hz 01.04 CURRENT CURRENT 10 = 1 A 01.05 TORQUE TORQUE 10 = 1% 01.06 POWER POWER 10 = 1%...
Page 189 Index Name Short Name FbEq Unit Range 02.24 MAIN CTRL WORD MAIN CW 0…65535 (Decimal) 02.25 FOLLOWER MCW FOLL MCW 0…65535 (Decimal) 02.26 MAIN STATUS WORD MAIN SW 0…65535 (Decimal) 02.27 AUX STATUS WORD AUX SW 0…65535 (Decimal) 02.28 AUX STATUS WORD 4 AUX SW4 0…65535 (Decimal) 02.31...
Page 190 Index Name Short Name FbEq Unit Range 09.02 AI2 SCALED AI2 SCAL 1000 = 1 mA 0…20000 09.03 AI3 SCALED AI3 SCAL 1000 = 1 mA 0…20000 09.04 AI5 SCALED AI5 SCAL 1000 = 1 mA 0…20000 09.05 AI6 SCALED AI6 SCAL 1000 = 1 mA 0…20000...
Page 191: Parameters
Parameters Index Name/Selection UNWIND UNWIND WINDER WINDER WINDER TENSION DANCER TENSION DANCER LEAD START/STOP/DIR 10.01 EXT1 STRT/STOP 10.02 EXT1 DIRECTION FORWARD FORWARD FORWARD FORWARD FORWARD 10.05 EXT1 STRT PTR +.000.000.00 +.000.000.00 +.000.000.00 +.000.000.00 +.000.000.00 REFERENCE SELECT 11.03 EXT1 REF SELECT KEYPAD KEYPAD KEYPAD...
Page 192 Index Name/Selection UNWIND UNWIND WINDER WINDER WINDER TENSION DANCER TENSION DANCER LEAD ANALOG OUTPUTS 15.01 A01 POINTER +.001.004.00 +.001.004.00 +.001.004.00 +.001.004.00 +.001.004.00 15.03 MINIMUM AO1 0 mA 0 mA 0 mA 0 mA 0 mA 15.04 FILTER AO1 ms 15.05 NOM VALUE AO1 100.0 100.0 100.0...
Page 193 Index Name/Selection UNWIND UNWIND WINDER WINDER WINDER TENSION DANCER TENSION DANCER LEAD 21.09 E-STOP MODE STOP STOP STOP STOP STOP RAMPING RAMPING RAMPING RAMPING RAMPING 21.10 ZERO SPEED DELAY 0.5 s 0.5 s 0.5 s 0.5 s 0.5 s 21.11 E-STOP COAST DLY ACCEL/DECEL 22.01 ACC/DEC 1/2 SEL ACC/DEC 1...
Page 194 Index Name/Selection UNWIND UNWIND WINDER WINDER WINDER TENSION DANCER TENSION DANCER LEAD BRAKE CHOPPER 27.01 BRAKE CHOPPER CTL 27.02 BR OVERLOAD FUNC 27.03 BR RESISTANCE 27.04 BR THERM TCONST 27.05 MAX CONT BR POWER 0 kW 0 kW 0 kW 0 kW 0 kW 27.06 BR CTRL MODE...
Page 195 Index Name/Selection UNWIND UNWIND WINDER WINDER WINDER TENSION DANCER TENSION DANCER LEAD 50.08 ENC CABLE CHECK 1008 FIELDBUS DATA STANDARD MODBUS 52.01 STATION NUMBER 1051 52.02 BAUDRATE 9600 9600 9600 9600 9600 1052 52.03 PARITY 1053 APPLIC CONTROLS 60.01 INERTIA COMP ENBL 1195 60.02 GEAR RATIO 1.00:1...
Page 196 Index Name/Selection UNWIND UNWIND WINDER WINDER WINDER TENSION DANCER TENSION DANCER LEAD 63.08 REV REG OUT YES - (not visible) NO - WINDER (not visible) (not visible) 1256 UNWIND 63.09 TENSION CTL ENABL (not visible) (not visible) (not visible) 1257 63.10 TENSION SETPOINT (not visible) (not visible)
Page 197 Index Name/Selection UNWIND UNWIND WINDER WINDER WINDER TENSION DANCER TENSION DANCER LEAD 65.15 SENSOR MIN DIA 1.0 inch 1.0 inch 1.0 inch 1.0 inch 1.0 inch 1299 65.16 DIA > LIM1 30.0 inch 30.0 inch 30.0 inch 30.0 inch 30.0 inch 1300 65.17 DIA >...
Page 198 Index Name/Selection UNWIND UNWIND WINDER WINDER WINDER TENSION DANCER TENSION DANCER LEAD 85.07 CONSTANT7 1651 85.08 CONSTANT8 1652 85.09 CONSTANT9 1653 85.10 CONSTANT10 1654 85.11 STRING1 MESSAGE1 MESSAGE1 MESSAGE1 MESSAGE1 MESSAGE1 1655 85.12 STRING2 MESSAGE2 MESSAGE2 MESSAGE2 MESSAGE2 MESSAGE2 1656 85.13 STRING3 MESSAGE3 MESSAGE3...
Page 199 Index Name/Selection UNWIND UNWIND WINDER WINDER WINDER TENSION DANCER TENSION DANCER LEAD 99.10 MOTOR ID RUN 1935 99.11 CALC MOTOR TORQUE (calculated) (calculated) (calculated) (calculated) (calculated) 1936 99.12 DEVICE NAME 1937 * Indicates parameters that are visible only after entering proper code in 16.03 PASS CODE.
Page 200 Additional data: actual signals and parameters...
Page 201: Appendix A1: Motor Rotor Inertia, Us
Appendix A1: Motor Rotor Inertia, US The following tables are an example of common Inverter Duty AC Motor Rotor Inertia. The data presented is from Marathon Motors’ Blue Max XRI Premium Efficiency Motor Performance Series. Base NEMA FL Amps / FL Torque Inertia Horsepower...
Page 202 Base NEMA FL Amps / FL Torque Inertia Horsepower Poles Frame 460 V (lbft) (lbft 3560 284TS 28.1 37.0 2.40 1774 284T 31.0 74.0 4.00 1180 324T 32.0 112.0 11.0 3560 286TS 33.8 44.5 2.60 1773 286T 36.5 88.5 4.50 1175 326T 38.5...
Page 203 Appendix A2: Motor Rotor Inertia, IEC This table is an example of common Inverter Duty AC Motor Rotor Inertia. Data is from the ABB Cast Iron totally enclosed squirrel cage Motors Catalog. The electrical ratings are based on 400 VAC 50 Hz sinusoidal input.
Page 204 Power FL Amps / FL Torque Inertia Poles Base RPM IEC Frame (kW) 400 V (Nm) (kgm 180 L 0.207 1460 160 L 0.09 2915 160 M 16.5 0.047 200 ML 0.37 18.5 1470 180 M 0.161 2915 160 L 32.5 0.054 200 ML...
Page 205 Power FL Amps / FL Torque Inertia Poles Base RPM IEC Frame (kW) 400 V (Nm) (kgm 315 ML 1272 1487 315 SM 2982 315 SM 355 S 1540 10.4 1486 315 SM 1028 2981 315 SM 355 SM 1925 12.5 1486 315 ML...
Page 206 Appendix A2: Motor Rotor Inertia, IEC...
Page 207 Appendix B: Software One-Line Diagrams Figure B-1 Diameter Calculator Appendix B: Software One-Line Diagrams...
Page 208 Figure B-2 Dancer Control Appendix B: Software One-Line Diagrams...
Page 209 Figure B-3 Tension Control Appendix B: Software One-Line Diagrams...
Page 210 Figure B-4 Torque Control Appendix B: Software One-Line Diagrams...
Page 211 Figure B-5 SPD/TQ Chain 1 Appendix B: Software One-Line Diagrams...
Page 212 Figure B-6 SPD/TQ Chain 2 Appendix B: Software One-Line Diagrams...
Page 214 ABB Oy Automation Technologies ABB Beijing Drive Systems Co. Ltd. AC Drives Drives & Motors No. 1, Block D, A-10 Jiuxianqiao Beilu P.O. Box 184 16250 West Glendale Drive Chaoyang District FI-00381 HELSINKI New Berlin, WI 53151 Beijing, P.R. China, 100015...

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Acs800-u2 Acs800-u7 Acs800-u4

ABB ACS800 Series Firmware Manual

Introduction to the Manual

Start-Up

Control Panel

Program Features

Master/Follower

Application Macros

Actual Signals and Parameters

Fieldbus Control

Fault Tracing

Additional Data: Actual Signals and Parameters

Appendix A1: Motor Rotor Inertia, US

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