ACS880-M04 Quick installation guide3AXD50000032345
ACX-AP-x Assistant control panels user’s manual3AUA0000085685
ACS-BP-S Basic control panels user’s manual3AXD50000032527
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:
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 07.05Firmware
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.
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.
Related documents
Note: A quick start-up sequence for a speed control application is provided by
ACS880-M04 Quick installation and start-up guide (3AXD50000032345), delivered
with the drive.
See the List of related manuals on the inside of front cover.
Terms and abbreviations
Introduction to the manual 13
Term /
abbreviation
ACS800A product family of ABB drives
ACS-AP-I,
ACS-AP-W
ACS-BP-SBasic control panel
AIAnalog input; interface for analog input signals
AOAnalog output; interface for analog output signals
DC linkDC circuit between rectifier and inverter
DDCSDistributed drives communication system; a protocol used in communication
DIDigital input; interface for digital input signals
DIODigital input/output; interface that can be used as a digital input or output
DODigital output; interface for digital output signals
DriveFrequency converter for controlling AC motors. The drive consists of a rectifier
Definition
Assistant control panel. Type of control panels used with ACS880-M04 drives
between ABB drive equipment
and an inverter connected together by the DC link. In drives up to
approximately 500 kW, these are integrated into a single module (drive
module). Larger drives typically consist of separate supply and inverter units.
The ACS880-M04 primary control program is used to control the inverter part
of the drive.
DriveBusA communication link used by, for example, ABB controllers. ACS880-M04
drives can be connected to the DriveBus link of the controller.
DTCDirect torque control. See page 45.
FBAFieldbus adapter
FCAN-01Optional CANopen adapter
FCNA-01Optional ControlNet adapter
FDCO-0xOptional DDCS communication module
FDNA-01Optional DeviceNet adapter
FECA-01Optional EtherCAT® adapter
FEN-01Optional TTL encoder interface module
FEN-11Optional absolute encoder interface module
FEN-21Optional resolver interface module
FEN-31Optional HTL encoder interface module
FENA-11Optional Ethernet/IP, Modbus/TCP and PROFINET IO adapter
FENA-21Optional dual-port Ethernet/IP, Modbus/TCP and PROFINET IO adapter
FEPL-02Optional POWERLINK adapter
FIO-01Optional digital I/O extension module
FIO-11Optional analog I/O extension module
FPBA-01Optional PROFIBUS DP adapter
FSCA-01Optional Modbus/RTU adapter
14 Introduction to the manual
Term/
Definition
abbreviation
FSO-xxOptional safety functions module
HTLHigh-threshold logic
ID runMotor identification run. During the identification run, the drive will identify the
characteristics of the motor for optimum motor control.
IGBTInsulated gate bipolar transistor; a voltage-controlled semiconductor type
widely used in inverters and IGBT supply units due to their easy controllability
and high switching frequency
Inverter unitIn large drives (> 500 kW approx.), the part of the drive that converts DC to
AC for the motor. Consists of one or more inverter modules and their auxiliary
components.
I/OInput/Output
ModuleBusA communication link used by, for example, ABB controllers. ACS880-M04
drives can be connected to the optical ModuleBus link of the controller.
Motor-side
See inverter unit.
converter
Network
control
With fieldbus protocols based on the Common Industrial Protocol (CIP
such as DeviceNet and Ethernet/IP, denotes the control of the drive using the
TM
),
Net Ctrl and Net Ref objects of the ODVA AC/DC Drive Profile. For more
information, see www.odva.org
, and the following manuals:
• FDNA-01 DeviceNet adapter module User’s manual (3AFE68573360
[English]), and
ParameterUser-adjustable operation instruction to the drive, or signal measured or
calculated by the drive
PLCProgrammable logic controller
Power unitContains the power electronics and power connections of the drive (or inverter
module). The drive control unit is connected to the power unit.
PTCPositive temperature coefficient
RFGRamp function generator.
RORelay output; interface for a digital output signal. Implemented with a relay.
SSISynchronous serial interface
STOSafe torque off
TTLTransistor-transistor logic
UPSUninterruptible power supply; power supply equipment with battery to
maintain output voltage during power failure
ZCUType of control unit used in ACS880-M04 drives (primarily in drive modules, or
inverter/supply units consisting of a single power module). Consists of an I/O
board built into a plastic housing.
Depending on the type of hardware, the control unit may be integrated into or
fitted onto the drive/inverter module, or installed separately.
Using the control panel 15
2
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]).
16 Using the control panel
3
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.
18 Start-up
Remote0.0 rpm
0.00
0.00
Motor torque
%
0.0
Motor current
A
Motor speed used
rpm
Options
12:34
Menu
ACS880
Remote0.0 rpm
Menu
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.
Highlight Settings on the menu using
Remote0.0 rpm
Settings
Language
Date & time
Back
12:34
Select
Edit texts
Display settings
x
ACS880
Reset to defaults
Next daylight saving start28.03.
Remote0.0 rpm
Date & time
Date
Back
12:35
Edit
Time
Show date as
01.01.1980
12:34:56
day.month.year
Show time as24-hour
Daylight savingEU
Remote0.0 rpm
Date
Cancel
12:35
Save
Day MonthYear
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).
20 Start-up
Remote0.0 rpm
0.00
0.00
Motor torque
%
0.0
Motor current
A
Motor speed used
rpm
Options
12:34
Menu
ACS880
Loc/Rem
Local0.0 rpm
0.00
0.00
Motor torque
%
0.0
Motor current
A
Motor speed used
rpm
Options
12:36
Menu
Local0.0 rpm
Menu
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).
Highlight Parameters and press
Local0.0 rpm
Parameters
Complete list
By function
Back
12:36
Select
Favorites
Modified
x
ACS880
Local0.0 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
Local0.0 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 settings0000
95.20 HW option wor......0 0000 0000
ACS880
95.04 Control board supply
Local0.0 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.
22 Start-up
Local0.0 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 settings0000
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
0.83
0.83
0.83
0.83
0.83
3GAA 202 001 - ADA
180
IEC 34-1
6210/C36312/C3
Cat. no
35
30
30
30
30
30
50
50
50
50
50
60
690 Y
400 D
660 Y
380 D
415 D
440 D
V
HzkW
r/minA
cos
IA/IN
t
E/s
Ins.cl. F
IP 55
No
IEC 200 M/L 55
3
motor
ABB Motors
3 ~ motorM2BJ 280SMB 10 B3
No 3424522
A
BB Motors
Ins.cl. FIP 55
V
400 DHz50kW55
r/min
600
A
103
cos
M
0.97
IA/IN
t
E/s
Prod. code 2GBJ285220-ADA405445477
6316/C3
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 99.04Motor 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 × INote: 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.
Hd
… 2 × IHd of the drive
Hd
Example of a nameplate of a permanent
magnet motor:
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.
N
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.
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.
Control locations and operating modes 25
4
Control locations and
operating modes
What this chapter contains
This chapter describes the control locations and operating modes supported by the
control program.
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
M
3~
I/O
1)
Embedded fieldbus
interface (EFB) or
master/follower link
External control
Local control
Encoder
ACS880-M04
Control panel
2)
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 19.16Local 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 (49.05Communication loss action) how the drive
reacts to a control panel or PC tool communication break. (The parameter has no
effect in external control.)
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 7083Panel 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.
28 Control locations and operating modes
Motor feedback
configuration
(p 569)
Speed
reference
source selection
I
(p 566)
Speed controller
(p 572)
Speed reference
source selection
II
(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.
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).
30 Control locations and operating modes
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