ABB ACS380 Firmware Manual

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ABB MACHINERY DRIVES

ACS380 machinery control program

Firmware manual

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List of related manuals

Drive hardware manuals and guides Code (English)

Drive/converter/inverter safety instructions ACS380 Hardware manual 3AXD50000029274

Drive firmware manuals and guides

ACS380 Firmware manual 3AXD50000029275 ACS380 Quick installation and start-up guide 3AXD50000018553 ACS380 User interface guide 3AXD50000022224

Option manuals and guides

ACS-AP-x Assistant control panels user’s manual 3AUA0000085685 ACS-BP-S Basic control panel user’s manual 3AXD50000032527 FCAN-01 CANopen adapter module user’s manual 3AFE68615500 FECA-01 EtherCAT adapter module user’s manual 3AUA0000068940 FENA-01/-11/-21 Ethernet adapter module user’s

manual FPBA-01 PROFIBUS DP adapter module user’s manual 3AFE68573271 FEPL-02 Ethernet POWERLINK adapter module user’s

manual

Tool and maintenance manuals and guides

Drive composer PC tool user’s manual 3AUA0000094606 Converter module capacitor reforming instructions 38FE64059629 Adaptive Programming Application guide 3AXD50000028574 NETA-21 remote monitoring tool user’s manual 3AUA0000096939 NETA-21 remote monitoring tool installation and start-

up guide

3AXD50000037978

3AUA0000093568

3AUA0000123527

3AUA0000096881

You can find manuals and other product documents in PDF format on the Internet. See section Document library on the Internet on the inside of the back cover. For manuals not available in the Document library, contact your local ABB representative.

The code below opens an online listing of the manuals applicable to the product:

Page 3

Firmware manual

ACS380 machinery control program

Table of contents

3. Start-up, ID run and use

3AXD50000029275 Rev E

EFFECTIVE: 2018-05-05

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Table of contents 5

Table of contents

1. Introduction to the manual

Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Applicability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Target audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Purpose of the manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Contents of the manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Terms and abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Related manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Cybersecurity disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

2. Control panel

Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Home view and Message view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Options menu and Main menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Options menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Main menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

3. Start-up, ID run and use

Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Start up the drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Do the identification (ID) run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Background information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

ID run steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Start and stop the drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Change the rotation direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Set the speed or frequency reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Set the drive parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Open Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Change the units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Safety

4. Control macros

Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

ABB standard macro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Default control connections for the ABB standard macro . . . . . . . . . . . . . . . . . . . . . . . . . 33

ABB limited macro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Default control connections for the ABB limited macro . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Fieldbus control macro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Default control connections for the Fieldbus macro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Alternate macro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Default control connections for the Alternate macro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

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6 Table of contents

Motor potentiometer macro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Default control connections for the Motor potentiometer macro . . . . . . . . . . . . . . . . . . . 42

PID control macro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Default control connections for PID control macro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Modbus macro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Default control connections for the Modbus macro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Parameter default values for different macros . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

5. Program features

Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Local and external control locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Local control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

External control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Operating modes and motor control modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Overview diagram of control hierarchy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Speed control mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Torque control mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Frequency control mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Special control modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Autophasing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Drive configuration and programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Programming via parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Adaptive programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Control interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Programmable analog inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Programmable analog outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Programmable digital inputs and outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Programmable relay outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Programmable I/O extensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Fieldbus control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Motor control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Motor types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Motor identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Power loss ride-through . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Vector control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Reference ramping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Constant speeds/frequencies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Critical speeds/frequencies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Rush control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Encoder echo support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Jogging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Speed control performance figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Torque control performance figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Scalar motor control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

User load curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

U/f ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Flux braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

DC magnetization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Energy optimization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

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Table of contents 7

Switching frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Speed compensated stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

Application control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

Control macros . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

Process PID control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

Mechanical brake control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

DC voltage control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

Overvoltage control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

Undervoltage control (power loss ride-through) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

Voltage control and trip limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

Brake chopper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

Limit to limit control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

Limit to limit control function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

Safety and protections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

Fixed/Standard protections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

Emergency stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

Motor thermal protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

Programmable protection functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

Automatic fault resets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

Signal supervision . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

Energy saving calculators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

Load analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

Backup and restore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

User parameter sets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

Data storage parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

Parameter checksum calculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

Motor potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

User lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

6. Parameters

Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

Terms and abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

Fieldbus addresses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

Summary of parameter groups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

Parameter listing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

01 Actual values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

03 Input references . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

04 Warnings and faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

05 Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

06 Control and status words . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

07 System info . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

09 Crane application signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

10 Standard DI, RO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

11 Standard DIO, FI, FO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

12 Standard AI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

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8 Table of contents

13 Standard AO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146

15 I/O extension module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149

19 Operation mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

20 Start/stop/direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

21 Start/stop mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169

22 Speed reference selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177

23 Speed reference ramp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190

24 Speed reference conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194

25 Speed control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195

26 Torque reference chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199

28 Frequency reference chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203

30 Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215

31 Fault functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223

32 Supervision . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232

34 Timed functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239

35 Motor thermal protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245

36 Load analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252

37 User load curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255

40 Process PID set 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259

41 Process PID set 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273

43 Brake chopper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276

44 Mechanical brake control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278

45 Energy efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284

46 Monitoring/scaling settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289

47 Data storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292

49 Panel port communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293

50 Fieldbus adapter (FBA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295

51 FBA A settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299

52 FBA A data in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300

53 FBA A data out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301

58 Embedded fieldbus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301

71 External PID1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320

76 Application features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322

90 Feedback selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327

91 Encoder adapter settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328

92 Encoder 1 configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329

95 HW configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329

96 System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330

97 Motor control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340

98 User motor parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345

99 Motor data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 347

Differences in the default values between 50 Hz and 60 Hz supply frequency settings . . . 354

7. Additional parameter data

Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355

Terms and abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355

Fieldbus addresses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 356

Parameter groups 1…9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 357

Parameter groups 10…99 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 360

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Table of contents 9

8. Fault tracing

Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 389

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 389

Indications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 390

Warnings and faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 390

Pure events . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 390

Warning/fault history . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 390

Event log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 390

Viewing warning/fault information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 390

QR Code generation for mobile service application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 391

Warning messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 392

Fault messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402

9. Fieldbus control through the embedded fieldbus interface (EFB)

Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 416

System overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 416

Modbus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 417

CANopen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 441

10. Fieldbus control through a fieldbus adapter

Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 481

System overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 481

Basics of the fieldbus control interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 483

Control word and Status word . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 484

References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 485

Actual values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 486

Contents of the fieldbus Control word (ABB Drives profile) . . . . . . . . . . . . . . . . . . . . . . 487

Contents of the fieldbus Status word (ABB Drives profile) . . . . . . . . . . . . . . . . . . . . . . . 488

The state diagram (valid for ABB drives profile only) . . . . . . . . . . . . . . . . . . . . . . . . . . . 489

Automatic drive configuration for fieldbus control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 491

Automatically changed parameters (all adapters) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 492

Specific fieldbus adapter parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 492

Setting up the drive for fieldbus control manually . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 494

11. Control chain diagrams

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 495

Frequency reference selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 496

Frequency reference modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 497

Speed reference source selection I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 498

Speed reference source selection II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 499

Speed reference ramping and shaping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500

Speed error calculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501

Speed controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 502

Torque reference source selection and modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 503

Reference selection for torque controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 504

Torque limitation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 505

Process PID setpoint and feedback source selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 506

Process PID controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 507

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10 Table of contents

External PID setpoint and feedback source selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 508

External PID controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 509

Direction lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 510

12. Appendix A - ACS380 in crane applications

Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 511

Overview of the crane control program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 512

Quick start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 513

Control through the I/O interface using a joystick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 514

Control through the I/O interface using the step reference logic/pendant control . . . . . 518

Control through the fieldbus interface using the fieldbus control word . . . . . . . . . . . . . . 522

Configuring speed feedback using a HTL/TTL pulse encoder . . . . . . . . . . . . . . . . . . . . 525

Configuring slowdown with two limits and stop limit logic . . . . . . . . . . . . . . . . . . . . . . . 527

Configuring Mechanical brake control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 531

Crane mechanical brake control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 533

Crane brake control timing diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 533

Brake system checks – overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 534

Brake system checks – Torque proving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 536

Brake system checks – Brake slip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 537

Brake safe closure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 538

Extended run time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 539

Speed matching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 540

Crane warning masking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 542

Dead-band function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 542

Start/stop interlocking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 543

Joystick zero position interlocking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 543

Joystick reference interlocking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 544

Crane stop limit function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 546

Crane slowdown function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 548

Slowdown with two limit inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 548

Fast stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 550

Power on acknowledgment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 551

Speed reference handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 554

Unipolar joysticks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 554

Parabolic speed reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 554

Step reference speed selection/Pendant control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 556

Crane motor potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 557

Conical motor control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 563

Further information

Page 11

Introduction to the manual 11

Introduction to the manual

• Applicability

• Safety instructions

• Target audience

• Purpose of the manual

• Contents of the manual

• Terms and abbreviations

• Related manuals

Applicability

The manual applies to the ACS

To check the version of the control program, see parameter 07.05 Firmware version.

Safety instructions

Follow all safety instructions.

• Read the complete safety instructions in the Hardware manual of the drive before you install, commission, or use the drive.

• Read the firmware function-specific warnings before changing parameter values. Chapter Parameters lists the relevant parameters and related warnings.

380 machinery control program 2.05 or later.

Page 12

12 Introduction to the manual

Target audience

The reader is expected to know the fundamentals of electricity, wiring, electrical components and electrical schematic symbols.

The manual is written for readers worldwide. Both SI and imperial units are shown.

Purpose of the manual

This manual provided information for designing, commissioning, or operating the drive system.

Contents of the manual

• Introduction to the manual (this chapter) describes the applicability, purpose and content of the manual, and terms and conditions.

• Control panel (page 17) introduces the internal control panel.

• Start-up, ID run and use (page 23) contains instructions on how to start up the drive and perform the ID run, and descriptions of the main use cases.

• Control macros (page 31) contains a short description of each macro together with a connection diagram. Macros are pre-defined applications and saves the user time when configuring the drive.

• Program features (page 51) describes the program features and parameters.

• Parameters (page 111) describes the parameters used to program the drive.

• Additional parameter data (page 355) contains further information on the parameters.

• Fault tracing (page 389) lists the warning and fault messages with possible causes and remedies.

• Fieldbus control through the embedded fieldbus interface (EFB) (page 415) describes the communication to and from a fieldbus network using the embedded fieldbus interface of the drive.

• Fieldbus control through a fieldbus adapter (page 481) describes the communication to and from a fieldbus network using an optional fieldbus module.

• Control chain diagrams (page 495) presents the reference chains of the drive.

• Appendix A - ACS380 in crane applications (page 511) describes the functions that are specific to the crane application. If required, these functions can be used for other applications.

Page 13

Introduction to the manual 13

Terms and abbreviations

Term/abbreviation Explanation

ACS-AP-x Assistant control panel, advanced operator keypad for

communication with the drive. The ACS380 support types ACS-AP-1, ACS-AP-S and ACS-APW (with a Bluetooth interface).

ACS-BP-S Basic control panel, basic operator keypad for communication

with the drive.

AI Analog input; interface for analog input signals

AO Analog output; interface for analog output signals

AsynM Asynchronous motor

BAPO-01 Optional side-mounted auxiliary power extension module

BCAN-11 CANopen interface

BCBL-01 Optional USB to RJ45 cable

BMIO-01 I/O and Modbus module

Brake chopper Conducts the surplus energy from the intermediate circuit of the

drive to the brake resistor when necessary. The chopper operates when the DC link voltage exceeds a certain maximum limit. The voltage rise is typically caused by deceleration (braking) of a high inertia motor.

Brake resistor Dissipates the drive surplus braking energy conducted by the

brake chopper to heat. Essential part of the brake circuit. See chapter Resistor breaking in the hardware manual of the drive.

BREL-01 Optional side-mounted relay output extension module

BTAC-02 Optional side-mounted pulse encoder interface module

Capacitor bank See DC link capacitors.

CCA-01 Optional cold configuration adapter

Control board Circuit board in which the control program runs

DC link DC circuit between rectifier and inverter

DC link capacitors Energy storage which stabilizes the intermediate circuit DC

DI Digital input; interface for digital input signals

DO Digital output; interface for digital output signals

Drive Frequency converter f or controlling AC motors

EFB Embedded fieldbus

FBA Fieldbus adapter

FCAN-01 / -01-M Optional CANopen adapter module

FCNA-01 Optional ControlNet adapter module

FDNA-01 Optional DeviceNet adapter module

FECA-01/-01-M Optional EtherCAT adapter module

voltage

Page 14

14 Introduction to the manual

FENA -21/-21-M Optional Ethernet adapter module for EtherNet/IP, Modbus TCP

and PROFINET IO protocols

FEPL-02 Ethernet POWERLINK adapter module

FPBA-01/-01-M Optional PROFIBUS DP adapter module

Frame (size) Refers to the drive physical size, for example R0 and R1. The

type designation label attached to the drive shows the frame of the drive, see the hardware manual of the drive.

ID run Motor identification run. During the identification run, the drive

Hexadecimal Describes binary numbers using a numbering system that has 16

IGBT Insulated gate bipolar transistor

Intermediate circuit See DC link.

Inverter Converts direct current and voltage to alternating current and

I/O Input/Output

LSW Least significant word

Macro Pre-defined default values of parameters in a drive control

NETA-21 Optional remote monitoring tool

Network control With fieldbus protocols based on the Common Industrial Protocol

Parameter User-adjustable operation instruction to the drive, or signal

PDO Process data object

PID controller Proportional–integral–derivative controller

PLC Programmable logic contr oller

PMSM Permanent magnet synchronous motor

PM Permanent magnet

PROFIBUS,

PROFIBUS DP,

PROFINET IO

R0, R1,... Frame (size)

will identify the characteristics of the motor for optimum motor control.

sequential numbers as base units. The hexadecimal numbers are 0-9 and the letters A-F.

voltage.

program. Each macro is intended for a specific application. See chapter Control macros.

(CIP™), such as DeviceNet and Ethernet/IP, denotes the control of the drive using the Net Ctrl and Net Ref object s of the ODVA AC/DC Drive Profile. For more information, see www.odva.org, and the following manuals:

• FDNA-01 DeviceNet adapter module user’s manual (3AFE68573360 [English]), and

• FENA-01/-11/-21 Ethernet adapter module user’s manual (3AUA0000093568 [English])

measured or calculated by the drive

Registered trademarks of PI - PROFIBUS & PROFINET International

Page 15

Introduction to the manual 15

RCD Residual current device

Rectifier Converts alternating current and voltage to direct current and

voltage.

RFI Radio frequency interference

RO Relay output; interface for a digital output signal. Implemented

with a relay.

SDO Service data object

SIL Safety integrity level. See chapter Safe torque off function in the

drive hardware manual.

STO Safe torque off. See chapter Safe torque off function in the drive

hardware manual.

Related manuals

The related manuals are listed behind the front cover under List of related manuals.

Cybersecurity disclaimer

This product is designed to be connected to and to communicate information and data via a network interface. It is Customer's sole responsibility to provide and continuously ensure a secure connection between the product and Customer network or any other network (as the case may be). Customer shall establish and maintain any appropriate measures (such as but not limited to the installation of firewalls, application of authentication measures, encryption of data, installation of anti-virus programs, etc) to protect the product, the network, its system and the interface against any kind of security breaches, unauthorized access, interference, intrusion, leakage and/or theft of data or information. ABB and its affiliates are not liable for damages and/or losses related to such security breaches, any unauthorized access, interference, intrusion, leakage and/or theft of data or information.

Control panel

• Control panel

• Home view and Message view

• Options menu

• Main menu

• Submenus

Control panel 17

Control panel

By default, ACS 380 has an integrated panel. If required, you can use external control panels such as assistant control panel or a basic panel. For more information, refer

ACX-AP-x assistant control panel’s user’s manual (3AUA0000085685 [English]) or ACS-BP-S basic control panel’s user’s manual (3AXD50000032527 [English])

1. Display - shows the Home view as default.

2. Main menu.

3. OK button - open the Main menu, select and save settings.

4. Start button - start the drive.

5. Menu navigation buttons - move in the menus and set values.

6. Stop button - stop the drive.

7. Back button - open the Options menu, and move back in the menu.

8. Options menu.

9. Status light - green and red colors indicate the state and potential problems.

Page 18

18 Control panel

Home view and Message view

The Home view is the main view. Open the Main menu and Options menu from the Home view.

Home view

1. Control selection - local or remote

2. Local start/stop control - enabled

3. Rotation direction - forward or reverse

4. Local reference setting - enabled

5. Speed - target

6. Speed - current

7. Main menu - menu list

8. Options menu - quick access menu

The Message view shows fault and warning messages. If there is an active fault or warning, the panel shows the Message view directly.

You can open the Message view from the Options menu or Diagnostics submenu.

Message view: Fault

Fault messages require your immediate attention.

Check the code in the Fault messages table on page 402 to troubleshoot the problem.

Message view: Warning

Warning messages show possible problems.

Check the code in the Warning messages table on page 392 to troubleshoot the problem.

Page 19

Options menu and Main menu

Control panel 19

Options menu

1. To open: press the Back button in the Home view.

Main menu

2. To open: press the OK button in the Home view.

 Options menu

The Options menu is a quick access menu.

1. Control location - set to local or remote control

2. Rotation direction - set to forward or reverse

3. Active faults - view possible faults

4. Reference speed - set the reference speed

5. Active warnings - view possible warnings

 Main menu

The Main menu is a scroll menu. The menu icons represent specific groups. The groups have submenus.

Note: You can define which Main menu items are visible (see parameter 49.30).

1. Motor data - motor parameters

2. Motor control - motor settings

3. Control macros

4. Diagnostics - faults, warnings, fault log and connection status

5. Energy efficiency - energy savings

6. Parameters - parameters

Page 20

20 Control panel

Submenus

The Main menu items have submenus. Some submenus also have menus and/or option lists. The content of the submenus depend on the drive type.

Motor Data

1. Motor type - AsynM, PMSM, SynRM

2. Control mode - Scalar, Vector

3. Nominal power

4. Nominal current

5. Nominal voltage

6. Nominal frequency

7. Nominal speed

8. Nominal torque

9. Phase order - U V W, U W V

10.Nominal Cosphi

11.Unit selection - SI or US units

Motor Data: Motor type

1. AsynM

2. PMSM

3. SynRM

Motor Data: Control mode

Motor Data: Phase order

Motor Data: Unit selection

1. Scalar

2. Vector

1. U V W

2. U W V

1. SI units

2. US units

Page 21

Motor Control

Control panel 21

1. Start mode - Const time, Automatic

2. Stop mode - Coast, Ramp, DC hold

3. Acceleration time

4. Deceleration time

5. Maximum allowed speed

6. Maximum allowed current

7. Minimum allowed speed

Motor Control: Start modes

1. Const time

2. Automatic

Motor Control: Stop modes

1. Coast

2. Ramp

3. DC hold

Control macros The control macros available depends on the option module

installed.

1. ABB standard (2-wire)

2. ABB limited (2-wire)

3. Alternate

4. Motor potentiometer

5. PID

6. Modbus RTU

7. PROFIBUS

8. PROFINET IO

9. EthernetIP

10.Modbus TCP

11. Ethe rCAT

12.CANopen

Page 22

22 Control panel

Diagnostics

Energy Efficiency

Parameters

1. Active Fault - shows the fault code

2. Fault History - list of latest fault codes (newest first)

3. Active Warnings - shows the warning code

4. Connection Status - Fieldbus and I/O signals

1. Saved energy in kWh

2. Saved money

3. Saved energy in MW

4. Saved money x 1000

5. Cost per kWh h

1. Complete parameter list - groups menu with complete parameters and parameter levels

2. Modified parameter list

3. Parameter restore - reset to factory default parameters

Page 23

Start-up, ID run and use 23

Start-up, ID run and use

• Start up the drive

• Do the identification (ID) run

• Start and stop the drive

• Change the rotation direction

• Set the speed or frequency reference

• Set the drive parameters

• Open Diagnostics

• Change the units

Note: In this chapter the drive uses an integrated panel to perform the start-up, ID run, and other actions. You can also perform these functions using an external control panel or a drive composer PC tool.

Start up the drive

1. Select the unit (international or US) and press OK.

The drive recognizes the connected adapter and sets the correct settings. This may take a few seconds depending on the adapter.

2. In the Motor data view, set the motor type:

AsynM: Asynchronous motor

PMSM: Permanent magnet motor, or

SynRM: Synchronous reluctance motor

3. Set the motor control mode:

Vector: Speed reference. This is suitable for most cases. The drive does an automatic stand-still ID run.

Page 24

24 Start-up, ID run and use

Scalar: Frequency reference. Use this mode when:

- The number of motors can change.

- The nominal motor current is less than 20% of the nominal drive current.

Scalar mode is not recommended for permanent magnet motors.

4. Set the nominal motor values:

• Nominal power

• Nominal current

• Nominal voltage

• Nominal frequency

• Nominal speed

• Nominal torque (optional)

• Nominal cosphi

5. Examine the direction of the motor. If it is necessary, set the motor direction with the Phase order setting or with the phase order of the motor cable.

6. In the Motor control view, set the start and stop mode.

7. Set the acceleration time and the deceleration time.

Note: The speed acceleration and deceleration ramp times are based on the value in parameter 46.01 Speed scaling/46.02 Frequency scaling.

8. Set the maximum and minimum speed or frequency. For more information, see parameters 30.11 Minimum speed /30.13 Minimum frequency and 30.12

Maximum speed/30.14 Maximum frequency on page 218.

9. In the Control macros view, select the applicable macro.

For units with a fieldbus adapter connected: you can see the fieldbus in the Control macros view. There are certain parameters that you need to change, eg. the station ID. See chapter Fieldbus control through a fieldbus adapter.

10. Tune the drive parameters to the application. You can use the Assistant control panel (ACS-AP-x), or the Drive Composer PC tool with the drive.

Page 25

Start-up, ID run and use 25

Do the identification (ID) run

 Background information

The drive automatically estimates motor characteristics using Standstill ID run when the drive is started for the first time, and after any motor parameter (group 99 Motor

data) is changed. This is valid when:

• parameter 99.13 ID run requested selection is Standstill and

• parameter 99.04 Motor control mode selection isVector.

In most applications there is no need to perform a separate ID run. Select the ID run for demanding motor control connections. For example:

• permanent magnet motor (PMSM) is used

• drive operates near zero speed references, or

• operation at torque range above the motor nominal torque, over a wide speed range is needed.

Note: If you change the motor parameters after the ID run, you need to repeat the run.

Note: If you have already parameterized your application using scalar motor control mode and you need to change to vector:

• in the Motor data submenu, set Motor control to Vector , or set parameter 99.04 Motor control mode selection to Vector.

• for I/O controlled drive, check parameters in groups 22 Speed reference

selection, 23 Speed reference ramp, 12 Standard AI, 30 Limits and 46 Monitoring/scaling settings.

• for torque controlled drive, check also parameters in group 26 Torque reference

chain.

 ID run steps

Warning! Make sure it is safe to run the procedure.

1. Open the Main menu.

2. Select the Parameters submenu.

3. Select All parameters.

4. Select 99 Motor data and press OK.

5. Select 99.13 ID run requested, select the wanted ID mode and press OK.

An AFF6 Identification run warning message is shown before you press Start.

The panel LED starts to blink green to indicate an active warning.

6. Press Start to start the ID run.

Page 26

26 Start-up, ID run and use

Do not to press any control panel keys during the ID run. If you need to stop the ID run, press Stop.

After the ID run is completed, the status light stops blinking.

If the ID run fails, the panel shows the fault FF61 ID run.

Page 27

Start and stop the drive

Change the rotation direction

1. In the Options menu, move to the rotation direction item with the arrow buttons.

2. Press the OK button to change the rotation direction.

Start-up, ID run and use 27

1. Press the Start button to st art the drive.

2. Press the Stop button to stop the drive.

Set the speed or frequency reference

1. In the Options menu, move to the speed or frequency reference item and press OK.

2. Press the arrow buttons to edit the value.

3. Press the OK button to confirm the new value.

Page 28

28 Start-up, ID run and use

Set the drive parameters

1. Select the Main menu from the Home view.

2. Scroll to Parameters, and press the OK button to open

3. Select the complete parameters list with the arrow button

4. Select the modified parameters list with the arrow button

5. Select the parameter and press the OK button.

See chapter Parameters for more information.

Open Diagnostics

1. Select the Main menu from the Home view.

2. Scroll to Diagnostics and press the OK button to open

3. Select the warning or fault with the arrow button and

the submenu.

and press the OK button, or

and press the OK button.

The parameters are shown in respective groups. The first two digits of the parameter number represent the parameter group. For example, parameters starting with 30 are in the Limits group.

the submenu.

press the OK button.

See chapter Fault tracing for more information.

Page 29

Change the units

Start-up, ID run and use 29

1. Select the Main menu from the Home view.

2. Scroll t o Motor data and press the OK button to open the submenu.

3. Scroll to the unit selection item and press the OK button.

4. Select the unit with the arrow button, then press the OK button.

You can see the selected unit on the Home view.

Page 30

30 Start-up, ID run and use

Page 31

Control macros

• ABB standard macro

• ABB limited macro

• Fieldbus control macro

• Alternate macro

• Motor potentiometer macro

• PID control macro

• Modbus macro

• Parameter default values for different macros

Control macros 31

Control macros are sets of default parameter values that apply to a specific control configuration. They make it faster and easier to set up a drive for use.

By default, macro for I/O controlled drive is set as ABB standard macro and macro for Fieldbus controlled drive is set as Fieldbus control macro.

Page 32

32 Control macros

ABB standard macro

ABB standard macro is suitable for an IO-controlled drive. Digital inputs control start/stop (2-wire), direction and constant speed selection (3 speeds) and acceleration and deceleration ramp selection.

You can activate the macro from the Control macros view, or by setting parameter

96.04 Macro select to value ABB standard.

This is the default macro for the standard drive variant (ACS380-04xS) and configured drive variant ACS380-4xC +L538.

Page 33

Control macros 33

 Default control connections for the ABB standard macro

This connection diagram is valid for the standard drive variant ACS380-04xS and the configured drive variant ACS380-04xC +L538 (with the ABB standard macro selected).

Terminals Description

Digital I/O connections Aux. +24 V DC, max 200 mA Aux. volt age output common Digital input common Stop (0) / Start (1) Forward (0) / Reverse (1) Constant frequency / speed selection Constant frequency / speed selection Ramp set 1 input (0) / Ramp set 2 input (1) Ready run output(0) / Not ready output (1) Digital output auxiliary voltage Digital input/output common

Analog I/O

Speed / freq.(0...10V) Analog input circuit common Not configured Analog input circuit common Output frequency (0...20 mA) Analog output circuit common Signal cable shield (screen) Ref. voltage +10 V DC

Safe torque off (STO)

Safe torque off. Connected at factory.

Drive starts only if both circuits are closed.

Relay output 1

No fault [Fault (-1)]

Notes:

Terminal sizes: 0.14 mm² … 1.5 mm²

Tightening torques: 0.5 N·m (0.4 lbf·ft).

Terminals DGND, AGND and SGND are internally connected to same reference potential.

Page 34

34 Control macros

DI3 DI4 Operation/Parameter

Scalar control (default) Vector control

0 0 Set frequency through AI1 Set speed through AI1

1028.26 Constant frequency 1 22.26 Constant speed 1

0128.27 Constant frequency 2 22.27 Constant speed 2

1128.28 Constant frequency 3 22.28 Constant speed 3

DIO1 Ramp set Parameters

01 28.71 Freq ramp set selection,...,

28.74 Freq acceleration time 212

Reference from the integrated panel.

In scalar control (default): See parameter group 28 Frequency reference chain.

In vector control

: See parameter group 22 Speed reference selection.

Select the correct control mode from the Motor data view or with parameter 99.04

Motor control mode.

Ground the outer shield of the cable 360 degrees under the grounding clamp on

the grounding shelf for the control cables.

Select the unit for analog input AI1 in the parameter 12.15 and for AI2 in the

parameter 12.25.

Input signals

• Start/Stop selection (DI1)

• Forward (0) / Reverse (1) (DI2)

• Speed selection (DI3)

• Speed selection (DI4)

• Ramp set 1 (0) / Ramp set 2 (1) selection (DIO1)

• Output frequency or motor speed reference (AI1)

Output signals

• Output frequency (AO)

• Ready to run (0) / Not ready (1) (DIO2)

• No Fault [Fault (-1)]

Page 35

Control macros 35

ABB limited macro

The ABB limited macro is suitable for an IO-controlled drive which has the minimum number of I/O available.

The ABB limited macro is optimized for the base drive variant (ACS380-04xN) with no optional module connected.

You can activate the macro from the Control macros view, or by setting parameter

96.04 Macro select to value ABB limited 2-wire.

 Default control connections for the ABB limited macro

This is the default control connection diagram for the base drive variant (ACS380-04xN) with the ABB limited macro selected.

Terminals Description

Digital I/O connections Aux. +24 V DC, max 200 mA Aux. voltage output common Digital input common Stop (0) / Start (1) Speed (1) / freq selection (2) Safe torque off (STO) Safe torque off. Connected at factory.

Drive starts only if both circuits are closed.

Relay output 1 No fault [Fault (-1)]

Notes:

Terminal sizes: 0.14 mm² … 1.5 mm²

Tightening torque: 0.5 N·m (0.4 lbf·ft).

Terminals DGND and SGND are internally connected to same reference potential.

Input signals

• Start / Stop (DI1)

• Output frequency or motor speed reference (DI2)

Output signals

• Relay output 1: Fault (-1)

• No Fault [Fault (-1)]

Page 36

36 Control macros

Fieldbus control macro

Fieldbus control macro is suitable for a fieldbus-controlled drive. The I/O signal interface is not in use as default.

In the initial start-up of the drive, the fieldbus control macro activates automatically whenever it detects a fieldbus adapter. For more information, see Automatic drive

configuration for fieldbus control on page 491.

You can activate the macro manually from the Control macros view, or by setting parameter 96.04 Macro select to the correct value based on the selected fieldbus.

The macro is optimal for the configured variant (ACS380-04xC) which is equipped with a fieldbus adapter module.

 Default control connections for the Fieldbus macro

This is the default control connection diagram for the configured variant (ACS380-04xC) with the Fieldbus macro selected.

Terminals Description

Digital I/O connections

Aux. +24 V DC, max 200 mA Aux. voltage output common Digital input common Fault reset Not configured Safe torque off (STO) Safe torque off. Connected at factory.

Drive starts only if both circuits are closed.

Relay output 1 No fault [Fault (-1)]

Fieldbus module connections +K457 FCAN-01-M CANopen +K454 FPBA-01-M PROFIBUS DP +K469 FECA-01-M EtherCAT +K475 FENA-21-M Ethernet/IP, PROFINET, Modbus TCP

+K495 BCAN-11 CANopen interface

Notes:

Terminal sizes: 0.14 mm² … 1.5 mm²

Tightening torque: 0.5 N·m (0.4 lbf·ft).

Terminals DGND and SGND are internally connected to same reference potential.

Page 37

Control macros 37

When the fieldbus adapter module is connected, the drive control signals are expected to come from the fieldbus typically.

When taking the drive variant ACS380-04xC +K495 (with the BCAN-11 CANopen interface module) into use, it is recommended that the cord is not connected during the first start. This is to avoid disturbing the CANopen bus when the drive attempts to recognize the attached module.

The software automatically sets the relevant parameters when the fieldbus adapter module is connected to the drive. For more information, see Automatic drive

configuration for fieldbus control on page 491. For CANopen parameters, see CANopen parameter settings for embedded fieldbus interface on page 443.

Input signals

• Fault reset (DI1)

• Control words and reference words through the fieldbus adapter module

Output signals

• Status words and status signals through the fieldbus adapter module

• No Fault [Fault (-1)]

Page 38

38 Control macros

Alternate macro

This macro provides an I/O configuration where one signal starts the motor in the forward direction and another signal starts the motor in the reverse direction.

You can activate the macro from the Control macros view, or by setting parameter

96.04 Macro select to value Alternate.

The macro is optimized for the standard drive variant (ACS380-04xS) and configured drive variant ACS380-04xC +L538. You can use it also with the base drive variant (ACS380-04xN) but then you cannot use all the I/O available in the macro.

Page 39

Control macros 39

 Default control connections for the Alternate macro

This connection diagram is valid for the standard drive variant ACS380-04xS and the configured drive variant ACS380-04xC +L538 (with the Alternate macro selected).

Terminals Description

Digital I/O connections Aux. +24 V DC, max 200 mA Aux. voltage output common Digital input common Start forward; If DI1 = DI2: stop Start reverse Constant speed / frequency selection Constant speed / frequency selection Ramp set 1(0) / Ramp set 2 (1) Ready run (0) / not ready run Digital output auxiliary voltage Digital input/output common

Analog I/O

Output freq./Speed ref.(0...10V) Analog input circuit common Not configured Analog input circuit common Output frequency (0...20 mA) Analog output circuit common Signal cable shield (screen) Ref. voltage +10 V DC

Safe torque off (STO)

Safe torque off. Connected at factory.

Drive starts only if both circuits are closed.

Relay output

No Fault [Fault (-1)

EIA-485 Modbus RTU Embedded Modbus RTU (EIA-485). See chapter

Fieldbus control through the embedded fieldbus interface (EFB).

Notes:

Terminal sizes: 0.14 mm² … 1.5 mm²

Tightening torque: 0.5 N·m (0.4 lbf·ft).

Terminals DGND, AGND and SGND are internally connected to same reference potential.

Page 40

40 Control macros

DI3 DI4 Operation/Parameter

Scalar control (default) Vector control

0 0 Set frequency through AI1 Set speed through AI1

1028.26 Constant frequency 1 22.26 Constant speed 1

0128.27 Constant frequency 2 22.27 Constant speed 2

1128.28 Constant frequency 3 22.28 Constant speed 3

DIO2 Ramp

set

Parameters

Scalar control (default) Vector control

0128.72 Freq acceleration time 1 23.12 Acceleration time 1

28.73 Freq deceleration time 1 23.13 Deceleration time 1

1228.74 Freq acceleration time 2 23.14 Acceleration time 2

28.75 Freq deceleration time 2 23.15 Deceleration time 2

In scalar control (default): See parameter group 28 Frequency reference chain.

In vector control

: See parameter group 22 Speed reference selection.

Select the correct control mode from the Motor data view or with parameter 99.04

Motor control mode.

In scalar control (default): See parameter group 28 Frequency reference chain.

In vector control

: See parameter group 23 Speed reference ramp.

Select the correct control mode from the Motor data view or with parameter 99.04

Motor control mode.

Ground the outer shield of the cable 360 degrees under the grounding clamp on

the grounding shelf for the control cables.

Select the unit for analog input AI1 in the parameter 12.15 and for AI2 in the

parameter 12.25.

Input signals

• Start motor forward (DI1)

• Start motor in reverse (DI2)

• Constant output frequency / motor speed selection (DI3)

• Constant output frequency / motor speed selection (DI4)

• Ramp set selection (DIO1)

Output signals

• Output frequency or motor speed reference (AI1)

• Output frequency (AO1)

• No Fault [Fault (-1)]

Page 41

Control macros 41

Motor potentiometer macro

This macro provides a way to adjust the speed with the help of two push buttons, or a cost-effective interface for PLCs that vary the speed of the motor using only digital signals.

You can activate the macro from the Control macros view, or by setting parameter

96.04 Macro select to value Motor potentiometer.

For more information on the motor potentiometer counter, see section Motor

potentiometer on page 108.

The macro is optimized for the standard drive variant (ACS380-04xS) and configured drive variant ACS380-04xC +L538.

Page 42

42 Control macros

 Default control connections for the Motor potentiometer macro

This connection diagram is valid for drives with the standard drive variant ACS380-04xS and the configured drive variant ACS380-04xC +L538 (with the Motor potentiometer macro selected).

Terminals Description

Digital I/O connections

Aux. +24 V DC, max 200 mA

Aux. voltage output common

Digital input common

Stop (0) / Start (1)

Forward (0) / Reverse (1)

Frequency / speed up

Frequency / speed down

Constant speed sel 1

Ready run (0) / Not ready run (1)

Digital output auxiliary voltage

Digital input/output common

Analog I/O

Not configured

Analog input circuit common

Not configured

Analog input circuit common

Not configured

Analog output circuit common

Signal cable shield (screen)

Ref. voltage +10 V DC

Safe torque off (STO)

Safe torque off. Connected at factory.

Drive starts only if both circuits are closed.

Notes:

Terminal sizes: 0.14 mm² … 1.5 mm²

Tightening torque: 0.5 N·m (0.4 lbf·ft).

Relay output

No Fault [Fault (-1)]

Page 43

Control macros 43

DIO1 Ramp

set

Parameters

Scalar control (default) Vector control

0128.72 Freq acceleration time 1 23.12 Acceleration time 1

28.73 Freq deceleration time 1 23.13 Deceleration time 1

1228.74 Freq acceleration time 2 23.14 Acceleration time 2

28.75 Freq deceleration time 2 23.15 Deceleration time 2

Terminals DGND, AGND and SGND are internally connected to same reference potential.

When the input signal is on, the speed/frequency increase or decrease along a parameter-defined change rate. See parameters 22.75, 22.76, and 22.77. If DI3 and DI4 are both active or inactive, the frequency/speed reference is unchanged. The existing frequency/speed reference is stored during stop and power down.

In scalar control (default): See parameter group 28 Frequency reference chain. In vector control

: See parameter group 23 Speed reference ramp.

Select the correct control mode from the Motor data view or with parameter 99.04

Motor control mode.

Ground the outer shield of the cable 360 degrees under the grounding clamp on the grounding shelf for the control cables.

Select the unit for analog input AI1 in the parameter 12.15 and for AI2 in the

parameter 12.25.

Input signals

• Stop (0) / Start (1) (DI1)

• Forward (0) / Reverse (1) (DI2)

• Frequency / speed up (DI3)

• Frequency / speed down (DI4)

• Constant speed selection 1 (DIO1)

Output signals

• No Fault [Fault (-1)]

Page 44

44 Control macros

PID control macro

This macro is suitable for applications where the drive is always controlled by PID and the reference comes from analog input AI1.

You can activate the macro from the Control macros view, or by setting parameter

96.04 Macro select to value PID.

The macro is optimized for the standard drive variant ACS380-04xS and the configured drive variant ACS380-04xC +L538.

 Default control connections for PID control macro

This connection diagram is valid for the standard drive variant ACS380-04xS and the configured drive variant ACS380-04xC +L538 (with the PID control macro selected).

Terminals Description

Digital I/O connections Aux. +24 V DC, max 200 mA Aux. voltage output common Digital input common Stop (0) / Start (1) Internal setpoint sel1 Internal setpoint sel2 Constant speed / frequency selection Run enable 1 source Ready run Digital output auxiliary voltage Digital input/output common

Analog I/O

External PID ref Analog input circuit common Actual PID feedback Analog input circuit common Output frequency (0...20 mA) Analog output circuit common Signal cable shield (screen) Ref. voltage +10 V DC

Safe torque off (STO) Safe torque off. Connected at factory.

Drive starts only if both circuits are closed.

3) 6)

4) 6)

Notes:

Terminal sizes: 0.14 mm² … 1.5 mm²

Relay output No Fault [Fault (-1)]

Page 45

Control macros 45

Source defined

by par. 40.19

DI2

Source def ined

by par. 40.20

DI3

Internal setpoint active

Setpoint source: AI1 (par. 40.16)

1 (par. 40.21)

2 (par. 40.22)

3 (par.40.23)

DI4 Operation/Parameter

Scalar control (default) Vector control

0 Set frequency through AI1 Set speed through AI1 1 28.26 Constant frequency 1 22.26 Constant speed 1

Tightening torque: 0.5 N·m (0.4 lbf·ft).

Terminals DGND, AGND and SGND are internally connected to same reference potential.

See parameters 40.19 Set 1 internal setpoint sel1 and 40.20 Set 1 internal setpoint

sel2 source table.

Select the correct control mode from the Motor data view or with parameter 99.04

Motor control mode.

PID: 0...10 V -> 0...100% PID setpoint.

The signal source is powered externally. See the manufacturer’s instructions. To use sensors supplied by the drive aux. voltage output, see connection examples of two-wire and three-wire sensors in the hardware manual of the drive.

Ground the outer shield of the cable 360 degrees under the grounding clamp on the grounding shelf for the control cables.

Select the unit for analog input AI1 in the parameter 12.15 and for AI2 in the

parameter 12.25.

Input signals

•External PID ref (AI1)

• Actual feedback from PID (AI2)

• Start/Stop selection (DI1)

• Constant setpoint 1 (DI2)

• Constant setpoint 2 (DI3)

• Speed/freq selection (DI4)

• Ramp pair selection (DIO1)

Output signals

• Output frequency (AO)

• No Fault [Fault (-1)]

Page 46

46 Control macros

Modbus macro

Modbus macro is suitable for a Modbus-controlled drive.

You can activate the macro from the Control macros view, or by setting parameter

96.04 Macro select to value Modbus TCP.

The macro is optimized for the standard drive variant ACS380-04xS and the configured drive variant ACS380-04xC +L538.

Page 47

Control macros 47

 Default control connections for the Modbus macro

This connection diagram is valid for the standard drive variant ACS380-04xS and the configured drive variant ACS380-04xC +L538 (with the Modbus macro selected).

Terminals Description

Digital I/O connections Aux. +24 V DC, max 200 mA Aux. voltage output common Digital input common Fault reset Not configured Not configured Not configured Not configured Not configured Digital output auxiliary voltage Digital input/output common

Analog I/O

Not configured Analog input circuit common Not configured Analog input circuit common Not configured Analog output circuit common Signal cable shield (screen) Ref. voltage +10 V DC

Safe torque off (STO)

Safe torque off. Connected at factory.

Drive starts only if both circuits are closed.

Relay output

No Fault [Fault (-1)]

EIA-485 Modbus RTU

Embedded Modbus RTU (EIA-485). See chapter Fieldbus control through the

embedded fieldbus interface (EFB).

Notes:

Terminal sizes: 0.14 mm² … 1.5 mm²

Tightening torque: 0.5 N·m (0.4 lbf·ft).

Terminals DGND, AGND and SGND are internally connected to same reference potential.

Page 48

48 Control macros

The embedded parameters also change, see the embedded macros 20.03 Ext1 in1

source (Not selected).

Select the unit for analog input AI1 in the parameter 12.15 and for AI2 in the

parameter 12.25.

Input signals

• Fault reset (DI1)

• Output frequency / speed reference (AI1)

Output signals

• Output frequency (AO)

• No Fault [Fault (-1)]

Page 49

Control macros 49

Parameter default values for different macros

Chapter Parameters shows the default values of all parameters for the ABB standard macro (factory macro). Some parameters have different default values for other macros. The tables below lists the default values for those parameters for each macro.

96.04 Macro select 1 = ABB standard

10.24 RO1 source 15 = Fault (-1) 15 = Fault (-1) 15 = Fault (-1) 15 = Fault (-1)

12 =

Alternate

3 =

Motor potentiometer

14 =

PID

12.20 AI1 scaled at AI1

13.12 AO1 source 2 = Output

13.18 AO1 source max 50.0 50.0 50.0 50.0

19.11 Ext1/Ext2

20.01 Ext1 commands 2 = In1 Start;

20.03 Ext1 in1 source 2 = DI1 2 = DI1 2 = DI1 2 = DI1

20.04 Ext1 in2 source 3 = DI2 3 = DI2 3 = DI2 0 = Always off

20.05 Ext1 in3 source 0 = Always off 0 = Always off 0 = Always off 0 = Always off

20.06 Ext2 commands 0 = Not

20.08 Ext2 in1 source 0 = Always off 0 = Always off 0 = Always off 0 = Always off

20.09 Ext2 in2 source

20.12 Run enable 1

21.05 Emergency stop

22.11 Ext1 speed ref1 1 = AI1 scaled 1 = AI1 scaled 15 = Motor

22.18 Ext2 speed ref1 0 = Zero 0 = Zero 0 = Zero 0 = Zero

max

selection

source

50.0 50.0 50.0 50.0

frequency

0 = EXT1 0 = EXT1 0 = EXT1 0 = EXT1

In2 Dir

selected

0 = Always off 0 = Always off 0 = Always off 0 = Always off

1 = Selected 1 = Selected 1 = Selected 10 = DIO1

1= Inactive

(true)

2 = Output

frequency

3 = In1 Start

fwd; In2 Start

0 = Not

selected

1= Inactive

(true)

2 = Output

frequency

2 = In1 Start;

In2 Dir

0 = Not

selected

1= Inactive

(true)

potentiometer

2 = Output

frequency

1 =In1 Start

0 = Not

selected

1= Inactive

(true)

16 = PID

22.22 Constant speed

22.23 Constant speed

sel1

sel2

4 = DI3 4 = DI3 10 = DIO1 5 = DI4

5 = DI4 5 = DI4 0 = Always off 0 = Always off

Page 50

50 Control macros

96.04 Macro select 1 =

22.71 Motor potentiometer function

22.73 Motor potentiometer up source

22.74 Motor potentiometer down source

23.11 Ramp set selection

28.11 Ext1 frequency ref1

28.15 Ext1 frequency ref2

28.22 Constant frequency sel1

28.23 Constant frequency sel2

28.71 Freq ramp set selection

40.07 Process PID operation mode

40.16 Set 1 setpoint 1 source

40.17 Set 1 setpoint 2 source

40.19 Set 1 internal setpoint sel1

40.20 Set 1 internal setpoint sel2

40.32 Set 1 gain 1.00 1.00 1.00 1.00

ABB standard

0 = Disabled 0 = Disabled 1 = Enabled

0 = Not

selected

0 = Not

selected

10 = DIO1 10 = DIO1 0 = Acc/Dec

1 = AI1 scaled 1 = AI1 scaled 15 = Motor

0 = Zero 0 = Zero 0 = Zero 0 = Zero

4 = DI3 4 = DI3 10 = DIO1 5 = DI4

5 = DI4 5 = DI4 0 = Always o ff 0 = Always off

10 = DIO1 10 =DIO1 0 =

0 = Off 0 = Off 0 = Off 2 = On when

11 = AI1

percent

0 = Not

selected

0 = Not

selected

0 = Not

selected

12 =

Alternate

0 = Not

selected

0 = Not

selected

11 = AI1

percent

0 = Not

selected

0 = Not

selected

0 = Not

selected

3 =

Motor potentiometer

(init at powerup)

4 = DI3 0 = Not

5 = DI4 0 = Not

time 1

potentiometer

Acc/Dec

time 1

11 = AI1

percent

0 = Not

selected

0 = Not

selected

0 = Not

selected

14 =

PID

0 = Disabled

selected

0 = Acc/Dec

time 1

16 = PID

0 = Acc/Dec

time 1

drive running

11 = AI1

percent

2 = Internal

setpoint

3 = DI2

4 = DI3

40.33 Set 1 integration time

60.0 60.0 60.0 60.0

Page 51

Program features

• Local and external control locations

• Operating modes and motor control modes

• Drive configuration and programming

• Control interfaces

• Motor control

• Application control

• DC voltage control

• Limit to limit control

• Safety and protections

• Diagnostics

• Miscellaneous

Program features 51

Page 52

52 Program features

Integrated panel, Assistant

control panel (optional) or Drive

composer PC tool (optional)

Fieldbus adapter (Fxxx)

MOTOR

PLC

(= Programmable

logic controller)

I/O

Embedded fieldbus interface

External control

Local control

Drive

Local and external control locations

There are two main control locations: local and external. Select the control by pressing the Loc/Rem key on the panels, or from the Drive composer PC tool.

 Local control

The control commands are given from the integrated control panel or from a PC equipped with Drive composer when the drive is in local control. Local control is mainly used during commissioning and maintenance. The control panel always overrides the external control signal sources when used in local control.

Changing the control location to local can be prevented by parameter 19.17 Local

control disable.

Note: You can use both assistant control panel/drive composer tool at the same time, but only one can be in local control at a time.

Settings

Parameters 19.17 Local control disable (page 155) and 49.05 Communication loss

action page (293).

Page 53

Program features 53

Timed function 1…3

Supervision 1…6

Other [ bit]

DI1

DI0 2

EXT1

Run enable

EFB MCW b it 3

Select

20.12

DI1

DIO2

FB A A MCW bi t 3

Off

Selected

Embedded fieldbus

Timed function

A bit in a parameter

Supervision

Fieldbus adapter

 External control

When the drive is in external control, control commands are given through:

• the I/O terminals (digital and analog inputs)

• the fieldbus interface (via the embedded fieldbus interface or an optional fieldbus adapter module)

• external panel (assistant panel).

Two external control locations, EXT1 and EXT2, are available. You can select the sources of the start and stop commands separately for each location by setting parameters 20.01...20.10. The operating mode can be selected separately for each location, which enables quick switching between different operating modes, for example speed and torque control. Selection between EXT1 and EXT2 is done via any binary source such as a digital input or fieldbus control word by parameter 19.11

Ext1/Ext2 selection. You can also select the source of reference for each operating

mode separately, and the operation mode.

Settings

Parameters 20.01... 20.10 and 19.11 Ext1/Ext2 selection (page154).

Block diagram: Run enable source for EXT1

The figure below shows the parameters that select the interface for run enable for external control location EXT1.

Settings

Parameters 19.11 Ext1/Ext2 selection (page154) and 20.01…20.10.

Page 54

54 Program features

Frequency reference

Parameter group 26

Torque reference chain

Speed reference

Parameter group 26

Torque reference

Tor que refere nce

Parameter group 26

Torque reference

Process PID

Vector motor control mode Scalar motor control mode

Frequency controllerTorque contro ller

Operating modes and motor control modes

The drive can operate in several operating modes with different types of reference. The operating mode is selectable for each control location (Local, EXT1 and EXT2) when the motor control mode is Vector (99.04). If the motor control mode is Scalar, the drive operation mode is fixed to frequency control mode.

An overview of the control hierarchy and different reference types and control chains is shown below.

Settings

Parameter group 19 Operation mode (page 153).

 Overview diagram of control hierarchy

The following is a more detailed representation of the drive control hierarchy reference types and control chains.

Page 55

Program features 55

Process PID setpoint and

feedback source selection

Tor que reference

source selection and

modification

Speed reference source selection I

Frequency reference

source selection and

modification

Speed reference source

selection II

Speed reference ramping and

shaping

Speed error calculation

Vector motor control mode Scalar motor control mode

Speed controller

Process PID controller

Torque limitation

Reference selection for torque

controller

Frequency controllerTorque controller

Page 56

56 Program features

 Speed control mode

In speed control mode, the motor follows a speed reference given to the drive. This mode can be used with either estimated or measured speed used as feedback.

Speed control mode is available in both local and external control locations. It is supported in vector motor control only.

Speed control uses speed reference chain. Select speed reference with parameters in group 22 Speed reference selection on page 177.

 Torque control mode

In torque control mode, the motor torque follows a torque reference given to the drive. Torque control mode is available in both local and external control locations. It is supported in vector motor control only.

Torque control uses torque reference chain. Select torque reference with parameters in group 26 Torque reference chain on page 199.

 Frequency control mode

In frequency control mode, the motor follows the drive output frequency reference. Frequency control is available in both local and external control location. It is supported in scalar motor control only.

Frequency control uses frequency reference chain. Select frequency reference with parameters in group 28 Frequency reference chain on page 203.

 Special control modes

In addition to the above-mentioned operating modes, the following special operating modes are available:

• Process PID control. For more information, see section Process PID control on page 81.

• Emergency stop modes OFF1 and OFF3: Drive stops along the defined deceleration ramp and drive modulation stops.

• Jogging mode: Drive starts and accelerates to the defined speed when the jogging signal is activated. For more information, see section Jogging on page 70.

• Pre-magnetization: DC magnetization of the motor before start. For more information, see section Pre-magnetization on page 77.

• DC hold: Locking the rotor at (near) zero speed in the middle of normal operation. For more information, see section DC hold on page 77.

• Pre-heating (motor heating): Keeping the motor warm when the drive is stopped. For more information, see section Pre-heating (Motor heating) on page 78.

Page 57

Program features 57

Absolute encoder/re solver

Rotor

 Settings

Parameter groups 19 Operation mode (page153) and 99.04 Motor control mode (page 347).

 Autophasing

Autophasing is an automatic measurement routine to determine the angular position of the magnetic flux of a permanent magnet synchronous motor or the magnetic axis of a synchronous reluctance motor. The motor control requires the absolute position of the rotor flux in order to control motor torque accurately.

Sensors like absolute encoders and resolvers indicate the rotor position at all times after the offset between the zero angle of rotor and that of the sensor has been established. On the other hand, a standard pulse encoder determines the rotor position when it rotates but the initial position is not known. However, a pulse encoder can be used as an absolute encoder if it is equipped with Hall sensors, albeit with coarse initial position accuracy. Hall sensors generate so-called commutation pulses that change their state six times during one revolution, so it is only known within which 60° sector of a complete revolution the initial position is.

Many encoders give a zero pulse (also called Z-pulse) once during each rotation. The position of the zero pulse is fixed. If this position is known with respect to zero position used by motor control, the rotor position at the instant of the zero pulse is also known.

Using the zero pulse improves the robustness of the rotor position measurement. The rotor position must be determined during starting because the initial value given by the encoder is zero. The autophasing routine determines the position, but there is a risk of some position error. If the zero pulse position is known in advance, the position found by autophasing can be corrected as soon as the zero pulse is detected for the first time after starting.

Page 58

58 Program features

The autophasing routine is performed with permanent magnet synchronous motors and synchronous reluctance motors in the following cases:

1. One-time measurement of the rotor and encoder position difference when an absolute encoder, a resolver, or an encoder with commutation signals is used

2. At every power-up when an incremental encoder is used

3. With open-loop motor control, repetitive measurement of the rotor position at every start

4. When the position of the zero pulse must be measured before the first start after power-up.

Note: In closed-loop control, autophasing is performed automatically after the motor identification run (ID run). Autophasing is also performed automatically before starting when necessary.

In open-loop control, the zero angle of the rotor is determined before starting. In closed-loop control, the actual angle of the rotor is determined with autophasing when the sensor indicates zero angle. The offset of the angle must be determined because the actual zero angles of the sensor and the rotor do not usually match. The autophasing mode determines how this operation is done both in open-loop and closed-loop control.

The rotor position offset used in motor control can also be given by the user – see parameter 98.15 Position offset user. Note that the autophasing routine also writes its result into this parameter. The results are updated even if user settings are not enabled by 98.01 User motor model mode.

Note: In open-loop control, the motor always turns when it is started as the shaft is turned towards the remanence flux.

Bit 4 of 06.21 Drive status word 3 indicates if the rotor position has already been determined.

Autophasing modes

The ACS380 uses turning mode (see parameter 21.13 Autophasing mode).

The turning mode (Turning ) is the most robust and accurate method. In turning mode, the motor shaft is turned back and forward (±360/polepairs)° in order to determine the rotor position. In case 3 (open-loop control), the shaft is turned only in one direction and the angle is smaller.

The drive is capable of determining the rotor position when started into a running motor in open-loop or closed-loop control. In this situation, the setting of 21.13

Autophasing mode has no effect.

The autophasing routine can fail and therefore it is recommended to perform the routine several times and check the value of parameter 98.15 Position offset user.

Page 59

Program features 59

An autophasing fault (3385 Autophasing) can occur with a running motor if the estimated angle of the motor differs too much from the measured angle. This could be caused by, for example, the following:

• The encoder is slipping on the motor shaft

• An incorrect value has been entered into 98.15 Position offset user

• The motor is already turning before the autophasing routine is started

• Turning mode is selected in 21.13 Autophasing mode but the motor shaft is locked

• The wrong motor type is selected in 99.03 Motor type

• Motor ID run has failed.

Settings

Parameters 06.21 Drive status word 3 (page 128), 21.13 Autophasing mode (page

173), 98.15 Position offset user (page 347) and 99.13 ID run requested (page 350).

Page 60

60 Program features

Application program

Firmware

Speed control Torque control Frequency control Drive logic I/O interface Fieldbus interface Protections

Parameter

interface

Function block

program

Standard block

library

Drive configuration and programming

The drive control program is divided into two parts:

• firmware program

• application program

Drive control program

The firmware program performs the main control functions, including speed, torque and frequency control, drive logic (start/stop), I/O, feedback, communication and protection functions. Firmware functions are configured and programmed with parameters, and can be extended by application programming

 Programming via parameters

Parameters configure all of the standard drive operations and can be set via

• the integrated panel, as described in chapter Control panel

• an external panel

• the Drive composer PC tool, as described in Drive composer PC tool user’s manual (3AUA0000094606 [English]), or

• the fieldbus interface, as described in chapters Fieldbus control through the

embedded fieldbus interface (EFB) and Fieldbus control through a fieldbus adapter.

All parameter settings are stored automatically to the permanent memory of the drive. However, if an external +24 V DC power supply is used for the drive control unit, it is highly recommended to force a save by using parameter 96.07 Parameter save

manually before powering down the control unit after any parameter changes have

been made.

If necessary, the default parameter values can be restored by parameter 96.06

Parameter restore.

Page 61

Program features 61

 Adaptive programming

Conventionally, you can control the operation of the drive by parameters. However, the standard parameters have a fixed set of choices or a setting range. To further customize the operation of the drive, an adaptive program can be constructed out of a set of function blocks.

The Drive composer pro PC tool (version 1.11 or later, available separately) has an Adaptive programming feature with a graphical user interface for building the custom program. The function blocks include the usual arithmetic and logical functions, as well as e.g., selection, comparison and timer blocks.

The physical inputs, drive status information, actual values, constants and parameters can be used as the input for the program. The output of the program can be used e.g., as a start signal, external event or reference, or connected to the drive outputs. See the table below for a listing of the available inputs and outputs.

If you connect the output of the adaptive program to a selection parameter that is a pointer parameter, the selection parameter will be write-protected.

Example:

If parameter 31.01 External event 1 source is connected to an adaptive programming block output, the parameter value is shown as Adaptive program on a control panel or PC-tool. The parameter is write-protected (= the selection cannot be changed).

The status of the adaptive program is shown by parameter 07.30 Adaptive program

status.

For more information, see the Adaptive programming application guide (3AXD50000028574 [English]).

Inputs available to the adaptive program

Input So urce I/O

DI1 10.02 DI delayed status, bit 0 DI2 10.02 DI delayed status, bit 1 DI3 10.02 DI delayed status, bit 2 1) DI4 10.02 DI delayed status, bit 3 1) AI1 12.11 AI1 actual value 1) AI2 12.21 AI2 actual value 1) DIO1 11 .02 DIO delayed status, bit 0 1) DIO2 11 .02 DIO delayed status, bit 1 1)

Actual signals

Motor speed 01.01 Motor speed used Output frequency 01.06 Output frequency Motor current 01.07 Motor current Motor torque 01.10 Motor torque Motor shaft power 01.17 Motor shaft power

Status

Enabled 06.16 Drive status word 1, bit 0

Page 62

62 Program features

Inputs available to the adaptive program

Input S ource

Inhibited 06.16 Drive status word 1, bit 1 Ready to start 06.16 Drive status word 1, bit 3 Tripped 06.11 Main status word, bit 3 At setpoint 06.11 Main status word, bit 8 Limiting 06.16 Drive status word 1, bit 7 Ext1 active 06.16 Drive status word 1 , bit 10 Ext2 active 06.16 Drive status word 1 , bit 11

Data storage

Data storage 1 real 32 47.01 Data storage 1 real32 Data storage 2 real 32 47.02 Data storage 2 real32 Data storage 3 real 32 47.03 Data storage 3 real32 Data storage 4 real 32 47.04 Data storage 4 real32

Available only if I/O and Modbus module is connected and in use.

Outputs available to the adaptive program

Output Target I/O

RO1 10.24 RO1 source AO1 13.12 AO1 source 2) DIO1 11 .0 6 DIO1 output source 2) DIO2 11 .1 0 DIO2 output source 2)

Start con trol

Ext1/Ext2 selection 19.11 Ext1/Ext2 selection Run enable 1 20.12 Run enable 1 source Ext1 in1 cmd 20.03 Ext1 in1 source Ext1 in2 cmd 20.04 Ext2 in2 source Ext1 in3 cmd 20.05 Ext1 in3 source Ext2 in1 cmd 20.08 Ext2 in2 cmd 20.09 Ext2 in2 source Ext2 in3 cmd 20.10 Ext2 in3 source Fault reset 31.11 Fault reset selec tion

Speed control

Ext1 speed reference 22.11 Ext1 speed ref1 Speed proportional gain 25.02 Speed proportional gain Speed integration time 25.03 Speed integration time Acceleration time 1 23.12 Acceleration time 1 Deceleration time 1 23 .13 Deceleration time 1

Frequency control

Ext1 frequency reference 28.11 Ext1 frequency ref1

Torque control

Ext1 torque reference 26.11 Torque ref1 source Ext2 torque reference 26.12 Torque ref2 source

Limit function

Minimum torque 2 30.21 Min torque 2 source Maximum torque 2 30.22 Max torque 2 source

Events

External event 1 31.01 External event 1 source External event 2 31.03 External event 2 source External event 3 31.05 External event 3 source

Ext2 in1 source

Page 63

Program features 63

Outputs available to the adaptive program

Output Target

External event 4 31.07 External event 4 source External event 5 31.09 External event 5 source

Data Storage

Data storage 1 real32 47.01 Data storage 1 real32 Data storage 2 real32 47.02 Data storage 2 real32 Data storage 3 real32 47.03 Data storage 3 real32 Data storage 4 real32 47.04 Data storage 4 real32

Process PID

Set 1 setpoint 1 40.16 Set 1 setpoint 1 source Set 1 setpoint 2 40.17 Set 1 setpoint 2 source Set 1 feedback 1 40.0 8 Set 1 feedback 1 source Set 1 feedback 2 40.0 9 Set 1 feedback 2 source Set 1 gain 40.32 Set 1 gain Set 1 integration time 40.33 Set 1 integration time Set 1 tracking mode 40.49 Set 1 tracking mode Set 1 track reference 40.5 0 Set 1 tracking ref selection

Available only if I/O and Modbus module is connected and in use.

Adaptive program fault and aux code formats

The format of the aux code:

Bits 24-31: State number Bits 16-23: block number Bits 0-15: error code

If the state number is zero but the block number has a value, the fault is related to a function block in the base program. If both state number and block number are zero, the fault is a generic fault that is not related to a specific block.

Sequence program

An adaptive program can contain base program and sequence program parts. Base program is run continuously when adaptive program is in running mode. The functionality of the base program is programmed using function blocks and system inputs and outputs.

Sequence program is a state machine. This means that only one state of the sequence program is run at a time. You can create a sequence program by adding states and programming the state programs using the same program elements as in the base program. You can program state transitions by adding state transition outputs to the state programs. The state transition rules are programmed using function blocks.

The number of the active state of the sequence program is shown by parameter

07.31 AP sequence state.

Page 64

64 Program features

Control interfaces

The number of inputs and outputs depend on the product variant and if the drive is equipped with any optional I/O extension modules.

S variant:

• 4 x Digital Inputs

• 2 x Digital Inputs/Outputs

• 2 x Analog Inputs

• 1 x Analog Output

• 1 x Relay Output

C variant:

• 2 x Digital Inputs

• 1 x Relay Output

 Programmable analog inputs

There are max two programmable analog inputs. Each of the inputs can be independently set as a voltage (0/2…10 V) or current (0/4…20 mA) input by a switch on the control unit. Each input can be filtered, inverted and scaled.

Settings

Parameter group 12 Standard AI (page 141).

 Programmable analog outputs

There is max one current (0...20mA) analog output. The output can be filtered, inverted and scaled.

Settings

Parameter group 13 Standard AO (page146).

 Programmable digital inputs and outputs

There are max four digital inputs, and two digital inputs/outputs (I/O that can be set as either an input or an output).

Digital inputs DI3 and DI4 can be used as frequency input and digital outputs DIO1 and DIO2 can be used as frequency output.

Settings

Parameter groups 10 Standard DI, RO (page 131) and 11 Standard DIO, FI, FO (page 135).

Page 65

Program features 65

 Programmable relay outputs

There is one relay output as standard. The signal indicated by the output can be selected by parameters.

Settings

Parameter groups 10 Standard DI, RO (page 131).

 Programmable I/O extensions

Inputs and outputs can be added by using I/O extension modules.

The table below shows the number of I/O on the control unit as well as optional I/O extension modules.

Location Digital

inputs

(DI)

Base unit 2----1

BREL -----4

BIO-01 3 1 - 1 - -

Digital

outputs

(DO)

Digital

I/Os

(DIO)

Analog

inputs

(AI)

Analog

outputs

(AO)

Note: The configuration parameter group contains parameters that display the values

of the inputs on the extension module. These parameters are the only way of utilizing the inputs on an I/O extension module as signal sources.

Relay

outputs

(RO)

Settings

Parameter groups 15 I/O extension module (page 149).

 Fieldbus control

The drive can be connected to several different automation systems through its fieldbus interfaces. See chapters Fieldbus control through the embedded fieldbus

interface (EFB) and Fieldbus control through a fieldbus adapter.

Settings

Parameter groups 50 Fieldbus adapter (FBA) (page 295), 51 FBA A settings (page

299), 52 FBA A data in (page 300), 53 FBA A data out (page 301) and 58 Embedded fieldbus (page 301).

Page 66

66 Program features

Motor control

 Motor types

The drive supports the following motor types:

• Asynchronous AC induction motors

• Permanent magnet (PM) motors

• Synchronous reluctance motors (SynRM).

Settings

Parameter 99.03 Motor type (page 347).

 Motor identification

The performance of vector control is based on an accurate motor model determined during the motor start-up.

A motor Identification magnetization is automatically performed 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. This identification method is suitable for most applications.

In demanding applications a separate Identification run (ID run) can be performed.

Settings

Parameter 99.13 ID run requested (page 350).

 Power loss ride-through

See section Undervoltage control (power loss ride-through) on page 90.

 Vector control

Vector control is the motor control mode which is intended for applications where high control accuracy is needed. It requires an identification run at startup. Vector control cannot be used in all applications.

The switching of the output semiconductors is controlled to achieve the required stator flux and motor torque. The switching frequency is changed only if the actual torque and stator flux values differ from their reference values by more than the allowed hysteresis. The reference value for the torque controller comes from the speed controller or directly from an external torque reference source.

Motor control requires measurement of the DC voltage and two motor phase currents. Stator flux is calculated by integrating the motor voltage in vector space. Motor torque is calculated as a cross product of the stator flux and the rotor current. By utilizing the identified motor model, the stator flux estimate is improved. Actual motor shaft speed is not needed for the motor control.

Page 67

Program features 67

The main difference between traditional control and vector control is that torque control operates at the same time level as the power switch control. There is no separate voltage and frequency controlled PWM modulator; the output stage switching is wholly based on the electromagnetic state of the motor.

The best motor control accuracy is achieved by activating a separate motor identification run (ID run).

See also section Speed control performance figures on page 73.

Settings

Parameters 99.04 Motor control mode (page 347) and 99.13 ID run requested (page

350).

 Reference ramping

Acceleration and deceleration ramping times can be set individually for speed, torque and frequency reference.

With a speed or frequency reference, the ramps are defined as the time it takes for the drive to accelerate or decelerate between zero speed or frequency and the value defined by parameter 46.01 Speed scaling or 46.02 Frequency scaling. The user can switch between two preset ramp sets using a binary source such as a digital input. For speed reference, also the shape of the ramp can be controlled.

With a torque reference, the ramps are defined as the time it takes for the reference to change between zero and nominal motor torque (01.30 Nominal torque scale).

Variable slope

Variable slope controls the slope of the speed ramp during a reference change. With this feature a constantly variable ramp can be used.

Variable slope is only supported in remote control.

Settings

Parameters 23.28 Variable slope enable (page 192) and 23.29 Variable slope rate (page 192).

Special acceleration/deceleration ramps

The acceleration/deceleration times for the jogging function can be defined separately; see section Jogging on page 70.

The change rate of the motor potentiometer function (page 108) is adjustable. The same rate applies in both directions.

A deceleration ramp can be defined for emergency stop (“Off3” mode).

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68 Program features

Settings

• Speed reference ramping - Parameters 23.11…23.15, 23.32 Shape time 1 (page

193), 23.33 Shape time 2 (page 193) and 46.01 Speed scaling (page 289).

• Torque reference ramping - Parameters 01.30 Nominal torque scale (page 117 ),

26.18 Torque ramp up time (page 202) and 26.19 Torque ramp down time (page

202).

• Frequency reference ramping - Parameters 28.71…28.75 and 46.02 Frequency

scaling (page 289).

• Jogging - Parameters 23.20 Acc time jogging (page 191) and 23.21 Dec time

jogging (page 191).

• Motor potentiometer - Parameter 22.75 Motor potentiometer ramp time (page

187).

• Emergency stop (“Off3” mode) - Parameter 23.23 Emergency stop time (page

192).

 Constant speeds/frequencies

Constant speeds and frequencies are predefined references that can be quickly activated, for example, through digital inputs. It is possible to define up to 7 speeds for speed control and 7 constant frequencies for frequency control.

WAR NIN G: Speeds and frequencies override the normal reference irrespective of where the reference is coming from.

Settings

Parameter groups 22 Speed reference selection (page 177) and 28 Frequency

reference chain (page 203).

 Critical speeds/frequencies

Critical speeds (sometimes called “skip speeds”) can be predefined for applications where it is necessary to avoid certain motor speeds or speed ranges because of, for example, mechanical resonance problems.

The critical speeds function prevents the reference from dwelling within a critical band for extended times. When a changing reference enters a critical range, the output of the function freezes until the reference exits the range. Any instant change in the output is smoothed out by the ramping function further in the reference chain.

When the drive is limiting the allowed output speeds/frequencies, it limits to the absolutely lowest critical speed (critical speed low or critical frequency low) when accelerating from standstill, unless the speed reference is over the upper critical speed/ frequency limit.

Page 69

Program features 69

540

690

1380

1560

1Par. 22.52 = 540 rpm

2Par. 22.53 = 690 rpm

3Par. 22.54 = 1380 rpm

4Par. 22.55 = 1560 rpm

1234

22.01 Speed ref unlimited (rpm)

(output of function)

22.87 Speed reference act 7 (rpm)

(input of function)

Example

A fan has vibrations in the range of 540 to 690 rpm and 1380 to 1560 rpm. To make the drive avoid these speed ranges,

• enable the critical speeds function by turning on bit 0 of parameter 22.51, and

• set the critical speed ranges as in the figure below.

Settings

• Critical speeds - Parameters 22.51…22.57.

• Critical frequencies - Parameters 28.51…28.57.

• Function input (speed) - Parameter 22.01 Speed ref unlimited (page 177).

• Function output (speed) - Parameter 22.87 Speed reference act 7 (page 188).

• Function input (frequency) - Parameter 28.96 Frequency ref act 7 (page 215).

• Function output (frequency) - Parameter 28.97 Frequency ref unlimited (page

215).

Page 70

70 Program features

Motor speed

Time

Overspeed trip level

31.30 Overspeed trip margin

30.12

30.11

Rush cont rol active

 Rush control

Rush control is automatically on when the operation mode is torque. In torque control, the motor could potentially rush if the load were suddenly lost. The control program has a rush control function that decreases the torque reference whenever the motor speed exceeds the set minimum speed or maximum speed.

The function is based on a PI controller. The program sets the proportional gain to

10.0 and integration time to 2.0 s.

Settings

Parameters 30.11 Minimum speed (page 217), 30.12 Maximum speed (page 217) and 31.30 Overspeed trip margin (page 229).

 Encoder echo support

The connection of one encoder to several drives with the BTAC-02 encoder interface module can be done by using a daisy chain wiring scheme. This means wiring channels A, B, Z and GND of multiple encoder modules together with the encoder.

Settings

Parameter groups 90 Feedback selection (page 327), 91 Encoder adapter settings (page 328) and 92 Encoder 1 configuration (page 329).

 Jogging

The jogging function enables the use of a momentary switch to briefly rotate the motor. The jogging function is typically used during servicing or commissioning to control the machinery locally.

Two jogging functions (1 and 2) are available, each with their own activation sources and references. The signal sources are selected by parameters 20.26 and 20.27.

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Program features 71

2314568 11 13141516

71891210 17

Jog cmd

Jog enable

Start cmd

Speed

When jogging is activated, the drive starts and accelerates to the defined jogging speed along the defined jogging acceleration ramp. After the activation signal switches off, the drive decelerates to a stop along the defined jogging deceleration ramp.

The figure and table below provide an example of how the drive operates during jogging. In the example, the ramp stop mode is used (21.03 Stop mode).

Jog cmd = State of source set by 20.26 or 20.27 Jog enable = State of source set by 20.25 Start cmd = State of drive start command.

Jog

Phase

cmd

enable

1-2 1 1 0 Drive accelerates to the jogging speed along the acceleration

2-3 1 1 0 Drive follows the jog reference.

3-4 0 1 0 Drive decelerates to zero speed along the deceleration ramp

4-5 0 1 0 Drive is stopped.

5-6 1 1 0 Drive accelerates to the jogging speed along the acceleration

6-7 1 1 0 Drive follows the jog reference.

7-8 0 1 0 Drive decelerates to zero speed along the deceleration ramp

8-9 0 1->0 0 Drive is stopped. As long as the jog enable signal is on, start

9-10 x 0 1 Drive accelerates to the speed reference along the selected

Start cmd

ramp of the jogging function.

of the jogging function.

ramp of the jogging function.

of the jogging function.

commands are ignored. After jog enable switches off, a fresh start command is required.

acceleration ramp (parameters 23.11…23.15).

Description

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72 Program features

Jog

Phase

cmd

enable

10-11 x 0 1 Drive follows the speed reference.

11-12 x 0 0 Drive decelerates to zero speed along the selected

12-13 x 0 0 Drive is stopped.

13-14 x 0 1 Drive accelerates to the speed reference along the selected

14-15 x 0->1 1 Drive follows the speed reference. As long as the start

15-16 0->1 1 0 Start command switches off. The drive starts to decelerate

16-17 1 1 0 Drive follows the jog reference.

17-18 0 1->0 0 Drive decelerates to zero speed along the deceleration ramp

Start cmd

deceleration ramp (parameters 23.11…23.15).

acceleration ramp (parameters 23.11…23.15).

command is on, the jog enable signal is ignored. If the jog enable signal is on when the start command switches off, jogging is enabled immediately.

along the selected deceleration ramp (parameters

23.11…23.15).

When the jog command switches on, the decelerating drive adopts the deceleration ramp of the jogging function.

of the jogging function.

Description

Notes:

• Jogging is not available when the drive is in local control.

• Jogging cannot be enabled when the drive start command is on, or the drive started when jogging is enabled. Starting the drive after the jog enable switches off requires a fresh start command.

WAR NIN G! If jogging is enabled and activated while the start command is on, jogging will activate as soon as the start command switches off.

• If both jogging functions are activated, the one that was activated first has priority.

• Jogging uses vector control.

• The inching functions activated through fieldbus (06.01 bits 8…9) use the references and ramp times defined for jogging, but do not require the jog enable signal.

Settings

Parameters 20.25 Jog enable (page 164), 20.26 Jog 1 start (page 165), 20.27 Jog 2

start (page 166), 22.42 Jogging 1 ref (page 185), 22.43 Jogging 2 ref (page 185),

23.20 Acc time jogging (page 191) and 23.21 Dec time jogging (page 191).

Page 73

Program features 73

100

t (s)

T T

(%)

load

act-nref

Area < 10% s

TN= rated motor torque n

= rated motor speed

act

= actual speed

ref

= speed reference

Speed control Performance

Static accuracy 20% of motor

nominal slip

Dynamic accuracy < 1% s with 100%

torque step

t (s)

TN= rated motor torque

ref

= torque reference

act

= actual torque

Torque control Performance

Non-linearity ± 5% with nominal

torque

(± 20% at the most dema nding operati ng point)

Torque step rise time < 10 ms with nominal

torque

100

< 5 ms

ref

act

(%)

 Speed control performance figures

The table below shows typical performance figures for speed control.

 Torque control performance figures

The drive can perform precise torque control without any speed feedback from the motor shaft. The table below shows typical performance figures for torque control.

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74 Program features

Motor voltage

f (Hz)

IR compensation

No compensation

 Scalar motor control

Scalar motor control is the default motor control method. It is suitable for applications which do not require the control accuracy available in vector control. In scalar control, you control the drive output frequency reference, and you do not need to do any motor identification run at the first start.

It is recommended to activate scalar motor control mode in the following special situations:

• In multimotor drives: 1) if the load is not equally shared between the motors, 2) if the motors are of different sizes, or 3) if the motors are going to be changed after motor identification (ID run)

• If the nominal current of the motor is less than 1/6 of the nominal output current of the drive Note: During this time, do not activate the motor phase loss fault (31.19 Motor

phase loss) as the drive cannot measure the motor current accurately.

• If the drive is used without a motor connected (for example, for test purposes)

• If the drive runs a medium-voltage motor through a step-up transformer.

In scalar control, some features are not available.

See also section Operating modes and motor control modes on page 54.

IR compensation for scalar motor control

IR compensation (also known as voltage boost) is available only when the motor control mode is scalar. When IR compensation is activated, the drive gives an extra voltage boost to the motor at low speeds. IR compensation is useful in applications that require a high break-away torque.

In vector control, no IR compensation is possible or needed as it is applied automatically.

Settings

Parameter group 28 Frequency reference chain (page 203).

Paramters 97.13 IR compensation (page 343) and 99.04 Motor control mode (page

347).

Page 75

Program features 75

Motor torque / Nominal torque

Output frequency (Hz)

1 = Overload curve (five points) 2 = Nominal process load curve 3 = Underload curve (five points)

1.2

1.0

0.8

0.6

0.2

0.4

0.0

-0.2 01020304050

 User load curve

The User load curve provides a supervisory function that monitors an input signal as a function of frequency or speed, and load. It shows the status of the monitored signal and can give a warning or fault based on the violation of a user defined profile.

The user load curve consists of an overload and an underload curve, or just one of them. Each curve is formed by five points that represent the monitored signal as a function of frequency or speed.

In the example below, the user load curve is constructed from the motor nominal torque to which a 10% margin is added and subtracted. The margin curves define a working envelope for the motor so that excursions outside the envelope can be supervised, timed and detected.

An overload warning and/or fault can be set to occur if the monitored signal stays continuously over the overload curve for a defined time. An underload warning and/or fault can be set to occur if the monitored signal stays continuously under the underload for a defined time.

Overload can be for example used to monitor for a saw blade hitting a knot or fan load profiles becoming too high.

Underload can be for example used to monitor for load dropping and breaking of conveyer belts or fan belts.

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76 Program features

(%)

Motor speed

No flux braking

Flux braking

= Braking torque

= 100 Nm

Flux braking

No flux braking

t (s)

f (Hz)

Settings

Parameter group 37 User load curve (page 255).

 U/f ratio

The U/f function is only available in scalar motor control mode, which uses frequency control.

The function has two modes: linear and squared.

In linear mode, the ratio of voltage to frequency is constant below the field weakening point. This is used in constant torque applications where it may be necessary to produce torque at or near the rated torque of the motor throughout the frequency range

In squared mode, the ratio of the voltage to frequency increases as the square of the frequency below the field weakening point. This is typically used in centrifugal pump or fan applications. For these applications, the torque required follows the square relationship with frequency. Therefore, if the voltage is varied using the square relationship, the motor operates at improved efficiency and lower noise levels in these applications.

The U/f function cannot be used with energy optimization; if parameter 45.11 Energy

optimizer is set to Enable, parameter 97.20 U/F ratio is ignored.

Settings

Parameter 97.20 U/F ratio (page 344).

 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.

The drive monitors the motor status continuously, also during flux braking. Therefore, flux braking can be used both for stopping the motor and for changing the speed. The other benefits of flux braking are:

Page 77

Program features 77

• The braking starts immediately after a stop command is given. The function does not need to wait for the flux reduction before it can start the braking.

• The cooling of the induction motor is efficient. The stator current of the motor increases during flux braking, not the rotor current. The stator cools much more efficiently than the rotor.

• Flux braking can be used with induction motors and permanent magnet motors.

Two braking power levels are available:

• Moderate braking provides faster deceleration compared to a situation where flux braking is disabled. The flux level of the motor is limited to prevent excessive heating of the motor.

• Full braking exploits almost all available current to convert the mechanical braking energy to motor thermal energy. Braking time is shorter compared to moderate braking. In cyclic use, motor heating may be significant.

WARNING: The motor needs to be rated to absorb the thermal energy generated by flux braking.

Settings

Parameter 97.05 Flux braking (page 341).

 DC magnetization

The drive has different magnetization functions for different phases of motor start/rotation/stop: pre-magnetization, DC hold, post-magnetization and pre-heating (motor heating).

Pre-magnetization

Pre-magnetization refers to DC magnetization of the motor before start. Depending on the selected start mode (vector or scalar) pre-magnetization can be applied to guarantee the highest possible breakaway torque, up to 200% of the nominal torque of the motor. By adjusting the pre-magnetization time, it is possible to synchronize the motor start and, for example, the release of a mechanical brake.

Settings

Parameters 21.01 Vector start mode (page 169), 21.19 Scalar start mode (page 175) and 21.02 Magnetization time (page 170).

DC hold

The function makes it possible to lock the rotor at (near) zero speed in the middle of normal operation. DC hold is activated by parameter 21.08. When both the reference and motor speed drop below a certain level, the drive will stop generating sinusoidal

Page 78

78 Program features

Reference

Motor speed

DC hold

21.09 DC hold speed

current and start to inject DC into the motor. The current is set by parameter 21.10. When the reference exceeds parameter 21.09, normal drive operation continues.

Settings

Parameters 21.08 DC current control (page 173), 21.09 DC hold speed (page 173) and 21.10 DC current reference (page 173).

Post-magnetization

The function keeps the motor magnetized for a certain period after stopping. This is to prevent the machinery from moving under load, for example before a mechanical brake can be applied. Post-magnetization is activated by parameter 21.08. The magnetization current is set by parameter 21.10.

Note: Post-magnetization is only available when ramping is the selected stop mode.

Settings

Parameters 21.01 Vector start mode (page 169), 21.02 Magnetization time (page

170), 21.03 Stop mode (page 170), 21.08 DC current control (page 173), 21.09 DC hold speed (page 173) and 21.11 Post magnetization time (page 173).

Pre-heating (Motor heating)

The pre-heating function keeps the motor warm and prevents condensation inside the motor by feeding it with DC current when the drive has been stopped. The heating can only be activated when the drive is in the stopped state, and starting the drive stops the heating.

When pre-heating is activated and the stop command is given, pre-heating starts immediately if the drive is running below the zero speed limit (see bit 0 in parameter

06.19 Speed control status word). If the drive is running above the zero speed limit,

Page 79

Program features 79

pre-heating is delayed by the time defined by parameter 21.15 Pre-heating time delay to prevent excessive current.

The function can be defined to be always active when the drive is stopped or it can be activated by a digital input, fieldbus, timed function or supervision function. For example, with the help of signal supervision function, the heating can be activated by a thermal measurement signal from the motor.

The pre-heating current fed to the motor can be defined as 0…30% of the nominal motor current.

Notes:

• In applications where the motor keeps rotating for a long time after the modulation is stopped, it is recommended to use ramp stop with pre-heating to prevent a sudden pull at the rotor when the pre-heating is activated.

• The heating function requires that STO is not triggered.

• The heating function requires that the drive is not faulted.

• Pre-heating uses DC hold to produce current.

Settings

Parameters 21.14 Pre-heating input source (page 174), 21.15 Pre-heating time delay and 21.16 Pre-heating current (page 174).

 Energy optimization

The Energy optimization function optimizes the motor flux so that total energy consumption and motor noise level are reduced when the drive operates below the nominal load. The total efficiency (motor and drive) can be improved by 1…20% depending on load torque and speed.

Note: With a permanent magnet motor and synchronous reluctance motor, energy optimization is always enabled.

Settings

Parameter 45.11 Energy optimizer (page 286).

 Switching frequency

The drive has two switching frequencies: reference switching frequency and minimum switching frequency. The drive tries to keep the highest allowed switching frequency (= reference switching frequency) if thermally possible, and then adjusts dynamically between the reference and minimum switching frequencies depending on the drive temperature. When the drive reaches the minimum switching frequency (= lowest allowed switching frequency), it starts to limit output current as the heating up continues.

For derating, see the hardware manual of the drive.

Page 80

80 Program features

Used

speed

Motor speed

Max.

speed

t (s)

Area A + Area B = Area C

Stop command

D1 = Delay defined by parameter

21.31

D2 = Additional delay calculated by

speed compensated stop

Example 1: If you need to fix the switching frequency to a certain value as with some external filters, e.g. with EMC C1 filters (see the hardware manual), set both the reference and the minimum switching frequency to this value and the drive will retain this switching frequency.

Example 2: If the reference switching frequency is set to 12 kHz and the minimum switching frequency is set to 1.5 kHz (or 1 kHz), the drive maintains the highest possible switching frequency to reduce motor noise and only when the drive heats it will decrease the switching frequency. This is useful, for example, in applications where low noise is necessary but higher noise can be tolerated when the full output current is needed.

Settings

Parameters 97.01 Switching frequency reference (page 340) and 97.02 Minimum

switching frequency (page 340).

 Speed compensated stop

Speed compensation stop is available for example for applications where a conveyer needs to travel a certain distance after receiving the stop command. At maximum speed, the motor is stopped normally along the defined deceleration ramp, after the application of a user defined delay to adjust the distance traveled. Below maximum speed, stop is delayed still more by running the drive at current speed before the motor is ramped to a stop. As shown in the figure, the distance traveled after the stop command is the same in both cases, that is, area A + area B equals area C.

Speed compensation does not take into account shape times (parameters 23.32

Shape time 1 and 23.33 Shape time 2). Positive shape times lengthen the distance

traveled.

Page 81

Program features 81

Process

PID

AI1

Process

actual

values

AI2

• • •

FBA

Setpoint

Speed, torque or frequency reference chain

Filter

Limitation

Speed compensation can be restricted to forward or reverse rotating direction. Speed compensation is supported in both vector and scalar motor control.

Settings

Parameters 21.30 Speed compensated stop mode (page 176), 21.31 Speed

compensated stop delay (page 177) and 21.32 Speed comp stop threshold (page

177).

Application control

 Control macros

Control macros are predefined parameter edits and I/O configurations. See chapter

Control macros.

 Process PID control

There is a built-in process PID controller in the drive. The controller can be used to control process such as pressure or flow in the pipe or fluid level in the container.

In process PID control, a process reference (setpoint) is connected to the drive instead of a speed reference. An actual value (process feedback) is also brought back to the drive. The process PID control adjusts the drive speed in order to keep the measured process quantity (actual value) at the desired level (setpoint). This means that user does not need to set a frequency/speed/torque reference to the drive but the drive adjust its operation according to the process PID.

The simplified block diagram below illustrates the process PID control.

The drive contains two complete sets of process PID controller settings that can be alternated whenever necessary; see parameter 40.57 PID set1/set2 selection.

Note: Process PID control is only available in external control; see section Local and

external control locations on page 52.

Page 82

82 Program features

Sleep and boost functions for process PID control

The sleep function is suitable for PID control applications where the consumption varies, such as clean water pumping systems. When used, it stops the pump completely during low demand, instead of running the pump slowly below its efficient operating range. The following example visualizes the operation of the function.

Example: The drive controls a pressure boost pump. The water consumption falls at night. As a consequence, the process PID controller decreases the motor speed. However, due to natural losses in the pipes and the low efficiency of the centrifugal pump at low speeds, the motor would never stop rotating. The sleep function detects the slow rotation and stops the unnecessary pumping after the sleep delay has passed. The drive shifts into sleep mode, still monitoring the pressure. The pumping resumes when the pressure falls under the predefined minimum level and the wakeup delay has passed.

The user can extend the PID sleep time by the boost functionality. The boost functionality increases the process setpoint for a predetermined time before the drive enters the sleep mode.

Page 83

Program features 83

Wake-up level (Setpoint - Wake-up deviation [40.47])

t < t

Motor speed

Actual value

STOP

= Sleep delay (40.44)

Sleep level (40.43)

START

Wake-up delay

(40.48)

Setpoint

Time

Sleep boost step (40.46)

Sleep mode

Sleep boost time (40.45)

Time

Non-inverted (40.31 = Not inverted (Ref - Fbk))

Wake-up level (Setpoint + Wake-up deviation [40.47])

Actual value

Time

Inverted (40.31 = Inverted (Fbk - Ref))

Page 84

84 Program features

Tracking

In tracking mode, the PID block output is set directly to the value of parameter 40.50

Set 1 tracking ref selection (or 41.50 Set 2 tracking ref selection).The internal I term

of the PID controller is set so that no transient is allowed to pass on to the output, so when the tracking mode is left, normal process control operation can be resumed without a significant bump.

Settings

Parameter 96.04 Macro select (page 332).

Parameter groups 40 Process PID set 1(page 259) and 41 Process PID set 2 (page

273).

 Mechanical brake control

A mechanical brake can be used for holding the motor and driven machinery at zero speed when the drive is stopped, or not powered. The brake control logic observes the settings of parameter group 44 Mechanical brake control as well as several external signals, and moves between the states presented in the diagram on page 85. The tables below the state diagram detail the states and transitions. The timing diagram on page 87 shows an example of a close-open-close sequence.

For application example, see section Crane mechanical brake control on page 533.

Inputs of the brake control logic

The start command of the drive (bit 5 of 06.16 Drive status word 1) is the main control source of the brake control logic. An optional external open/close signal can be selected by 44.12 Brake close request. The two signals interact as follows:

• Start command = 1 AND signal selected by 44.12 Brake close request = 0

→

Request brake to open

• Start command = 0 OR signal selected by 44.12 Brake close request = 1

→

Request brake to close

Another external signal – for example, from a higher-level control system – can be connected via parameter 44.11 Keep brake closed to prevent the brake from opening.

Other signals that affect the state of the control logic are

• brake status acknowledgment (optional, defined by parameter 44.07 Brake

acknowledge selection),

• bit 2 of 06.11 Main status word (indicates whether the drive is ready to follow the given reference or not),

• bit 6 of 06.16 Drive status word 1 (indicates whether the drive is modulating or not).

Page 85

Program features 85

BRAKE CLOSING

DELAY

BRAKE CLOSING WAIT

BRAKE DISABLED BRAKE OPENING

BRAKE OPENING WAIT

BRAKE OPENING

DELAY

BRAKE CLOSED

BRAKE OPENBRAKE CLOSING

(from any state)

Outputs of the brake control logic

The mechanical brake is controlled by bit 0 of parameter 44.01 Brake control status. This bit should be selected as the source of a relay output (or a digital input/output in output mode) which is then wired to the brake actuator through a relay. See the wiring example on page 88.

The brake control logic, in various states, will request the drive control logic to hold the motor, increase the torque, or ramp down the speed. These requests are visible in parameter 44.01 Brake control status.

Brake state diagram

State descriptions

State name Description

BRAKE DISABLED Brake control is disabled (paramete r 44.06 Brake control enable = 0, and 44.01

BRAKE OPENING BRAKE OPENING WAIT Brake has been requested to open. The drive logic is requested to increase the

Brake control status b4 = 0). The open signal is active (44.01 Brake control status b0 = 1).

torque up to opening torque to hold the load in place (44.01 Brake control status b1 = 1 and b2 = 1). The state of 44.11 Keep brake closed is checked; if it is not 0 within a reasonable time, the drive trips on a 71A5 Mechanical brake opening

not allowed fault

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86 Program features

State name Description

BRAKE OPENING DELAY Opening conditions have been met and open signal activated (44.01 Brake

BRAKE OPEN The brake is open (44.01 Brake control status b0 = 1). Hold request is removed

BRAKE CLOSING BRAKE CLOSING WAIT Brake has been requeste d to close. The drive logic is requested to ram p down

BRAKE CLOSING DELAY Closing conditions have been met. The open signal is deactivated (44.01 Brake

BRAKE CLOSED The brake is closed (44.01 Brake control status b0 = 0). The drive is not

*) A warning can alternatively be select ed by parameter 44.17 Brake fault function; if so, the drive will keep modulating and remain in this state.

State change conditions ()

1 Brake control disabled (parameter 44.06 Brake control enable → 0). 2 06.11 Main status word, bit 2 = 0. 3 Brake has been requested to open and 44.16 Brake reopen delay has expired. 4 Brake open conditions (such as 44.10 Brake open torque) fulfilled and 44.11 Keep brake closed = 0. 5 44.08 Brake open delay has elapsed and brake open acknowledgement (if chosen by 44.07 Brake

acknowledge sele ction) has been received.

6 Brake has been requested to close. 7 Motor speed has remained below closing speed 44.14 Brake close level for the duration of 44 .15

Brake close level delay.

8 44.13 Brake close delay has elapsed and brake close acknowledgment (if chosen by 44.07 Brake

acknowledge sele ction) has been received.

9 Brake has been requested to open.

10 Brake control enabled (parameter 44.06 Brake control enable → 1).

control status b0 is set). The opening torque request is removed (44.01 Brake control status b1 → 0). The load is held in place by the speed control of the

drive until 44.08 Brake open delay elapses. At this point, if 44.07 Brake acknowledge selection is set to No acknowledge, the logic proceeds to BRAKE OPEN state. If an acknowledgement signal source has been selected, its state is checked; if the state is not “brake open”, the drive trips on a 71A3 Mechanical brake opening failed fault

(44.01 Brake control status b2 = 0), and the drive is allowed to follow the reference.

the speed to a stop (44.01 Brake control status b3 = 1). The open signal is kept active (44.01 Brake control status b0 = 1). The brake logic will remain in this state until the motor speed is below 44.14 Brake close level for the time defined by 44.15 Brake close level delay.

control status b0 → 0). The ramp-down request is maintained (44.01 Brake control status b3 = 1). The brake logic will remain in this state until 44.13 Brake close delay has elapsed.

At this point, if 44.07 Brake acknowledge selection is set to No acknowledge, the logic proceeds to BRAKE CLOSED state. If an acknowledgment signal source has been selected, its state is checked; if the state is not “brake closed”, the drive generates an A7A1 Mechanical brake closing failed warning. If 44.17

Brake fault function = Fault, the drive will trip on a 71A2 Mechanical brake closing failed fault after 44.18 Brake fault delay.

necessarily modulating. Note concerning open-loop (encoder-less) applications: If the brake is kept

closed by a brake close request (either from parameter 44.12) against a modulating drive for longer than 5 seconds, the brake is forced to closed state and the drive trips on a fault, 71A5 Mechanical brake opening not allowed.

Page 87

Timing diagram

Start torque at brake open (parameter 44. 03 Brake open torque reference)

mem

Stored torque value at brake close (44.02 Brake torque memory)

Motor magnetizati on delay

Brake open delay (parameter 44.08 Brake open delay)

Brake close spee d (parameter 44.14 Brake close level)

ccd

Brake close comm and delay (paramet er 44.15 Brake close level delay)

Brake close delay (parameter 44.13 Brake close delay)

cfd

Brake close fault delay (parameter 44.18 Brake fault delay)

rod

Brake reopen delay (parameter 44.16 Brake reopen delay) BOW BRAKE OPENING WAIT BOD BRAKE OPENING DELAY BCW BRAKE CLOSING WAIT BCD BRAKE CLOSING DELAY

Start command

(06.16 b5)

Modulating (06.16 b6)

mem

1 2345 6 7 89

Ready ref (06.11 b2)

Torque reference

Speed reference

Brake control signal

(44.01 b0)

Opening torque

request (44.01 b1 )

Ramp to stopped

request (44.01 b3 )

Hold stopped request

(44.01 b2)

ccd

cfd

rod

BRAKE

CLOSED

State

BRAKE

CLOSED

BRAKE OPE N

BRAKE OPE NING BRAKE C LOSING

BOW BOD BCW BCD

The simplified timing diagram below illustrates the operation of the brake control function. Refer to the Brake state diagram on page 85.

Program features 87

Page 88

88 Program features

Motor

115/230 VAC

Drive control unit

Mechanical brake

Brake control

hardware

Emergency

brake

XRO1

1 NC

2 COM

3 NO

XD24

XDIO

4 +24VD

5 DIO2

Wiring example

The figure below shows a brake control wiring example. The brake control hardware and wiring is to be sourced and installed by the customer.

WAR NIN G! Make sure that the machinery into which the drive with brake

control function is integrated fulfills the personnel safety regulations. Note that the frequency converter (a Complete Drive Module or a Basic Drive Module, as defined in IEC/EN 61800-2), is not considered as a safety device mentioned in the European Machinery Directive and related harmonized standards. Thus, the personnel safety of the complete machinery must not be based on a specific frequency converter feature (such as the brake control function), but it has to be implemented as defined in the application specific regulations.

The brake is controlled by bit 0 of parameter 44.01 Brake control status. The source of brake acknowledge (status supervision) is selected by parameter 44.07 Brake

acknowledge selection. In this example,

• parameter 10.24 RO1 source is set to Open brake command (ie. bit 0 of 44.01

Brake control status), and

• parameter 44.07 Brake acknowledge selection is set to DIO1.

Page 89

Program features 89

Settings

Parameters 06.11 Main status word (page 124), 06.16 Drive status word 1 (page 125) and parameter group 44 Mechanical brake control (page 278).

Events A7A1 Mechanical brake closing failed (page 396), 71A2 Mechanical brake

closing failed (page 407), 71A3 Mechanical brake opening failed (page 408) and 71A5 Mechanical brake opening not allowed (page 408).

Page 90

90 Program features

130

260

390

520

1.6 5.8 8 11.2 15.4

t (s)

out

UDC = Intermediate circuit voltage of the drive, f

out

= Output frequency of the drive,

= Motor torque.

Loss of supply voltage at nominal load (f

out

= 40 Hz). The intermediate circuit DC voltage drops to the minimum limit. The controller keeps the voltage steady as long as the input power is switched off. The drive runs the motor in generator mode. The motor speed falls but the drive is operational as long as the motor has enough kinetic energy.

input power

120

160

(N·m)

out

(Hz)

(Vdc)

DC voltage control

 Overvoltage control

Overvoltage control of the intermediate DC link is typically needed when the motor is in generating mode. The motor can generate when it decelerates or when the load overhauls the motor shaft, causing the shaft to turn faster than the applied speed or frequency. To prevent the DC voltage from exceeding the overvoltage control limit, the overvoltage controller automatically decreases the generating torque when the limit is reached. The overvoltage controller also increases any programmed deceleration times if the limit is reached; to achieve shorter deceleration times, a brake chopper and resistor may be required.

 Undervoltage control (power loss ride-through)

If the incoming supply voltage is cut off, the drive will continue to operate by utilizing the kinetic energy of the rotating motor. The drive will be fully operational as long as the motor rotates and generates energy to the drive. The drive can continue operation after the break if the main contactor (if present) remained closed.

Note: Units equipped with a main contactor must be equipped with a hold circuit (e.g. UPS) to keep the contactor control circuit closed during a short supply break.

Page 91

Program features 91

Implementing the undervoltage control (power loss ride-through)

Implement the undervoltage control function as follows:

• Check that the undervoltage control function of the drive is enabled with parameter 30.31 Undervoltage control.

• Parameter 21.01 Vector start mode must be set to Automatic (in vector mode) or parameter 21.19 Scalar start mode to Automatic (in scalar mode) to make flying start (starting into a rotating motor) possible.

If the installation is equipped with a main contactor, prevent its tripping at the input power break. For example, use a time delay relay (hold) in the contactor control circuit.

WARNING! Make sure that the flying restart of the motor will not cause any danger. If you are in doubt, do not implement the undervoltage control function.

Automatic restart

It is possible to restart the drive automatically after a short (max. 10 seconds) power supply failure by using the Automatic restart function, provided that the drive is allowed to run for 10 seconds without the cooling fans operating.

When enabled, the function takes the following actions upon a supply failure to enable a successful restart:

• The undervoltage fault is suppressed (but a warning is generated).

• Modulation and cooling is stopped to conserve any remaining energy.

• DC circuit pre-charging is enabled.

If the DC voltage is restored before the expiration of the period defined by parameter

21.18 Auto restart time and the start signal is still on, normal operation will continue.

However, if the DC voltage remains too low at that point, the drive trips on a fault,

3220 DC link undervoltage.

WARNING! Before you activate the function, make sure that no dangerous situations can occur. The function restarts the drive automatically and

continues operation after a supply break.

 Voltage control and trip limits

The control and trip limits of the intermediate DC voltage regulator are relative to the supply voltage as well as drive/inverter type. The DC voltage (U

1.35 times the line-to-line supply voltage, and is displayed by parameter 01.11 DC

voltage.

) is approximately

Page 92

92 Program features

The following table shows the values of the selected DC voltage levels in volts. Note that the absolute voltages vary according to drive/inverter type and AC supply voltage range.

DC voltage level [V]

See 95.01 Supply vo ltage.

Supply voltage range [V]

380…415

Overvoltage fault limit 840 840

Overvoltage control limit 780 780

Internal brake choppe r start limit 780 780

Internal brake chopper stop limit 760 760

Overvoltage warni ng limit 745 745

Undervoltage warning limit 0.85×1.41×par 95. 03 value

0.85×1.41×380 = 455

Undervoltage control limit 0.75×1.41×par 95.03 value 1)0.75×1.41×par 95.03 value

0.75×1.41×380 = 402

Charging relay closing limit 0.75×1.41×par 95.03 value 1)0.75×1.41×par 95.03 value

0.75×1.41×380 = 402

Charging relay opening limit 0.65×1.41×par 95.03 value 1)0.65×1.41 ×par 95.03 value

DC voltage at upper bound of supply voltage range (U

DCmax

)

DC voltage at lower bound of supply voltage range (U

DCmin

)

0.65×1.41×380 = 348

560 648

513 594

Charging activation/standby limit 0.65×1.41×par 95.03 value

0.65×1.41×380 = 348

Undervoltage fault limit 0.45×1.41×par 95.03 value 1)0.45×1.41×par 95.03 value

0.45×1.41×380 = 241

If parameter 95.01 Supply voltage is set to Automatic / not selected and 95.02 Adaptive voltage limits is set to Enable, the value of parameter 95.03 Estimated AC supply voltage is used,

otherwise the lower limit of the range selected with parameter 95.01 Supply voltage is used.

Supply voltage range [V]

440…480

0.85×1.41×par 95.03 value

0.85×1.41×440 = 5 27

0.75×1.41×440 = 4 65

0.65×1.41×440 = 4 03

0.65×1.41×par 95.03 value

0.65×1.41×440 = 4 03

0.45×1.41×440 = 2 79

 Settings

Parameters 01.11 DC voltage (page 116), 30.30 Overvoltage control (page 221),

30.31 Undervoltage control (page 221), 95.01 Supply voltage (page 329) and 95.02 Adaptive voltage limits (page 329).

Page 93

Program features 93

 Brake chopper

A brake chopper can be used to handle the energy generated by a decelerating motor. When the DC voltage rises high enough, the chopper connects the DC circuit to an external brake resistor. The chopper operation is based on hysteresis.

The internal brake choppers in the drive (in frames R0…R3) start conducting at internal brake chopper start limit 780 V and stop conducting at internal brake chopper stop limit 760 V (AC supply 380…480 V).

For information on external brake choppers, refer to the respective user manual.

Note: Overvoltage control needs to be disabled for the chopper to operate.

Settings

Parameters 01.11 DC voltage (page 116), 30.30 Overvoltage control (page 221) and parameter group 43 Brake chopper (page 276).

Page 94

94 Program features

Limit to limit control

The Limit to limit control function restricts the forward and reverse movement of a load inside two extreme points. The function supports the monitoring of two sensors at both ends of the movement range: one for the slow down point and the other for the stop point. The system installer must install the sensors (eg, limit switches) and connect them to the drive.

In the forward direction, the function allows normal operation of the drive until the movement reaches the forward limiting points:

- When the drive receives the forward slow down signal, it decelerates the speed to the slow down speed. Slow down speed allows smooth transition to stop at a later stage. Vector mode uses the Speed reference ramp (23.11... 23.15) and Scalar mode the Freq reference ramp (28.71... 28.75).

- When the drive receives the forward stop signal, it stops the motor. It uses the drive stop mode selection (21.03). The function allows start only in the reverse direction.

In the reverse direction, the function monitors reverse slow down and reverse stop signals. The operation is similar as in the forward direction.

You can enable the function by a parameter, and define the signal sources for the forward slow down, forward stop, reverse slow down and reverse stop. You can also define the slow down speed by a parameter.

The Limit to limit function detects the signal status changes only when the function is active, and the load is moved by the drive and motor. The function does not update the signal states in its state machine despite of the actual status changes:

1. when the user has deactivated or disabled the function

2. when the function has stopped the motor but the load is moved by a force other than the drive and motor (e.g., by a gravity).

For application example, see sections Crane stop limit function on page 546, Crane

slowdown function on page 548, and Fast stop on page 550.

Page 95

 Limit to limit control function

LIMIT-TO-LIMIT

PHASE 1

FWD

REV

MAX

+SLOW

ZERO

-SLOW

MIN

STATES

REV ZERO - FWD MAX

REV SLOW - FWD MAX

REV MAX - FWD SLOW

REV MAX - FWD MAX

REV MAX - FWD ZERO

REV - STOP - SIG

REV - SLOW - SIG

FWD - SLOW - SIG

FWD - STOP - SIG

Program features 95

 Limitations

• The external stop or slow down signals (in either direction) must not be on when the Limit to limit function is activated for the first time. If that is not possible, change the state manually to match the actual status in the Limit to limit state parameter (76.01).

• When drive is stopped, the load must not be moved with external force (the drive cannot monitor direction). If this happens, the Limit to limit state can be manually changed to the correct one in parameter Limit to limit state parameter (76.01).

• Coast stop without mechanical brake may cause load moving without Limit to limit control (drive is not controlling load movement). If this happens, the Limit to limit state can be manually changed to the correct one in parameter Limit to limit state parameter (76.01).

• When Limit to limit control is in Pulse mode then the state is saved over power cycle. The load must not be moved when the drive is powered off. If this happens, then Limit to limit state can be manually changed to the correct one in parameter Limit to limit state parameter (76.01).

Page 96

96 Program features

 Tips

• You can connect Slow down and Stop signals into the same signal source by setting the Stop limit and Slow down parameters to the same digital input (76.01 Forward stop limit = DI2 and 76.05 Forward slow down limit = DI2).

• You can change the Limit to limit state machine state with the parameter Limit to limit state parameter (76.01), in case of maintenance.

Settings

Parameter groups 21 Start/stop mode (page 169), 23 Speed reference ramp (page

190) and 28 Frequency reference chain (page 203).

Paramters 76.01 Limit to limit control status (page 322), 76.02 Enable limit to limit

control (page 322), 76.03 Limit to limit trigger type (page 323), 76.04 Forward stop limit (page 323), 76.05 Forward slow down limit (page 324), 76.06 Reverse stop limit

(page 325), 76.07 Reverse slow down limit (page 325), 76.08 Slow down speed (page 325) and 76.09 Slow down frequency (page 325).

Page 97

Program features 97

Safety and protections

 Fixed/Standard protections

Overcurrent

If the output current exceeds the internal overcurrent limit, the IGBTs are shut down immediately to protect the drive.

DC overvoltage

See section Overvoltage control on page 90.

DC undervoltage

See section Undervoltage control (power loss ride-through) on page 90.

Drive temperature

If the temperature rises high enough, the drive first starts to limit the switching frequency and then the current to protect itself. If it is still keeps heating up, for example because of a fan failure, an overtemperature fault is generated.

Short circuit

In case of a short circuit, the IGBTs are shut down immediately to protect the drive.

 Emergency stop

The emergency stop signal is connected to the input selected by parameter 21.05

Emergency stop source. An emergency stop can also be generated through fieldbus

(parameter 06.01 Main control word, bits 0…2).

The mode of the emergency stop is selected by parameter 21.04 Emergency stop

mode. The following modes are available:

• Off1: Stop along the standard deceleration ramp defined for the particular reference type in use

• Off2: Stop by coasting

• Off3: Stop by the emergency stop ramp defined by parameter 23.23 Emergency

stop time.

• Stop torque.

With Off1 or Off3 emergency stop modes, the ramp-down of the motor speed can be supervised by parameters 31.32 Emergency ramp supervision and 31.33 Emergency

ramp supervision delay.

Page 98

98 Program features

Notes:

• The installer of the equipment is responsible for installing the emergency stop devices and all additional devices needed for the emergency stop function to fulfill the required emergency stop categories.

• After an emergency stop signal is detected, the emergency stop function cannot be canceled even though the signal is canceled.

• If the minimum (or maximum) torque limit is set to 0%, the emergency stop function may not be able to stop the drive.

• During an emergency stop, the speed and torque reference parameters such as reference ramp shapes (23.32 Shape time 1 and 23.33 Shape time 2) are not considered.

Settings

Parameters 21.04 Emergency stop mode (page 170), 21.05 Emergency stop source (page 171), 23.23 Emergency stop time (page 192), 31.32 Emergency ramp

supervision (page 230) and 31.33 Emergency ramp supervision delay (page 231).

 Motor thermal protection

The control program features two separate motor temperature monitoring functions. The temperature data sources and warning/trip limits can be set up independently for each function.

The motor temperature can be monitored using

• the motor thermal protection model (estimated temperature derived internally inside the drive), or

• sensors installed in the windings. This will result in a more accurate motor model.

Motor thermal protection model

The drive calculates the temperature of the motor on the basis of the following assumptions:

1. When power is applied to the drive for the first time, the motor is assumed to be at ambient temperature (defined by parameter 35.50 Motor ambient temperature). After this, when power is applied to the drive, the motor is assumed to be at the estimated temperature.

2. Motor temperature is calculated using the user-adjustable motor thermal time and motor load curve. The load curve should be adjusted in case the ambient temperature exceeds 30 °C.

Note: The motor thermal model can be used when only one motor is connected to the inverter.

Page 99

Program features 99

AI1

GND

One sensor

GND

AI1

GND

Three sensors

Motor

3.3 nF

Motor

3.3 nF

Motor temperature measurement through the standard I/O

This section describes the temperature measurement of one motor when the drive I/O terminals are used as the connection interface.

Motor temperature can be measured using Pt100 or PTC sensors connected to analog input and output.

Warning! According to IEC 60664, the connection of the motor temperature sensor requires double or reinforced insulation between motor live parts and the sensor. Reinforced insulation entails a clearance and creepage distance of 8 mm (0.3 in) (400/500 V AC equipment).

If the assembly does not fulfill the requirement, the I/O board terminals must be protected against contact and they may not be connected to other equipment, or the temperature sensor must be isolated from the I/O terminals.

Temperature monitoring using Pt100 sensors

1…3 Pt100 sensors can be connected in series to an analog input and an analog output.

The analog output feeds a constant excitation current of 9.1 mA through the sensor. The sensor resistance increases as the motor temperature rises, as does the voltage over the sensor. The temperature measurement function reads the voltage through the analog input and converts it into degrees Celsius.

It is possible to adjust the motor temperature supervision limits and select how the drive reacts when overtemperature is detected.

For the wiring of the sensor, see chapter Electrical installation, AI1 and AI2 as Pt100, Pt1000, Ni1000, KTY83 and KTY84 sensor inputs (X1) in the Hardware manual of the drive.

Page 100

100 Program features

Temperature monitoring using Pt1000 sensors

1…3 Pt1000 sensors can be connected in series to an analog input and an analog output.

The analog output feeds a constant excitation current of 0.1 mA through the sensor. The sensor resistance increases as the motor temperature rises, as does the voltage over the sensor. The temperature measurement function reads the voltage through the analog input and converts it into degrees Celsius.

For the wiring of the sensor, see chapter Electrical installation, AI1 and AI2 as Pt100, Pt1000, Ni1000, KTY83 and KTY84 sensor inputs (X1) in the Hardware manual of the drive.

Temperature monitoring using Ni1000 sensors

One Ni1000 sensor can be connected to an analog input and an analog output on the control unit.

For the wiring of the sensor, see chapter Electrical installation, AI1 and AI2 as Pt100, Pt1000, Ni1000, KTY83 and KTY84 sensor inputs (X1) in the Hardware manual of the drive.

Temperature monitoring using KTY84 sensors

One KTY84 sensor can be connected to an analog input and an analog output on the control unit.

The analog output feeds a constant excitation current of 2.0 mA through the sensor. The sensor resistance increases as the motor temperature rises, as does the voltage over the sensor. The temperature measurement function reads the voltage through the analog input and converts it into degrees Celsius.

The figure and table on page 146 show typical KTY84 sensor resistance values as a function of the motor operating temperature.

For the wiring of the sensor, see chapter Electrical installation, AI1 and AI2 as Pt100, Pt1000, Ni1000, KTY83 and KTY84 sensor inputs (X1) in the Hardware manual of the drive.

Temperature monitoring using KTY83 sensors

One KTY83 sensor can be connected to an analog input and an analog output on the control unit.

The analog output feeds a constant excitation current of 1.0 mA through the sensor. The sensor resistance increases as the motor temperature rises, as does the voltage

ABB ACS380 Firmware Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Introduction to the manual

Contents

Applicability

Safety instructions

Target audience

Purpose of the manual

Contents of the manual

Terms and abbreviations

Related manuals

Cybersecurity disclaimer

Control panel

Contents

Control panel

Home view and Message view

Options menu and Main menu

Options menu

Main menu

Submenus

Start-up, ID run and use

Contents

Start up the drive

Do the identification (ID) run

 Background information

 ID run steps

Start and stop the drive

Change the rotation direction

Set the speed or frequency reference

Set the drive parameters

Open Diagnostics

Change the units

Control macros

Contents

ABB standard macro

 Default control connections for the ABB standard macro

ABB limited macro

 Default control connections for the ABB limited macro

Fieldbus control macro

 Default control connections for the Fieldbus macro

Alternate macro

 Default control connections for the Alternate macro

Motor potentiometer macro

 Default control connections for the Motor potentiometer macro

PID control macro

 Default control connections for PID control macro

Modbus macro

 Default control connections for the Modbus macro

Parameter default values for different macros

Program features

Contents

Local control

Local and external control locations

Settings

 External control

Settings

Block diagram: Run enable source for EXT1

Settings

Operating modes and motor control modes

Settings

 Overview diagram of control hierarchy

 Speed control mode

 Torque control mode

 Frequency control mode

 Special control modes

 Settings

 Autophasing

Autophasing modes

Settings

Drive configuration and programming

 Programming via parameters

 Adaptive programming

Adaptive program fault and aux code formats

Sequence program

Control interfaces

 Programmable analog inputs

Settings

 Programmable analog outputs