ABB ACS880-M04 Firmware Manual

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Page 1

ABB industrial drives

Firmware manual

ACS880-M04 machinery control program

Page 2

List of related manuals

Drive hardware manuals Code (English)

ACS880-M04 drives hardware manual 3AXD50000028613 *ACS880-01 drives hardware manual 3AUA0000078093 *ACS880-04 drive modules (200 to 710 kW, 300 to 700 hp)

hardware manual

Drive firmware manuals and guides

Adaptive programming application guide 3AXD50000028574 Drive (IEC 61131-3) application programming manual 3AUA0000127808

Option manuals and guides

ACS880-M04 Quick installation guide 3AXD50000032345 ACX-AP-x Assistant control panels user’s manual 3AUA0000085685 ACS-BP-S Basic control panels user’s manual 3AXD50000032527 Drive composer Start-up and maintenance PC tool User’s

manual Manuals and quick guides for I/O extension modules,

fieldbus adapters, encoder interfaces, etc.

3AUA0000128301

3AUA0000094606

You can find manuals and other product documents in PDF format on the Internet. See section

Document library on the Internet on the inside of the back cover. For manuals not available in the

Document library, contact your local ABB representative. *A list of links to all manuals applicable to this product is available in the Document library:

Page 3

Firmware manual

ACS880-M04 machinery control program

Table of contents

3AXD50000030629 Rev A

EFFECTIVE: 2016-04-11

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Table of contents 5

Table of contents

List of related manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1. Introduction to the manual

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

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

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

Target audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

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

Related documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

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

2. Using the control panel

Safety

3. Start-up

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Before you start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

4. Control locations and operating modes

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Local control vs. external control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Local control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

External control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Operating modes of the drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Speed control mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Torque control mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Frequency control mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Special control modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

5. Program features

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Drive configuration and programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Programming via parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Adaptive programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Application programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Control interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Programmable analog inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Programmable analog outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Programmable digital inputs and outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Programmable relay outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Programmable I/O extensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Fieldbus control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

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6 Table of contents

Master/follower functionality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

External controller interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Motor control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Direct torque control (DTC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Reference ramping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Constant speeds/frequencies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Critical speeds/frequencies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Speed controller autotune . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Oscillation damping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Rush control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Encoder support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Position counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Jogging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Scalar motor control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Autophasing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Flux braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

DC magnetization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Application control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Application macros . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Motor potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

DC voltage control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Overvoltage control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Undervoltage control (power loss ride-through) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Voltage control and trip limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Brake chopper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Safety and protections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Emergency stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Motor thermal protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Thermal protection of motor cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Other programmable protection functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Automatic fault resets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Fault and warning messages, data logging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Signal supervision . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Maintenance timers and counters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Energy saving calculators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

Load analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

User parameter sets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

Data storage parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

du/dt filter support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

6. Application macros

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

Factory macro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

Default parameter settings for the Factory macro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

Default control connections for the Factory macro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

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Table of contents 7

7. Parameters

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

Terms and abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

Summary of parameter groups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

Parameter listing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

01 Actual values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

03 Input references . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

04 Warnings and faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

05 Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

06 Control and status words . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

07 System info . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

10 Standard DI, RO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

11 Standard DIO, FI, FO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

12 Standard AI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

13 Standard AO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

14 I/O extension module 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147

15 I/O extension module 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169

19 Operation mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173

20 Start/stop/direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176

21 Start/stop mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188

22 Speed reference selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198

23 Speed reference ramp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209

24 Speed reference conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217

25 Speed control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220

26 Torque reference chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234

28 Frequency reference chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243

30 Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255

31 Fault functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263

32 Supervision . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276

33 Generic timer & counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280

35 Motor thermal protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290

36 Load analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304

43 Brake chopper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308

44 Mechanical brake control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310

45 Energy efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316

46 Monitoring/scaling settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320

47 Data storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 324

49 Panel port communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327

50 Fieldbus adapter (FBA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330

51 FBA A settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341

52 FBA A data in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 342

53 FBA A data out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343

54 FBA B settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344

55 FBA B data in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345

56 FBA B data out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346

58 Embedded fieldbus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346

60 DDCS communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 357

61 D2D and DDCS transmit data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 366

62 D2D and DDCS receive data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 370

90 Feedback selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 379

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91 Encoder module settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 391

92 Encoder 1 configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 395

93 Encoder 2 configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403

95 HW configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406

96 System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410

97 Motor control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419

98 User motor parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 423

99 Motor data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 425

200 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 433

8. Additional parameter data

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 435

Terms and abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 435

Fieldbus addresses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 436

Parameter groups 1…9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 437

Parameter groups 10…99 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 442

9. Fault tracing

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 479

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 479

Indications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 479

Warnings and faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 479

Pure events . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 480

Editable messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 480

Warning/fault history and analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 480

Event logs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 480

Other data loggers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 481

Parameters that contain warning/fault information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 481

QR Code generation for mobile service application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 482

Warning messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 483

Fault messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 503

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

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 527

System overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 527

Connecting the fieldbus to the drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 528

Setting up the embedded fieldbus interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 529

Setting the drive control parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 530

Basics of the embedded fieldbus interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 533

Control word and Status word . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 534

References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 534

Actual values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 534

Data input/outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 534

Register addressing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 535

About the control profiles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 536

The ABB Drives profile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 537

Control Word . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 537

Status Word . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 539

Page 9

Table of contents 9

State transition diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 540

References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 541

Actual values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 542

Modbus holding register addresses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 543

The Transparent profile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 544

Modbus function codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 545

Exception codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 546

Coils (0xxxx reference set) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 547

Discrete inputs (1xxxx reference set) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 548

Error code registers (holding registers 400090…400100) . . . . . . . . . . . . . . . . . . . . . . . . . . . 550

11. Fieldbus control through a fieldbus adapter

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 551

System overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 551

Basics of the fieldbus control interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 554

Control word and Status word . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 555

References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 556

Actual values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 557

Contents of the fieldbus Control word . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 558

Contents of the fieldbus Status word . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 559

The state diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 560

Setting up the drive for fieldbus control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 561

Parameter setting example: FPBA (PROFIBUS DP) . . . . . . . . . . . . . . . . . . . . . . . . . . . 562

12. Control chain diagrams

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 565

Speed reference source selection I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 566

Speed reference source selection II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 567

Speed reference ramping and shaping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 568

Motor feedback configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 569

Load feedback and position counter configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 570

Speed error calculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 571

Speed controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 572

Torque reference source selection and modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 573

Operating mode selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 574

Reference selection for torque controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 575

Torque limitation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 576

Torque controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 577

Frequency reference selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 578

Frequency reference modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 579

Master/Follower communication I (Master) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 580

Master/Follower communication II (Follower) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 581

Further information

Product and service inquiries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 583

Product training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 583

Providing feedback on ABB Drives manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 583

Document library on the Internet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 583

Page 10

10 Table of contents

Page 11

Introduction to the manual 11

Introduction to the manual

What this chapter contains

This chapter describes the contents of the manual. It also contains information on the compatibility, safety and intended audience.

Applicability

This manual applies to ACS880-M04 machinery control program version 2.4x.

The firmware version of the control program is visible in parameter 07.05 Firmware

version, or the System info in the main menu on the drive control panel.

Safety instructions

Obey 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 delivered with the drive as part of the Hardware manual as a separate document.

• Read the firmware function-specific warnings and notes before changing parameter values. These warnings and notes are included in the parameter descriptions presented in chapter Parameters.

Target audience

This manual is intended for people who design, commission, or operate the drive system.

Page 12

12 Introduction to the manual

Contents of the manual

This manual contains the following chapters:

• Using the control panel provides basic instructions for the use of the control panel.

• Control locations and operating modes describes the control locations and operating modes of the drive.

• Program features contains descriptions of the features of the ACS880-M04 primary control program.

• Application macros contains a short description of each macro together with a connection diagram. Macros are pre-defined applications which will save the user time when configuring the drive.

• Parameters describes the parameters used to program the drive.

• Additional parameter data contains further information on the parameters.

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

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

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

• Control chain diagrams showing the parameter structure within the drive.

Using the control panel

Refer to

• ACX-AP-x assistant control panels user’s manual (3AUA0000085685 [English]) and

• ACS-BP-S assistant control panels user’s manual (3AXD50000032527 [English]).

Page 16

16 Using the control panel

Page 17

Start-up

Start-up 17

Contents of this chapter

This chapter describes the basic start-up sequence of an ACS880-M04 machinery drive.

In this guide, the drive is set up using the ACS-AP-I control panel. The start-up sequence can also be carried out using the Drive composer PC tool.

Before you start

Make sure the drive is mechanically and electrically installed as described in the Quick installation guide and/or Hardware manual.

Safety

WARNING! Follow all safety instructions of the drive. Only qualified electricians are

allowed to start up the drive. Never work on the drive, the brake chopper circuit, the motor cable or the motor when power is applied to the drive. Always make sure by measuring that no voltage is actually present.

WARNING! Make sure that the machinery into which the drive with brake

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

Page 18

18 Start-up

Remote 0.0 rpm

0.00

Motor torque %

0.0

Motor current A

Motor speed used rpm

Options

12:34

ACS880

Remote 0.0 rpm

Parameters

Assistants

Energy efficiency

Event log

Exit

12:34

Select

Start-up

Safety

WARNING! Obey all safety instructions for the drive. Only qualified electricians are

allowed to start up the drive.

Check the installation. See the installation checklist in the Hardware 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 an incorrect direction of rotation, or

•a Normal ID run is required during the drive start-up, when the load torque is higher

than 20% or the machinery is not able to withstand the nominal torque transient during the ID run.

1 – Power-up, date and time settings

Power up the drive. Note: It is normal that warning messages

appear at various points along the start-up process. To hide a message and to resume the start-up process, press .

Hide any warnings now to enter the Home view (shown on the right).

The two commands at the bottom of the display (in this case, Options and Menu), show the functions of the two softkeys and located below the display. The commands assigned to the softkeys vary depending on the context.

In the Home view, press (Menu). The main Menu (right) appears.

Page 19

Highlight Settings on the menu using

Remote 0.0 rpm

Settings

Language

Date & time

Back

12:34

Select

Edit texts Display settings

ACS880

Reset to defaults

Next daylight saving start 28.03.

Remote 0.0 rpm

Date & time

Date

Back

12:35

Edit

Time Show date as

01.01.1980

12:34:56

day.month.year Show time as 24-hour Daylight saving EU

Remote 0.0 rpm

Date

Cancel

12:35

Save

Day Month Year

Tuesday

.01.198001

and and press (Select).

In the Settings menu, highlight Date & time (if not already highlighted) and press (Select).

Start-up 19

In the Date & time menu, highlight Date (if not already highlighted) and press (Select).

Page 20

20 Start-up

Remote 0.0 rpm

0.00

Motor torque %

0.0

Motor current A

Motor speed used rpm

Options

12:34

ACS880

Loc/Rem

Local 0.0 rpm

0.00

Motor torque %

0.0

Motor current A

Motor speed used rpm

Options

12:36

Local 0.0 rpm

Parameters

Assistants

Energy efficiency

Event log

Exit

12:36

Select

Set the correct date:

• Use and to move the cursor left and right.

• Use and to change the value.

•Press (Save) to accept the new setting.

Check/adjust all the remaining settings in the Date & time menu.

The Show clock setting determines whether the time is shown at all times in the bottom pane of the display.

After you have made the settings, press

(Back or Exit) repeatedly until the

Home view (right) reappears.

2 – Supply voltage and motor data settings

Switch to local control to ensure that external control is disabled by pressing the key. Local control is indicated by the text “Local” in the top pane.

Open the main Menu by pressing (Menu).

Page 21

Highlight Parameters and press

Local 0.0 rpm

Parameters

Complete list

By function

Back

12:36

Select

Favorites Modified

ACS880

Local 0.0 rpm

Complete list

01 Actual values

03 Input references 04 Warnings and faults 05 Diagnostics 06 Control and status words 07 System info

Back

12:36

Select

Local 0.0 rpm

95 HW configuration

95.01 Supply voltage

Back

12:36

Edit

95.08 DC switch monitoring

Not given

Internal 24 V

Disable

95.15 Special HW settings 0000

95.20 HW option wor... ...0 0000 0000

ACS880

95.04 Control board supply

Local 0.0 rpm

95.01 Supply voltage

[0] Not given

[1] 208…240 V

Cancel

12:36

Save

[2] 380…415 V [3] 440…480 V [4] 500 V

(Select).

Highlight Complete list using and and press (Select).

A listing of parameter groups is displayed.

Start-up 21

Highlight parameter group 95 HW

configuration and press (Select).

Note that the list wraps around in either direction between groups 99 and 01. In this case, it is quicker to use to locate group 95 on the list.

After selecting a group, a listing of parameters within the group is displayed.

Highlight parameter 95.01 Supply voltage (if not already highlighted) and press (Edit).

The available parameter settings are listed.

Page 22

22 Start-up

Local 0.0 rpm

95 HW configuration

95.01 Supply voltage

Back

12:36

Edit

95.08 DC switch monitoring

380...415 V

Internal 24 V

Disable

95.15 Special HW settings 0000

95.20 HW option wor... ...0 0000 0000

ACS880

95.04 Control board supply

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

3 ~ motor M2BJ 280SMB 10 B3

No 3424522

BB Motors

Ins.cl. F IP 55

400 DHz50kW55

r/min

600

103

cos

0.97

IA/IN

E/s

Prod. code 2GBJ285220-ADA405445477

6316/C3

630kg

IEC 34-1

S1 SPEC INSUL.

JK-21640-1

Highlight the correct setting on the list and press (Save).

Press (Back) to display the list of parameter groups again. Select parameter group

99 Motor data, and set parameter 99.03 Motor type.

Set parameter 99.04 Motor control mode.

DTC = Direct torque control; Scalar

DTC is suitable for most cases. Scalar mode is recommended if

• the nominal current of the motor is less than 1/6 of the nominal current of the drive,

• the drive is used for test purposes with no motor connected, or

• the drive controls multiple motors and the number of motors connected is variable.

Refer to the motor nameplate for the following parameter settings. Whenever possible, enter the values exactly

as shown on the motor nameplate.

Example of a nameplate of an induction (asynchronous) motor:

99.06 Motor nominal current

The allowable range is

• in DTC mode: 1/6 × I

• in Scalar mode: 0 … 2 × I Note: With numerical parameter values:

• Use and to change the value of a digit.

• Use and to move the cursor left and right.

•Press (Save) to enter the value.

… 2 × IHd of the drive

Example of a nameplate of a permanent magnet motor:

Page 23

Make the following parameter settings in the same manner.

99.07 Motor nominal voltage

Start-up 23

The allowable range is 1/6 × U

… 2 × UN of the drive.

With permanent magnet motors, the nominal voltage is the BackEMF voltage at nominal speed. If the voltage is given in volt/rpm (eg. 60 V per 1000 rpm), the voltage at a nominal speed of 3000 rpm is 3 × 60 V = 180 V. Note that nominal voltage is not the same as equivalent DC motor voltage (EDCM) given by some manufacturers. The nominal voltage can be calculated by dividing the EDCM voltage by 1.7 (or square root of 3).

99.08 Motor nominal frequency

With permanent magnet motors, if the nominal frequency is not shown on the nameplate, it can be calculated using the following formula:

f = n × p / 60 where n = nominal motor speed, p = number of pole pairs.

99.09 Motor nominal speed

99.10 Motor nominal power

99.11 Motor nominal cos Φ

99.12 Motor nominal torque

These values are not required, but can be entered to improve control accuracy. If you do not know the correct values, leave the parameters at 0. DO NOT enter estimated values.

99.13 ID run requested

This parameter selects the mode of the identification run (DTC motor control mode only).

Note: The drive must be in local control for the identification run.

WARNING! The identification run modes marked thus * will run the motor in the

forward direction (see below for details). Make sure it is safe to run the motor

before choosing any of these modes. *Normal mode should be selected whenever possible.. The driven machinery must be de-

coupled from the motor if

• the load torque is higher than 20%, or

• the machinery is not able to withstand the nominal torque transient during the identification run.

*Reduced mode should be selected if the mechanical losses are higher than 20%, ie. the load cannot be de-coupled, or full flux is required to keep the motor brake open (eg. with conical motors).

The Standstill mode should be selected if neither the *Normal or *Reduced mode can be used. Notes:

• This mode cannot be used with a permanent magnet motor if the load torque is higher than 20% of nominal.

• Mechanical brake is not opened by the logic for the identification run.

Ensure that the Safe torque off and emergency stop circuits (if present) are closed.

Start the identification run by pressing the

(Start) button.

A warning will indicate that the identification run is in progress.

Page 24

24 Start-up

Check that the motor runs in the correct direction (forward direction shown below).

The identification run has completed when the drive stops and the value of parameter

99.13 reverts to None.

If the motor ran in the wrong direction, correct the motor cabling or adjust parameter

99.16 Motor phase order.

Page 25

Control locations and operating modes 25

Control locations and operating modes

What this chapter contains

This chapter describes the control locations and operating modes supported by the control program.

Page 26

26 Control locations and operating modes

Control panel or Drive

composer PC tool (optional)

Fieldbus adapter (Fxxx)

1) Extra inputs/outputs can be added by installing optional I/O extension modules (FIO-xx) in drive slots.

2) Encoder or resolver interface module(s) (FEN-xx) installed in drive slots.

MOTOR

PLC

I/O

Embedded fieldbus interface (EFB) or master/follower link

External control

Local control

Encoder

ACS880-M04

Control panel

Local control vs. external control

The ACS880-M04 has two main control locations: external and local. The control location is selected with the Loc/Rem key on the control panel or in the PC tool.

 Local control

The control commands are given from the control panel keypad or from a PC equipped with Drive composer when the drive is set to local control. Speed and torque control modes are available for local control; frequency mode is available when scalar motor control mode is used (see parameter 19.16 Local control mode).

Local control is mainly used during commissioning and maintenance. The control panel always overrides the external control signal sources when used in local control. Changing the control location to local can be prevented by parameter 19.17 Local

control disable.

The user can select by a parameter (49.05 Communication loss action) how the drive reacts to a control panel or PC tool communication break. (The parameter has no effect in external control.)

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Control locations and operating modes 27

 External control

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

• the I/O terminals (digital and analog inputs), or optional I/O extension modules

• the embedded fieldbus interface or an optional fieldbus adapter module

• the master/follower link, and/or

• the control panel.

Two external control locations, EXT1 and EXT2, are available. The user can select the sources of the start and stop commands separately for each location by parameters 20.01…20.10. The operating mode can be selected separately for each location (in parameter group 19 Operation mode), which enables quick switching between different operating modes, for example speed and torque control. Selection between EXT1 and EXT2 is done via any binary source such as a digital input or fieldbus control word (see parameter 19.11 Ext1/Ext2 selection). The source of reference is selectable for each operating mode separately.

Using the control panel as an external control source

The control panel can also be used as a source of start/stop commands and/or reference in external control. Selections for the control panel are available in the start/stop command source and reference source selection parameters.

Reference source selection parameters have two selections for the control panel. The difference between the two selections is in the initial reference value after the reference source switches to the control panel.

The panel reference is saved whenever another reference source is selected. If the reference source selection parameter is set to Control panel (ref saved), the saved value is used as the initial reference when control switches back to the panel. Note that only one type of reference can be saved at a time: for example, attempting to use the same saved reference with different operating modes (speed, torque, etc.) causes the drive to trip on 7083 Panel reference conflict. The panel reference can be separately limited by parameters in group 49 Panel port communication.

With the reference source selection parameter set to Control panel (ref copied), the initial panel reference value depends on whether the operating mode changes with the reference source. If the source switches to the panel and the operating mode does not change, the last reference from the previous source is adopted. If the operating mode changes, the drive actual value corresponding to the new mode is adopted as the initial value.

Page 28

28 Control locations and operating modes

Motor feedback

configuration

(p 569)

Speed

reference

source selection

(p 566)

Speed controller

(p 572)

Speed reference

source selection

(p 567)

Speed reference

ramping and

shaping

(p 568)

Speed error

calculation

(p 571)

Torque

reference

source selection and modification

(p 573)

Reference

selection for

torque controller

(p 575)

Frequency

reference

source selection and modification

(p 578)

Operating mode

selection

(p 574)

Torque

controller

(p 577)

DTC motor

control mode

Scalar motor control mode

Torque limitation

(p 576)

Frequency

reference

modification

(p 579)

Load feedback

and position

counter

configuration

(p 570)

Operating modes of the drive

The drive can operate in several operating modes with different types of reference. The mode is selectable for each control location (Local, EXT1 and EXT2) in parameter group 19 Operation mode.

The following is a general representation of the reference types and control chains. The page numbers refer to detailed diagrams in chapter Control chain diagrams.

Page 29

Control locations and operating modes 29

 Speed control mode

The motor follows a speed reference given to the drive. This mode can be used either with estimated speed as feedback, or with an encoder or resolver for better speed control accuracy.

Speed control mode is available in both local and external control. It is also available both in DTC (Direct Torque Control) and scalar motor control modes.

 Torque control mode

Motor torque follows a torque reference given to the drive. Torque control is possible without feedback, but is much more dynamic and accurate when used in conjunction with a feedback device such as an encoder or a resolver. It is recommended that a feedback device is used in crane, winch or lift control situations.

Torque control mode is available in DTC motor control mode for both local and external control locations.

 Frequency control mode

The motor follows a frequency reference given to the drive. Frequency control is only available in scalar motor control mode.

 Special control modes

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

• Emergency stop modes Off1 and Off3: Drive stops along the defined deceleration ramp and drive modulation stops.

• Jogging mode: Drive starts and accelerates to the defined speed when the jogging signal is activated. For more information, see section Jogging (page 57).

Page 30

30 Control locations and operating modes

Page 31

Program features

Program features 31

What this chapter contains

The control program contains all of the parameters (including actual signals) within the drive. This chapter describes some of the more important functions within the control program, how to use them and how to program them to operate.

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32 Program features

Application program

Firmware

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

Standard

block library

Function block

program

Drive control program

Parameter

interface

Drive configuration and programming

The drive control program is divided into two parts:

• firmware program

• application program.

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

 Programming via parameters

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

• the control panel, as described in chapter Using the control panel

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

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

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

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

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

been made.

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

Parameter restore.

Page 33

Program features 33

 Adaptive programming

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

The Drive composer pro PC tool (version 1.9 or later, available separately) has an Adaptive programming feature with a graphical user interface for building the custom program. The function blocks include the usual arithmetic and logical functions, as well as eg. selection, comparison and timer blocks. The program can contain approximately 20 blocks depending on block size and the number of inputs and outputs used.

The physical inputs, drive status information, actual values, constants and data storage parameters can be used as the input for the program. The output of the program can be used eg. as a start signal, external event or reference, or connected to the drive outputs. See below for a listing of the available inputs and outputs. Note that connecting the output of the adaptive program to a selection parameter will writeprotect the parameter.

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

status.

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

Inputs available to the adaptive program

Input Source I/O

DI1 10.02 DI delayed status, bit 0 DI2 10.02 DI delayed status, bit 1 DI3 10.02 DI delayed status, bit 2 DI4 10.02 DI delayed status, bit 3 DI5 10.02 DI delayed status, bit 4 DI6 10.02 DI delayed status, bit 5 DIIL 10.02 DI delayed status, bit 15 AI1 12.11 AI1 actual value AI2 12.21 AI2 actual value DIO1 11. 0 2 DIO delayed status, bit 0 DIO2 11. 0 2 DIO delayed status, bit 1

Actual signals

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

Status

Enabled 06.16 Drive status word 1, bit 0 Inhibited 06.16 Drive status word 1, bit 1 Ready to start 06.16 Drive status word 1, bit 3

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34 Program features

Inputs available to the adaptive program

Input Source

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

Data storage

Data storage 1 real32 47.01 Data storage 1 real32 Data storage 2 real32 47.02 Data storage 2 real32 Data storage 3 real32 47.03 Data storage 3 real32 Data storage 4 real32 47.04 Data storage 4 real32 Data storage 5 real32 47.05 Data storage 5 real32 Data storage 6 real32 47.06 Data storage 6 real32 Data storage 7 real32 47.07 Data storage 7 real32 Data storage 8 real32 47.08 Data storage 8 real32

Outputs available to the adaptive program

Output Target I/O

RO1 10.24 RO1 source RO2 10.27 RO2 source RO3 10.30 RO3 source AO1 13.12 AO1 source AO2 13.22 AO2 source DIO1 11.06 DIO1 output source DIO2 11.10 DIO2 output source

Start control

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

Speed control

Ext1 speed reference 22.11 Speed ref1 source Ext2 speed reference 22.12 Speed ref2 source Speed additive 1 22.15 Speed additive 1 source

Frequency control

Ext1 frequency reference 28.11 Frequency ref1 source Ext2 frequency reference 28.12 Frequency ref2 source

Torque control

Ext1 torque reference 26.11 Torque ref1 source Ext2 torque reference 26.12 Torque ref2 source Torque additive 2 26.25 Torque additive 2 source

Limit function

Minimum torque 2 30.21 Minimum torque 2 source Maximum torque 2 30.22 Maximum torque 2 source

20.04 Ext1 in2 source

Page 35

Program features 35

Outputs available to the adaptive program

Output Target Events

External event 1 31.01 External event 1 source External event 2 31.03 External event 2 source External event 3 31.05 External event 3 source External event 4 31.07 External event 4 source External event 5 31.09 External event 5 source

 Application programming

The functions of the firmware program can be extended with application programming. Application programmability is optionally available for the ACS880M04 primary control program.

Application programs can be built out of function blocks based on the IEC 61131-3 standard using a PC tool available separately.

For more information, see Programming manual: Drive application programming

(IEC 61131-3) (3AUA0000127808 [English]).

Page 36

36 Program features

Control interfaces

 Programmable analog inputs

The control unit has two programmable analog inputs. Each of the inputs can be independently set as a voltage (0/2…10 V or -10…10 V) or current (0/4…20 mA) input by a jumper or switch on the control unit. Each input can be filtered, inverted and scaled. The number of analog inputs can be increased by installing FIO-11 I/O extensions (see Programmable I/O extensions below).

The drive can be set to perform an action (for example, to generate a warning or fault) if the value of an analog input moves out of a predefined range.

Settings

Parameter group 12 Standard AI (page 136).

 Programmable analog outputs

The control unit has two current (0…20 mA) analog outputs. Each output can be filtered, inverted and scaled. The number of analog outputs can be increased by installing FIO-11 I/O extensions (see Programmable I/O extensions below).

Settings

Parameter group 13 Standard AO (page 141).

 Programmable digital inputs and outputs

The control unit has six digital inputs, a digital start interlock input, and two digital input/outputs (I/O that can be set as either an input or an output).

One digital input (DI6) doubles as a PTC thermistor input. See section Motor thermal

protection (page 73).

Digital input/output DIO1 can be used as a frequency input, DIO2 as a frequency output.

The number of digital inputs/outputs can be increased by installing FIO-01 or FIO-11 I/O extensions (see Programmable I/O extensions below).

Settings

Parameter groups 10 Standard DI, RO (page 122) and 11 Standard DIO, FI, FO (page 130).

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Program features 37

 Programmable relay outputs

The control unit has three relay outputs. The signal to be indicated by the outputs can be selected by parameters.

Relay outputs can be added by installing FIO-01 I/O extensions.

Settings

Parameter group 10 Standard DI, RO (page 122).

 Programmable I/O extensions

Inputs and outputs can be added by using I/O extension modules. One or two modules can be mounted on the slots of the control unit.

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

Digital

Location

Control unit 6 + DIIL2223

FIO-01 - 4 - - 2

FIO-11 -231 -

inputs

(DI)

Digital I/Os

(DIO)

Analog

inputs

(AI)

Analog

outputs

(AO)

Relay

outputs

(RO)

Two I/O extension modules can be activated and configured using parameter groups 14…15.

Note: Each configuration parameter group contains parameters that display the values of the inputs on that particular extension module. These parameters are the only way of utilizing the inputs on I/O extension modules as signal sources. To connect to an input, choose the setting Other in the source selector parameter, then specify the appropriate value parameter (and bit, for digital signals) in group 14 and

15.

Settings

Parameter groups 14 I/O extension module 1 (page 147) and 15 I/O extension

module 2 (page 169).

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38 Program features

 Fieldbus control

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

interface (EFB) (page 527) and Fieldbus control through a fieldbus adapter (page

551).

Settings

Parameter groups 50 Fieldbus adapter (FBA) (page 330), 51 FBA A settings (page

341), 52 FBA A data in (page 342), and 53 FBA A data out (page 343), 54 FBA B settings (page 344), 55 FBA B data in (page 345), 56 FBA B data out (page 346), and 58 Embedded fieldbus (page 346).

Page 39

Program features 39

(For example)

Control word

Speed reference

Torque reference

(For example)

Status word

01.01 Motor speed used

01.10 Motor torque

Master

Master/follower link

DDCS

Follower

DDCS

Fieldbus control

External control system (eg. PLC)

Process master

Process follower

Speed-controlled master

Torque- or speedcontrolled follower

 Master/follower functionality

General

The master/follower functionality can be used to link several drives together so that the load can be evenly distributed between the drives. This is ideal in applications where the motors are coupled to each other via gearing, chain, belt, etc.

The external control signals are typically connected to one drive only which acts as the master. The master controls up to 10 followers by sending broadcast messages over an electrical cable or fiber optic link. The master can read feedback signals from up to 3 selected followers.

Page 40

40 Program features

The master drive is typically speed-controlled and the other drives follow its torque or speed reference. In general, a follower should be

• torque-controlled when the motor shafts of the master and the follower are rigidly coupled by gearing, chain etc. so that no speed difference between the drives is possible

• speed-controlled when the motor shafts of the master and the follower are flexibly coupled so that a slight speed difference is possible. When both the master and the follower are speed-controlled, drooping is also typically used (see parameter

25.08 Drooping rate). The distribution of load between the master and follower

can alternatively be adjusted as described under Load share function with a

speed-controlled follower below.

Note: With a speed-controlled follower (without load sharing), pay attention to the acceleration and deceleration ramp times of the follower. If the ramp times are set longer than in the master, the follower will follow its own acceleration/deceleration ramp times rather than those from the master. In general, it is recommended to set identical ramp times in both the master and the follower(s). Any ramp shape settings (see parameters 23.16…23.19) should only be applied in the master.

In some applications, both speed control and torque control of the follower are required. In those cases, the operating mode can be switched by parameter (19.12

Ext1 control mode or 19.14 Ext2 control mode). Another method is to set one external

control location to speed control mode, the other to torque control mode. Then, a digital input of the follower can be used to switch between the control locations. See chapter Control locations and operating modes (page 25).

With torque control, follower parameter 26.15 Load share can be used to scale the incoming torque reference for optimal load sharing between the master and the follower. Some torque-controlled follower applications, eg. where the torque is very low, or very low speed operation is required, may require encoder feedback.

If a drive needs to quickly switch between master and follower statuses, one user parameter set (see page 82) can be saved with the master settings, another with the follower settings. The suitable settings can then be activated using eg. digital inputs.

Load share function with a speed-controlled follower

Load sharing between the master and a speed-controlled follower can be used in various applications. The load share function is implemented by fine-tuning the follower speed reference with an additional term based on a torque reference. The torque reference is selected by parameter 23.42 Follower speed corr torq source (by default, reference 2 received from the master). Load share is adjusted by parameter

26.15 Load share and activated by the source selected by 23.40 Follower speed correction enable. Parameter 23.41 Follower speed correction gain provides a gain

adjustment for the speed correction. The final correction term added to the speed reference is shown by 23.39 Follower speed correction out. See the block diagram on page 571.

Page 41

Program features 41

Notes:

• The function can be enabled only when the drive is a speed-controlled follower in remote control mode.

• Drooping (25.08 Drooping rate) is ignored when the load share function is active.

• The master and follower should have the same speed control tuning values.

• The speed correction term is limited by the speed error window parameters 24.44

Speed error window low and 24.43 Speed error window high. An active limitation

is indicated by 06.19 Speed control status word.

Communication

A master/follower link can be built by connecting the drives together with fiber optic cables (may require additional equipment depending on existing drive hardware), or by wiring together the XD2D connectors of the drives. The medium is selected by parameter 60.01 M/F communication port.

Parameter 60.03 M/F mode defines whether the drive is the master or a follower on the communication link. Typically, the speed-controlled process master drive is also configured as the master in the communication.

The communication on the master/follower link is based on the DDCS protocol, which employs data sets (specifically, data set 41). One data set contains three 16-bit words. The contents of the data set are freely configurable using parameters

61.01…61.03. The data set broadcast by the master typically contains the control

word, speed reference and torque reference, while the followers return a status word with two actual values.

The default setting of parameter 61.01 M/F data 1 selection is Follower CW. With this setting in the master, a word consisting of bits 0…11 of 06.01 Main control word and four bits selected by parameters 06.45…06.48 is broadcast to the followers. However, bit 3 of the follower control word is modified so that it remains on as long as the master is modulating, and its switching to 0 causes the follower to coast to a stop. This is to synchronize the stopping of both master and follower.

Note: When the master is ramping down to a stop, the follower observes the decreasing reference but receives no stop command until the master stops modulating and clears bit 3 of the follower control word. Because of this, the maximum and minimum speed limits on the follower drive should not have the same sign – otherwise the follower would be pushing against the limit until the master finally stops.

Three words of additional data can optionally be read from each follower. The followers from which data is read are selected by parameter 60.14 M/F follower

selection in the master. In each follower drive, the data to be sent is selected by

parameters 61.01…61.03. The data is transferred in integer format over the link, and displayed by parameters 62.28…62.36 in the master. The data can then be forwarded to other parameters using 62.04…62.12.

Page 42

42 Program features

Master/follower wiring with electrical cable

Master Termination ON

XD2D

BGND

Shield

BGND

Shield

BGND

Shield

Follower 1 Termination OFF

Follower n Termination ON

See the hardware manual of the drive for wiring and termination details.

To indicate faults in the followers, each follower must be configured to transmit its status word as one of the above-mentioned data words. In the master, the corresponding target parameter must be set to Follower SW. The action to be taken when a follower is faulted is selected by 60.17 Follower fault action. External events (see parameter group 31 Fault functions) can be used to indicate the status of other bits of the status word.

Block diagrams of the master/follower communication are presented on pages 580 and 581.

Construction of the master/follower link

The master/follower link is formed by connecting the drives together using shielded twisted-pair cable between the XD2D terminals of the drives.

Example parameter settings

The following is a checklist of parameters that need to be set when configuring the master/follower link. In this example, the master broadcasts the Follower control word, a speed reference and a torque reference. The follower returns a status word and two actual values (this is not compulsory but is shown for clarity).

Master settings

• Master/follower link activation

• 60.01 M/F communication port (XD2D selection)

•(60.02 M/F node address = 1)

• 60.03 M/F mode = D2D master

Page 43

Program features 43

• 60.05 M/F HW connection (Ring for fiber optic)

• Data to be broadcast to the followers

• 61.01 M/F data 1 selection = Follower CW (Follower control word)

• 61.02 M/F data 2 selection = Used speed reference

• 61.03 M/F data 3 selection = Torque reference act 5

• Data to be read from the followers (optional)

• 60.14 M/F follower selection (selection of followers that data is read from)

• 62.04 Follower node 2 data 1 sel … 62.12 Follower node 4 data 3 sel

(mapping of data received from followers)

Follower settings

• Master/follower link activation

• 60.01 M/F communication port (XD2D selection)

• 60.02 M/F node address = 2…60

• 60.03 M/F mode = D2D follower

• 60.05 M/F HW connection

• Mapping of data received from master

• 62.01 M/F data 1 selection = CW 16bit

• 62.02 M/F data 2 selection = Ref1 16bit

• 62.03 M/F data 3 selection = Ref2 16bit

• Selection of operating mode and control location

• 19.12 Ext1 control mode = Speed or Torq ue

• 20.01 Ext1 commands = M/F link

• 20.02 Ext1 start trigger type = Level

• Selection of reference sources

• 22.11 Speed ref1 source = M/F reference 1

• 26.11 Torque ref1 source = M/F reference 2

• Selection of data to be sent to master (optional)

• 61.01 M/F data 1 selection = SW 16bit

• 61.02 M/F data 2 selection = Act1 16bit

• 61.03 M/F data 3 selection = Act2 16bit

Settings and diagnostics

Parameter groups 60 DDCS communication (page 357), 61 D2D and DDCS transmit

data (page 366) and 62 D2D and DDCS receive data (page 370).

Page 44

44 Program features

3 3 . 1

3 2 . 1

3 2 . 2

3 3 . 3

3 2 . 3

3 3 . 2

1 9 . 0 1

1 2 3 4

2 4 . 0 3 4 3 0 0

. . .

Data set

Par.

Value

Parameter write to drive

Parameter read from drive

Transmit address Value = 4865*

Transmit data Value = 1234

Transmit address feedback Value = 4865*

Inquire address

Value = 6147** Inquired data Value = 4300 Inquire address feedback Value = 6147**

MASTER

FOLLOWER

*19.01 -> 13h.01h -> 1301h = 4865 **24.03 -> 18h.03h -> 1803h = 6147

 External controller interface

Communication

The communication between the master and the follower consists of data sets of three 16-bit words each. The master sends a data set to the follower, which returns the next data set to the master.

The communication uses data sets 10…33. The contents of the data sets are freely configurable, but data set 10 typically contains the control word and one or two references, while data set 11 returns the status word and selected actual values.

The word that is defined as the control word is internally connected to the drive logic; the coding of the bits is as presented in section Contents of the fieldbus Control word (page 558). Likewise, the coding of the status word is as shown in section Contents of

the fieldbus Status word (page 559).

By default, data sets 32 and 33 are dedicated for the mailbox service, which enables the setting or inquiry of parameter values as follows:

The update intervals of the data sets are as follows:

• Data sets 10…11: 2 ms

• Data sets 12…13: 4 ms

• Data sets 14…17: 10 ms

• Data sets 18…25, 32, 33: 100 ms.

Settings

Parameter groups 60 DDCS communication (page 357), 61 D2D and DDCS transmit

data (page 366) and 62 D2D and DDCS receive data (page 370).

Page 45

Program features 45

Motor control

 Direct torque control (DTC)

The motor control of the ACS880-M04 is based on direct torque control (DTC), the ABB premium motor control platform. The switching of the output semiconductors is controlled to achieve the required stator flux and motor torque. The switching frequency is changed only if the actual torque and stator flux values differ from their reference values by more than the allowed hysteresis. The reference value for the torque controller comes from the speed controller or directly from an external torque reference source.

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

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

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

See also section Scalar motor control (page 59).

Settings

Parameters 99.04 Motor control mode (page 426) and 99.13 ID run requested (page

429).

 Reference ramping

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

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

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

scale).

Page 46

46 Program features

Special acceleration/deceleration ramps

The acceleration/deceleration times for the jogging function can be defined separately; see section Jogging (page 57).

The change rate of the motor potentiometer function (page 67) is adjustable. The same rate applies in both directions.

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

Settings

• Speed reference ramping: Parameters 23.11…23.19 and 46.01 (pages 209 and 320).

• Torque reference ramping: Parameters 01.30, 26.18 and 26.19 (pages 96 and 237).

• Frequency reference ramping: Parameters 28.71…28.75 and 46.02 (pages 250 and 320).

• Jogging: Parameters 23.20 and 23.21 (page 212).

• Motor potentiometer: Parameter 22.75 (page 207).

• Emergency stop (“Off3” mode): Parameter 23.23 Emergency stop time (page 213).

 Constant speeds/frequencies

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

WARNING: Constant speeds and frequencies override the normal reference irrespective of where the reference is coming from.

Settings

Parameter groups 22 Speed reference selection (page 198) and 28 Frequency

reference chain (page 243).

 Critical speeds/frequencies

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

The critical speeds function prevents the reference from dwelling within a critical band for extended times. When a changing reference (22.87 Speed reference act 7) enters a critical range, the output of the function (22.01 Speed ref unlimited) freezes until the reference exits the range. Any instant change in the output is smoothed out by the ramping function further in the reference chain.

Page 47

Program features 47

540

690

1380

1560

1Par. 22.52 = 540 rpm

2Par. 22.53 = 690 rpm

3Par. 22.54 = 1380 rpm

4Par. 22.55 = 1560 rpm

1234

22.01 Speed ref unlimited (rpm)

(output of function)

22.87 Speed reference act 7 (rpm)

(input of function)

The function is also available for scalar motor control with a frequency reference. The input of the function is shown by 28.96 Frequency ref act 7, the output by 28.97

Frequency ref unlimited.

Example

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

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

speed function, and

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

Settings

• Critical speeds: parameters 22.51…22.57 (page 204)

• Critical frequencies: parameters 28.51…28.57 (page 249).

 Speed controller autotune

The speed controller of the drive can be automatically adjusted using the autotune function. Autotuning is based on an estimation of the mechanical time constant (inertia) of the motor and machine.

The autotune routine will run the motor through a series of acceleration/deceleration cycles, the number of which can be adjusted by parameter 25.40 Autotune repeat

times. Higher values will produce more accurate results, especially if the difference

between initial and maximum speeds is small.

The maximum torque reference used during autotuning will be the initial torque (ie. torque when the routine is activated) plus 25.38 Autotune torque step, unless limited by the maximum torque limit (parameter group 30 Limits) or the nominal motor torque (99 Motor data). The calculated maximum speed during the routine is the initial speed (ie. speed when the routine is activated) + 25.39 Autotune speed step, unless limited by 30.12 Maximum speed or 99.09 Motor nominal speed.

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48 Program features

Initial torque + [25.38]

Initial torque

Initial speed + [25.39]

Initial speed

The diagram below shows the behavior of speed and torque during the autotune routine. In this example, 25.40 Autotune repeat times is set to 2.

Notes:

• If the drive cannot produce the requested braking power during the routine, the results will be based on the acceleration stages only, and not as accurate as with full braking power.

• The motor will exceed the calculated maximum speed slightly at the end of each acceleration stage.

Before activating the autotune routine

The prerequisites for performing the autotune routine are:

• The motor identification run (ID run) has been successfully completed

• Speed and torque limits (parameter group 30 Limits) have been set

• The speed feedback has been monitored for noise, vibrations and other disturbances caused by the mechanics of the system, and

• speed feedback filtering (parameter group 90 Feedback selection)

• speed error filtering (24 Speed reference conditioning) and

• zero speed (parameters 21.06 and 21.07) have been set to eliminate these disturbances.

• The drive has been started and is running in speed control mode.

After these conditions have been fulfilled, autotuning can be activated by parameter

25.33 Speed controller autotune (or the signal source selected by it).

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Program features 49

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

Autotune modes

Autotuning can be performed in three different ways depending on the setting of parameter 25.34 Speed controller autotune mode. The selections Smooth, Normal and Tight define how the drive torque reference should react to a speed reference step after tuning. The selection Smooth will produce a slow but robust response;

Tight will produce a fast response but possibly too high gain values for some

applications. The figure below shows speed responses at a speed reference step (typically 1…20%).

Autotune results

At the end of a successful autotune routine, its results are automatically transferred into parameters

• 25.02 Speed proportional gain (proportional gain of the speed controller)

• 25.03 Speed integration time (integration time of the speed controller)

• 25.37 Mechanical time constant (mechanical time constant of the motor and machine).

Nevertheless, it is still possible to manually adjust the controller gain, integration time and derivation time.

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50 Program features

Derivative

Proportional, integral

Derivative acceleration compensation

Torque reference

Speed

reference

Actual speed

Error value

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

Warning indications

A warning message, AF90 Speed controller autotuning, will be generated if the autotune routine does not complete successfully. See chapter Fault tracing (page

479) for further information.

Settings

Parameters 25.33…25.40 (page 232).

 Oscillation damping

The oscillation damping function can be used to cancel out oscillations caused by mechanics or an oscillating DC voltage. The input – a signal reflecting the oscillation – is selected by parameter 26.53 Oscillation compensation input. The oscillation damping function outputs a sine wave (26.58 Oscillation damping output) which can be summed with the torque reference with a suitable gain (26.57 Oscillation damping

gain) and phase shift (26.56 Oscillation damping phase).

The oscillation damping algorithm can be activated without connecting the output to the reference chain, which makes it possible to compare the input and output of the function and make further adjustments before applying the result.

Page 51

Tuning procedure for oscillation damping

• Select the input by 26.53 Oscillation compensation input

• Activate algorithm by 26.51 Oscillation damping

•Set 26.57 Oscillation damping gain to 0

• Calculate the oscillation frequency from the signal (use the Drive composer PC tool) and set 26.55 Oscillation damping frequency

•Set 26.56 Oscillation damping phase*

• Increase 26.57 Oscillation damping gain gradually so that the algorithm starts to take effect.

oscillation amplitude decreases oscillation amplitude increases

• Increase 26.57 Oscillation damping gain and adjust 26.56 Oscillation damping

phase if necessary

• Try other values for 26.56 Oscillation

damping phase

• Increase 26.57 Oscillation damping gain to suppress the oscillation totally.

*If the phasing of a DC oscillation cannot be determined by measuring, the value of 0 degrees is usually a suitable initial value.

Program features 51

Note: Changing the speed error low-pass filter time constant or the integration time of the speed controller can affect the tuning of the oscillation damping algorithm. It is recommended to tune the speed controller before the oscillation damping algorithm. (The speed controller gain can be adjusted after the tuning of this algorithm.)

Settings

Parameters 26.51…26.58 (page 239).

 Rush control

In torque control, the motor could potentially rush if the load were suddenly lost. The control program has a rush control function that decreases the torque reference whenever the motor speed exceeds 30.11 Minimum speed or 30.12 Maximum speed.

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52 Program features

Motor speed

Time

Overspeed trip level

31.30 Overspeed trip margin

30.12

30.11

Rush control active

The function is based on a PI controller. The proportional gain and integration time can be defined by parameters. Setting these to zero disables rush control.

Settings

Parameters 26.81 Rush control gain and 26.82 Rush control integration time (page

243).

 Encoder support

The program supports two single-turn or multiturn encoders (or resolvers). The following optional interface modules are available:

• TTL encoder interface FEN-01: two TTL inputs, TTL output (for encoder emulation and echo) and two digital inputs

• Absolute encoder interface FEN-11: absolute encoder input, TTL input, TTL output (for encoder emulation and echo) and two digital inputs

• Resolver interface FEN-21: resolver input, TTL input, TTL output (for encoder emulation and echo) and two digital inputs

• HTL encoder interface FEN-31: HTL encoder input, TTL output (for encoder emulation and echo) and two digital inputs

• HTL/TTL encoder interface FSE-31 (for use with an FSO-xx safety functions module): Two HTL/TTL encoder inputs.

Install the interface module onto one of the option slots on the drive control unit.

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Program features 53

Encoder echo and emulation

Both encoder echo and emulation are supported by the above-mentioned FEN-xx interfaces.

Encoder echo is available with TTL, TTL+ and HTL encoders. The signal received from the encoder is relayed to the TTL output unchanged. This enables the connection of one encoder to several drives.

Encoder emulation also relays the encoder signal to the output, but the signal is either scaled, or position data converted to pulses. Emulation can be used when absolute encoder or resolver position needs to be converted to TTL pulses, or when the signal must be converted to a different pulse number than the original.

Quick configuration of HTL encoder feedback

1. Specify the type of the encoder interface module (parameter 91.11 Module 1 type = FEN-31) and the slot the module is installed into (91.12 Module 1 location).

2. Specify the type of the encoder (92.01 Encoder 1 type = HTL). The parameter listing will be re-read from the drive after the value is changed.

3. Specify the interface module that the encoder is connected to (92.02 Encoder 1

source = Module 1).

4. Set the number of pulses according to encoder nameplate (92.10 Pulses/revolution).

5. If the encoder rotates at a different speed to the motor (ie. is not mounted directly on the motor shaft), enter the gear ratio in 90.43 Motor gear numerator and

90.44 Motor gear denominator.

6. Set parameter 91.10 Encoder parameter refresh to Refresh to apply the new parameter settings. The parameter will automatically revert to Done.

7. Check that 91.02 Module 1 status is showing the correct interface module type (FEN-31). Also check the status of the module; both LEDs should be glowing green.

8. Start the motor with a reference of eg. 400 rpm.

9. Compare the estimated speed (01.02 Motor speed estimated) with the measured speed (01.04 Encoder 1 speed filtered). If the values are the same, set the encoder as the feedback source (90.41 Motor feedback selection = Encoder 1).

10. Specify the action taken in case the feedback signal is lost (90.45 Motor feedback

fault).

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54 Program features

Position

initialization

Encoder 1

Load

Encoder 2

Encoder 1

Encoder 2

90.4390.53

90.44

90.54

90.62

90.61

90.63

90.64

Position estimate

90.07

90.58

 Position counter

The control program contains a position counter feature that can be used to indicate the position of a load, eg. the position of a conveyor belt or the height of the load on a crane. The output of the counter function, parameter 90.07 Load position scaled int, indicates the scaled number of revolutions read from an encoder through either encoder interface. A position estimate calculated internally by the motor control can be used instead of encoder feedback. (The estimate is also used until next stop if the selected feedback is lost and its monitoring parameter is set to warning instead of fault.)

The source of the measurement is selected by 90.51 Load feedback selection. Any gear ratio between the encoder and load is defined by 90.53 Load gear numerator and 90.54 Load gear denominator. In case the internal position estimate is chosen as the source, the gear between the motor and load must be defined in 90.61 Gear

numerator and 90.62 Gear denominator.

The relation between revolutions of the motor shaft and the translatory movement of the load (in any given unit of distance) is defined by parameters 90.63 Feed constant

numerator and 90.64 Feed constant denominator.

By default, all of the ratios mentioned above are 1:1.

Page 55

Program features 55

-21474838

+2147483

(Proximity switch) Source set by 90.67

1 0 1 0

1 0

(Initialization inhibit) Source set by 90.68

90.35 Pos counter status

bit 4, Pos counter init ready

(Re-init request) Source set by 90.69

Drive fault

90.07 Load position scaled int

(Initial value) Source set by 90.59

(by default, 90.58)

90.35 Pos counter status

bit 5, Position counter re-init disabled

The position counter is initialized by setting a known physical position of the load into the control program. The initial position (for example, the home/zero position, or the distance from it) can be entered manually in a parameter (90.58 Pos counter init

value int), or taken from another parameter. This position is set as the value of the

position counter (90.07 Load position scaled int) when the source selected by 90.67

Pos counter init cmd source, such as a proximity switch connected to a digital input, is

activated. A successful initialization is indicated by bit 4 of 90.35 Pos counter status.

Any subsequent initialization of the counter must first be enabled by 90.69 Reset pos

counter init ready. To define a time window for initializations, 90.68 Disable pos counter initialization can be used to inhibit the signal from the proximity switch. An

active fault in the drive will also prevent counter initialization.

Reading/writing position counter values through fieldbus

The parameters of the position counter function, such as 90.07 Load position scaled

int and 90.58 Pos counter init value int, can be accessed from an upper-level control

system in the following formats:

• 16-bit integer (if 16 bits are sufficient for the application)

• 32-bit integer (can be accessed as two consequent 16-bit words).

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56 Program features

For example, to read parameter 90.07 Load position scaled int through fieldbus, set the selection parameter of the desired dataset (in group 52) to Other – 90.07, and select the format. If you select a 32-bit format, the subsequent data word is also automatically reserved.

Example: ACS 600 / ACS800 compatibility

With ACS 600 and ACS800 drives, both the rising and falling edges from encoder channels A and B are typically counted to achieve best possible accuracy. Thus the received pulse number per revolution equals four times the nominal pulse number of the encoder.

In this example, an HTL-type 2048-pulse encoder is fitted directly on the motor shaft. The desired initial position to correspond the proximity switch is 66770.

In the ACS880-M04, the following settings are made:

• 92.01 Encoder 1 type = HTL

• 92.02 Encoder 1 source = Module 1

• 92.10 Pulses/revolution = 2048

• 92.13 Position estimation enable = Enable

• 90.51 Load feedback selection = Encoder 1

• 90.63 Feed constant numerator = 8192 (ie. 4 × value of 92.10, as the received number of pulses is 4 times nominal. See also parameter 92.12 Resolver

polepairs)

• The desired “data out” parameter is set to Other – 90.58 Pos counter init value

int (32-bit format). Only the high word needs to be specified – the subsequent

data word is reserved for the low word automatically.

• The desired sources (such as digital inputs or user bits of the control word) are selected in 90.67 Pos counter init cmd source and 90.69 Reset pos counter

init ready.

In the PLC, if the initial value is set in 32-bit format using low and high words (corresponding to ACS800 parameters POS COUNT INIT LO and POS COUNT INIT HI), enter the value 66770 into these words as follows:

Eg. PROFIBUS:

• FBA data out x = POS COUNT INIT HI = 1 (as bit 16 equals 66536)

• FBA data out (x + 1) = POS COUNT INIT LO = 1234.

ABB Automation using DDCS communication, eg.:

• Data set 12.1 = POS COUNT INIT HI

• Data set 12.2 = POS COUNT INIT LO

To test the configuration of the PLC, initialize the position counter with the encoder connected. The initial value sent from the PLC should immediately be reflected by

90.07 Load position scaled int in the drive. The same value should then appear in the

PLC after having been read from the drive.

Page 57

Program features 57

2314568 11 13141516

71891210 17

Jog cmd

Jog enable

Start cmd

Speed

Settings

Parameter groups 90 Feedback selection (page 379), 91 Encoder module settings (page 391), 92 Encoder 1 configuration (page 395) and 93 Encoder 2 configuration (page 403).

 Jogging

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

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

source and 20.27 Jogging 2 start source. When jogging is activated, the drive starts

and accelerates to the defined jogging speed (22.42 Jogging 1 ref or 22.43 Jogging 2

ref) along the defined jogging acceleration ramp (23.20 Acc time jogging). After the

activation signal switches off, the drive decelerates to a stop along the defined jogging deceleration ramp (23.21 Dec time jogging).

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

mode).

Jog cmd = State of source set by 20.26 Jogging 1 start source or 20.27 Jogging 2

start source

Jog enable = State of source set by 20.25 Jogging enable Start cmd = State of drive start command.

Phase

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

Jog

cmd

Jog

enable

Start

cmd

Description

ramp of the jogging function.

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58 Program features

Phase

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

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

4-5 0 1 0 Drive is stopped.

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

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

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

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

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

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

Jog

cmd

Jog

enable

Start cmd

Description

of the jogging function.

ramp of the jogging function.

of the jogging function.

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

acceleration ramp (parameters 23.11…23.19).

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

deceleration ramp (parameters 23.11…23.19).

12-13 x 0 0 Drive is stopped.

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

acceleration ramp (parameters 23.11…23.19).

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

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

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

along the selected deceleration ramp (parameters

23.11…23.19).

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

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

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

of the jogging function.

Settings

Parameters 20.25 Jogging enable (page 186), 20.26 Jogging 1 start source (page

187), 20.27 Jogging 2 start source (page 187), 22.42 Jogging 1 ref (page 204), 22.43 Jogging 2 ref (page 204), 23.20 Acc time jogging (page 212) and 23.21 Dec time jogging (page 212).

 Scalar motor control

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

It is recommended to activate scalar motor control mode

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

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

• if the drive runs a medium-voltage motor through a step-up transformer, or

• in multimotor drives, if

• the load is not equally shared between the motors,

• the motors are of different sizes, or

• the motors are going to be changed after motor identification (ID run)

In scalar control, some standard features are not available.

See also section Operating modes of the drive (page 28).

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60 Program features

Motor voltage

f (Hz)

IR compensation

No compensation

IR compensation for scalar motor control

IR compensation (also known as voltage boost) is available only when the motor control mode is scalar. When IR compensation is activated, the drive gives an extra voltage boost to the motor at low speeds. IR compensation is useful in applications that require a high breakaway torque. In step-up applications, voltage cannot be fed through the transformer at 0 Hz, so an additional breakpoint is available for defining the compensation near zero frequency.

In Direct Torque Control (DTC), no IR compensation is possible or needed as it is applied automatically.

Settings

• Parameters 19.20 Scalar control reference unit (page 175), 97.12 IR comp step-

up frequency (page 421), 97.13 IR compensation (page 422) and 99.04 Motor control mode (page 426)

• Parameter group 28 Frequency reference chain (page 243).

 Autophasing

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

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

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

Using the zero pulse improves the robustness of the rotor position measurement. The rotor position must be determined during starting because the initial value given by the encoder is zero. The autophasing routine determines the position, but there is a

Page 61

Program features 61

Absolute encoder/resolver

Rotor

risk of some position error. If the zero pulse position is known in advance, the position found by autophasing can be corrected as soon as the zero pulse is detected for the first time after starting.

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

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

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

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

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

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

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

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

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62 Program features

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

Autophasing modes

Several autophasing modes are available (see parameter 21.13 Autophasing mode).

The turning mode (Turn in g) is recommended especially with case 1 (see the list above) as it is the most robust and accurate method. In turning mode, the motor shaft is turned back and forward (±360/polepairs)° in order to determine the rotor position. In case 3 (open-loop control), the shaft is turned only in one direction and the angle is smaller.

Another turning mode, Turning with Z-pulse, can be used if there is difficulty using the normal turning mode, for example, because of significant friction. With this mode, the rotor is turned slowly until a zero pulse is detected from the encoder. When the zero pulse is detected for the first time, its position is stored into parameter 98.15 Position

offset user, which can be edited for fine-tuning. Note that it is not mandatory to use

this mode with a zero pulse encoder. In open-loop control, the two turning modes are identical.

The standstill modes (Standstill 1, Standstill 2) can be used if the motor cannot be turned (for example, when the load is connected). As the characteristics of motors and loads differ, testing must be done to find out the most suitable standstill mode.

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

Autophasing mode has no effect.

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

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

• The encoder is slipping on the motor shaft

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

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

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

• Turning with Z-pulse mode is selected in 21.13 Autophasing mode but no zero pulse is detected within a revolution of the motor

• The wrong motor type is selected in 99.03 Motor type

• Motor ID run has failed.

Settings

Parameters 21.13 Autophasing mode (page 195), 98.15 Position offset user (page

425) and 99.13 ID run requested (page 429).

Page 63

Program features 63

(%)

Motor speed

No flux braking

Flux braking

= Braking torque

= 100 Nm

Flux braking

No flux braking

t (s)

f (Hz)

 Flux braking

The drive can provide greater deceleration by raising the level of magnetization in the motor. By increasing the motor flux, the energy generated by the motor during braking can be converted to motor thermal energy.

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

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

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

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

Two braking power levels are available:

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

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

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

Settings

Parameter 97.05 Flux braking (page 419).

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64 Program features

 DC magnetization

DC magnetization can be applied to the motor to

• heat the motor to remove or prevent condensation, or

• to lock the rotor at, or near, zero speed.

Pre-heating

A motor pre-heating function is available to prevent condensation in a stopped motor, or to remove condensation from the motor before start. Pre-heating involves feeding a DC current into the motor to heat up the windings.

Pre-heating is deactivated at start, or when one of the other DC magnetization functions is activated. With the drive stopped, pre-heating is disabled by the safe torque off function, or a drive fault state. Pre-heating can only start after one minute has elapsed from stopping the drive.

A digital source to control pre-heating is selected by parameter 21.14 Pre-heating

input source. The heating current is set by 21.16 Pre-heating current.

Pre-magnetization

Pre-magnetization refers to DC magnetization of the motor before start. Depending on the selected start mode (21.01 Start mode or 21.19 Scalar start mode), pre- magnetization can be applied to guarantee the highest possible breakaway torque, up to 200% of the nominal torque of the motor. By adjusting the pre-magnetization time (21.02 Magnetization time), it is possible to synchronize the motor start and, for example, the release of a mechanical brake.

DC hold

The function makes it possible to lock the rotor at (near) zero speed in the middle of normal operation. DC hold is activated by parameter 21.08 DC current control. When both the reference and motor speed drop below a certain level (parameter 21.09 DC

hold speed), the drive will stop generating sinusoidal current and start to inject DC

into the motor. The current is set by parameter 21.10 DC current reference. When the reference exceeds parameter 21.09 DC hold speed, normal drive operation continues.

Page 65

Program features 65

Reference

Motor speed

DC hold

21.09 DC hold speed

Notes:

• DC hold is only available in speed control in DTC motor control mode (see page

28).

• The function applies the DC current to one phase only, depending on the position of the rotor. The return current will be shared between the other phases.

Post-magnetization

This feature keeps the motor magnetized for a certain period (parameter 21.11 Post

magnetization time) after stopping. This is to prevent the machinery from moving

under load, for example before a mechanical brake can be applied. Postmagnetization is activated by parameter 21.08 DC current control. The magnetization current is set by parameter 21.10 DC current reference.

Note: Post-magnetization is only available in speed control in DTC motor control mode (see page 28), and only when ramping is the selected stop mode (see parameter 21.03 Stop mode).

Continuous magnetization

A digital signal, such as a user bit in the fieldbus control word, can be selected to activate continuous magnetization. This can be especially useful in processes requiring motors to be stopped (for example, to stand by until new material is processed), then quickly started without magnetizing them first.

Note: Continuous magnetization is only available in speed control in DTC motor control mode (see page 28), and only when ramping is the selected stop mode (see parameter 21.03 Stop mode).

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66 Program features

WARNING: The motor must be designed to absorb or dissipate the thermal energy generated by continuous magnetization, for example by forced

ventilation.

Settings

Parameters 06.21 Drive status word 3 (page 113), 21.01 Start mode, 21.01 Start

mode, 21.02 Magnetization time, 21.08…21.12, 21.14 Pre-heating input source and

21.16 Pre-heating current (page 188).

Page 67

Program features 67

22.80

22.74

22.73

22.77

22.76

22.75

Application control

 Application macros

Application macros are predefined application parameter edits and I/O configurations. See chapter Application macros (page 85).

 Motor potentiometer

The motor potentiometer is, in effect, a counter whose value can be adjusted up and down using two digital signals selected by parameters 22.73 Motor potentiometer up

source and 22.74 Motor potentiometer down source. Note that these signals have no

effect when the drive is stopped.

When enabled by 22.71 Motor potentiometer function, the motor potentiometer assumes the value set by 22.72 Motor potentiometer initial value. Depending on the mode selected in 22.71, the motor potentiometer value is either retained or reset over a stop or a power cycle.

The change rate is defined in 22.75 Motor potentiometer ramp time as the time it would take for the value to change from the minimum (22.76 Motor potentiometer min

value) to the maximum (22.77 Motor potentiometer max value) or vice versa. If the up

and down signals are simultaneously on, the motor potentiometer value does not change.

The output of the function is shown by 22.80 Motor potentiometer ref act, which can directly be set as the source of any selector parameter such as 22.11 Speed ref1

source.

The following example shows the behavior of the motor potentiometer value.

Settings

Parameters 22.71…22.80 (page 205).

Page 68

68 Program features

DC voltage control

 Overvoltage control

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

 Undervoltage control (power loss ride-through)

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

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

Page 69

Program features 69

130

260

390

520

1.6 4.8 8 11.2 14.4

(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 mains 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.

mains

120

160

(V DC)

out

(Hz)

(Nm)

Automatic restart

It is possible to restart the drive automatically after a short (max. 5 seconds) power supply failure by using the Automatic restart function provided that the drive is allowed to run for 5 seconds without the cooling fans operating.

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

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

• Modulation and cooling is stopped to conserve any remaining energy

• DC circuit pre-charging is enabled.

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

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

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

3280 Standby timeout.

WARNING! Before you activate the function, make sure that no dangerous

continues operation after a supply break.

situations can occur. The function restarts the drive automatically and

Page 70

70 Program features

 Voltage control and trip limits

The control and trip limits of the intermediate DC voltage regulator are relative to the supply voltage as well as drive/inverter type. The DC voltage is approximately 1.35 times the line-to-line supply voltage, and is displayed by parameter 01.11 DC voltage.

The following table shows the values of selected DC voltage levels in volts. All voltages are relative to the supply voltage range selected in parameter 95.01 Supply

voltage.

Supply voltage range [V] (see 95.01 Supply voltage)

Level 208…240 380…415 440…480 500 525…600 660…690

Overvoltage fault limit 489/440* 800 878 780 1113 1218

Overvoltage control limit 389 700 778 810 1013 1118

Internal brake chopper at 100% pulse width

Internal brake chopper at 0% pulse width

Overvoltage warning limit 373 644 745 776 932 1071

DC voltage at upper bound of supply voltage range (U

DC voltage at lower bound of supply voltage range

Undervoltage control and warning limit

Charging activation/standby limit 225 410 475 540 567 713

Undervoltage fault limit 168 308 356 405 425 535

*489 V with frames R1…R3, 440 V with frames R4…R8.

DCmax

)

403 697 806 806 1008 1159

375 648 749 780 936 1077

324 560 648 675 810 932

281 513 594 675 709 891

239 436 505 574 602 757

Settings

Parameters 01.11 DC voltage (page 95), 30.30 Overvoltage control (page 262), 30.31

Undervoltage control (page 262) and 95.01 Supply voltage (page 406).

 Brake chopper

A brake chopper can be used to handle the energy generated by a decelerating motor. When the DC voltage rises high enough, the chopper connects the DC circuit to an external brake resistor. The chopper operates on the pulse width modulation principle.

The internal brake choppers of ACS880-M04 drives start conducting when the DC link voltage reaches 1.156 × U

1.2 × U

DCmax

and trip limits above. (U

, depending on supply voltage range – see table under Voltage control

DCmax

is the DC voltage corresponding to the maximum of the AC supply voltage range.) For information on external brake choppers, refer to their documentation.

. 100% pulse width is reached at approximately

Page 71

Program features 71

Note: For runtime braking, overvoltage control (parameter 30.30 Overvoltage control) needs to be disabled for the chopper to operate.

Settings

Parameters 01.11 DC voltage (page 95) and 30.30 Overvoltage control (page 262).

Page 72

72 Program features

Safety and protections

 Emergency stop

The emergency stop signal is connected to the input selected by parameter 21.05

Emergency stop source. An emergency stop can also be generated through fieldbus

(parameter 06.01 Main control word, bits 0…2).

The mode of the emergency stop is selected by parameter 21.04 Emergency stop

mode. The following modes are available:

• Off1: Stop along the standard deceleration ramp defined for the particular reference type in use

• Off2: Stop by coasting

• Off3: Stop by the emergency stop ramp defined by parameter 23.23 Emergency

stop time.

With Off1 or Off3 emergency stop modes, the ramp-down of the motor speed can be supervised by parameters 31.32 Emergency ramp supervision and 31.33 Emergency

ramp supervision delay.

Notes:

• For SIL 3 / PL e-level emergency stop functions, the drive can be fitted with a TÜV-certified FSO-xx safety options module. The module can then be incorporated into certified safety systems.

• The installer of the equipment is responsible for installing the emergency stop devices and all additional devices needed for the emergency stop function to fulfill the required emergency stop categories. For more information, contact your local ABB representative.

• After an emergency stop signal is detected, the emergency stop function cannot be canceled even though the signal is canceled.

• If the minimum (or maximum) torque limit is set to 0%, the emergency stop function may not be able to stop the drive.

• Speed and torque reference additives (parameters 22.15, 22.17, 26.16, 26.25 and

26.41) and reference ramp shapes (23.16…23.19) are ignored in case of

emergency ramp stops.

Settings

Parameters 06.17 Drive status word 2 (page 110), 06.18 Start inhibit status word (page 111 ), 21.04 Emergency stop mode (page 191), 21.05 Emergency stop source (page 191), 23.23 Emergency stop time (page 213), 25.13 Min torq sp ctrl em stop (page 227), 25.14 Max torq sp ctrl em stop (page 227), 25.15 Proportional gain em

stop (page 227), 31.32 Emergency ramp supervision (page 272) and 31.33 Emergency ramp supervision delay (page 272).

Page 73

Program features 73

DI6

+24VD

 Motor thermal protection

The control program features two separate motor temperature monitoring functions. The temperature data sources and warning/trip limits can be set up independently for each function.

The motor temperature can be monitored using

• the motor thermal protection model (estimated temperature derived internally inside the drive), or

• sensors installed in the windings. This will result in a more accurate motor model.

In addition to temperature monitoring, a protection function is available for ‘Ex’ motors installed in a potentially explosive atmosphere.

Motor thermal protection model

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

1. When power is applied to the drive for the first time, the motor is assumed to be at ambient temperature (defined by parameter 35.50 Motor ambient temperature). After this, when power is applied to the drive, the motor is assumed to be at the estimated temperature.

2. Motor temperature is calculated using the user-adjustable motor thermal time and motor load curve. The load curve should be adjusted in case the ambient temperature exceeds 30 °C.

Note: The motor thermal model can be used when only one motor is connected to the inverter.

Temperature monitoring using PTC sensors

One PTC sensor can be connected to digital input DI6.

The resistance of the PTC sensor increases when its temperature rises. The increasing resistance of the sensor decreases the voltage at the input, and eventually its state switches from 1 to 0, indicating overtemperature.

1…3 PTC sensors can also be connected in series to an analog input and an analog output. The analog output feeds a constant excitation current of 1.6 mA through the sensor. The sensor resistance increases as the motor temperature rises, as does the

Page 74

74 Program features

100

550

1330

4000

Ohm

voltage over the sensor. The temperature measurement function calculates the resistance of the sensor and generates an indication if overtemperature is detected.

For wiring of the sensor, refer to the Hardware Manual of the drive.

The figure below shows typical PTC sensor resistance values as a function of temperature.

In addition to the above, optional FEN-xx encoder interfaces have connections for PTC sensors. Refer to the module-specific documentation for more information.

Temperature monitoring using Pt100 or Pt1000 sensors

1…3 Pt100 or Pt1000 sensors can be connected in series to an analog input and an analog output.

The analog output feeds a constant excitation current of 9.1 mA (Pt100) or 1 mA (Pt1000) through the sensor. The sensor resistance increases as the motor temperature rises, as does the voltage over the sensor. The temperature measurement function reads the voltage through the analog input and converts it into degrees Celsius.

The warning and fault limits can be adjusted by parameters.

For the wiring of the sensor, refer to the Hardware Manual of the drive.

Temperature monitoring using KTY84 sensors

One KTY84 sensor can be connected to an analog input and an analog output on the control unit.

The analog output feeds a constant excitation current of 2.0 mA through the sensor. The sensor resistance increases as the motor temperature rises, as does the voltage over the sensor. The temperature measurement function reads the voltage through the analog input and converts it into degrees Celsius.

Page 75

Program features 75

1000

2000

3000

Ohm

KTY84 scaling

90 °C = 936 ohm 110 °C = 1063 ohm 130 °C = 1197 ohm 150 °C = 1340 ohm

-100

0 100 200 300

FEN-xx encoder interfaces (optional) also have a connection for one KTY84 sensor.

The figure and table below show typical KTY84 sensor resistance values as a function of the motor operating temperature.

The warning and fault limits can be adjusted by parameters.

For the wiring of the sensor, refer to the Hardware Manual of the drive.

Motor fan control logic (parameters 35.100…35.106)

If the motor has an external cooling fan, it is possible to use a drive signal (for example, running/stopped) to control the starter of the fan via a relay or digital output. A digital input can be selected for fan feedback. A loss of the feedback signal will optionally cause a warning or a fault.

Start and stop delays can be defined for the fan. In addition, a feedback delay can be set to define the time within which feedback must be received after the fan starts.

Ex motor support (parameter 95.15, bit 0)

The control program has a temperature protection function for Ex motors located in a potentially explosive atmosphere. The protection is enabled by setting bit 0 of parameter 95.15 Special HW settings.

Settings

Parameter groups 35 Motor thermal protection (page 290) and 91 Encoder module

settings (page 391); parameter 95.15 Special HW settings (page 408).

Page 76

76 Program features

 Thermal protection of motor cable

The control program contains a thermal protection function for the motor cable. This function should be used, for example, when the nominal current of the drive exceeds the current-carrying capacity of the motor cable.

The program calculates the temperature of the cable on the basis of the following data:

• Measured output current (parameter 01.07 Motor current)

• Nominal continuous current rating of the cable, specified by 35.61 Cable nominal

current, and

• Thermal time constant of the cable, specified by 35.62 Cable thermal rise time.

When the calculated temperature of the cable reaches 102% of the rated maximum, a warning (A480 Motor cable overload) is given. The drive trips on a fault (4000 Motor

cable overload) when 106% is reached.

Settings

Parameters 35.60…35.62 (page 300).

 Other programmable protection functions

External events (parameters 31.01…31.10)

Five different event signals from the process can be connected to selectable inputs to generate trips and warnings for the driven equipment. When the signal is lost, an external event (fault, warning, or a mere log entry) is generated. The contents of the messages can be edited on the control panel by selecting Menu - Settings - Edit

texts.

Motor phase loss detection (parameter 31.19)

The parameter selects how the drive reacts whenever a motor phase loss is detected.

Earth (Ground) fault detection (parameter 31.20)

The earth fault detection function is based on sum current measurement. Note that

• an earth fault in the supply cable does not activate the protection

• in a grounded supply, the protection activates within 2 milliseconds

• in an ungrounded supply, the supply capacitance must be 1 microfarad or more

• the capacitive currents caused by shielded motor cables up to 300 meters will not activate the protection

• the protection is deactivated when the drive is stopped.

Supply phase loss detection (parameter 31.21)

The parameter selects how the drive reacts whenever a supply phase loss is detected.

Page 77

Program features 77

Safe torque off detection (parameter 31.22)

The drive monitors the status of the Safe torque off input, and this parameter selects which indications are given when the signals are lost. (The parameter does not affect the operation of the Safe torque off function itself). For more information on the Safe torque off function, see the Hardware manual.

Swapped supply and motor cabling (parameter 31.23)

The drive can detect if the supply and motor cables have accidentally been swapped (for example, if the supply is connected to the motor connection of the drive). The parameter selects if a fault is generated or not. Note that the protection should be disabled in drive/inverter hardware supplied from a common DC bus.

Stall protection (parameters 31.24…31.28)

The drive protects the motor in a stall situation. It is possible to adjust the supervision limits (current, frequency and time) and choose how the drive reacts to a motor stall condition.

Overspeed protection (parameter 31.30)

The user can set overspeed limits by specifying a margin that is added to the currently-used maximum and minimum speed limits.

Ramp stop supervision (parameters 31.32, 31.33, 31.37 and 31.38)

The control program has a supervision function for both the normal and emergency stop ramps. The user can either define a maximum time for stopping, or a maximum deviation from the expected deceleration rate. If the drive fails to stop in the expected manner, a fault is generated and the drive coasts to a stop.

Custom motor current fault limit (parameter 31.42)

The control program sets a motor current limit based on drive hardware. In most cases, the default value is appropriate. However, a lower limit can be manually set by the user, for example, to protect a permanent magnet motor from demagnetization.

Local control loss detection (parameter 49.05)

The parameter selects how the drive reacts to a control panel or PC tool communication break.

Page 78

78 Program features

 Automatic fault resets

The drive can automatically reset itself after overcurrent, overvoltage, undervoltage and external faults. The user can also specify a fault that is automatically reset.

By default, automatic resets are off and must be specifically activated by the user.

WARNING! Before you activate the function, make sure that no dangerous situations can occur. The function resets the drive automatically and continues

operation after a fault.

Settings

Parameters 31.12…31.16 (page 266).

Page 79

Program features 79

Diagnostics

 Fault and warning messages, data logging

See chapter Fault tracing (page 479).

 Signal supervision

Three signals can be selected to be supervised by this function. Whenever a supervised signal exceeds or falls below predefined limits, a bit in 32.01 Supervision

status is activated, and a warning or fault generated. The contents of the message

can be edited on the control panel by selecting Menu - Settings - Edit texts.

The supervised signal is low-pass filtered.

Settings

Parameter group 32 Supervision (page 276).

 Maintenance timers and counters

The program has six different maintenance timers or counters that can be configured to generate a warning when a pre-defined limit is reached. The contents of the message can be edited on the control panel by selecting Menu - Settings - Edit texts.

The timer/counter can be set to monitor any parameter. This feature is especially useful as a service reminder.

There are three types of counters:

• On-time timers. Measures the time a binary source (for example, a bit in a status word) is on.

• Signal edge counters. The counter is incremented whenever the monitored binary source changes state.

• Value counters. The counter measures, by integration, the monitored parameter. A warning is given when the calculated area below the signal peak exceeds a user-defined limit.

Settings

Parameter group 33 Generic timer & counter (page 280).

Page 80

80 Program features

 Energy saving calculators

This feature consists of the following functionalities:

• An energy optimizer that adjusts the motor flux in such a way that the total system efficiency is maximized

• A counter that monitors used and saved energy by the motor and displays them in kWh, currency or volume of CO

• A load analyzer showing the load profile of the drive (see separate section on page 80).

Note: The accuracy of the energy savings calculation is directly dependent on the accuracy of the reference motor power given in parameter 45.19 Comparison power.

Settings

Parameter group 45 Energy efficiency (page 316).

emissions, and

 Load analyzer

Peak value logger

The user can select a signal to be monitored by a peak value logger. The logger records the peak value of the signal along with the time the peak occurred, as well as motor current, DC voltage and motor speed at the time of the peak. The peak value is sampled at 2 ms intervals.

Amplitude loggers

The control program has two amplitude loggers.

For amplitude logger 2, the user can select a signal to be sampled at 200 ms intervals, and specify a value that corresponds to 100%. The collected samples are sorted into 10 read-only parameters according to their amplitude. Each parameter represents an amplitude range 10 percentage points wide, and displays the percentage of the collected samples that have fallen within that range.

Page 81

Program features 81

Percentage of samples

0…10%

10…20%

20…30%

30…40%

40…50%

50…60%

60…70%

70…80%

80…90%

>90%

Amplitude ranges

(parameters 36.40…36.49)

Amplitude logger 1 is fixed to monitor motor current, and cannot be reset. With amplitude logger 1, 100% corresponds to the maximum output current of the drive

, as given in the hardware manual). The measured current is logged

max

continuously. The distribution of samples is shown by parameters 36.20…36.29.

Settings

Parameter group 36 Load analyzer (page 304).

Page 82

82 Program features

Miscellaneous

 User parameter sets

The drive supports four user parameter sets that can be saved to the permanent memory and recalled using drive parameters. It is also possible to use digital inputs to switch between user parameter sets.

A user parameter set contains all editable values in parameter groups 10…99 except

• forced I/O values such as parameters 10.03 DI force selection and 10.04 DI force

data

• I/O extension module settings (groups 14…15)

• data storage parameters (group 47)

• fieldbus communication settings (groups 51…56 and 58)

• encoder configuration settings (groups 92…93), and

• parameter 95.01 Supply voltage.

As the motor settings are included in the user parameter sets, make sure the settings correspond to the motor used in the application before recalling a user set. In an application where different motors are used with the drive, the motor ID run needs to be performed with each motor and the results saved to different user sets. The appropriate set can then be recalled when the motor is switched.

Settings

Parameters 96.10…96.13 (page 413).

 Data storage parameters

Twenty-four (sixteen 32-bit, eight 16-bit) parameters are reserved for data storage. These parameters are unconnected by default and can be used for eg. linking, testing and commissioning purposes. They can be written to and read from using other parameters’ source or target selections.

Note that “Analog src” type parameters (see page 435) expect a 32-bit real (floating point) source – in other words, parameters 47.01…47.08 can be used as a value source of other parameters while 47.11…47.28 cannot.

To use a 16-bit integer (received in DDCS data sets) as the source of another parameter, write the value into one of the “real32” type storage parameters (47.01…47.08). Select the storage parameter as the source, and define a suitable scaling method between the 16-bit and 32-bit values in parameters 47.31…47.38.

Settings

Parameter group 47 Data storage (page 324).

Page 83

Program features 83

 du/dt filter support

With an external du/dt filter connected to the output of the drive, bit 13 of 95.20 HW

options word 1 must be switched on. The setting enables an overtemperature

protection for the filter. Note that the setting is not to be activated with inverter modules with internal du/dt filters.

Settings

Parameter 95.20 HW options word 1 (page 409).

Page 84

84 Program features

Page 85

Application macros

Application macros 85

What this chapter contains

This chapter describes the intended use, operation and default control connections of the application macros.

More information on the connectivity of the control unit is given in the Hardware manual of the drive.

General

Application macros are sets of default parameter values suitable for the application in question. When starting up the drive, the user typically selects the best-suited application macro as a starting point, then makes any necessary changes to tailor the settings to the application. This usually results in a much lower number of user edits compared to the traditional way of programming a drive.

Application macros can be selected by parameter 96.04 Macro select. User parameter sets are managed by the parameters in group 96 System.

Page 86

86 Application macros

Factory macro

The Factory macro is suited to relatively straightforward speed control applications such as conveyors, pumps and fans, and test benches.

The drive is speed-controlled with the reference signal connected to analog input AI1. The start/stop commands are given through digital input DI1; running direction is determined by DI2. This macro uses control location EXT1.

Faults are reset through digital input DI3.

DI4 switches between acceleration/deceleration time sets 1 and 2. The acceleration and deceleration times, as well as ramp shapes, are defined by parameters

23.12…23.19.

DI5 activates constant speed 1.

 Default parameter settings for the Factory macro

The default parameter settings for the Factory macro are listed under Parameter

listing (page 94).

Page 87

 Default control connections for the Factory macro

Fault

XPOW External power input

1 +24VI

24 V DC, 2 A

2 GND

XAI Reference voltage and analog inputs

1 +VREF 10 V DC, RL 1…10 kohm 2 -VREF -10 V DC, RL 1…10 kohm 3 AGND Ground 4 AI1+ Speed reference

0(2)…10 V, R

> 200 kohm

5 AI1- 6 AI2+ By default not in use.

0(4)…20 mA, R

> 100 ohm

7 AI2-

XAO Analog outputs

1 AO1 Motor speed rpm

0…20 mA, R

< 500 ohm

2 AGND 3 AO2 Motor current

0…20 mA, R

< 500 ohm

4 AGND

XD2D Drive-to-drive link

1 B

Drive-to-drive link

2 A 3 BGND

XRO1, XRO2, XRO3 Relay outputs

1 NC

Ready run

250 V AC / 30 V DC 2 A

2 COM 3 NO 1 NC

Running

250 V AC / 30 V DC 2 A

2 COM 3 NO 1 NC

Fault (-1)

250 V AC / 30 V DC 2 A

2 COM 3 NO

XD24 Digital interlock

1 DIIL Run enable 2 +24VD +24 V DC 200 mA 3 DICOM Digital input ground 4 +24VD +24 V DC 200 mA 5 DIOGND Digital input/output ground

XDIO Digital input/outputs

1 DIO1 Output: Ready run 2 DIO2 Output: Running

XDI Digital inputs

1 DI1 Stop (0) / Start (1) 2 DI2 Forward (0) / Reverse (1) 3 DI3 Reset 4 DI4 Acc/Dec time set 1 (0) / set 2 (1) 5 DI5 Constant speed 1 (1 = On) 6 DI6 By default, not in use.

XSTO

Safe torque off circuits must be closed for the drive to start. See Hardware manual of drive.

X12 Safety options connection X13 Control panel connection

X205 Memory unit connection

Application macros 87

Page 88

88 Application macros

Page 89

Parameters

Parameters 89

What this chapter contains

The chapter describes the parameters, including actual signals, of the control program.

Page 90

90 Parameters

Terms and abbreviations

Term Definition

Actual signal

Def

FbEq16

Other

Type of parameter that is the result of a measurement or calculation by the drive, or contains status information. Most actual signals are read-only, but some (especially counter-type actual signals) can be reset.

(In the following table, shown on the same row as the parameter name) The default value of a parameter when used in the Factory macro. For

information on other macro-specific parameter values, see chapter Application

macros (page 85).

Note: Certain configurations or optional equipment may require specific default values. These are labelled as follows:

(95.20 bx) = Default changed or write-protected by parameter 95.20, bit x. (In the following table, shown on the same row as the parameter range, or for

each selection) 16-bit fieldbus equivalent: The scaling between the value shown on the panel

and the integer used in communication when a 16-bit value is selected for transmission to an external system.

A dash (-) indicates that the parameter is not accessible in 16-bit format. The corresponding 32-bit scalings are listed in chapter Additional parameter

data (page 435).

The value is taken from another parameter.

Other [bit]

Parameter

p.u.

Choosing “Other” displays a parameter list in which the user can specify the source parameter.

Note: The source parameter must be a 32-bit real (floating point) number. To use a 16-bit integer (for example, received from an external device in data sets) as the source, data storage parameters 47.01…47.08 (page 324) can be used.

The value is taken from a specific bit in another parameter. Choosing “Other” displays a parameter list in which the user can specify the

source parameter and bit. Either a user-adjustable operating instruction for the drive, or an actual signal. Per unit

Page 91

Parameters 91

Summary of parameter groups

Group Contents Page

01 Actual values Basic signals for monitoring the drive. 94 03 Input references Values of references received from various sources. 98 04 Warnings and faults Information on warnings and faults that occurred last. 99 05 Diagnostics Various run-time-type counters and measurements

related to drive maintenance.

06 Control and status words

07 System info Drive hardware and firmware information. 120 10 Standard DI, RO Configuration of digital inputs and relay outputs. 122 11 Standard DIO, FI, FO Configuration of digital input/outputs and frequency

12 Standard AI Configuration of standard analog inputs. 136 13 Standard AO Configuration of standard analog outputs. 141 14 I/O extension module 1 Configuration of I/O extension module 1. 147 15 I/O extension module 2 Configuration of I/O extension module 2. 169 19 Operation mode Selection of local and external control location sources

20 Start/stop/direction Start/stop/direction and run/start/jog enable signal source

21 Start/stop mode Start and stop modes; emergency stop mode and signal

Drive control and status words. 108

inputs/outputs.

and operating modes.

selection; positive/negative reference enable signal source selection.

source selection; DC magnetization settings; autophasing mode selection.

106

130

173

176

188

22 Speed reference selection

23 Speed reference ramp Speed reference ramp settings (programming of the

24 Speed reference conditioning

25 Speed control Speed controller settings. 220 26 Torque reference chain Settings for the torque reference chain. 234

28 Frequency reference chain

30 Limits Drive operation limits. 255 31 Fault functions Configuration of external events; selection of behavior of

32 Supervision Configuration of signal supervision functions 1…3. 276

33 Generic timer & counter

Speed reference selection; motor potentiometer settings. 198

209

acceleration and deceleration rates for the drive). Speed error calculation; speed error window control

configuration; speed error step.

Settings for the frequency reference chain. 243

the drive upon fault situations.

Configuration of maintenance timers/counters. 280

217

263

Page 92

92 Parameters

Group Contents Page

35 Motor thermal protection

36 Load analyzer Peak value and amplitude logger settings. 304 43 Brake chopper Settings for the internal brake chopper. 308

44 Mechanical brake control

45 Energy efficiency Settings for the energy saving calculators. 316

46 Monitoring/scaling settings

47 Data storage Data storage parameters that can be written to and read

49 Panel port communication

50 Fieldbus adapter (FBA) Fieldbus communication configuration. 330 51 FBA A settings Fieldbus adapter A configuration. 341 52 FBA A data in Selection of data to be transferred from drive to fieldbus

Motor thermal protection settings such as temperature measurement configuration, load curve definition and motor fan control configuration.

Configuration of mechanical brake control. 310

Speed supervision settings; actual signal filtering; general scaling settings.

from using other parameters’ source and target settings. Communication settings for the control panel port on the

drive.

controller through fieldbus adapter A.

290

320

324

327

342

53 FBA A data out Selection of data to be transferred from fieldbus controller

to drive through fieldbus adapter A.

54 FBA B settings Fieldbus adapter B configuration. 344 55 FBA B data in Selection of data to be transferred from drive to fieldbus

controller through fieldbus adapter B.

56 FBA B data out Selection of data to be transferred from fieldbus controller

to drive through fieldbus adapter B.

58 Embedded fieldbus Configuration of the embedded fieldbus (EFB) interface. 346 60 DDCS communication DDCS communication configuration. 357

61 D2D and DDCS transmit data

62 D2D and DDCS receive data

90 Feedback selection Motor and load feedback configuration. 379

91 Encoder module settings

92 Encoder 1 configuration

Defines the data sent to the DDCS link. 366

Mapping of data received through the DDCS link. 370

Configuration of encoder interface modules. 391

Settings for encoder 1. 395

343

345

346

93 Encoder 2 configuration

95 HW configuration Various hardware-related settings. 406 96 System Language selection; access levels; macro selection;

Settings for encoder 2. 403

410

parameter save and restore; control unit reboot; user parameter sets; unit selection.

Page 93

Parameters 93

Group Contents Page

97 Motor control Motor model settings. 419 98 User motor parameters Motor values supplied by the user that are used in the

motor model.

99 Motor data Motor configuration settings. 425 200 Safety FSO-xx settings. 433

423

Page 94

94 Parameters

Parameter listing

No. Name/Value Description Def/FbEq16

01 Actual values

01.01 Motor speed used

-30000.00 …

30000.00 rpm

01.02 Motor speed estimated

-30000.00 …

30000.00 rpm

01.03 Motor speed % Shows the value of 01.01 Motor speed used in

-1000.00 …

1000.00%

Basic signals for monitoring the drive.

All parameters in this group are read-only unless otherwise noted.

Measured or estimated motor speed depending on which type of feedback is used (see parameter

90.41 Motor feedback selection). A filter time

constant for this signal can be defined by parameter

46.11 Filter time motor speed.

Measured or estimated motor speed. See par.

Estimated motor speed in rpm. A filter time constant for this signal can be defined by parameter 46.11

Filter time motor speed.

Estimated motor speed. See par.

percent of the synchronous speed of the motor. Measured or estimated motor speed. See par.

46.01

10 = 1%

46.01

01.04 Encoder 1 speed filtered

-30000.00 …

30000.00 rpm

01.05 Encoder 2 speed filtered

-30000.00 …

30000.00 rpm

01.06 Output frequency Estimated drive output frequency in Hz. A filter time

-500.00 …

500.00 Hz

01.07 Motor current Measured (absolute) motor current in A. -

0.00 …

30000.00 A

Speed of encoder 1 in rpm. A filter time constant for this signal can be defined by parameter 46.11 Filter

time motor speed.

Encoder 1 speed. See par.

Speed of encoder 2 in rpm. A filter time constant for this signal can be defined by parameter 46.11 Filter

time motor speed.

Encoder 2 speed. See par.

constant for this signal can be defined by parameter

46.12 Filter time output frequency.

Estimated output frequency. See par.

Motor current. See par.

46.01

46.02

46.05

Page 95

Parameters 95

No. Name/Value Description Def/FbEq16

01.10 Motor torque Motor torque in percent of the nominal motor

torque. See also parameter 01.30 Nominal torque

scale.

A filter time constant for this signal can be defined by parameter 46.13 Filter time motor torque.

-1600.0 …

1600.0%

01.11 DC voltage Measured DC link voltage. -

0.00 …

2000.00 V

01.13 Output voltage Calculated motor voltage in V AC. -

0…2000 V Motor voltage. 1 = 1 V

01.14 Output power Drive output power. The unit is selected by

-32768.00 …

32767.00 kW or hp

Motor torque. See par.

DC link voltage. 10 = 1 V

parameter 96.16 Unit selection. A filter time constant for this signal can be defined by parameter

46.14 Filter time power out.

Output power. 1 = 1 unit

46.03

01.15 Output power % of motor nom

-300.00 …

300.00%

01.17 Motor shaft power

-32768.00 …

32767.00 kW or hp

01.18 Inverter GWh motoring

0…32767 GWh Motoring energy in GWh. 1 = 1 GWh

01.19 Inverter MWh motoring

Shows the value of 01.14 Output power in percent of the nominal power of the motor.

Output power. 1 = 1%

Estimated mechanical power at motor shaft. The unit is selected by parameter 96.16 Unit selection. A filter time constant for this signal can be defined by parameter 46.14 Filter time power out.

Motor shaft power. 1 = 1 unit

Amount of energy that has passed through the drive (towards the motor) in full gigawatt-hours. The minimum value is zero.

Amount of energy that has passed through the drive (towards the motor) in full megawatt-hours. Whenever the counter rolls over, 01.18 Inverter

GWh motoring is incremented.The minimum value

is zero.

0…999 MWh Motoring energy in MWh. 1 = 1 MWh

Page 96

96 Parameters

No. Name/Value Description Def/

01.20 Inverter kWh motoring

0…999 kWh Motoring energy in kWh. 10 = 1 kWh

01.21 U-phase current Measured U-phase current. -

-30000.00 …

30000.00 A

01.22 V-phase current Measured V-phase current. -

-30000.00 …

30000.00 A

01.23 W-phase current Measured W-phase current. -

-30000.00 …

30000.00 A

01.24 Flux actual % Used flux reference in percent of nominal flux of

Amount of energy that has passed through the drive (towards the motor) in full kilowatt-hours. Whenever the counter rolls over, 01.19 Inverter

MWh motoring is incremented.The minimum value

is zero.

U-phase current. See par.

V-phase current. See par.

W-phase current. See par.

motor.

46.05

FbEq16

0…200% Flux reference. 1 = 1%

01.29 Speed change rate

-15000 … 15000 rpm/s

01.30 Nominal torque scale

0.000… N·m or lb·ft

01.31 Ambient temperature

Rate of actual speed change. Positive values indicate acceleration, negative values indicate deceleration.

See also parameters 31.32 Emergency ramp

supervision, 31.33 Emergency ramp supervision delay, 31.37 Ramp stop supervision and 31.38 Ramp stop supervision delay.

Rate of speed change. 1 = 1 rpm/s

Torque that corresponds to 100% of nominal motor torque. The unit is selected by parameter 96.16

Unit selection

Note: This value is copied from parameter 99.12

Motor nominal torque if entered. Otherwise the

value is calculated from other motor data. Nominal torque. 1 = 100 unit

Measured temperature of incoming cooling air. The unit is selected by parameter 96.16 Unit selection.

-40 … 120 °C or °FCooling air temperature. 1 = 1°

01.32 Inverter GWh regenerating

0…32767 GWh Motoring energy in GWh. 1 = 1 GWh

Amount of energy that has passed through the drive (towards the supply) in full gigawatt-hours. The minimum value is zero.

Page 97

Parameters 97

No. Name/Value Description Def/

01.33 Inverter MWh regenerating

0…999 MWh Motoring energy in MWh. 1 = 1 MWh

01.34 Inverter kWh regenerating

0…999 kWh Motoring energy in kWh. 10 = 1 kWh

01.35 Mot - regen energy GWh

-32768… 32767 GWh

01.36 Mot - regen energy MWh

Amount of energy that has passed through the drive (towards the supply) in full megawatt-hours. Whenever the counter rolls over, 01.32 Inverter

GWh regenerating is incremented.The minimum

value is zero.

Amount of energy that has passed through the drive (towards the supply) in full kilowatt-hours. Whenever the counter rolls over, 01.33 Inverter

MWh regenerating is incremented.The minimum

value is zero.

Amount of net energy (motoring energy regenerating energy) that has passed through the drive in full gigawatt-hours.

Motoring energy in GWh. 1 = 1 GWh

Amount of net energy (motoring energy regenerating energy) that has passed through the drive in full megawatt-hours. Whenever the counter rolls over, 01.35 Mot - regen energy GWh is incremented or decremented.

FbEq16

-999…999 MWh Motoring energy in MWh. 1 = 1 MWh

01.37 Mot - regen energy kWh

-999…999 kWh Motoring energy in kWh. 10 = 1 kWh

01.61 Abs motor speed used

0.00 …

30000.00 rpm

01.62 Abs motor speed %Absolute value of 01.03 Motor speed %.-

0.00 …

1000.00%

01.63 Abs output frequency

0.00 …

500.00 Hz

Amount of energy (motoring energy - regenerating energy) that has passed through the drive in full kilowatt-hours. Whenever the counter rolls over,

01.36 Mot - regen energy MWh is incremented or

decremented.

Absolute value of 01.01 Motor speed used.-

Measured or estimated motor speed. See par.

Absolute value of 01.06 Output frequency.-

Estimated output frequency. See par.

46.01

46.02

01.64 Abs motor torque Absolute value of 01.10 Motor torque.-

0.0 … 1600.0% Motor torque. See par.

46.03

Page 98

98 Parameters

No. Name/Value Description Def/FbEq16

01.65 Abs output power Absolute value of 01.14 Output power.-

0.00 … 32767.00

Output power. 1 = 1 unit

kW or hp

01.66 Abs output power % motor nom

Absolute value of 01.15 Output power % of motor

nom.

0.00 … 300.00% Output power. 1 = 1%

01.68 Abs motor shaft

Absolute value of 01.17 Motor shaft power.-

power

0.00 … 32767.00

Motor shaft power. 1 = 1 unit

kW or hp

03 Input references

Values of references received from various sources.

All parameters in this group are read-only unless otherwise noted.

03.01 Panel reference Local reference given from the control panel or PC

tool.

-100000.00 …

Local control panel or PC tool reference. 1 = 10

100000.00

03.02 Panel reference 2Remote reference given from the control panel or

PC tool.

-30000.00 …

Remote control panel or PC tool reference. 1 = 10

30000.00

03.05 FB A reference 1 Reference 1 received through fieldbus adapter A.

See also chapter Fieldbus control through a

fieldbus adapter (page 551).

-100000.00 …

Reference 1 from fieldbus adapter A. 1 = 10

100000.00

03.06 FB A reference 2 Reference 2 received through fieldbus adapter A. -

-100000.00 …

Reference 2 from fieldbus adapter A. 1 = 10

100000.00

03.07 FB B reference 1 Reference 1 received through fieldbus adapter B. -

-100000.00 …

Reference 1 from fieldbus adapter B. 1 = 10

100000.00

03.08 FB B reference 2 Reference 2 received through fieldbus adapter B. -

-100000.00 …

Reference 2 from fieldbus adapter B. 1 = 10

100000.00

03.09 EFB reference 1 Scaled reference 1 received through the embedded

fieldbus interface. The scaling is defined by 58.26

EFB ref1 type.

1 = 10

-30000.00 …

30000.00

Reference 1 received through the embedded fieldbus interface.

1 = 10

Page 99

Parameters 99

No. Name/Value Description Def/FbEq16

03.10 EFB reference 2 Scaled reference 2 received through the embedded

fieldbus interface. The scaling is defined by 58.27

EFB ref2 type.

-30000.00 …

30000.00

Reference 2 received through the embedded fieldbus interface.

03.13 M/F or D2D ref1 Master/follower reference 1 received from the

master. The value has been scaled according to parameter 60.10 M/F ref1 type.

See also section Master/follower functionality (page 39).

-30000.00 …

Scaled reference 1 received from master. 1 = 10

30000.00

03.14 M/F or D2D ref2 Master/follower reference 2 received from the

master. The value has been scaled according to parameter 60.11 M/F ref2 type.

-30000.00 …

Scaled reference 2 received from master. 1 = 10

30000.00

04 Warnings and faults

Information on warnings and faults that occurred last.

For explanations of individual warning and fault codes, see chapter Fault tracing.

All parameters in this group are read-only unless otherwise noted.

1 = 10

04.01 Tripping fault Code of the 1st active fault (the fault that caused

the current trip).

0000h…FFFFh 1st active fault. 1 = 1

04.02 Active fault 2 Code of the 2nd active fault. -

0000h…FFFFh 2nd active fault. 1 = 1

04.03 Active fault 3 Code of the 3rd active fault. -

0000h…FFFFh 3rd active fault. 1 = 1

04.04 Active fault 4 Code of the 4th active fault. -

0000h…FFFFh 4th active fault. 1 = 1

04.05 Active fault 5 Code of the 5th active fault. -

0000h…FFFFh 5th active fault. 1 = 1

04.06 Active warning 1 Code of the 1st active warning. -

0000h…FFFFh 1st active warning. 1 = 1

04.07 Active warning 2 Code of the 2nd active warning. -

0000h…FFFFh 2nd active warning. 1 = 1

04.08 Active warning 3 Code of the 3rd active warning. -

0000h…FFFFh 3rd active warning. 1 = 1

04.09 Active warning 4 Code of the 4th active warning. -

0000h…FFFFh 4th active warning. 1 = 1

Page 100

100 Parameters

No. Name/Value Description Def/FbEq16

04.10 Active warning 5 Code of the 5th active warning. -

0000h…FFFFh 5th active warning. 1 = 1

04.11 Latest fault Code of the 1st stored (non-active) fault. -

0000h…FFFFh 1st stored fault. 1 = 1

04.12 2nd latest fault Code of the 2nd stored (non-active) fault. -

0000h…FFFFh 2nd stored fault. 1 = 1

04.13 3rd latest fault Code of the 3rd stored (non-active) fault. -

0000h…FFFFh 3rd stored fault. 1 = 1

04.14 4th latest fault Code of the 4th stored (non-active) fault. -

0000h…FFFFh 4th stored fault. 1 = 1

04.15 5th latest fault Code of the 5th stored (non-active) fault. -

0000h…FFFFh 5th stored fault. 1 = 1

04.16 Latest warning Code of the 1st stored (non-active) warning. -

0000h…FFFFh 1st stored warning. 1 = 1

04.17 2nd latest warning

0000h…FFFFh 2nd stored warning. 1 = 1

04.18 3rd latest warning

0000h…FFFFh 3rd stored warning. 1 = 1

04.19 4th latest warning

0000h…FFFFh 4th stored warning. 1 = 1

04.20 5th latest warning

0000h…FFFFh 5th stored warning. 1 = 1

Code of the 2nd stored (non-active) warning. -

Code of the 3rd stored (non-active) warning. -

Code of the 4th stored (non-active) warning. -

Code of the 5th stored (non-active) warning. -