ABB ACS800 Firmware Manual

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ACS800

Firmware Manual ACS800 Standard Control Program 7.x

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ACS800 Standard Control Program 7.x

Firmware Manual

3AFE64527592 REV K

EFFECTIVE: 14.12.2009

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Table of contents

Introduction to the manual

Chapter overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Reader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Product and service inquiries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Product training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Providing feedback on ABB Drives manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Start-up and control through the I/O

Chapter overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

How to start-up the drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

How to perform the guided start-up (covers all essential settings) . . . . . . . . . . . . . . . . . . . . . . . 15

How to perform the limited start-up (covers only the basic settings) . . . . . . . . . . . . . . . . . . . . . 17

How to control the drive through the I/O interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

How to perform the ID Run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

ID Run Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Control panel

Chapter overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Overview of the panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Panel operation mode keys and displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Status row . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Drive control with the panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

How to start, stop and change direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

How to set speed reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Actual signal display mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

How to select actual signals to the display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

How to display the full name of the actual signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

How to view and reset the fault history . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

How to display and reset an active fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

About the fault history . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Parameter mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

How to select a parameter and change the value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

How to adjust a source selection (pointer) parameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Function mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

How to enter an assistant, browse and exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

How to upload data from a drive to the panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Table of contents

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How to download data from the panel to a drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

How to set the contrast of the display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Drive selection mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

How to select a drive and change its panel link ID number . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Reading and entering packed boolean values on the display . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Program features

Chapter overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Start-up Assistant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

The default order of the tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

List of tasks and the relevant drive parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Contents of the assistant displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Local control vs. external control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Local control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

External control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Block diagram: start, stop, direction source for EXT1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Block diagram: reference source for EXT1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Reference types and processing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Reference trimming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Programmable analogue inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Update cycles in the Standard Control Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Programmable analogue outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Update cycles in the Standard Control Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Programmable digital inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Update cycles in the Standard Control Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Programmable relay outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Update cycles in the Standard Control Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Actual signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Motor identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Power loss ride-through . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Automatic Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Table of contents

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Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

DC Magnetising . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

DC Hold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Flux Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Flux Optimisation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Acceleration and deceleration ramps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

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

Critical speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

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

Constant speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

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

Speed controller tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Speed control performance figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Torque control performance figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Scalar control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

IR compensation for a scalar controlled drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Hexagonal motor flux . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Programmable protection functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

AI<Min . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Panel Loss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

External Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Motor Thermal Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Motor temperature thermal model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Use of the motor thermistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Stall Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Underload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Motor Phase Loss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Earth Fault Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Communication Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Supervision of optional IO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Preprogrammed faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

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Page 8

Overcurrent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

DC overvoltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

DC undervoltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Drive temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Enhanced drive temperature monitoring for ACS800, frame sizes R7 and R8 . . . . . . . . . . . . . 65

Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Short circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Input phase loss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Control board temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Overfrequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Internal fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Operation limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Power limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Automatic resets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Supervisions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Parameter lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Process PID control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Block diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Sleep function for the process PID control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Motor temperature measurement through the standard I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Motor temperature measurement through an analogue I/O extension . . . . . . . . . . . . . . . . . . . . . . 73

Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Adaptive Programming using the function blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

DriveAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Control of a mechanical brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Operation time scheme . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

State shifts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

Master/Follower use of several drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

Settings and diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

Jogging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

Reduced Run function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

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Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

User load curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

Overload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

Application macros

Chapter overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

Overview of macros . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

Note on external power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

Parameter settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

Factory macro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

Default control connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

Hand/Auto macro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

Default control connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

PID Control macro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

Connection example, 24 VDC / 4…20 mA two-wire sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

Default control connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

Torque Control macro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

Default control connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

Sequential Control macro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

Operation diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

Default control connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

User macros . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

Actual signals and parameters

Chapter overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

Terms and abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

01 ACTUAL SIGNALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

02 ACTUAL SIGNALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

03 ACTUAL SIGNALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

04 ACTUAL SIGNALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

09 ACTUAL SIGNALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

10 START/STOP/DIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

11 REFERENCE SELECT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

12 CONSTANT SPEEDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

13 ANALOGUE INPUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

14 RELAY OUTPUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

15 ANALOGUE OUTPUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

16 SYST CTRL INPUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

20 LIMITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

21 START/STOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

22 ACCEL/DECEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

23 SPEED CTRL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

24 TORQUE CTRL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

25 CRITICAL SPEEDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

26 MOTOR CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138

27 BRAKE CHOPPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140

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30 FAULT FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

31 AUTOMATIC RESET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147

32 SUPERVISION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148

33 INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149

34 PROCESS VARIABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150

35 MOT TEMP MEAS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152

40 PID CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154

42 BRAKE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159

45 ENERGY OPT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161

50 ENCODER MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162

51 COMM MODULE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163

52 STANDARD MODBUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163

60 MASTER/FOLLOWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163

70 DDCS CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165

72 USER LOAD CURVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166

83 ADAPT PROG CTRL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168

84 ADAPTIVE PROGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169

85 USER CONSTANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170

90 D SET REC ADDR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171

92 D SET TR ADDR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172

95 HARDWARE SPECIF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172

96 EXTERNAL AO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175

98 OPTION MODULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177

99 START-UP DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183

Fieldbus control

Chapter overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187

System overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187

Redundant fieldbus control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188

Setting up communication through a fieldbus adapter module . . . . . . . . . . . . . . . . . . . . . . . . . . 189

Setting up communication through the Standard Modbus Link . . . . . . . . . . . . . . . . . . . . . . . . . . 191

Modbus addressing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192

Setting up communication through Advant controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193

Drive control parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195

The fieldbus control interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198

The Control Word and the Status Word . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199

References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199

Fieldbus reference selection and correction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199

Reference handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200

Actual Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201

Block diagram: Control data input from fieldbus when a type Rxxx fieldbus adapter is used . 202 Block diagram: Actual value selection for fieldbus when a type Rxxx fieldbus adapter is used 203 Block diagram: Control data input from fieldbus when a type Nxxx fieldbus adapter is used . 204 Block Diagram: Actual value selection for fieldbus when a type Nxxx fieldbus adapter is used 205

Communication profiles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206

ABB Drives communication profile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206

03.01 MAIN CONTROL WORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207

03.02 MAIN STATUS WORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208

Fieldbus reference scaling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210

Table of contents

Page 11

Generic Drive communication profile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211

Drive commands supported by the Generic Drive communication profile . . . . . . . . . . . . . . 212

Fieldbus reference scaling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213

CSA 2.8/3.0 communication profile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214

CONTROL WORD for the CSA 2.8/3.0 communication profile . . . . . . . . . . . . . . . . . . . . . . 214

STATUS WORD for the CSA 2.8/3.0 communication profile . . . . . . . . . . . . . . . . . . . . . . . . 214

Diverse status, fault, alarm and limit words . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215

03.03 AUXILIARY STATUS WORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215

03.04 LIMIT WORD 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216

03.05 FAULT WORD 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216

03.06 FAULT WORD 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217

03.07 SYSTEM FAULT WORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218

03.08 ALARM WORD 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218

03.09 ALARM WORD 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219

03.13 AUXILIARY STATUS WORD 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219

03.14 AUXILIARY STATUS WORD 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220

03.15 FAULT WORD 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220

03.16 ALARM WORD 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221

03.17 FAULT WORD 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221

03.18 ALARM WORD 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222

03.19 INT INIT FAULT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222

03.30 LIMIT WORD INV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223

03.31 ALARM WORD 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223

03.32 EXT IO STATUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224

03.33 FAULT WORD 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224

04.01 FAULTED INT INFO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225

04.02 INT SC INFO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226

Fault tracing

Chapter overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227

Warning and fault indications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227

How to reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227

Fault history . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227

Warning messages generated by the drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228

Warning messages generated by the control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235

Fault messages generated by the drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236

Analogue Extension Module

Chapter overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245

Speed control through the analogue extension module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245

Basic checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245

Settings of the analogue extension module and the drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245

Parameter settings: bipolar input in basic speed control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246

Parameter settings: bipolar input in joystick mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247

Table of contents

Page 12

Additional data: actual signals and parameters

Chapter overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249

Terms and abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249

Fieldbus addresses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249

Rxxx adapter modules (such as RPBA-01, RDNA-01, etc.) . . . . . . . . . . . . . . . . . . . . . . . . . . 249

Nxxx adapter modules (such as NPBA-12, NDNA-02, etc.) . . . . . . . . . . . . . . . . . . . . . . . . . . 249

NPBA-12 Profibus Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249

NIBA-01 InterBus-S Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250

NMBP-01 ModbusPlus® Adapter and NMBA-01 Modbus Adapter . . . . . . . . . . . . . . . . . . . 250

Actual signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251

Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254

Control block diagrams

Chapter overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263

Reference control chain, sheet 1: FACTORY, HAND/AUTO, SEQ CTRL and T CTRL macros

(continued on the next page …) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264

Reference control chain sheet 1: PID CTRL macro (continued on the next page …) . . . . . . . . . 266

Reference control chain sheet 2: All macros (continued on the next page …) . . . . . . . . . . . . . . 268

Handling of Start, Stop, Run Enable and Start Interlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270

Handling of Reset and On/Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271

Index

Table of contents

Page 13

Introduction to the manual

Chapter overview

The chapter includes a description of the contents of the manual. In addition it contains information about the compatibility, safety and intended audience.

Compatibility

The manual is compatible with Standard Control Program version ASXR7360. See parameter 33.01 SOFTWARE VERSION.

Safety instructions

Follow all safety instructions delivered with the drive.

• Read the complete safety instructions before you install, commission, or use the drive. The complete safety instructions are given at the beginning of the Hardware Manual.

Reader

• Read the software function specific warnings and notes before changing the default settings of the function. For each function, the warnings and notes are given in this manual in the section describing the related user-adjustable parameters.

The reader of the manual is expected to know the standard electrical wiring practices, electronic components, and electrical schematic symbols.

The manual consists of the following chapters:

• Start-up and control through the I/O instructs in setting up the application program, and how to start, stop and regulate the speed of the drive.

• Control panel gives instructions for using the panel.

• Program features contains the feature descriptions and the reference lists of the user settings and diagnostic signals.

• Application macros contains a short description of each macro together with a connection diagram.

• Actual signals and parameters describes the actual signals and parameters of the drive.

• Fieldbus control describes the communication through the serial communication links.

Introduction to the manual

Page 14

• Fault tracing lists the warning and fault messages with the possible causes and remedies.

• Analogue Extension Module, describes the communication between the drive and the analogue I/O extension (optional).

• Additional data: actual signals and parameters contains more information on the actual signals and parameters.

• Control block diagrams contains block diagrams concerning reference control chains and handling of Start, Stop, Run Enable and Start Interlock.

Product and service inquiries

Address any inquiries about the product to your local ABB representative, quoting the type code and serial number of the unit in question. A listing of ABB sales, support and service contacts can be found by navigating to www.abb.com/drives selecting Sales, Support and Service network.

Product training

For information on ABB product training, navigate to www.abb.com/drives and select Training courses.

and

Providing feedback on ABB Drives manuals

Your comments on our manuals are welcome. Go to www.abb.com/drives and select

Document Library – Manuals feedback form (LV AC drives).

Introduction to the manual

Page 15

Start-up and control through the I/O

Chapter overview

The chapter instructs how to:

• do the start-up

• start, stop, change the direction of rotation, and adjust the speed of the motor through the I/O interface

• perform an Identification Run for the drive.

How to start-up the drive

There are two start-up methods between which the user can select: Run the Start-up Assistant, or perform a limited start-up. The Assistant guides the user through all essential settings to be done. In the limited start-up, the drive gives no guidance: The user goes through the very basic settings by following the instructions given in the manual.

• If you want to run the Assistant, follow the instructions given in section How to

perform the guided start-up (covers all essential settings) on page 15.

• If you want to perform the limited start-up, follow the instructions given in section How to perform the limited start-up (covers only the basic settings) on page 17.

How to perform the guided start-up (covers all essential settings)

Before you start, ensure you have the motor nameplate data on hand.

SAFETY

The start-up may only be carried out by a qualified electrician. The safety instructions must be followed during the start-up procedure. See the

appropriate hardware manual for safety instructions.

Check the installation. See the installation checklist in the appropriate hardware/installation manual.

Check that the starting of the motor does not cause any danger. De-couple the driven machine if:

- there is a risk of damage in case of incorrect direction of rotation, or

- a Standard ID Run needs to be performed during the drive start-up. (ID Run is essential only in applications which require the ultimate in motor control accuracy.)

Start-up and control through the I/O

Page 16

POWER-UP

Apply the main power. The control panel first shows the panel identification data …

… then the Identification Display of the drive …

… then the Actual Signal Display …

…after which the display suggests starting the Language Selection.

(If no key is pressed for a few seconds, the display starts to alternate between the Actual Signal Display and the suggestion on selecting the language.)

The drive is now ready for the start-up.

SELECTING THE LANGUAGE

Press the FUNC key.

Scroll to the desired language by the arrow keys ( or ) and press ENTER to accept.

(The drive loads the selected language into use, shifts back to the Actual Signal Display and starts to alternate between the Actual Signal Display and the suggestion on starting the guided motor set-up.)

CDP312 PANEL Vx.xx

.......

ACS800 ID NUMBER 1

1 -> 0.0 rpm O FREQ 0.00 Hz CURRENT 0.00 A POWER 0.00 %

1 -> 0.0 rpm O *** INFORMATION *** Press FUNC to start Language Selection

Language Selection 1/1

LANGUAGE ? [ENGLISH] ENTER:OK ACT:EXIT

1 -> 0.0 rpm O *** INFORMATION *** Press FUNC to start guided Motor Setup

STARTING THE GUIDED MOTOR SET-UP

Press FUNC to start the guided motor set-up.

(The display shows which general command keys to use when stepping through the assistant.)

Press ENTER to step forward. Follow the instructions given on the display.

Motor Setup 1/10 ENTER: Ok/Continue ACT: Exit FUNC: More Info

Motor Setup 2/10 MOTOR NAMEPLATE DATA AVAILABLE? ENTER:Yes FUNC:Info

Start-up and control through the I/O

Page 17

How to perform the limited start-up (covers only the basic settings)

Before you start, ensure you have the motor nameplate data at your hand.

SAFETY

The start-up may only be carried out by a qualified electrician. The safety instructions must be followed during the start-up procedure. See the

appropriate hardware manual for safety instructions.

Check the installation. See the installation checklist in the appropriate hardware/installation manual.

Check that the starting of the motor does not cause any danger. De-couple the driven machine if:

- there is a risk of damage in case of incorrect direction of rotation, or

- a Standard ID Run needs to be performed during the drive start-up. (ID Run is essential only in applications which require the ultimate in motor control accuracy.)

POWER-UP

Apply the main power. The control panel first shows the panel identification data …

… then the Identification Display of the drive …

… then the Actual Signal Display …

…after which the display suggests starting the Language Selection.

(If no key is pressed for a few seconds, the display starts to alternate between the Actual Signal Display and the suggestion on starting the Language Selection.)

Press ACT to remove the suggestion on starting the language selection.

The drive is now ready for the limited start-up.

MANUAL START-UP DATA ENTERING (parameter group 99)

Select the language. The general parameter setting procedure is described below.

The general parameter setting procedure:

- Press PAR to select the Parameter Mode of the panel.

- Press the double-arrow keys ( or ) to scroll the parameter groups.

- Press the arrow keys ( or ) to scroll parameters within a group.

- Activate the setting of a new value by ENTER.

- Change the value by the arrow keys ( or ), fast change by the doublearrow keys ( or ).

- Press ENTER to accept the new value (brackets disappear).

CDP312 PANEL Vx.xx

.......

ACS800 ID NUMBER 1

1 -> 0.0 rpm O

REQ 0.00 Hz

F CURRENT 0.00 A POWER 0.00 %

1 -> 0.0 rpm O *** INFORMATION *** Press FUNC to start Language Selection

1 -> 0.0 rpm O FREQ 0.00 Hz CURRENT 0.00 A POWER 0.00 %

1 -> 0.0 rpm O 99 START-UP DATA 01 LANGUAGE ENGLISH

1 -> 0.0 rpm O 99 START-UP DATA 01 LANGUAGE [ENGLISH]

Start-up and control through the I/O

Page 18

M2AA 200 MLA 4

1475

1475 1470 1470

1475 1770

32.5 56 34 59 54 59

0.83

3GAA 202 001 - ADA

180

IEC 34-1

6210/C36312/C3

Cat. no

50 50 50

50 50

690 Y 400 D 660 Y 380 D 415 D 440 D

Hz kW

r/min A

cos

IA/IN

E/s

Ins.cl. F

IP 55

IEC 200 M/L 55

motor

ABB Motors

380 V

input

voltage

Select the Application Macro. The general parameter setting procedure is given above.

The default value FACTORY is suitable in most cases.

Select the motor control mode. The general parameter setting procedure is given above.

DTC is suitable in most cases. The SCALAR control mode is recommended

- for multimotor drives when the number of the motors connected to the drive is variable

- when the nominal current of the motor is less than 1/6 of the nominal current of the inverter

- when the inverter is used for test purposes with no motor connected.

Enter the motor data from the motor nameplate:

1 -> 0.0 rpm O 99 START-UP DATA 02 APPLICATION MACRO [ ]

1 -> 0.0 rpm O 99 START-UP DATA 04 MOTOR CTRL MODE [DTC]

Note: Set the motor data to exactly the same value as on the motor nameplate. For example, if the motor nominal speed is 1440 rpm on the nameplate, setting the value of parameter

99.08 MOTOR NOM SPEED to 1500 rpm results in the wrong operation of the drive.

- motor nominal voltage

Allowed range: 1/2 · U each of the nominal voltage ranges: 415 VAC for 400 VAC units, 500 VAC for 500 VAC units and 690 VAC for 600 VAC units.)

- motor nominal current

Allowed range: approx. 1/6 · I

99.04 = SCALAR))

- motor nominal frequency

Range: 8 … 300 Hz

- motor nominal speed

Range: 1 …18000 rpm

-motor nominal power

Range: 0 …9000 kW

Start-up and control through the I/O

… 2 · U

2hd

of ACS800. (UN refers to the highest voltage in

… 2 · I

of ACS800 (0 … 2 · I

2hd

if parameter

2hd

1 -> 0.0 rpm O 99 START-UP DATA 05 MOTOR NOM VOLTAGE [ ]

1 -> 0.0 rpm O 99 START-UP DATA 06 MOTOR NOM CURRENT [ ]

1 -> 0.0 rpm O 99 START-UP DATA 07 MOTOR NOM FREQ [ ]

1 -> 0.0 rpm O 99 START-UP DATA 08 MOTOR NOM SPEED [ ]

1 -> 0.0 rpm O 99 START-UP DATA 09 MOTOR NOM POWER [ ]

Page 19

When the motor data has been entered, two displays (warning and information) start to alternate. Move to next step without pressing any key.

1 -> 0.0 rpm O ACS800 ** WARNING ** ID MAGN REQ

Note: If you select STANDARD ID Run, the brake is opened when the Start command is given from the control panel and the brake remains open until the STANDARD ID Run is completed. If you select ID MAGN, the brake is kept closed during the ID Run sequence.

1 -> 0.0 rpm I *** Information *** Press green button to start ID MAGN

Select the motor identification method. The default value ID MAGN (ID Magnetisation) is suitable for most applications. It is applied

in this basic start-up procedure. If your selection is ID Magnetisation, move to next step without pressing any key.

The ID Run (STANDARD or REDUCED) should be selected if:

- The operation point is near zero speed constantly, and/or

- Operation at torque range above the motor nominal torque within a wide speed range and without any measured speed feedback is required.

If your selection is ID Run, continue by following the separate instructions given a few pages ahead in section How to perform the ID Run on page 22.

IDENTIFICATION MAGNETISATION (with Motor ID Run selection ID MAGN)

Press the LOC/REM key to change to local control (L shown on the first row).

Press to start the Identification Magnetisation. The motor is magnetised at zero speed for 20 to 60 s. Three warnings are displayed:

The first warning is displayed when the magnetisation starts. The second warning is displayed while the magnetisation is on. The third warning is displayed after the magnetisation is completed.

1 L -> 1242.0 rpm I ** WARNING ** MOTOR STARTS

1 L-> 0.0 rpm I ** WARNING ** ID MAGN

1 L-> 0.0 rpm O ** WARNING ** ID DONE

Start-up and control through the I/O

Page 20

forward direction

reverse direction

DIRECTION OF ROTATION OF THE MOTOR

Check the direction of rotation of the motor.

- Press ACT to get the status row visible.

- Increase the speed reference from zero to a small value by pressing REF and then the arrow keys ( , , or ).

- Press to start the motor.

- Check that the motor is running in the desired direction.

- Stop the motor by pressing .

To change the direction of rotation of the motor:

- Disconnect the main power from the drive, and wait 5 minutes for the intermediate circuit capacitors to discharge. Measure the voltage between each input terminal (U1, V1 and W1) and earth with a multimeter to ensure that the frequency converter is discharged.

- Exchange the position of two motor cable phase conductors at the motor terminals or at the motor connection box.

- Verify your work by applying the main power and repeating the check as described above.

SPEED LIMITS AND ACCELERATION/DECELERATION TIMES

Set the minimum speed.

1 L->[xxx] rpm I FREQ xxx Hz CURRENT xx A POWER xx %

1 L-> 0.0 rpm O 20 LIMITS 01 MINIMUM SPEED [ ]

Set the maximum speed.

Set the acceleration time 1. Note: Check also acceleration time 2, if two acceleration times will

be used in the application.

Set the deceleration time 1. Note: Set also deceleration time 2, if two deceleration times will be

used in the application.

The drive is now ready for use.

1 L-> 0.0 rpm O 20 LIMITS 02 MAXIMUM SPEED [ ]

1 L-> 0.0 rpm O 22 ACCEL/DECEL 02 ACCELER TIME 1 [ ]

1 L-> 0.0 rpm O 22 ACCEL/DECEL 03 DECELER TIME 1 [ ]

Start-up and control through the I/O

Page 21

How to control the drive through the I/O interface

The table below instructs how to operate the drive through the digital and analogue inputs, when:

• the motor start-up is performed, and

• the default (factory) parameter settings are valid.

PRELIMINARY SETTINGS

Ensure the Factory macro is active.

If you need to change the direction of rotation, change the setting of parameter 10.03 to REQUEST.

Ensure the control connections are wired according to the connection diagram given for the Factory macro.

Ensure the drive is in external control mode. Press the LOC/REM key to change between external and local control.

STARTING AND CONTROLLING THE SPEED OF THE MOTOR

Start by switching digital input DI1 on.

Regulate the speed by adjusting the voltage of analogue input AI1.

CHANGING THE DIRECTION OF ROTATION OF THE MOTOR

Forward direction: Switch digital input DI2 off.

See parameter 99.02.

See chapter Application

macros.

In External control, there is no L visible on the first row of the panel display.

1 -> 0.0 rpm I

REQ 0.00 Hz

F CURRENT 0.00 A POWER 0.00 %

1 -> 500.0 rpm I FREQ 16.66 Hz CURRENT 12.66 A POWER 8.33 %

Reverse direction: Switch digital input DI2 on.

STOPPING THE MOTOR

Switch off digital input DI1.

1 <- 500.0 rpm I

REQ 16.66 Hz

F CURRENT 12.66 A POWER 8.33 %

1 -> 500.0 rpm O

REQ 0.00 Hz

F CURRENT 0.00 A POWER 0.00 %

Start-up and control through the I/O

Page 22

99 START-UP DATA 10 MOTOR ID RUN [STANDARD]

1 L ->1242.0 rpm O

1 L ->1242.0 rpm O ACS800 **WARNING** ID RUN SEL

How to perform the ID Run

The drive performs the ID Magnetisation automatically at the first start. In most applications there is no need to perform a separate ID Run. The ID Run (Standard or Reduced) should be selected if:

• The operation point is near zero speed, and/or

• Operation at torque range above the motor nominal torque within a wide speed range and without any measured speed feedback is required.

The Reduced ID Run is to be performed instead of the Standard if it is not possible to disengage the driven machine from the motor.

ID Run Procedure

Note: If parameter values (Group 10 to 98) are changed before the ID Run, check

that the new settings meet the following conditions:

• 20.01 MINIMUM SPEED <

0 rpm

• 20.02 MAXIMUM SPEED > 80% of motor rated speed

• 20.03 MAXIMUM CURRENT >

100% · I

• 20.04 MAXIMUM TORQUE > 50%

• Ensure that the panel is in the local control mode (L displayed on the status row). Press the LOC/REM key to switch between modes.

• Change the ID Run selection to STANDARD or REDUCED.

•Press ENTER to verify selection. The following message will be displayed:

Start-up and control through the I/O

Page 23

• To start the ID Run, press the key. The Start Interlock (digital input DI_IL) and Run Enable signals (parameter 16.01 RUN ENABLE) must be active.

Warning when the ID Run is

started

1 L -> 1242.0 rpm I ACS800 **WARNING** MOTOR STARTS

In general it is recommended not to press any control panel keys during the ID run. However:

• The Motor ID Run can be stopped at any time by pressing the control panel stop key ( ).

• After the ID Run is started with the start key ( ), it is possible to monitor the actual values by first pressing the ACT key and then a double-arrow key ( ).

Warning during the ID Run Warning after a successfully

completed ID Run

1 L -> 1242.0 rpm I ACS800 **WARNING** ID RUN

1 L -> 1242.0 rpm I ACS800 **WARNING** ID DONE

Start-up and control through the I/O

Page 24

Start-up and control through the I/O

Page 25

Control panel

1 L -> 1242.0 rpm I

REQ 45.00 Hz CURRENT 80.00 A POWER 75.00 %

ACT PA R FU NC DR IV E

ENTER

LOC RESET REF

REM

1367

5 24

The LCD type display has 4 lines of 20 characters.

The language is selected at start-up (parameter 99.01).

The control panel has four operation modes:

- Actual Signal Display Mode (ACT key)

- Parameter Mode (PAR key)

- Function Mode (FUNC key)

- Drive Selection Mode (DRIVE key)

The use of single arrow keys, double arrow keys and ENTER depend on the operation mode of the panel.

The drive control keys are:

No. Use

1Start

2Stop

3 Activate reference setting

4 Forward direction of rotation

5 Reverse direction of rotation

6 Fault reset

7 Change between Local / Remote (external)

control

Chapter overview

The chapter describes how to use the control panel CDP 312R.

The same control panel is used with all ACS800 series drives, so the instructions given apply to all ACS800 types. The display examples shown are based on the Standard Control Program; displays produced by other application programs may differ slightly.

Overview of the panel

Control panel

Page 26

Parameter Mode

Function Mode

Drive Selection Mode

Act. signal / Fault history

Enter selection mode Accept new signal

Group selection

Parameter selection

Enter change mode Accept new value

Fast value change

Slow value change

Function start

Drive selection

Enter change mode Accept new value

Actual Signal Display Mode

ENTER

selection

ID number change

Status row

ACT

PAR

FUNC

DRIVE

1 L -> 1242.0 rpm O F

REQ 45.00 Hz CURRENT 80.00 A POWER 75.00 %

1 L -> 1242.0 rpm O 10 START/STOP/DIR 01 EXT1 STRT/STP/DIR DI1,2

1 L -> 1242.0 rpm O Motor Setup Application Macro Speed Control EXT1

ACS800

ASXR7260 xxxxxx ID NUMBER 1

Act. signal / Fault message scrolling

Actual signal names and values

Parameter group

Parameter

Parameter value

Status row

List of functions

Device type

SW loading package name and ID number

Row selection

Page selection

Drive ID number

Drive control status

L = Local control

R = Remote control

“ “ = External control

Drive status I = Running O = Stopped “ “ = Run disabled

1 L -> 1242.0 rpm I

Direction of rotation

-> = Forward <- = Reverse

Drive reference

Panel operation mode keys and displays

The figure below shows the mode selection keys of the panel, and the basic operations and displays in each mode.

Status row

The figure below describes the status row digits.

Control panel

Page 27

Drive control with the panel

ACT PA R

FUNC

LOC

REM

The user can control the drive with the panel as follows:

• start, stop, and change direction of the motor

• give the motor speed reference or torque reference

• give a process reference (when the process PID control is active)

• reset the fault and warning messages

• change between local and external drive control.

The panel can be used for control of the drive control always when the drive is under local control and the status row is visible on the display.

How to start, stop and change direction

Step Action Press Key Display

1. To show the status row. 1 ->1242.0 rpm I

REQ 45.00 Hz

F CURRENT 80.00 A POWER 75.00 %

2. To switch to local control.

(only if the drive is not under local control, i.e. there is no L on the first row of the display.)

3. To stop 1 L ->1242.0 rpm O

4. To start 1 L ->1242.0 rpm I

5. To change the direction to reverse. 1 L <-1242.0 rpm I

6. To change the direction to forward. 1 L ->1242.0 rpm I

1 L ->1242.0 rpm I

REQ 45.00 Hz

F CURRENT 80.00 A POWER 75.00 %

REQ 45.00 Hz

F CURRENT 80.00 A POWER 75.00 %

FREQ 45.00 Hz CURRENT 80.00 A POWER 75.00 %

REQ 45.00 Hz

F CURRENT 80.00 A POWER 75.00 %

FREQ 45.00 Hz CURRENT 80.00 A POWER 75.00 %

Control panel

Page 28

ACT PAR

FUNC

LOC

REM

REF

ENTER

How to set speed reference

Step Action Press Key Display

1. To show the status row. 1 ->1242.0 rpm I

REQ 45.00 Hz CURRENT 80.00 A POWER 75.00 %

2. To switch to local control.

(Only if the drive is not under local control, i.e. there is no L on the first row of the display.)

1 L ->1242.0 rpm I

REQ 45.00 Hz

F CURRENT 80.00 A POWER 75.00 %

3. To enter the Reference Setting function. 1 L ->[1242.0 rpm]I

REQ 45.00 Hz

F CURRENT 80.00 A POWER 75.00 %

4. To change the reference.

(slow change)

1 L ->[1325.0 rpm]I F

REQ 45.00 Hz CURRENT 80.00 A POWER 75.00 %

(fast change)

5. To save the reference.

(The value is stored in the permanent memory; it is restored automatically after power switch-off.)

1 L -> 1325.0 rpm I

REQ 45.00 Hz

F CURRENT 80.00 A POWER 75.00 %

Control panel

Page 29

Actual signal display mode

ACT

ENTER

ACT

FUNC DRIVE

PAR

In the Actual Signal Display Mode, the user can:

• show three actual signals on the display at a time

• select the actual signals to display

• view the fault history

• reset the fault history.

The panel enters the Actual Signal Display Mode when the user presses the ACT key, or if he does not press any key within one minute.

How to select actual signals to the display

Step Action Press key Display

1. To enter the Actual Signal Display Mode. 1 L -> 1242.0 rpm I

REQ 45.00 Hz CURRENT 80.00 A POWER 75.00 %

2. To select a row (a blinking cursor indicates the selected row).

3. To enter the actual signal selection function. 1 L -> 1242.0 rpm I

4. To select an actual signal.

To change the actual signal group.

5.a To accept the selection and to return to the Actual Signal Display Mode.

5.b To cancel the selection and keep the original selection.

The selected keypad mode is entered.

1 L -> 1242.0 rpm I FREQ 45.00 Hz

URRENT 80.00 A

C POWER 75.00 %

1 ACTUAL SIGNALS 04 CURRENT

80.00 A

1 L -> 1242.0 rpm I 1 ACTUAL SIGNALS 05 TORQUE 70.00 %

1 L -> 1242.0 rpm I FREQ 45.00 Hz

ORQUE 70.00 %

T POWER 75.00 %

1 L -> 1242.0 rpm I FREQ 45.00 Hz C

URRENT 80.00 A

POWER 75.00 %

Control panel

Page 30

ACT

RESET

How to display the full name of the actual signals

Step Action Press key Display

1. To display the full name of the three actual signals. Hold 1 L -> 1242.0 rpm I

REQUENCY CURRENT POWER

2. To return to the Actual Signal Display Mode. Release 1 L -> 1242.0 rpm I

FREQ 45.00 Hz CURRENT 80.00 A POWER 75.00 %

How to view and reset the fault history

Note: The fault history cannot be reset if there are active faults or warnings.

Step Action Press key Display

1. To enter the Actual Signal Display Mode. 1 L -> 1242.0 rpm I

REQ 45.00 Hz

F CURRENT 80.00 A POWER 75.00 %

2. To enter the Fault History Display. 1 L -> 1242.0 rpm I

1 LAST FAULT +OVERCURRENT 6451 H 21 MIN 23 S

3. To select the previous (UP) or the next fault/warning (DOWN).

1 L -> 1242.0 rpm I 2 LAST FAULT +OVERVOLTAGE 1121 H 1 MIN 23 S

To clear the Fault History. 1 L -> 1242.0 rpm I

2 LAST FAULT H MIN S

4. To return to the Actual Signal Display Mode. 1 L -> 1242.0 rpm I

REQ 45.00 Hz

F CURRENT 80.00 A POWER 75.00 %

Control panel

Page 31

How to display and reset an active fault

ACT

RESET

1 L -> 1242.0 rpm I 2 LAST FAULT +DC OVERVOLT (3210) 1121 H 1 MIN 23 S

Event Information on display

Drive detects a fault and generates a fault message

Sequential number of the event and LAST FAULT text.

Name of the fault and a “+” sign in front of the name.

Total power-on time.

User resets the fault message. Sequential number of the event and

LAST FAULT text.

-RESET FAULT text.

Total power-on time.

Drive generates a warning message.

Sequential number of the event and LAST WARNING text.

Name of the warning and a “+” sign in front of the name.

Total power-on time.

Drive deactivates the warning message.

Sequential number of the event and LAST WARNING text.

Name of the warning and a “-” sign in front of the name.

Total power-on time.

Sequential number (1 is the most recent event)

Sign

Power-

on time

Name and

code

A Fault History View

WARNING! If an external source for start command is selected and it is ON, the

drive will start immediately after fault reset. If the cause of the fault has not been removed, the drive will trip again.

Step Action Press Key Display

1. To display an active fault. 1 L -> 1242.0 rpm

ACS800 ** FAULT ** ACS800 TEMP

2. To reset the fault. 1 L -> 1242.0 rpm O

REQ 45.00 Hz

F CURRENT 80.00 A POWER 75.00 %

About the fault history

The fault history restores information on the latest events (faults, warnings and resets) of the drive. The table below shows how the events are stored in the fault history.

Control panel

Page 32

PAR

ENTER

ACT

FUNC DRIVE

PAR

Parameter mode

In the Parameter Mode, the user can:

• view the parameter values

• change the parameter settings.

The panel enters the Parameter Mode when the user presses the PAR key.

How to select a parameter and change the value

Step Action Press key Display

1. To enter the Parameter Mode. 1 L -> 1242.0 rpm O

10 START/STOP/DIR 01 EXT1 STRT/STP/DIR DI1,2

2. To select a group. 1 L -> 1242.0 rpm O

11 REFERENCE SELECT 01 KEYPAD REF SEL REF1 (rpm)

3. To select a parameter within a group. 1 L -> 1242.0 rpm O

11 REFERENCE SELECT 03 EXT REF1 SELECT AI1

4. To enter the parameter setting function. 1 L -> 1242.0 rpm O

11 REFERENCE SELECT 03 EXT REF1 SELECT [AI1]

5. To change the parameter value.

- (slow change for numbers and text)

- (fast change for numbers only)

6a. To save the new value. 1 L -> 1242.0 rpm O

6b. To cancel the new setting and keep the original value,

press any of the mode selection keys.

The selected mode is entered.

1 L -> 1242.0 rpm O 11 REFERENCE SELECT 03 EXT REF1 SELECT [AI2]

11 REFERENCE SELECT 03 EXT REF1 SELECT AI2

1 L -> 1242.0 rpm O 11 REFERENCE SELECT 03 EXT REF1 SELECT AI1

Control panel

Page 33

How to adjust a source selection (pointer) parameter

PAR

ENTER

1 L ->1242.0 rpm O 84 ADAPTIVE PROGRAM 06 INPUT1 [±001.018.00]

Inversion field

Group field

Index field

Bit field

Inversion field inverts the selected parameter value. Plus sign (+): no inversion, minus (-) sign: inversion.

Bit field selects the bit number (relevant only if the parameter value is a packed boolean word).

Index field selects the parameter index.

Group field selects the parameter group.

Most parameters define values that are used directly in the drive application program. Source selection (pointer) parameters are exceptions: They point to the value of another parameter. The parameter setting procedure differs somewhat from that of the other parameters.

Step Action Press Key Display

1. See the table above to

- enter the Parameter Mode

- select the correct parameter group and parameter

- enter the parameter setting mode

2. To scroll between the inversion, group, index and bit

3. To adjust the value of a field. 1 L ->1242.0 rpm O

4. To accept the value.

fields.

1 L ->1242.0 rpm O 84 ADAPTIVE PROGRAM 06 INPUT1 [±000.000.00]

1 L ->1242.0 rpm O 84 ADAPTIVE PROGRAM 06 INPUT1 [±000.000

84 ADAPTIVE PROGRAM 06 INPUT1 [±000.018

.00]

Note: Instead of pointing to another parameter, it is also possible to define a constant by the source selection parameter. Proceed as follows:

- Change the inversion field to C. The appearance of the row changes. The rest of the line is now a constant setting field.

- Give the constant value to the constant setting field.

- Press Enter to accept.

Control panel

Page 34

The parameter groups 98, 99 and the results of the motor identification are not included by default. The restriction prevents downloading of unfit motor data. In special cases it is, however, possible to download all. For more information, please contact your local ABB representative.

Function mode

In the Function Mode, the user can:

• start a guided procedure for adjusting the drive settings (assistants)

• upload the drive parameter values and motor data from the drive to the panel.

• download group 1 to 97 parameter values from the panel to the drive.

• adjust the contrast of the display.

The panel enters the Function Mode when the user presses the FUNC key.

Control panel

Page 35

How to enter an assistant, browse and exit

FUNC

ENTER

)(

FUNC, ACT

FUNC

ENTER

RESET

The table below shows the operation of the basic keys which lead the user through an assistant. The Motor Setup task of the Start-up Assistant is used as an example.

The Start-up Assistant is not available in Scalar mode or when the parameter lock is on. (99.04 MOTOR CTRL MODE = SCALAR or 16.02 PARAMETER LOCK = LOCKED or 16.10 ASSIST SEL = OFF)

Step Action Press Key Display

1. To enter the Function Mode. 1 L -> 1242.0 rpm O

otor Setup

M Application Macro Speed Control EXT1

2. To select a task or function from the list (a flashing cursor indicates the selection).

Double arrows: To change page to see more assistants/ functions.

3. To enter the task. Motor Setup 1/10

4. To accept and continue. Motor Setup 2/10

5. To accept and continue. Motor Setup 3/10

6. a. To adjust the requested drive parameter. Motor Setup 3/10

b. To ask for information on the requested value.

(To scroll the information displays

and return to the task).

1 L -> 1242.0 rpm O M

otor Setup Application Macro Speed Control EXT 1

ENTER: Ok/Continue ACT: Exit FUNC: More Info

MOTOR NAMEPLATE DATA AVAILABLE? ENTER:Yes FUNC:Info

MOTOR NOM VOLTAGE? [0 V] ENTER:Ok RESET:Back

MOTOR NOM VOLTAGE? [415 V] ENTER:Ok RESET:back

INFO P99.05 Set as given on the motor nameplate.

7. a. To accept a value and step forward. Motor Setup 4/10

MOTOR NOM CURRENT? [0.0 A] ENTER:Ok RESET:Back

b. To cancel the setting and take one step back. Motor Setup 3/10

MOTOR NOM VOLTAGE? [415 V] ENTER:Ok RESET:back

Control panel

Page 36

2 x ACT

FUNC

ENTER

LOC

REM

Step Action Press Key Display

8. To cancel and exit.

Note: 1 x ACT returns to the first display of the task.

How to upload data from a drive to the panel

Note:

• Upload before downloading.

• Ensure the firmware of the destination drive is the same (e.g. standard firmware).

• Before removing the panel from a drive, ensure the panel is in remote operating mode (change with the LOC/REM key).

• Stop the drive before downloading.

Before upload, repeat the following steps in each drive:

• Setup the motors.

• Activate the communication to the optional equipment. (See parameter group 98

OPTION MODULES.)

Before upload, do the following in the drive from which the copies are to be taken:

1 L -> 0.0 rpm O FREQ 0.00 Hz CURRENT 0.00 A POWER 0.00 %

• Set the parameters in groups 10 to 97 as preferred.

• Proceed to the upload sequence (below).

Step Action Press Key Display

1. Enter the Function Mode. 1 L -> 1242.0 rpm O

otor Setup

M Application Macro Speed Control EXT1

2. Enter the page that contains the upload, download and contrast functions.

3. Select the upload function (a flashing cursor indicates the selected function).

4. Enter the upload function. 1 L -> 1242.0 rpm O

5. Switch to external control.

(No L on the first row of the display.)

1 L -> 1242.0 rpm O

PLOAD <=<=

U DOWNLOAD =>=> CONTRAST 4

1 L -> 1242.0 rpm O U

PLOAD <=<= DOWNLOAD =>=> CONTRAST 4

UPLOAD <=<=

1 -> 1242.0 rpm O

PLOAD <=<=

U DOWNLOAD =>=> CONTRAST 4

Control panel

Page 37

Step Action Press Key Display

LOC

REM

FUNC

ENTER

6. Disconnect the panel and reconnect it to the drive into which the data will be downloaded.

How to download data from the panel to a drive

Consider the notes in section How to upload data from a drive to the panel on page

36.

Step Action Press Key Display

1. Connect the panel containing the uploaded data to the drive.

2. Ensure the drive is in local control (L shown on the first row of the display). If necessary, press the LOC/REM key to change to local control.

1 L -> 1242.0 rpm I F

REQ 45.00 Hz CURRENT 80.00 A POWER 75.00 %

3. Enter the Function Mode. 1 L -> 1242.0 rpm O

otor Setup

M Application Macro Speed Control EXT1

4. Enter the page that contains the upload, download and contrast functions.

1 L -> 1242.0 rpm O UPLOAD <=<= DOWNLOAD =>=> CONTRAST 4

5. Select the download function (a flashing cursor indicates the selected function).

1 L -> 1242.0 rpm O UPLOAD <=<= DOWNLOAD =>=> CONTRAST 4

6. Start the download. 1 L -> 1242.0 rpm O

DOWNLOAD =>=>

Control panel

Page 38

FUNC

ENTER

ACT

FUNC

DRIVE

PAR

How to set the contrast of the display

Step Action Press Key Display

1. Enter the Function Mode. 1 L -> 1242.0 rpm O

Motor Setup Application Macro Speed Control EXT1

2. Enter the page that contains the upload, download and contrast functions.

1 L -> 1242.0 rpm O

PLOAD <=<=

U DOWNLOAD =>=> CONTRAST 4

3. Select a function (a flashing cursor indicates the selected function).

1 L -> 1242.0 rpm O UPLOAD <=<= DOWNLOAD =>=>

ONTRAST 4

4. Enter the contrast setting function. 1 L -> 1242.0 rpm O

CONTRAST [4]

5. Adjust the contrast. 1 L -> 1242.0 rpm

CONTRAST [6]

6.a Accept the selected value. 1 L -> 1242.0 rpm O

UPLOAD <=<= DOWNLOAD =>=> CONTRAST 6

6.b Cancel the new setting and retain the original value by pressing any of the mode selection keys.

1 L -> 1242.0 rpm I FREQ 45.00 Hz CURRENT 80.00 A

The selected mode is entered.

POWER 75.00 %

Control panel

Page 39

Drive selection mode

DRIVE

PAR

FUNC

ACT

In normal use the features available in the Drive Selection Mode are not needed; the features are reserved for applications where several drives are connected to one panel link. (For more information, see the Installation and Start-up Guide for the Panel Bus Connection Interface Module, NBCI, [3AFY58919748 (English)].

In the Drive Selection Mode, the user can:

• Select the drive with which the panel communicates through the panel link.

• Change the identification number of a drive connected to the panel link.

• View the status of the drives connected on the panel link.

The panel enters the Drive Selection Mode when the user presses the DRIVE key.

Each on-line station must have an individual identification number (ID). By default, the ID number of the drive is 1.

Note: The default ID number setting of the drive should not be changed unless the drive is to be connected to the panel link with other drives on-line.

How to select a drive and change its panel link ID number

Step Action Press key

1. To enter the Drive Selection Mode. ACS800

ASAAA5000 xxxxxx ID NUMBER 1

2. To select the next drive/view.

The ID number of the station is changed by first pressing ENTER (the brackets round the ID number appear) and then adjusting the value with arrow buttons. The new value is accepted with ENTER. The power of the drive must be switched off to validate its new ID number setting.

The status display of all devices connected to the Panel Link is shown after the last individual station. If all stations do not fit on the display at once, press the double-arrow up to view the rest of them.

3. To connect to the last displayed drive and to enter another mode, press one of the mode selection keys.

The selected mode is entered.

ACS800

ASAAA5000 xxxxxx

ID NUMBER 1

Status Display Symbols:

= Drive stopped, direction

forward

= Drive running, direction reverse F = Drive tripped on a fault

1 L -> 1242.0 rpm I F

REQ 45.00 Hz CURRENT 80.00 A POWER 75.00 %

Display

Control panel

Page 40

Boolean 0000 0000 0001 1010

Hex 0 0 1 A

Bit 15 Bit 0

Reading and entering packed boolean values on the display

Some actual values and parameters are packed boolean, i.e. each individual bit has a defined meaning (explained at the corresponding signal or parameter). On the control panel, packed boolean values are read and entered in hexadecimal format.

In this example, bits 1, 3 and 4 of the packed boolean value are ON:

Control panel

Page 41

Program features

Chapter overview

The chapter describes program features. For each feature, there is a list of related user settings, actual signals, and fault and warning messages.

Start-up Assistant

Introduction

The assistant guides the user through the start-up procedure, helping the user to feed the requested data (parameter values) to the drive. The assistant also check that the entered values are valid, i.e. within the allowed range. At the first start, the drive suggests entering the first task of the assistant, Language Select, automatically.

The Start-up Assistant is divided into tasks. The user may activate the tasks either one after the other as the Start-up Assistant suggests, or independently. The user may also adjust the drive parameters in the conventional way without using the assistant at all.

See chapter Control panel on how to start the assistant, browse and exit.

The default order of the tasks

Depending on the selection made in the Application task (parameter 99.02), the Start-up Assistant decide which consequent tasks it suggests. The default tasks are shown in the table below.

Application Selection

FACTORY, SEQ CTRL

HAND/AUTO Language Select, Motor Set-up, Application, Option Modules, Speed Control EXT2, Start/Stop

T CTRL Language Select, Motor Set-up, Application, Option Modules, Torque Control, Start/Stop Control,

PID CTRL Language Select, Motor Set-up, Application, Option Modules, PID Control, Start/Stop Control, Speed

Default Tasks

Language Select, Motor Set-up, Application, Option Modules, Speed Control EXT1, Start/Stop Control, Protections, Output Signals

Control, Speed Control 1, Protections, Output Signals

Speed Control EXT1, Protections, Output Signals

Control EXT1, Protections, Output Signals

Program features

Page 42

List of tasks and the relevant drive parameters

Name Description Set parameters

Language Select Selecting the language 99.01

Motor Set-up Setting the motor data

Performing the motor identification. (If the speed limits are not in the allowed range: Setting the limits).

Application Selecting the application macro 99.02, parameters associated to

Option Modules Activating the option modules Group 98, 35, 52

Speed Control EXT1

Speed Control EXT2

Tor q ue Cont r ol Selecting the source for the torque reference 11.06

PID Control Selecting the source for the process reference 11.06

Start/Stop Control Selecting the source for start and stop signals of the two external

Protections Setting the torque and current limits 20.03, 20.04

Output Signals Selecting the signals indicated through the relay outputs RO1,

Selecting the source for the speed reference 11.03

(If AI1 is used: Setting analogue input AI1 limits, scale, inversion)

Setting the reference limits 11.04, 11.05

Setting the speed (frequency) limits 20.02, 20.01, (20.08, 20.07)

Setting acceleration and deceleration times 22.02, 22.03

(Setting up the brake chopper if activated by parameter 27.01) (Group 27, 20.05, 14.01)

(If 99.02 is not SEQ CTRL: Setting constant speeds) (Group 12)

Setting the source for the speed reference 11.06

(If AI1 is used: Setting analogue input AI1 limits, scale, inversion)

Setting the reference limits 11.08, 11.07

(If AI1 is used: Setting analogue input AI1 limits, scale, inversion)

Setting the reference limits 11.08, 11.07

Setting the torque ramp up and ramp down times 24.01, 24.02

(If AI1 is used: Setting analogue input AI1 limits, scale, inversion)

Setting the reference limits 11.08, 11.07

Setting the speed (reference) limits 20.02, 20.01 (20.08, 20.07)

Setting the source and limits for the process actual value 40.07, 40.09, 40.10

control locations, EXT1 and EXT2

Selecting between EXT1 and EXT2 11.02

Defining the direction control 10.03

Defining the start and stop modes 21.01, 21.02, 21.03

Selecting the use of Run Enable signal 16.01, 21.07

Setting the ramp time for the Run Enable function 22.07

RO2, RO3 and optional RO’s (if installed)

Selecting the signals indicated through the analogue output AO1, AO2 and optional AO’s (if installed). Setting the minimum, maximum, scaling and inversion.

99.05, 99.06, 99.09, 99.07, 99.08,

99.04

99.10 (20.8, 20.07)

the macro

(13.01, 13.02, 13.03, 13.04,

13.05, 30.01)

(13.01, 13.02, 13.03, 13.04,

13.05, 30.01)

(13.01, 13.02, 13.03, 13.04,

13.05, 30.01)

(13.01, 13.02, 13.03, 13.04,

13.05, 30.01)

10.01, 10.02

Group 14

15.01, 15.02, 15.03, 15.04, 15.05, (Group 96)

Program features

Page 43

Contents of the assistant displays

Main Display Information Display

1 2 3 4

Motor Setup 3/10 MOTOR NOM VOLTAGE? [0 V] ENTER:Ok RESET:Back

INFO P99.05 Set as given on the motor nameplate.

1 Name of the assistant, step

number / total number of steps

Text INFO, index of parameter to be set

2 Request/question Help text …

3 Feed-in field … help text continued

4 Commands: accept value and

step forward or cancel and step backwards

double arrow symbol (indicates that the text continues)

Slot 1

CH0 (DDCS)

Fieldbus

ACS800

RDCO

module

Control panel

DriveWindow

External controlLocal control

Standard I/O

Slot 1 or Slot 2

RTAC/RDIO/RAIO

adapter

module

CH3

(DDCS)

Fieldbus adapter Nxxx

Advant controller (e.g. AC 80, AC 800M)

CH1 (DDCS)

RTAC/RDIO/RAIO

AIMA-01 I/O adapter module

module

There are two types of displays in the Start-up Assistant: The main displays and the information displays. The main displays prompt the user to feed in information or answer a question. The assistant steps through the main displays. The information displays contain help texts for the main displays. The figure below shows a typical example of both and explanations of the contents.

Local control vs. external control

The drive can receive start, stop and direction commands and reference values from the control panel or through digital and analogue inputs. An optional fieldbus adapter enables control over an open fieldbus link. A PC equipped with DriveWindow can also control the drive.

Program features

Page 44

1 L ->1242 rpm I

External Control through the Input/ Output terminals, or through the fieldbus interfaces

1 R ->1242 rpm I 1 ->1242 rpm I

External Control by control panel

Local control

The control commands are given from the control panel keypad when the drive is in local control. L indicates local control on the panel display.

The control panel always overrides the external control signal sources when used in local mode.

External control

When the drive is in external control, the commands are given through the standard I/O terminals (digital and analogue inputs), optional I/O extension modules and/or the fieldbus interface. In addition, it is also possible to set the control panel as the source for the external control.

External control is indicated by a blank on the panel display or with an R in those special cases when the panel is defined as a source for external control.

The user can connect the control signals to two external control locations, EXT1 or EXT2. Depending on the user selection, either one is active at a time. This function operates on a 12 ms time level.

Settings

Panel key Additional information

LOC/REM Selection between local and external control

Parameter

11. 02 Selection between EXT1 and EXT2

10.01 Start, stop, direction source for EXT1

11. 03 Reference source for EXT1

10.02 Start, stop, direction source for EXT2

11. 06 Reference source for EXT2

Group 98 OPTION

MODULES

Activation of the optional I/O and serial communication

Diagnostics

Actual signals Additional information

01.11, 01.12 EXT1 reference, EXT2 reference

03.02 EXT1/EXT2 selection bit in a packed boolean word

Program features

Page 45

Block diagram: start, stop, direction source for EXT1

DI1 / Std IO

Fb. selection

See chapter

Fieldbus control.

Fieldbus adapter slot 1

KEYPAD

EXT1

DI6 / Std IO

DI1 / DIO ext 1 DI2 / DIO ext 1

DI1 / DIO ext 2 DI2 / DIO ext 2

I/O Extensions

See group 98

OPTION MODULES.

DI7 to DI9

COMM. CW

DI1

DI6

Control panel

Start/stop/

DI1 / Std IO = Digital input DI1 on the standard I/O terminal block

DI1 / DIO ext 1 = Digital input DI1 on the digital I/O extension module 1

direction

10.01

Select

CH0 / RDCO board Standard Modbus® Link

EXT1

AI1 / Std IO

AI1 / AIO ext AI2 / AIO ext

11.0 3

Select

DI1 / DIO ext 3 DI2 / DIO ext 3

KEYPAD

COMM. REF

Control panel

I/O Extensions

See parameter group 98 OPTION

MODULES.

AI2 / Std IO AI3 / Std IO DI3 / Std IO DI4 / Std IO

AI1, AI2, AI3, DI3, DI4

Fb. selection

See chapter

Fieldbus control.

AI5, AI6

DI11, DI12

REF1 (rpm)

Reference

AI1 / Std IO = Analogue input AI1 on the standard I/O terminal block

AI1 / AIO ext = Analogue input AI1 on the analogue I/O extension module

Fieldbus adapter slot 1 CH0 / RDCO board Standard Modbus Link

The figure below shows the parameters that select the interface for start, stop, and direction for external control location EXT1.

Block diagram: reference source for EXT1

The figure below shows the parameters that select the interface for the speed reference of external control location EXT1.

Program features

Page 46

Reference types and processing

The drive can accept a variety of references in addition to the conventional analogue input signal and control panel signals.

• The drive reference can be given with two digital inputs: One digital input increases the speed, the other decreases it.

• The drive accepts a bipolar analogue speed reference. This feature allows both the speed and direction to be controlled with a single analogue input. The minimum signal is full speed reversed and the maximum signal is full speed forward.

• The drive can form a reference out of two analogue input signals by using mathematical functions: Addition, subtraction, multiplication, minimum selection, and maximum selection.

• The drive can form a reference out of an analogue input signal and a signal received through a serial communication interface by using mathematical functions: addition and multiplication.

It is possible to scale the external reference so that the signal minimum and maximum values correspond to a speed other than the minimum and maximum speed limits.

Settings

Parameter Additional information

Group 11 REFERENCE

SELECT

Group 20 LIMITS Operating limits

Group 22 ACCEL/DECEL Speed reference acceleration and deceleration ramps

Group 24 TORQUE CTRL Torque reference ramp times

Group 32 SUPERVISION Reference supervision

External reference source, type and scaling

Diagnostics

Actual signal Additional information

01.11, 01.12 Values of external references

Group 02 ACTUAL SIGNALS The reference values in different stages of the reference processing

chain.

Parameter

Group 14 RELAY OUTPUTS Active reference / reference loss through a relay output

Group 15 ANALOGUE

OUTPUTS

Reference value

Program features

Page 47

Reference trimming

40.14

Select

%ref

Mul.

Add

%ref= The drive reference before trimming %ref’ = The drive reference after trimming max. speed= Par. 20.02 (or 20.01 if the absolute value is greater) max. freq = Par. 20.08 (or 20.07 if the absolute value is greater) max. torq = Par. 20.14 (or 20.13 if the absolute value is greater)

%ref

%ref’

DIRECT (3)

PROPOR. (2)

OFF (1)

max.speed

Switch

max.freq

99.04 (DTC)

40.17

PID

tref k ti td i dFiltT errVInv rInt oh1 ol1

Actual Values

40.05

40.07 AI1 AI2 AI3 AI5 AI6

IMOT

40.19

Filter

40.15

Select

AI1 AI2

...

40.16

40.01

40.02

40.03

40.04

40.05

40.13

PIDmax

PIDmin

. . .

40.18

Select

max.torque

In reference trimming, the external %-reference (External reference REF2) is corrected depending on the measured value of a secondary application variable. The block diagram below illustrates the function.

Settings

Parameter Additional information

40.14…40.18 Trimming function settings

40.01…40.13, 40.19 PID control block settings

Group 20 LIMITS Drive operation limits

Program features

Page 48

Drive rollers (pull)

Tension measurement

Speed controlled conveyor line

PID

Add

Tension measurement

Speed reference

Tension setpoint

Trimmed speed reference

Simplified block diagram

Example

The drive runs a conveyor line. It is speed-controlled but the line tension also needs to be taken into account: If the measured tension exceeds the tension setpoint, the speed will be slightly decreased, and vice versa.

To accomplish the desired speed correction, the user:

• activates the trimming function and connects the tension setpoint and the measured tension to it

• tunes the trimming to a suitable level.

Program features

Page 49

Programmable analogue inputs

The drive has three programmable analogue inputs: one voltage input (0/2 to 10 V or

-10 to 10 V) and two current inputs (0/4 to 20 mA). Two extra inputs are available if an optional analogue I/O extension module is used. Each input can be inverted and filtered, and the maximum and minimum values can be adjusted.

Update cycles in the Standard Control Program

Input Cycle

AI / standard 6 ms

AI / extension 6 ms (100 ms

Update cycle in the motor temperature measurement function. See group 35 MOT TEMP MEAS.

Settings

Parameter Additional information

Group 11 REFERENCE

SELECT

Group 13 ANALOGUE

INPUTS

30.01 Supervision of AI loss

Group 40 PID

CONTROL

35.01 AI in a motor temperature measurement

40.15 AI in a drive reference trimming

42.07 AI in a mechanical brake control function

98.06 Activation of optional analogue inputs

98.13 Optional AI signal type definition (bipolar or unipolar)

98.14 Optional AI signal type definition (bipolar or unipolar)

AI as a reference source

Processing of the standard inputs

AI as a PID process control reference or actual values

)

Diagnostics

Actual value Additional information

01.18, 01.19, 01.20 Values of standard inputs

01.38, 01.39 Value of optional inputs

Group 09 ACTUAL

SIGNALS

Scaled analogue input values (integer values for function block programming)

Program features

Page 50

Programmable analogue outputs

Two programmable current outputs (0/4 to 20 mA) are available as standard, and two outputs can be added by using an optional analogue I/O extension module. Analogue output signals can be inverted and filtered.

The analogue output signals can be proportional to motor speed, process speed (scaled motor speed), output frequency, output current, motor torque, motor power, etc.

It is possible to write a value to an analogue output through a serial communication link.

Update cycles in the Standard Control Program

Output Cycle

AO / standard 24 ms

AO / extension 24 ms (1000 ms

Update cycle in the motor temperature measurement function. See group 35 MOT TEMP MEAS.

Settings

)

Parameter Additional information

Group 15 ANALOGUE

OUTPUTS

30.20 Operation of an externally controlled AO in a communication break

30.22 Supervision of the use of optional AO

Group 35 MOT TEMP

MEAS

Group 96 EXTERNAL AOOptional AO value selection and processing

Group 98 OPTION

MODULES

AO value selection and processing (standard outputs)

AO in motor temperature measurement

Activation of optional I/O

Diagnostics

Actual value Additional information

01.22, 01.23 Values of the standard outputs

01.28, 01.29 Values of the optional outputs

Warning

IO CONFIG (FF8B) Improper use of optional I/O

Program features

Page 51

Programmable digital inputs

The drive has six programmable digital inputs as a standard. Six extra inputs are available if optional digital I/O extension modules are used.

Update cycles in the Standard Control Program

Input Cycle

DI / standard 6 ms

DI / extension 12 ms

Settings

Parameter Additional information

Group 10 START/STOP/

DIR

Group 11 REFERENCE

SELECT

Group 12 CONSTANT

SPEEDS

Group 16 SYST CTRL

INPUTS

22.01 DI as acceleration and deceleration ramp selection signal

30.03 DI as external fault source

30.05 DI in motor overtemperature supervision function

30.22 Supervision of optional I/O use

40.20 DI as sleep function activation signal (in PID process control)

42.02 DI as mechanical brake acknowledgement signal

98.03…96.05 Activation of the optional digital I/O extension modules

98.09…98.11 Naming of the optional digital inputs in the application program

DI as start, stop, direction

DI in reference selection, or reference source

DI in constant speed selection

DI as external Run Enable, fault reset or user macro change signal

Diagnostics

Actual value Additional information

01.17 Values of the standard digital inputs

01.40 Values of the optional digital inputs

Warning

IO CONFIG (FF8B) Improper use of optional I/O

Fault

I/O COMM ERR (7000) Communication loss to I/O

Program features

Page 52

Programmable relay outputs

As standard there are three programmable relay outputs. Six outputs can be added by using the optional digital I/O extension modules. By means of a parameter setting it is possible to choose which information to indicate through the relay output: ready, running, fault, warning, motor stall, etc.

It is possible to write a value to a relay output through a serial communication link.

Update cycles in the Standard Control Program

Output Cycle

RO / standard 100 ms

RO / extension 100 ms

Settings

Parameter Additional information

Group 14 RELAY

OUTPUTS

30.20 Operation of an externally controlled relay output on a communication break

Group 42 BRAKE

CONTROL

Group 98 OPTION

MODULES

RO value selections and operation times

RO in a mechanical brake control

Activation of optional relay outputs

Diagnostics

Actual value Additional information

01.21 Standard relay output states

01.41 Optional relays output states

Program features

Page 53

Actual signals

Several actual signals are available:

• Drive output frequency, current, voltage and power

• Motor speed and torque

• Supply voltage and intermediate circuit DC voltage

• Active control location (Local, EXT1 or EXT2)

• Reference values

• Drive temperature

• Operating time counter (h), kWh counter

• Digital I/O and Analogue I/O status

• PID controller actual values (if the PID Control macro is selected)

Three signals can be shown simultaneously on the control panel display. It is also possible to read the values through the serial communication link or through the analogue outputs.

Settings

Parameter Additional information

Group 15 ANALOGUE

OUTPUTS

Group 92 D SET TR

ADDR

Diagnostics

Actual value Additional information

Group 01 ACTUAL

SIGNALS … 09 ACTUAL SIGNALS

Motor identification

The performance of Direct Torque Control is based on an accurate motor model determined during the motor start-up.

A motor Identification Magnetisation is automatically done the first time the start command is given. During this first start-up, the motor is magnetised at zero speed for several seconds to allow the motor model to be created. This identification method is suitable for most applications.

Selection of an actual signal to an analogue output

Selection of an actual signal to a data set (serial communication)

Lists of actual signals

In demanding applications a separate Identification Run can be performed.

Settings

Parameter 99.10.

Program features

Page 54

130

260

390

520

1.6 4.8 8 11.2 14.4

t(s)

out

UDC= Intermediate circuit voltage of the drive, f

out

= output frequency of the drive,

TM = 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 supply voltage 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.

120

160

(Nm)

out

(Hz)

(V d.c.)

Power loss ride-through

If the incoming supply voltage is cut off, the drive will continue to operate by utilising 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 the operation after the break if the main contactor remained closed.

Note: Cabinet assembled units equipped with main contactor option have a “hold circuit” that keeps the contactor control circuit closed during a short supply break. The allowed duration of the break is adjustable. The factory setting is five seconds.

Automatic Start

Since the drive can detect the state of the motor within a few milliseconds, the starting is immediate under all conditions. There is no restart delay. E.g. the starting of turbining pumps or windmilling fans is easy.

Settings

Parameter 21.01.

Program features

Page 55

DC Magnetising

DC hold

Motor

DC Hold

speed

DC hold speed

Speed

Reference

Speed

Flux Braking

No Flux Braking

t (s)

Motor

Flux Braking

No Flux Braking

f (Hz)

(%)

= 100 Nm

= Braking Torque

Speed

50 HZ / 60 Hz

When DC Magnetising is activated, the drive automatically magnetises the motor before starting. This feature guarantees the highest possible breakaway torque, up to 200% of motor nominal torque. By adjusting the premagnetising time, it is possible to synchronise the motor start and e.g. a mechanical brake release. The Automatic Start feature and DC Magnetising cannot be activated at the same time.

Settings

Parameters 21.01 and 21.02.

DC Hold

By activating the motor DC Hold feature it is possible to lock the rotor at zero speed. When both the reference and the motor speed fall below the preset DC hold speed, the drive stops the motor and starts to inject DC into the motor. When the reference speed again exceeds the DC hold speed, the normal drive operation resumes.

Settings

Flux Braking

Parameters 21.04, 21.05, and 21.06.

The drive can provide greater deceleration by raising the level of magnetisation in the motor. By increasing the motor flux, the energy generated by the motor during braking can be converted to motor thermal energy. This feature is useful in motor power ranges below 15 kW.

Program features

Page 56

120

5 1020304050

120

5 1020304050

4 5

f (Hz)

Braking Torque (%)

f (Hz)

Flux Braking

No Flux Braking

2.2 kW 15 kW 37 kW 75 kW 250 kW

Rated Motor Power

The drive monitors the motor status continuously, also during the 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:

• 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 motor is efficient. The stator current of the motor increases during the Flux Braking, not the rotor current. The stator cools much more efficiently than the rotor.

Settings

Parameter 26.02.

Flux Optimisation

Flux Optimisation reduces the total energy consumption and motor noise level when the drive operates below the nominal load. The total efficiency (motor and the drive) can be improved by 1% to 10%, depending on the load torque and speed.

Settings

Parameter 26.01.

Program features

Page 57

Acceleration and deceleration ramps

Linear

t (s)

Motor

speed

S-curve

Two user-selectable acceleration and deceleration ramps are available. It is possible to adjust the acceleration/deceleration times and the ramp shape. Switching between the two ramps can be controlled via a digital input.

The available ramp shape alternatives are Linear and S-curve.

Linear: Suitable for drives requiring steady or slow acceleration/deceleration.

S-curve: Ideal for conveyors carrying fragile loads, or other applications where a smooth transition is required when changing the speed.

Settings

Parameter group 22 ACCEL/DECEL.

Critical speeds

A Critical Speeds function is available for applications where it is necessary to avoid certain motor speeds or speed bands because of e.g. mechanical resonance problems.

Settings

Parameter group 25 CRITICAL SPEEDS.

Constant speeds

It is possible to predefine 15 constant speeds. Constant speeds are selected with digital inputs. Constant speed activation overrides the external speed reference.

This function operates on a 6 ms time level.

Settings

Parameter group 12 CONSTANT SPEEDS.

Program features

Page 58

A: Undercompensated B: Normally tuned (autotuning) C: Normally tuned (manually). Better dynamic performance than with B D: Overcompensated speed controller

Derivative

Proportional, integral

Derivative acceleration compensation

To rq u e reference

Speed reference

Actual speed

Error value

Speed controller tuning

During the motor identification, the speed controller is automatically tuned. It is, however, possible to manually adjust the controller gain, integration time and derivation time, or let the drive perform a separate speed controller Autotune Run. In Autotune Run, the speed controller is tuned based on the load and inertia of the motor and the machine. The figure below shows speed responses at a speed reference step (typically, 1 to 20%).

Program features

The figure below is a simplified block diagram of the speed controller. The controller output is the reference for the torque controller.

Settings

Parameter group 23 SPEED CTRL and 20 LIMITS.

Diagnostics

Actual signal 01.02.

Page 59

Speed control performance figures

100

t (s)

(%)

load

act-nref

0.1 - 0.4 %sec

TN = rated motor torque nN = rated motor speed n

act

= actual speed

ref

= speed reference

*Dynamic speed error depends on speed controller tuning.

Speed Control No Pulse

Encoder

With Pulse

Encoder

Static speed error, % of n

+ 0.1 to 0.5%

(10% of nominal slip)

+ 0.01%

Dynamic speed error

0.4 %sec.* 0.1 %sec.*

*When operated around zero frequency, the error may be greater.

Torque Control No Pulse

Encoder

With Pulse Encoder

Linearity error +

4%* + 3%

Repeatability error

3%* + 1%

Torque rise time 1 to 5 ms 1 to 5 ms

100

t(s)

< 5 ms

(%)

ref

act

TN = rated motor torque T

ref

= torque reference

act

= actual torque

The table below shows typical performance figures for speed control when Direct Torque Control is used.

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, when Direct Torque Control is used.

Program features

Page 60

f (Hz)

Motor Voltage

No compensation

IR Compensation

Scalar control

It is possible to select Scalar Control as the motor control method instead of Direct Torque Control (DTC). In the Scalar Control mode, the drive is controlled with a frequency reference. The outstanding performance of the default motor control method, Direct Torque Control, is not achieved in Scalar Control.

It is recommended to activate the Scalar Control mode in the following special applications:

• In multimotor drives: 1) if the load is not equally shared between the motors, 2) if

• If the nominal current of the motor is less than 1/6 of the nominal output current of

• If the drive is used without a motor connected (e.g. for test purposes)

• The drive runs a medium voltage motor via a step-up transformer.

In the Scalar Control mode, some standard features are not available.

Settings

the motors are of different sizes, or 3) if the motors are going to be changed after the motor identification

the drive

Parameter 99.04.

IR compensation for a scalar controlled drive

IR Compensation is active only when the motor control mode is Scalar (see section Scalar control on page 60). 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 high breakaway torque. In Direct Torque Control, no IR Compensation is possible/needed.

Settings

Parameter 26.03.

Program features

Page 61

Hexagonal motor flux

Typically the drive controls the motor flux in such a way that the rotating flux vector follows a circular pattern. This is ideal in most applications. When operated above the field weakening point (FWP, typically 50 or 60 Hz), it is, however, not possible to reach 100% of the output voltage. The peak load capacity of the drive is lower than with the full voltage.

If hexagonal flux control is selected, the motor flux is controlled along a circular pattern below the field weakening point, and along a hexagonal pattern in the field weakening range. The applied pattern is changed gradually as the frequency increases from 100% to 120% of the FWP. Using the hexagonal flux pattern, the maximum output voltage can be reached; The peak load capacity is higher than with the circular flux pattern but the continuous load capacity is lower in the frequency range of FWP to 1.6

Settings

Parameter 26.05.

· FWP, due to increased losses.

Programmable protection functions

AI<Min

AI<Min function defines the drive operation if an analogue input signal falls below the preset minimum limit.

Settings

Parameter 30.01.

Panel Loss

Panel Loss function defines the operation of the drive if the control panel selected as control location for the drive stops communicating.

Settings

Parameter 30.02.

External Fault

External Faults can be supervised by defining one digital input as a source for an external fault indication signal.

Settings

Parameter 30.03.

Program features

Page 62

Motor

100%

Temp.

63%

Motor thermal time

100%

100

150

Zero speed load

Motor load curve

Break point

Motor

Speed

Load

Current

(%)

Rise

Motor Thermal Protection

The motor can be protected against overheating by activating the Motor Thermal Protection function and by selecting one of the motor thermal protection modes available.

The Motor Thermal Protection modes are based either on a motor temperature thermal model or on an overtemperature indication from a motor thermistor.

Motor temperature thermal model

The drive calculates the temperature of the motor on the basis of the following assumptions:

1) The motor is at the estimated temperature (value of 01.37 MOTOR TEMP EST

saved at power switch off) when power is applied to the drive. When power is applied for the first time, the motor is at the ambient temperature (30°C).

2) Motor temperature is calculated using either the user-adjustable or automatically

calculated motor thermal time and motor load curve (see the figures below). The load curve should be adjusted in case the ambient temperature exceeds 30°C.

Use of the motor thermistor

Settings

Program features

It is possible to detect motor overtemperature by connecting a motor thermistor (PTC) between the +24 VDC voltage supply offered by the drive and digital input DI6. In normal motor operation temperature, the thermistor resistance should be less than 1.5 kohm (current 5 mA). The drive stops the motor and gives a fault indication if the thermistor resistance exceeds 4 kohm regulations for protecting against contact.

. The installation must meet the

Parameters 30.04 to 30.09.

Note: It is also possible to use the motor temperature measurement function. See sections Motor temperature measurement through the standard I/O on page 71 and

Motor temperature measurement through an analogue I/O extension on page 73.

Page 63

Stall Protection

The drive protects the motor in a stall situation. It is possible to adjust the supervision limits (torque, frequency, time) and choose how the drive reacts to a motor stall condition (warning indication / fault indication & stop the drive / no reaction).

The torque and current limits, which define the stall limit, must be set according to the maximum load of the used application. Note: Stall limit is restricted by internal current limit 03.04 TORQ_INV_CUR_LIM.

When the application reaches the stall limit and the output frequency of the drive is below the stall frequency: Fault is activated after the stall time delay.

Settings

Parameters 30.10 to 30.12.

Parameters 20.03, 20.13 and 20.14 (Define the stall limit.)

Underload Protection

Loss of motor load may indicate a process malfunction. The drive provides an underload function to protect the machinery and process in such a serious fault condition. Supervision limits - underload curve and underload time - can be chosen as well as the action taken by the drive upon the underload condition (warning indication / fault indication & stop the drive / no reaction).

Settings

Parameters 30.13 to 30.15.

Motor Phase Loss

The Phase Loss function monitors the status of the motor cable connection. The function is useful especially during the motor start: the drive detects if any of the motor phases is not connected and refuses to start. The Phase Loss function also supervises the motor connection status during normal operation.

Settings

Parameter 30.16.

Program features

Page 64

Earth Fault Protection

The earth fault protection detects earth faults in the motor or motor cable. The protection is based on sum current measurement.

• An earth fault in the supply cable does not activate the protection.

• In an earthed (grounded) supply, the protection activates in 200 microseconds.

• In an unearthed (ungrounded) supply, the supply capacitance should be 1 microfarad or more.

• The capacitive currents caused by shielded motor cables up to 300 metres do not activate the protection.

• Earth fault protection is deactivated when the drive is stopped.

Note: With parallel connected inverter modules, the earth fault indication is CUR UNBAL xx. See chapter Fault tracing.

Settings

Parameter 30.17.

Communication Fault

The Communication Fault function supervises the communication between the drive and an external control device (e.g. a fieldbus adapter module).

Settings

Parameters 30.18 to 30.21.

Supervision of optional IO

The function supervises the use of the optional analogue and digital inputs and outputs in the application program, and warns if the communication to the input/ output is not operational.

Settings

Parameter 30.22.

Preprogrammed faults

Overcurrent

The overcurrent trip limit for the drive is 1.65 to 2.17 · I type.

DC overvoltage

depending on the drive

max

Program features

The DC overvoltage trip limit is 1.3 × 1.35 × U value of the supply voltage range. For 400 V units, U

is 500 V. For 690 V units, U

1max

is 690 V. The actual voltage in the

1max

, where U

is 415 V. For 500 V units,

1max

is the maximum

1max

intermediate circuit corresponding to the supply voltage trip level is 728 V DC for 400 V units, 877 V DC for 500 V units, and 1210 V DC for 690 V units.

Page 65

DC undervoltage

The DC undervoltage trip limit is 0.6 × 1.35 × U value of the supply voltage range. For 400 V and 500 V units, U 690 V units, U

is 525 V. The actual voltage in the intermediate circuit

1min

, where U

is the minimum

1min

is 380 V. For

1min

corresponding to the supply voltage trip level is 307 V DC for 400 V and 500 V units, and 425 V DC for 690 V units.

Drive temperature

The drive supervises the inverter module temperature. There are two supervision limits: warning limit and fault trip limit.

Enhanced drive temperature monitoring for ACS800, frame sizes R7 and R8

Traditionally, drive temperature monitoring is based on the power semiconductor (IGBT) temperature measurement which is compared with a fixed maximum IGBT temperature limit. However, certain abnormal conditions such as cooling fan failure, insufficient cooling air flow or excessive ambient temperature might cause overheating inside the converter module, which the traditional temperature monitoring alone does not detect. The Enhanced drive temperature monitoring improves the protection in these situations.

The function monitors the converter module temperature by checking cyclically that the measured IGBT temperature is not excessive considering the load current, ambient temperature, and other factors that affect the temperature rise inside the converter module. The calculation uses an experimentally defined equation that simulates the normal temperature changes in the module depending on the load. Drive generates a warning when the temperature exceeds the limit, and trips when temperature exceeds the limit by 5°C.

Note: The monitoring is available for ACS800-02, -04 and -07, frame sizes R7 and R8 with Standard Control Program version ASXR7360 (and later versions). For ACS800-U2, -U4 and -U7, frame sizes R7 and R8, the monitoring is available with Standard Control Program version ASXR730U (and later versions).

Types to which the enhanced drive temperature monitoring is available:

ACS800-XX -0080-2

-0100-2

-0120-2

-0140-2/3/7

-0170-2/3/5/7

-0210-2/3/5/7

-0230-2

-0260-2/3/5/7

-0270-5

-0300-2/5

-0320-3/5/7

-0400-3/5/7

Program features

Page 66

-0440-3/5/7

-0490-3/5/7

-0550-5/7

-0610-5/7

Settings

Parameter Additional information

95.10 TEMP INV AMBIENT Ambient temperature

Diagnostics

Warning/Fault Additional information

INV OVERTEMP Excessive converter module temperature

Short circuit

There are separate protection circuits for supervising the motor cable and the inverter short circuits. If a short circuit occurs, the drive will not start and a fault indication is given.

Input phase loss

Input phase loss protection circuits supervise the supply cable connection status by detecting intermediate circuit ripple. If a phase is lost, the ripple increases. The drive is stopped and a fault indication is given if the ripple exceeds 13%.

Control board temperature

The drive supervises the control board temperature. A fault indication CTRL B TEMP is given, if the temperature exceeds 88°C.

Overfrequency

If the drive output frequency exceeds the preset level, the drive is stopped and a fault indication is given. The preset level is 50 Hz over the operating range absolute maximum speed limit (Direct Torque Control mode active) or frequency limit (Scalar Control active).

Internal fault

If the drive detects an internal fault, the drive is stopped and a fault indication is given.

Operation limits

ACS800 has adjustable limits for speed, current (maximum), torque (maximum) and DC voltage.

Settings

Program features

Parameter group 20 LIMITS.

Page 67

Power limit

Power limitation is used to protect the input bridge and the DC intermediate circuit. If the maximum allowed power is exceeded, the drive torque is automatically limited. Maximum overload and continuous power limits depend on the drive hardware. For specific values refer to the appropriate hardware manual.

Automatic resets

The drive can automatically reset itself after overcurrent, overvoltage, undervoltage and “analogue input below a minimum” faults. The Automatic Resets must be activated by the user.

Settings

Parameter group 31 AUTOMATIC RESET.

Supervisions

The drive monitors whether certain user selectable variables are within the userdefined limits. The user may set limits for speed, current etc.

The supervision functions operate on a 100 ms time level.

Settings

Parameter group 32 SUPERVISION.

Diagnostics

Actual Signals Additional information

03.02 Supervision limit indicating bits in a packed boolean word

03.04 Supervision limit indicating bits in a packed boolean word

03.14 Supervision limit indicating bits in a packed boolean word

Group 14 RELAY

OUTPUTS

Parameter lock

The user can prevent parameter adjustment by activating the parameter lock.

Settings

Parameters 16.02 and 16.03.

Supervision limit indication through a relay output

Program features

Page 68

ACT PA R FUNC DRIV E

ENT ER

LOC

REM

RESET

REF

A C S 6 0 0

0 . . . 1 0 b a r 4 . . . 2 0 m A

PID

ref k ti td i dFiltT errVInv rInt oh1 ol1

Actual Values

40.06

40.12 AI1 AI2 AI3 AI5 AI6

IMOT

40.19

Filter

%ref

40.01

40.02

40.03

40.04

40.05

40.13

PIDmax

PIDmin

Switch

Speed reference

Frequency reference

99.04 = 0 (DTC)

Example:

. .

PID Control Block Diagram

%ref = external reference EXT REF2 (see parameter 11. 06)

Pressure boost pump

ACS800

Process PID control

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

When the process PID control is activated, 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 (reference).

The control operates on a 24 ms time level.

Block diagrams

The block diagram below right illustrates the process PID control.

The figure on the left shows an application example: The controller adjusts the speed of a pressure boost pump according to the measured pressure and the set pressure reference.

Program features

Page 69

Settings

1) 1 = Activate sleeping 0 = Deactivate sleeping

40.20

Select

Compare

1<2

40.22

Delay

40.21

Mot.speed

DI1

And

%refActive

PIDCtrlActive

modulating

Set/Reset

S/R

Compare

1<2

40.23

INTERNAL

DI1

40.24

Delay

StartRq

03.02 (B1)

03.02 (B2)

01.34

INTERNAL

. .

40.20

Select

. .

Mot.speed: Actual speed of the motor

%refActive: The % reference (EXT REF2) is in use. See parameter 11.02.

PIDCtrlActive: 99.02 is PID CTRL

modulating: The inverter IGBT control is operating

Parameter Purpose

99.02 Process PID control activation

40.01...40.13, 40.19,

The settings of the process PID controller

40.25...40.27

32.13...32.18 The supervision limits for the process reference REF2 and the variables

ACT1 and ACT2

Diagnostics

Actual Signals Purpose

01.12, 01.24, 01.25,

01.26 and 01.34

Group 14 RELAY

OUTPUTS

Group 15 ANALOGUE

OUTPUTS

Group 96 EXTERNAL AOPID process controller values through optional analogue outputs

PID process controller reference, actual values and error value

Supervision limit exceeded indication through a relay output

PID process controller values through standard analogue outputs

Sleep function for the process PID control

The sleep function operates on a 100 ms time level.

The block diagram below illustrates the sleep function enable/disable logic. The sleep function can be put into use only when the process PID control is active.

Program features

Page 70

Actual Value

Wake-up level

Parameter 42.23

Motor Speed

Sleep level

Par. 40.21

Time

START

STOP

t<t

td = Sleep delay, parameter 40.22

Text on display

SLEEP MODE

twd = Wake-up delay, parameter 40.24

Wake-up level

Parameter 42.23

Time

Actual Value

No inversion, i.e. par. 40.05 is NO.

Inverted, i.e. par. 40.05 is YES.

Example

The time scheme below visualises the operation of the sleep function.

Settings

Diagnostics

Program features

Sleep function for a PID controlled pressure boost pump: The water consumption falls at night. As a consequence, the PID process 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 does not stop but keeps 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 restarts when the pressure falls under the allowed minimum level and the wake-up delay has passed.

Parameter Additional information

99.02 Process PID control activation

40.05 Inversion

40.20...40.24 Sleep function settings

Warning SLEEP MODE on the panel display.

Page 71

Motor temperature measurement through the standard I/O

Motor

RMIO board

AI1+

AI1-

AO1+

AO1-

Motor

RMIO board

AI1+

AI1-

AO1+

AO1-

One sensor

Three sensors

The minimum voltage of the capacitor must be 630 VAC.

10 nF

630 VAC)

10 nF

630 VAC)

This section describes the temperature measurement of one motor when the drive control board RMIO is used as the connection interface.

WARNING! According to IEC 664, the connection of the motor temperature sensor to the RMIO board, requires double or reinforced insulation between motor live parts and the sensor. Reinforced insulation entails a clearance and creepage distance of 8 mm (400 / 500 VAC equipment). If the assembly does not fulfil the requirement:

• The RMIO board terminals must be protected against contact and they may not be connected to other equipment.

• The temperature sensor must be isolated from the RMIO board terminals.

See also section Motor Thermal Protection on page 62.

Program features

Page 72

Settings

Parameter Additional information

15.01 Analogue output in a motor 1 temperature measurement. Set to M1 TEMP

MEAS.

35.01…35.03 Settings of motor 1 temperature measurement

Other

Parameters 13.01 to 13.05 (AI1 processing) and 15.02 to 15.05 (AO1 processing) are not effective.

At the motor end the cable shield should be earthed through a 10 nF capacitor. If this is not possible, the shield is to be left unconnected.

Diagnostics

Actual values Additional information

01.35 Temperature value

Warnings

MOTOR 1 TEMP (4312) Measured motor temperature has exceeded the set alarm limit.

T MEAS ALM (FF91) Motor temperature measurement is out of acceptable range.

Faults

MOTOR 1 TEMP (4312) Measured motor temperature has exceeded the set fault limit.

Program features

Page 73

Motor temperature measurement through an analogue I/O extension

Motor

RAIO module

AI1+

AI1-

AO1+

AO1-

SHLD

Motor

One sensor

Three sensors

RAIO module

AI1+

AI1-

AO1+

AO1-

SHLD

10 nF

630 VAC)

10 nF

630 VAC)

The minimum voltage of the capacitor must be 630 VAC.

This section describes the motor temperature measurement of one motor when an optional analogue I/O extension module RAIO is used as the connection interface.

WARNING! According to IEC 664, the connection of the motor temperature sensor to the RAIO module, requires double or reinforced insulation between motor live parts and the sensor. Reinforced insulation entails a clearance and creepage distance of 8 mm (400 / 500 VAC equipment). If the assembly does not fulfil the requirement:

• The RAIO module terminals must be protected against contact and they may not be connected to other equipment.

• The temperature sensor must be isolated from the RAIO module terminals.

See also section Motor Thermal Protection on page 62.

Program features

Page 74

Settings

Parameter Additional information

35.01 … 35.03 Settings of motor 1 temperature measurement

98.12 Activation of optional analogue I/O for motor temperature measurement

Other

Parameters 13.16 to 13.20 (AI1 processing) and 96.01 to 96.05 (AO1 signal selection and processing) are not effective.

At the motor end the cable shield should be earthed through a 10 nF capacitor. If this is not possible, the shield is to be left unconnected.

Diagnostics

Actual values Additional information

01.35 Temperature value

Warnings

MOTOR 1 TEMP (4312) Measured motor temperature has exceeded the set alarm limit

T MEAS ALM (FF91) Motor temperature measurement is out of acceptable range.

Faults

MOTOR 1 TEMP (4312) Measured motor temperature has exceeded the set fault limit

Adaptive Programming using the function blocks

Conventionally, the user can control the operation of the drive by parameters. Each parameter has a fixed set of choices or a setting range. The parameters make the programming easy, but the choices are limited. The user cannot customise the operation any further. The Adaptive Program makes freer customising possible without the need of a special programming tool or language:

• The program is built of standard function blocks included in the drive application program.

• The control panel is the programming tool.

• The user can document the program by drawing it on block diagram template sheets.

The maximum size of the Adaptive Program is 15 function blocks. The program may consist of several separate functions.

For more information, see the Application Guide for Adaptive Program [3AFE64527274 (English)].

DriveAP

DriveAP is a Windows based tool for Adaptive Programming. With DriveAP it is possible to upload the Adaptive Program from the drive and edit it with PC.

Program features

For more information, see the DriveAP User’s Manual [3AFE64540998 (English)].

Page 75

Control of a mechanical brake

Motor

230 VAC

RMIO board

Mechanical brake

Brake control

hardware

Emergency

brake

X25

1 RO1

2 RO1

3 RO1

X22

5 DI5

7 +24 V

Brake control logic is integrated in the drive application program. The brake control hardware and wirings needs to be done by the user.

- Brake on/off control through relay output RO1.

- Brake supervision through digital input DI5 (optional).

- Emergency brake switch in the brake control circuit.

The mechanical brake is used for holding the motor and driven machinery at zero speed when the drive is stopped, or not powered.

Example

The figure below shows a brake control application example.

WARNING! Make sure that the machinery into which the drive with brake control function is integrated fulfils the personnel safety regulations. Note that the frequency converter (a Complete Drive Module or a Basic Drive Module, as defined in IEC 61800-2), is not considered as a safety device mentioned in the European Machinery Directive and related harmonised 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.

Program features

Page 76

Start torque at brake release (Parameter 42.07 and 42.08)

Motor magnetising delay

Brake open delay (Parameter 42.03)

Brake close speed (Parameter 42.05)

Brake close delay (Parameter 42.04)

Start command

Inverter modulating

Motor magnetised

Open brake command

Internal speed reference (actual motor speed)

Torque reference

time

External speed reference

Operation time scheme

The time scheme below illustrates the operation of the brake control function. See also the state machine on the following page.

Program features

Page 77

State shifts

RFG INPUT

TO ZERO

CLOSE BRAKE

BRAKE

ACK FAULT

OPEN

BRAKE

From any state

1/1/1

0/1/1

1/1/1

1/1/0

0/0/1

RELEASE RFG

INPUT

10)

11)

12)

13)

MODULATION

0/0/1

Stat e (Symbol )

- NN: State name

- X/Y/Z: State outputs/operations X = 1 Open the brake. The relay output set to brake on/off control energises. Y = 1 Forced start. The function keeps the internal Start on until the brake is closed in spite of the

status of the external Start signal.

Z = 1 Ramp in zero. Forces the used speed reference (internal) to zero along a ramp.

X/Y/Z

State change conditions (Symbol )

1) Brake control active 0 -> 1 OR Inverter is modulating = 0

2) Motor magnetised = 1 AND Drive running = 1

3) Brake acknowledgement = 1 AND Brake open delay passed AND Start = 1

4) Start = 0

5) Start = 0

6) Start = 1

7) Actual motor speed < Brake close speed AND Start = 0

8) Start = 1

9) Brake acknowledgement = 0 AND Brake close delay passed = 1 AND Start = 0

Only if parameter 42.02 OFF:

10) Brake acknowledgement = 0 AND Brake open delay passed =1

11) Brake acknowledgement = 0

12) Brake acknowledgement = 0

13) Brake acknowledgement = 1 AND Brake close delay passed = 1

RFG = Ramp Function Generator in the speed control loop (reference handling).

(rising edge)

Program features

Page 78

Supply

Solidly coupled motor shafts:

- Speed-controlled Master

- Follower follows the torque reference of the Master

External control signals

Supply

Master/ Follower Link

Follower fault supervision

Master/Follower Link

Follower fault supervision

External control signals

Supply

Flexibly coupled motor shafts:

- Speed-controlled Master

- Follower follows the speed reference of the Master

Supply

M/F Application, Overview

Settings

Parameter Additional information

14.01 Relay output for the brake control (set to BRAKE CTRL)

Group 42 BRAKE CONTROL Brake function settings

Diagnostics

Actual value Additional information

03.01 Ramp in zero bit

03.13 The state of bit “brake open/close command”

Warnings

BRAKE ACKN (FF74) Unexpected state of brake acknowledge signal

Faults

BRAKE ACKN (FF74) Unexpected state of brake acknowledge signal

Master/Follower use of several drives

In a Master/Follower application, the system is run by several drives, the motor shafts of which are coupled to each other. The master and follower drives communicate via a fibre optic link. The figures below illustrate two basic application types.

Program features

Settings and diagnostics

Parameter Additional information

Group 60 MASTER/

FOLLOWER

Other

Master/Follower Application Guide [3AFE64590430 (English)] explains the functionality in further detail.

Master/Follower parameters

Page 79

Jogging

Time

Speed

12 345 6 7 89 1011 1213

15 16

The jogging function is typically used to control a cyclical movement of a machine section. One push button controls the drive through the whole cycle: When it is on, the drive starts, accelerates to a preset speed at a preset rate. When it is off, the drive decelerates to zero speed at a preset rate.

The figure and table below describe the operation of the drive. They also represent how the drive shifts to normal operation (= jogging inactive) when the drive start command is switched on. Jog cmd = State of the jogging input, Start cmd = State of the drive start command.

The function operates on a 100 ms time level.

Phase Jog

cmd

1-2 1 0 Drive accelerates to the jogging speed along the acceleration ramp of the jogging function.

2-3 1 0 Drive runs at the jogging speed.

3-4 0 0 Drive decelerates to zero speed along the deceleration ramp of the jogging function.

4-5 0 0 Drive is stopped.

5-6 1 0 Drive accelerates to the jogging speed along the acceleration ramp of the jogging function.

6-7 1 0 Drive runs at the jogging speed.

7-8 x 1 Normal operation overrides the jogging. Drive accelerates to the speed reference along the

8-9 x 1 Normal operation overrides the jogging. Drive follows the speed reference.

9-10 0 0 Drive decelerates to zero speed along the active deceleration ramp.

10-11 0 0 Drive is stopped.

11-12 x 1 Normal operation overrides the jogging. Drive accelerates to the speed reference along the

12-13 x 1 Normal operation overrides the jogging. Drive follows he speed reference.

13-14 1 0 Drive decelerates to the jogging speed along the deceleration ramp of the jogging function.

14-15 1 0 Drive runs at the jogging speed.

15-16 0 0 Drive decelerates to zero speed along the deceleration ramp of the jogging function.

Start cmd

x = State can be either 1 or 0.

Description

active acceleration ramp.

Program features

Page 80

Note: The jogging is not operational when:

• the drive start command is on, or

• the drive is in local control (L visible on the first row of the panel display).

Note: The jogging speed overrides the constant speeds.

Note: The ramp shape time is set to zero during the jogging.

Settings

Parameter Additional information

10.06 Input for the on/off control of the jogging.

12.15 Jogging speed

21.10 Switch off delay for the inverter IGBT control. A delay keeps the inverter

22.04, 22.05 Acceleration and deceleration times used during the jogging.

22.06 Acceleration and deceleration ramp shape time: Set to zero during the

Reduced Run function

modulation live over a short standstill period enabling a smooth restart.

jogging.

Reduced Run function is available for parallel connected inverters. Reduced Run function makes it possible to continue the operation with limited current if an inverter module(s) is out of order. If one of the modules is broken, it must be removed. Parameter change is needed to continue the run with reduced current (95.03 INT CONFIG USER). For instructions on how to remove and reconnect an inverter module, see the appropriate drive hardware manual.

Settings

Parameter Additional information

95.03 INT CONFIG

USER

Number of existing parallel connected inverters

Diagnostics

Actual value Additional information

04.01 INT board fault

Faults

INT CONFIG Number of inverter modules is not equal to original number of inverters.

Program features

Page 81

User load curve

50 Hz

0 Hz

100 Hz

Frequency

T/T

Normal motor load capacity

User load curve

Current

output

user curve

72.20

COOLING TIME

Frequency / Time

Overload

Motor temperature rise can be limited by limiting the drive output current. The user can define a load curve (output current as a function of frequency). The load curve is defined by eight points by parameters 72.02...72.17. If the load curve is exceeded, a fault / warning / current limitation is activated.

Overload

Overload supervision can be applied to the user load curve by setting parameters

72.18 LOAD CURRENT LIMIT... 72.20 COOLING TIME according to the overload

values defined by the motor manufacturer.

, ∫I

The supervision is based on an integrator

dt. Whenever the drive output current exceeds the user load curve, the integrator is started. When the integrator has reached the overload limit defined by parameters 72.18 and 72.19, the drive reacts as defined by parameter 72.01 OVERLOAD FUNC. The output of the integrator is set to zero if the current stays continuously below the user load curve for the cooling time defined by parameter 72.20 COOLING TIME.

If the overload time 72.19 LOAD THERMAL TIME is set to zero, the drive output current is limited to the user load curve.

Program features

Page 82

Settings

Parameter Additional information

Group 72 USER LOAD

CURVE

Diagnostics

Actual value Additional information

02.20 Measured motor current in percent of the user load curve current

Warnings

USER L CURVE Integrated motor current has exceeded load curve.

Faults

USER L CURVE Integrated motor current has exceeded load curve.

User load curve

Program features

Page 83

Application macros

Chapter overview

This chapter describes the intended use, operation and the default control connections of the standard application macros. It also describes how to save a user macro, and how to recall it.

Overview of macros

Application macros are preprogrammed parameter sets. While starting up the drive, the user typically selects one of the macros - the one that is best suited to his needs

- by parameter 99.02, makes the essential changes and saves the result as a user macro.

There are five standard macros and two user macros. The table below contains a summary of the macros and describes suitable applications.

Macro Suitable Applications

Factory Ordinary speed control applications where no, one, two or three constant speeds

are used:

- Conveyors

- Speed-controlled pumps and fans

- Test benches with predefined constant speeds

Hand/Auto Speed control applications. Switching between two external control devices is

possible.

PID Control Process control applications e.g. different closed loop control systems such as

pressure control, level control, and flow control. For example:

- pressure boost pumps of municipal water supply systems

- level controlling pumps of water reservoirs

- pressure boost pumps of district heating systems

- material flow control on a conveyor line.

It is also possible to switch between process and speed control.

Torque Control

Sequential Control

User The user can save the customised standard macro i.e. the parameter settings

Torque control applications. Switching between torque and speed control is possible.

Speed control applications in which speed reference, seven constant speeds and two acceleration and deceleration ramps can be used.

including group 99, and the results of the motor identification into the permanent memory, and recall the data at a later time. Two user macros are essential when switching between two different motors is required

Application macros

Page 84

Note on external power supply

External +24 V power supply for the RMIO board is recommended if

• the application requires a fast start after connecting the input power supply

• fieldbus communication is required when the input power supply is disconnected.

The RMIO board can be supplied from an external power source via terminal X23 or X34 or via both X23 and X34. The internal power supply to terminal X34 can be left connected when using terminal X23.

WARNING! If the RMIO board is supplied from an external power source via terminal X34, the loose end of the cable removed from the RMIO board terminal must be secured mechanically to a location where it cannot come into contact with electrical parts. If the screw terminal plug of the cable is removed, the wire ends must be individually insulated.

Parameter settings

In Standard Control Program, set parameter 16.09 CTRL BOARD SUPPLY to EXTERNAL 24V if the RMIO board is powered from an external supply.

Application macros

Page 85

Factory macro

All drive commands and reference settings can be given from the control panel or from an external control location. The active control location is selected with the LOC/REM key of the panel. The drive is speed-controlled.

In external control, the control location is EXT1. The reference signal is connected to analogue input AI1 and Start/Stop and Direction signals are connected to digital inputs DI1 and DI2. By default, the direction is fixed to FORWARD (parameter

10.03). DI2 does not control the direction of rotation unless parameter 10.03 is

changed to REQUEST.

Three constant speeds are selected by digital inputs DI5 and DI6. Two acceleration/ deceleration ramps are preset. The acceleration and deceleration ramps are used according to the state of digital input DI4.

Two analogue signals (speed and current) and three relay output signals (ready, running and inverted fault) are available.

The default signals on the display of the control panel are FREQUENCY, CURRENT and POWER.

Application macros

Page 86

X20 1 VREF Reference voltage -10 VDC 2GND1kohm <

RL < 10 kohm X21 1 VREF Reference voltage 10 VDC

1kohm <

RL < 10 kohm

2GND 3 AI1+ Speed reference 0(2) … 10 V, R

> 200 kohm 4AI15 AI2+ By default, not in use. 0(4) … 20 mA, R

100 ohm

6AI27 AI3+ By default, not in use. 0(4) … 20 mA, R

100 ohm

8AI39 AO1+ Motor speed 0(4) … 20 mA 0 … motor nom.

speed, R

< 700 ohm

10 AO111 AO2+ Output current 0(4) … 20 mA 0 … motor

nom. current, R

< 700 ohm

12 AO2X22 1 DI1 Stop/Start

2 DI2 Forward/reverse

1, 2)

3 DI3 By default, not in use.

4 DI4 Acceleration & deceleration select

5 DI5 Constant speed select

6 DI6 Constant speed select

7 +24 V +24 VDC, max. 100 mA 8+24 V 9 DGND1 Digital ground 10 DGND2 Digital ground 11 DI IL Start interlock (0 = stop)

X23 1 +24 V Auxiliary voltage output and input, non-

isolated, 24 V DC 250 mA

2GND X25 1 RO11 Relay output 1

Ready

2RO12 3RO13 X26 1 RO21 Relay output 2

Running

2RO22 3RO23 X27 1 R031 Relay output 3

Inverted fault

2 R032 3 R033

rpm

Fault

Effective only if parameter 10.03 is

switched to REQUEST by the user.

The US default settings differ as

follows:

0 = ramp times according to par.

22.02 and 22.03. 1 = ramp times

according to par. 22.04 and 22.05.

See parameter group 12

CONSTANT SPEEDS:

See parameter 21.09.

Total maximum current shared between this output and optional modules installed on the board.

DI1 Start (Pulse: 0->1) DI2 Stop (Pulse: 1->0) DI3 Forward/Reverse

DI5 DI6 Operation

0 0 Set speed through AI1 1 0 Speed 1 0 1 Speed 2 1 1 Speed 3

Default control connections

Application macros

The figure below shows the external control connections for the Factory macro. The markings of the standard I/O terminals on the RMIO board are shown.

Page 87

Hand/Auto macro

Start/Stop and Direction commands and reference settings can be given from one of two external control locations, EXT1 (Hand) or EXT2 (Auto). The Start/Stop/Direction commands of EXT1 (Hand) are connected to digital inputs DI1 and DI2, and the reference signal is connected to analogue input AI1. The Start/Stop/Direction commands of EXT2 (Auto) are connected to digital inputs DI5 and DI6, and the reference signal is connected to analogue input AI2. The selection between EXT1 and EXT2 is dependent on the status of digital input DI3. The drive is speed controlled. Speed reference and Start/Stop and Direction commands can be given from the control panel keypad also. One constant speed can be selected through digital input DI4.

Speed reference in Auto Control (EXT2) is given as a percentage of the maximum speed of the drive.

Two analogue and three relay output signals are available on terminal blocks. The default signals on the display of the control panel are FREQUENCY, CURRENT and CTRL LOC.

Application macros

Page 88

rpm

Fault

X20 1 VREF Reference voltage -10 VDC 2GND1kohm <

RL < 10 kohm X21 1 VREF Reference voltage 10 VDC, kohm <

RL <

10 kohm

2GND 3 AI1+ Speed reference (Hand control). 0(2) … 10 V,

> 200 kohm

4AI15 AI2+ Speed reference (Auto control). 0(4) …

20 mA, R

= 100 ohm

6AI27 AI3+ By default, not in use. 0(4) … 20 mA,

= 100 ohm.

8AI39 AO1+ Motor speed 0(4) … 20 mA 0 … motor nom.

speed, R

< 700 ohm

10 AO111 AO2+ Output current 0(4) … 20 mA 0 … motor

nom. current, R

< 700 ohm

12 AO2X22 1 DI1 Stop/Start (Hand control) 2 DI2 Forward/Reverse (Hand control) 3 DI3 Hand/Auto control select

4 DI4 Constant speed 4: Par. 12.05 5 DI5 Forward/Reverse (Auto control) 6 DI6 Stop/Start (Auto control) 7 +24 V +24 VDC, max. 100 mA 8 +24 V 9 DGND1 Digital ground 10 DGND2 Digital ground 11 DI IL Start interlock (0 = stop)

X23 1 +24 V Auxiliary voltage output and input, non-

isolated, 24 V DC 250 mA

2GND X25 1 RO11 Relay output 1

Ready

2RO12 3RO13 X26 1 RO21 Relay output 2

Running

2RO22 3RO23 X27 1 R031 Relay output 3

Inverted fault

2R032 3R033

Selection between two external

control locations, EXT1 and EXT2.

See parameter 21.09.

Total maximum current shared between this output and optional modules installed on the board.

Default control connections

The figure below shows the external control connections for the Hand/Auto macro. The markings of the standard I/O terminals on the RMIO board are shown.

Application macros

Page 89

PID Control macro

X21 / RMIO board 5 AI2+ Process actual value measurement. 0(4) …

20 mA, R

= 100 ohm

6AI2… X23 / RMIO board 1 +24 V Auxiliary voltage output, non-isolated,

24 VDC, 250 mA

2GND

4…20 mA

The PID Control macro is used for controlling a process variable – such as pressure or flow – by controlling the speed of the driven motor.

Process reference signal is connected to analogue input AI1 and process feedback signal to analogue input AI2.

Alternatively, a direct speed reference can be given to the drive through analogue input AI1. Then the PID controller is bypassed and the drive no longer controls the process variable. Selection between the direct speed control and the process variable control is done with digital input DI3.

Two analogue and three relay output signals are available on terminal blocks. The default signals on the display of the control panel are SPEED, ACTUAL VALUE1 and CONTROL DEVIATION.

Connection example, 24 VDC / 4…20 mA two-wire sensor

Note: The sensor is supplied through its current output. Thus the output signal must be 4…20 mA, not 0…20 mA.

Application macros

Page 90

rpm

X20 1 VREF Reference voltage -10 VDC 2GND1kohm < RL < 10 kohm X21 1 VREF Reference voltage 10 VDC

1 kohm <

RL < 10 kohm

2GND 3 AI1+ Speed ref. (speed cntrl) or process ref.

(process cntrl). 0(2) … 10 V, R

> 200 kohm

4AI15 AI2+ Process actual value measurement. 0(4) …

20 mA, R

= 100 ohm

6AI27 AI3+ By default, not in use. 0(4) … 20 mA, R

100 ohm.

8AI39 AO1+ Motor speed 0(4) … 20 mA

0 … motor nom. speed, R

< 700 ohm

10 AO111 AO2+ Output current 0(4) … 20 mA

0 … motor nom. current, R

< 700 ohm

12 AO2X22 1 DI1 Stop/Start (speed control) 2 DI2 By default, not in use. 3 DI3 Speed / process control select

4 DI4 Constant speed 4: Par. 12.05

5 DI5 Run Enable.

6 DI6 Stop/Start (process control) 7 +24 V +24 VDC, max. 100 mA 8+24 V 9 DGND1 Digital ground 10 DGND2 Digital ground 11 DI IL Start interlock (0 = stop)

X23 1 +24 V Auxiliary voltage output and input, non-

isolated, 24 V DC 250 mA

2GND X25 1 RO11 Relay output 1

Ready

2RO12 3RO13 X26 1 RO21 Relay output 2

Running

2RO22 3RO23 X27 1 R031 Relay output 3

Inverted fault

2 R032 3 R033

Fault

Selection between two external

control locations, EXT1 and EXT2

In use only when the speed control

is active (DI3 = 0)

Off = Run Enable off. Drive will not start or stops. On = Run Enable on. Normal operation.

See parameter 21.09.

The sensor needs to be powered. See the manufacturer’s instructions. A connection example of a two-wire 24 VDC / 4…20 mA sensor is shown on previous page.

Total maximum current shared between this output and optional modules installed on the board.

Default control connections

The figure below shows the external control connections for the PID Control macro. The markings of the standard I/O terminals on the RMIO board are shown.

Application macros

Page 91

Torque Control macro

Torque Control macro is used in applications in which torque control of the motor is required. Torque reference is given through analogue input AI2 as a current signal. By default, 0 mA corresponds to 0 %, and 20 mA to 100 % of the rated motor torque. The Start/Stop/Direction commands are given through digital inputs DI1 and DI2. The Run Enable signal is connected to DI6.

Through digital input DI3 it is possible to select speed control instead of torque control. It is also possible to change the external control location to local (i.e. to control panel) by pressing the LOC/REM key. The panel controls the speed by default. If torque control with panel is required, the value of parameter 11.01 should be changed to REF2 (%).

Two analogue and three relay output signals are available on terminal blocks. The default signals on the display of the control panel are SPEED, TORQUE and CTRL LOC.

Application macros

Page 92

X20 1 VREF Reference voltage -10 VDC 2GND1kohm <

RL < 10 kohm X21 1 VREF Reference voltage 10 VDC

1 kohm <

RL < 10 kohm

2GND 3 AI1+ Speed reference. 0(2) … 10 V, R

200 kohm

4AI15 AI2+ Torque reference. 0(4) … 20 mA, R

= 100

ohm

6AI27 AI3+ By default, not in use. 0(4) … 20 mA, R

100 ohm

8AI39 AO1+ Motor speed 0(4) … 20 mA 0 … motor nom.

speed, R

< 700 ohm

10 AO111 AO2+ Output current 0(4) … 20 mA 0 … motor

nom. current, R

< 700 ohm

12 AO2X22 1 DI1 Stop/Start 2 DI2 Forward/Reverse 3 DI3 Speed / torque control select

4 DI4 Constant speed 4: Par. 12.05

5 DI5 Acceleration & deceleration select

6 DI6 Run Enable

7 +24 V +24 VDC, max. 100 mA 8 +24 V 9 DGND1 Digital ground 10 DGND2 Digital ground 11 DI IL Start interlock (0 = stop)

X23 1 +24 V Auxiliary voltage output and input, non-

isolated, 24 V DC 250 mA

2GND X25 1 RO11 Relay output 1

Ready

2RO12 3RO13 X26 1 RO21 Relay output 2

Running

2RO22 3RO23 X27 1 R031 Relay output 3

Inverted fault

2R032 3R033

Fault

Selection between external control

locations EXT1 and EXT2

In use only when the speed control

is active (DI3 = 0)

Off = Ramp times according to par.

22.02 and 22.03. On = Ramp times

according to par. 22.04 and 22.05.

Off = Run Enable off. Drive will not start or stops. On = Run Enable on. Normal operation.

See parameter 21.09.

Total maximum current shared between this output and optional modules installed on the board.

rpm

Default control connections

The figure below shows the external control connections for the Torque Control macro. The markings of the standard I/O terminals on the RMIO board are shown.

Application macros

Page 93

Sequential Control macro

Accel1

Accel2

Decel2

Speed 3

Speed 2

Speed 1

Spee d

Time

Start/Stop

Accel1/Decel1

Spee d 1

Spee d 2 Accel2/Decel2

Spee d 3

Stop with deceleration ramp

This macro offers seven preset constant speeds which can be activated by digital inputs DI4 to DI6. Two acceleration/deceleration ramps are preset. The acceleration and deceleration ramps are applied according to the state of digital input DI3. The Start/Stop and Direction commands are given through digital inputs DI1 and DI2.

External speed reference can be given through analogue input AI1. The reference is active only when all of the digital inputs DI4 to DI6 are 0 VDC. Giving operational commands and setting reference is possible also from the control panel.

Two analogue and three relay output signals are available on terminal blocks. Default stop mode is ramp. The default signals on the display of the control panel are FREQUENCY, CURRENT and POWER.

Operation diagram

The figure below shows an example of the use of the macro.

Application macros

Page 94

rpm

X20 1 VREF Reference voltage -10 VDC 2GND1kohm <

RL < 10 kohm X21 1 VREF Reference voltage 10 VDC

1kohm <

RL < 10 kohm

2GND 3 AI1+ External speed reference 0(2) … 10 V, R

200 kohm

4AI15 AI2+ By default, not in use. 0(4) … 20 mA, R

100 ohm

6AI27 AI3+ By default, not in use. 0(4) … 20 mA, R

100 ohm

8AI39 AO1+ Motor speed 0(4) … 20 mA 0 … motor nom.

speed, R

< 700 ohm

10 AO111 AO2+ Output current 0(4) … 20 mA 0 … motor

nom. current, R

< 700 ohm

12 AO2X22 1 DI1 Stop/Start 2 DI2 Forward/Reverse 3 DI3 Acceleration & deceleration selection

4 DI4 Constant speed select

5 DI5 Constant speed select

6 DI6 Constant speed select

7 +24 V +24 VDC, max. 100 mA 8 +24 V 9 DGND1 Digital ground 10 DGND2 Digital ground 11 DI IL Start interlock (0 = stop)

X23 1 +24 V Auxiliary voltage output and input, non-

isolated, 24 V DC 250 mA

2GND X25 1 RO11 Relay output 1

Ready

2RO12 3RO13 X26 1 RO21 Relay output 2

Running

2RO22 3RO23 X27 1 R031 Relay output 3

Inverted fault

2R032 3R033

Fault

Off = Ramp times according to par.

22.02 and 22.03. On = Ramp times

according to par. 22.04 and 22.05.

See parameter group 12

CONSTANT SPEEDS:

See parameter 21.09.

Total maximum current shared between this output and optional modules installed on the board.

DI4 DI5 DI6 Operation

0 0 0 Set speed through AI1 1 0 0 Speed 1 0 1 0 Speed 2 1 1 0 Speed 3 0 0 1 Speed 4 1 0 1 Speed 5 0 1 1 Speed 6 1 1 1 Speed 7

Default control connections

The figure below shows the external control connections for the Sequential Control macro. The markings of the standard I/O terminals on the RMIO board are shown.

Application macros

Page 95

User macros

In addition to the standard application macros, it is possible to create two user macros. The user macro allows the user to save the parameter settings including Group 99, and the results of the motor identification into the permanent memory, and recall the data at a later time. The panel reference is also saved, if the macro is saved and loaded in Local control mode. Remote control location setting is saved into the user macro, but Local control location setting is not.

To create User Macro 1:

• Adjust the parameters. Perform the motor identification if not performed yet.

• Save the parameter settings and the results of the motor identification by changing parameter 99.02 to USER 1 SAVE (press ENTER). The storing takes 20 s to 1 min.

Note: If user macro save function is executed several times, drive memory fills up and file compression starts. File compression can last up to 10 minutes. Macro saving will be completed after the file compression. (Operation is indicated on the last row of the control panel display by blinking dots).

To recall the user macro:

• Change parameter 99.02 to USER 1 LOAD.

•Press ENTER to load.

The user macro can also be switched via digital inputs (see parameter 16.05).

Note: User macro load restores also the motor settings in group 99 START-UP

DATA and the results of the motor identification. Check that the settings correspond

to the motor used.

Example: The user can switch the drive between two motors without having to adjust the motor parameters and to repeat the motor identification every time the motor is changed. The user needs only to adjust the settings and perform the motor identification once for both motors and then to save the data as two user macros. When the motor is changed, only the corresponding User macro needs to be loaded, and the drive is ready to operate.

Application macros

Page 96

Application macros

Page 97

Actual signals and parameters

Chapter overview

The chapter describes the actual signals and parameters and gives the fieldbus equivalent values for each signal/parameter. More data is given in chapter Additional

data: actual signals and parameters.

Terms and abbreviations

Term Definition

Absolute Maximum Frequency

Absolute Maximum Speed

Actual signal Signal measured or calculated by the drive. Can be monitored by the

FbEq Fieldbus equivalent: The scaling between the value shown on the panel

Parameter A user-adjustable operation instruction of the drive.

Value of 20.08, or 20.07 if the absolute value of the minimum limit is greater than the maximum limit.

Value of parameter 20.02, or 20.01 if the absolute value of the minimum limit is higher than the maximum limit.

user. No user setting possible.

and the integer used in serial communication.

Actual signals and parameters

Page 98

No. Name/Value Description FbEq

01 ACTUAL SIGNALS

01.01 PROCESS VARIABLE Process variable based on settings in parameter group 34 PROCESS

01.02 SPEED Calculated motor speed in rpm. Filter time setting by parameter 34.04. -20000 =

01.03 FREQUENCY Calculated drive output frequency. -100 = -1 Hz

01.04 CURRENT Measured motor current. 10 = 1 A

01.05 TORQUE Calculated motor torque. 100 is the motor nominal torque. Filter time

01.06 POWER Motor power. 100 is the nominal power. -1000 =

01.07 DC BUS VOLTAGE V Measured intermediate circuit voltage. 1 = 1 V

01.08 MAINS VOLTAGE Calculated supply voltage. 1 = 1 V

01.09 OUTPUT VOLTAGE Calculated motor voltage. 1 = 1 V

01.10 ACS800 TEMP Calculated IGBT temperature. 10 = 1%

01.11 EXTERNAL REF 1 External reference REF1 in rpm. (Hz if value of parameter 99.04 is

01.12 EXTERNAL REF 2 External reference REF2. Depending on the use, 100% is the motor

01.13 CTRL LOCATION Active control location. (1,2) LOCAL; (3) EXT1; (4) EXT2. See section

01.14 OP HOUR COUNTER Elapsed time counter. Runs when the control board is powered. 1 = 1 h

01.15 KILOWATT HOURS kWh counter. Counts inverter output kWh during operation (motor side -

01.16 APPL BLOCK OUTPUT Application block output signal. E.g. the process PID controller output

01.17 DI6-1 STATUS Status of digital inputs. The first digit reflects the Start Interlock input, and

01.18 AI1 [V] Value of analogue input AI1. 1 = 0.001 V

01.19 AI2 [mA] Value of analogue input AI2. 1 = 0.001 mA

01.20 AI3 [mA] Value of analogue input AI3. 1 = 0.001 mA

01.21 RO3-1 STATUS Status of relay outputs. Example: 001 = RO1 is energised, RO2 and

01.22 AO1 [mA] Value of analogue output AO1. 1 =0.001 mA

Basic signals for monitoring of the drive.

VAR IABLE .

setting by parameter 34.05.

SCALAR.)

maximum speed, motor nominal torque, or maximum process reference.

Local control vs. external control on page 43.

generator side).

when the PID Control macro is active.

is followed by digital inputs from DI6 to DI1. Example: 0000001 = Start Interlock off, DI6 to DI2 off, DI1 on.

RO3 are de-energised.

1 = 1

-100% 20000 = 100% of motor abs. max. speed

100 = 1 Hz

-10000 =

-100% 10000 = 100% of motor nom. torque

-100% 1000 = 100% of motor nom. power

1 = 1 rpm

0 = 0% 10000 = 100% 1)

See descr.

1 = 100 kWh

0 = 0% 10000 = 100%

Actual signals and parameters

Page 99

No. Name/Value Description FbEq

01.23 AO2 [mA] Value of analogue output AO2. 1 = 0.001 mA

01.24 ACTUAL VALUE 1 Feedback signal for the process PID controller. Updated only when parameter 99.02 = PD CTRL

01.25 ACTUAL VALUE 2 Feedback signal for the process PID controller. Updated only when parameter 99.02 = PID CTRL.

01.26 CONTROL DEVIATION Deviation of the process PID controller, i.e. the difference between the reference value and the actual value. Updated only when parameter

99.02 = PID CTRL.

01.27 APPLICATION MACRO Active application macro (value of parameter 99.02). See 99.02

01.28 EXT AO1 [mA] Value of output 1 of the analogue I/O extension module (optional). 1 = 0.001 mA

01.29 EXT AO2 [mA] Value of output 2 of the analogue I/O extension module (optional). 1 = 0.001 mA

01.30 PP 1 TEMP Measured heatsink temperature in inverter no. 1. 1 = 1°C

01.31 PP 2 TEMP Measured heatsink temperature in inverter no. 2 (used only in high power units with parallel inverters).

01.32 PP 3 TEMP Measured heatsink temperature in inverter no. 3 (used only in high power units with parallel inverters).

01.33 PP 4 TEMP Measured heatsink temperature in inverter no. 4 (used only in high power units with parallel inverters).

01.34 ACTUAL VALUE Process PID controller actual value. See parameter 40.06.0 = 0%

01.35 MOTOR 1 TEMP Measured temperature of motor 1. See parameter 35.01. 1 = 1°C/ohm

01.36 MOTOR 2 TEMP Measured temperature of motor 2. See parameter 35.04. 1 = 1°C/ohm

01.37 MOTOR TEMP EST Estimated motor temperature. Signal value is saved at power switch off. 1 = 1°C

01.38 AI5 [mA] Value of analogue input AI5 read from AI1 of the analogue I/O extension module (optional). A voltage signal is also displayed in mA (instead of V).

01.39 AI6 [mA] Value of analogue input AI6 read from AI2 of the analogue I/O extension module (optional).

01.40 DI7-12 STATUS Status of digital inputs DI7 to DI12 read from the digital I/O extension modules (optional). E.g. value 000001: DI7 is on, DI8 to DI12 are off.

01.41 EXT RO STATUS Status of the relay outputs on the digital I/O extension modules (optional). E.g. value 0000001: RO1 of module 1 is energised. Other relay outputs are de-energised.

01.42 PROCESS SPEED REL Motor actual speed in percent of the Absolute Maximum Speed. If parameter 99.04 is SCALAR, the value is the relative actual output frequency.

01.43 MOTOR RUN TIME Motor run time counter. The counter runs when the inverter modulates. Can be reset by parameter 34.06.

01.44 FAN ON-TIME Running time of the drive cooling fan.

Note: Resetting of the counter is recommended when the fan is replaced. For more information, contact your local ABB representative.

01.45 CTRL BOARD TEMP Control board temperature. 1 = 1°C

01.46 SAVED KWH Energy saved in kWh compared to direct-on-line motor connection.

See parameter group 45 ENERGY OPT on page 161.

01.47 SAVED GWH Energy saved in GWh compared to direct-on-line motor connection. 1 = 1 GWh

A voltage signal is also displayed in mA (instead of V).

0 = 0% 10000 = 100%

-10000 =

-100% 10000 = 100%

1 = 1°C

10000 = 100%

1 = 0.001 mA

1 = 1

1 = 10 h

1 = 100 kWh

Actual signals and parameters

Page 100

100

No. Name/Value Description FbEq

01.48 SAVED AMOUNT Monetary savings compared to direct-on-line motor connection. This value is a multiplication of parameters 01.46 SAVED KWH and 45.02 ENERGY TARIFF1.

See parameter group 45 ENERGY OPT on page 161.

01.49 SAVED AMOUNT M Monetary savings in millions compared to direct-on-line motor connection.

01.50 SAVED CO2 Reduction in CO motor connection. This value is calculated by multiplying saved energy in megawatt-hours by 500 kg/MWh.

See parameter group 45 ENERGY OPT on page 161.

01.51 SAVED CO2 KTON Reduction in CO connection.

02 ACTUAL SIGNALS

02.01 SPEED REF 2 Limited speed reference. 100% corresponds to the Absolute Maximum

02.02 SPEED REF 3 Ramped and shaped speed reference. 100% corresponds to the

02.09 TORQUE REF 2 Speed controller output. 100% corresponds to the motor nominal torque. 0 = 0% 10000

02.10 TORQUE REF 3 Torque reference. 100% corresponds to the motor nominal torque. 10000 = 100%

02.13 TORQ USED REF Torque reference after frequency, voltage and torque limiters. 100%

02.14 FLUX REF Flux reference in percent. 10000 = 100%

02.17 SPEED ESTIMATED Estimated motor speed. 100% corresponds to the Absolute Maximum

02.18 SPEED MEASURED Measured motor actual speed (zero when no encoder is used). 100%

02.19 MOTOR ACCELERATIO Calculated motor acceleration from signal 01.02 MOTOR SPEED. 1=1 rpm/s.

02.20 USER CURRENT Measured motor current in percent of the user load curve current. User

03 ACTUAL SIGNALS

03.01 MAIN CTRL WORD A 16-bit data word. See section 03.01 MAIN CONTROL WORD on page

03.02 MAIN STATUS WORD A 16-bit data word. See section 03.02 MAIN STATUS WORD on page

03.03 AUX STATUS WORD A 16-bit data word. See section 03.03 AUXILIARY STATUS WORD on

03.04 LIMIT WORD 1 A 16-bit data word. See section 03.04 LIMIT WORD 1 on page 216.

03.05 FAULT WORD 1 A 16-bit data word. See section 03.05 FAULT WORD 1 on page 216.

03.06 FAULT WORD 2 A 16-bit data word. See section 03.06 FAULT WORD 2 on page 217.

Speed and torque reference monitoring signals.

Speed of the motor.

Absolute Maximum Speed of the motor.

corresponds to the motor nominal torque.

Speed of the motor.

corresponds to the Absolute Maximum Speed of the motor.

load curve current is defined by parameters 72.02...72.09. See section

User load curve on page 81.

Data words for monitoring of fieldbus communication (each signal is a 16bit data word).

207.

208.

page 215.

emissions in kilograms compared to direct-on-line

emissions in kilotons compared to direct-on-line motor

1 = 100 cur

1 = 1 Mcur

1 = 100 kg

1 = 1 kton

0 = 0% 20000 = 100% of motor absolute max. speed

20000 = 100%

= 100% of motor nominal torque

10000 = 100%

20000 = 100%

10 = 1%

Actual signals and parameters

ABB ACS800 Firmware Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Table of contents

Introduction to the manual

Chapter overview

Compatibility

Safety instructions

Reader

Contents

Product and service inquiries

Product training

Providing feedback on ABB Drives manuals

Start-up and control through the I/O

Chapter overview

How to start-up the drive

How to perform the guided start-up (covers all essential settings)

How to perform the limited start-up (covers only the basic settings)

How to control the drive through the I/O interface

How to perform the ID Run

ID Run Procedure

Control panel

Chapter overview

Overview of the panel

Status row

Panel operation mode keys and displays

Drive control with the panel

How to start, stop and change direction

How to set speed reference

Actual signal display mode

How to select actual signals to the display

How to display the full name of the actual signals

How to view and reset the fault history

How to display and reset an active fault

About the fault history

Parameter mode

How to select a parameter and change the value

How to adjust a source selection (pointer) parameter

Function mode

How to enter an assistant, browse and exit

How to upload data from a drive to the panel

How to download data from the panel to a drive

How to set the contrast of the display

Drive selection mode

How to select a drive and change its panel link ID number

Reading and entering packed boolean values on the display

Program features

Chapter overview

Start-up Assistant

Introduction

The default order of the tasks

List of tasks and the relevant drive parameters

Contents of the assistant displays

Local control vs. external control

Local control

External control

Settings

Diagnostics

Block diagram: start, stop, direction source for EXT1

Block diagram: reference source for EXT1

Reference types and processing

Settings

Diagnostics

Reference trimming

Settings

Example

Programmable analogue inputs

Update cycles in the Standard Control Program

Settings

Diagnostics

Programmable analogue outputs

Update cycles in the Standard Control Program

Settings

Diagnostics

Programmable digital inputs

Update cycles in the Standard Control Program

Settings

Diagnostics

Programmable relay outputs