Page 1 ACS800 Firmware Manual Crane Control Program (+N697)
Page 2 (available on request) Fieldbus Control Application Guide 3AUA0000046481 (English) Load Speed Control Application Guide 3AUA0000046482 (English) Functional Specification for Conical Motor Function 3AUA0000046480 (English) The special application guides as well as this manual can be found and downloaded from ABB IHMM.
Page 5: Table Of Contents
Table of contents Table of contents Introduction to the manual Chapter overview ............. . 15 Compatibility .
Page 6 Control panel Chapter overview ............. . 37 Overview of the panel .
Page 7 Programmable analogue outputs ..........61 Update cycles in the Crane control program .
Page 8 Settings ..............74 Motor thermal protection .
Page 9 Diagnostics ..............89 Power ON acknowledge and internal fault reset .
Page 10 Safety functions ............. . 117 External 24 V supply of RMIO board .
Page 11 Actual signals and parameters Chapter overview ............. 151 Terms and abbreviations .
Page 12 03.02 MAIN STATUS WORD ..........251 State Machine for the ABB Drives communication profile ......252 Fieldbus reference scaling .
Page 13 03.17 FAULT WORD 5 ........... . 268 03.18 ALARM WORD 5 .
Page 14 Providing feedback on ABB Drives manuals ........
Page 15: Introduction To The Manual
Control Boards. See parameter 33.01 SOFTWARE VERSION. The Crane control program version AQCR7xxxx is also compatible with the ACS800 Anti-sway control program version A9XRxxx. For more information, see ACS800 Anti-sway Control Program (+N816) Supplement (3AUA0000094750 [English]). With the DriveWindow PC tool version 2.xx, it is possible create a full back-up of the software (*.bpg file).
Page 16: Contents
I/O extension (optional). • Additional data: actual signals and parameters contains more information on the actual signals and parameters. • Control block diagrams • DriveWindow contains a screenshot of DriveWindow connected to the ACS800 RMIO/RDCO board and channel CH3.
Page 17: Start-Up And Control Through The I/O Interface
Start-up and control through the I/O interface Chapter overview The chapter instructs how to: • do the start-up • start, stop, change the direction of rotation, and adjust the speed of the motor through the I/O interface • perform an identification run for the drive. How to start-up the drive You can perform a limited start-up.
Page 18: How To Perform The Limited Start-Up (Covers Only The Basic Settings)
Apply mains power. The control panel first shows the panel CDP312 PANEL Vx.xx ..identification data … … then the Identification Display of the drive … ACS800 ID NUMBER 1 … then the Actual Signal Display … -> 0.0 rpm FREQ 0.00 Hz...
Page 19 - motor nominal current -> 0.0 rpm 99 START-UP DATA … Allowed range: approx. 1/6 · I 2 · I of ACS800 (0 … 2 · I if parameter 06 MOTOR NOM CURRENT 99.04 = SCALAR)) - motor nominal frequency -> 0.0 rpm 99 START-UP DATA …...
Page 20 When the motor data has been entered, two displays (warning and -> 0.0 rpm ACS800 information) start to alternate. Move to next step without pressing ** WARNING ** any key. ID MAGN REQ L-> 0.0 rpm *** Information *** Press green button...
Page 21 DIRECTION OF ROTATION OF THE MOTOR Check the direction of rotation of the motor. L->[xxx] rpm FREQ xxx Hz Note: CURRENT xx A In the crane application, POWER xx % - the forward direction (positive) must be the UP direction. - the reverse direction (negative) must be the DOWN direction.
Page 22 Set the deceleration time 1. L-> 0.0 rpm 22 ACCEL/DECEL 03 DECEL TIME 1 Set the deceleration time 2. L-> 0.0 rpm 22 ACCEL/DECEL Note: The default setting of acceleration and deceleration selection 05 DECEL TIME 2 is ACC/DEC DIR, where the acceleration time 1 and deceleration time 1 are used if the motor is running in the forward direction, and acceleration time 2 and deceleration time 2 are used if the motor is running in the reverse direction.
Page 23: How To Control The Drive Through The I/O Interface
How to control the drive through the I/O interface The table below instructs how to operate the drive through the digital and analogue inputs when: • the motor start-up is performed, and • the default (Crane) parameter settings are valid. PRELIMINARY SETTINGS Ensure the Crane macro is active.
Page 24: How To Perform The Id Run
10 MOTOR ID RUN [STANDARD] • Press ENTER to verify the selection. The following message is displayed: 1 L ->1242.0 rpm ACS800 **WARNING** ID RUN SEL • If brake control is active, the brake is opened when STANDARD ID run is selected.
Page 25 It is recommended not to press any control panel keys during the ID run. However: • The Motor ID run can be stopped at any time by pressing the control panel stop key ( • After the ID run is started with the start key ( ), it is possible to monitor the actual values by first pressing the ACT key and then a double-arrow key ( •...
Page 26 Start-up and control through the I/O interface...
Page 27: Quick Start-Up Guide
Quick start-up guide Chapter overview This chapter describes the quick start-up procedure while using different control schemes and a different drive configuration. Crane macro This section describes the checklist for configuring the drive in different control schemes, as well as the other various configuration settings to be done for the crane application.
Page 28: Checklist For Controlling The Drive From The Joystick
• After the ID run, check the direction of rotation of the motor: Forward direction (positive) must be the UP direction. • Select the external control location EXT1 / EXT2 (Par. 11.02). For example: EXT1 selected. • Select the start/stop control (Par. 10.01). For example: DI1 F, DI2 R. •...
Page 29: Checklist For Controlling The Drive Using Step Reference
• Press the Local/Remote button on the CDP to put the drive in Remote mode. • Select the Crane macro (Par. 99.02). • Enter the motor name plate data into group 99. • Open the group 99 read-only lock using passcode 584 (Par. 16.03). •...
Page 30: Safety Control Configuration
• Select the Crane macro (Par. 99.02). • Enter the motor name plate data into group 99. • Open the group 99 read-only lock using passcode 584 (Par. 16.03). • Perform the ID run (Par. 99.10). • After the ID run, check the direction of rotation of the motor: Forward direction (positive) must be the UP direction.
Page 31: Brake Control Configuration
• Select the acceleration/deceleration function (Par. 22.10). • Set the acceleration times (Par. 22.02, 22.04). • Set the deceleration times (Par. 22.03, 22.05). Brake control configuration This section explains how the brake control configuration has to be done. Checklist for the brake control configuration •...
Page 32 • Select the drive mode as speed/torque (Par. 60.02). • Select the number of Followers attached to the drive (Par. 60.10). • Select the mode of the Follower drives (Par. 60.11). • Select the signal to be sent to the Follower as reference 1 (Par. 60.07). For example: 202 for speed.
Page 33: Shaft Synchronisation Configuration
Shaft synchronisation configuration This section explains how to configure the drive as a Master or a Follower in the Shaft synchronisation mode. A maximum of four Followers can be used in synchronisation with a Master drive using the CH2 communication link. The Shaft synchronisation works only when the drive is in EXT2 control.
Page 34: Load Speed Control Configuration
• Select the start/stop control as COMM.CW, if the Master command is to be used (Par. 10.02). • Select the direction control as REQUEST (Par. 10.03). • Select the drive reference control as COMM.REF(Par. 11.06). • Set the minimum reference limits (Par. 11.07). •...
Page 35 • Set the speed limit values for the forward direction (Par. 77.05, 77.07, 77.09 77.11). Par. 77.05 can be set with the maximum allowed speed in empty hook condition in the forward direction. Par. 77.11 can be set with the minimum allowed speed in maximum load condition, in the forward direction.
Page 36 Quick start-up guide...
Page 37: Control Panel
Control panel Chapter overview The chapter describes how to use the control panel CDP 312R. The same control panel is used with all ACS800 series drives, so the instructions given apply to all ACS800 types. Overview of the panel The LCD type display has 4 lines of 20 characters.
Page 38: Panel Operation Mode Keys And Displays
Row selection UPLOAD <=<= DOWNLOAD =>=> List of functions Page selection CONTRAST Function start ENTER Drive Selection Mode ACS800 Device type Drive selection DRIVE ID number change AQCR7190 xxxxxx SW loading package Enter change mode ENTER name and ID number...
Page 39: Status Row - How To Read The Drive Status At A Glance
L = Local control new start. Direction of rotation Drive reference R = Remote control -> “ “ = ACS800 is not ready for = Forward “ “ = External control <- start (fault or any interlock open). = Reverse...
Page 40: Drive Control With The Panel
Drive control with the panel You can control the drive with the panel as follows: • start, stop, and change direction of the motor • give the motor speed reference or torque reference • reset the fault and warning messages •...
Page 41: How To Set Speed Reference
How to set speed reference Step Action Press Key Display To show the status row. ->1242.0 rpm FREQ 45.00 Hz CURRENT 80.00 A FUNC POWER 75.00 % To switch to local control. 1 L ->1242.0 rpm FREQ 45.00 Hz (Only if the drive is not under local control, that is, there is CURRENT 80.00 A no L on the first row of the display.)
Page 42: Actual Signal Display Mode
Actual signal display mode In the Actual Signal Display Mode, you can: • have three actual signals on the display at a time • select the actual signals to display • view the fault history • reset the fault history. The panel enters the Actual Signal Display Mode when you press the ACT key, or if you do not press any key within one minute.
Page 43: How To Display The Full Name Of The Actual Signals
How to display the full name of the actual signals Step Action Press key Display To display the full name of the three actual signals. Hold 1 L -> 1242.0 rpm I FREQUENCY CURRENT POWER To return to the Actual Signal Display Mode. Release 1 L ->...
Page 44: How To Display And Reset An Active Fault
Step Action Press Key Display To display an active fault. 1 L -> 1242.0 rpm ACS800 ** FAULT ** ACS800 TEMP To reset the fault. 1 L -> 1242.0 rpm O RESET FREQ 45.00 Hz CURRENT 80.00 A POWER 75.00 %...
Page 45: Parameter Mode
Parameter mode In the Parameter Mode, you can: • view the parameter values • change the parameter settings. The panel enters the Parameter Mode when you press the PAR key. How to select a parameter and change the value Step Action Press key Display...
Page 46: How To Adjust A Source Selection (Pointer) Parameter
How to adjust a source selection (pointer) parameter Most parameters define values that are used directly in the drive control program. Source selection (pointer) parameters are exceptions: They point to the value of another parameter. The parameter setting procedure differs somewhat from that of the other parameters.
Page 47: Function Mode
By default, the parameter groups 98, 99 and the results of the motor identification are not included. The restriction prevents downloading of unfit motor data. In special cases it is, however, possible to download all. For more information, please contact your local ABB representative. Control panel...
Page 48: How To Download Data From The Panel To A Drive
Step Action Press Key Display Disconnect the panel and reconnect it to the drive into which the data will be downloaded. How to download data from the panel to a drive Consider the notes in section How to upload data from a drive to the panel on page Step Action...
Page 49: How To Set The Contrast Of The Display
How to set the contrast of the display Step Action Press Key Display Enter the Function Mode. 1 L -> 1242.0 rpm O UPLOAD <=<= DOWNLOAD =>=> FUNC CONTRAST Select a function (a flashing cursor indicates the selected 1 L -> 1242.0 rpm O function).
Page 50: Drive Selection Mode
How to select a drive and change its panel link ID number Step Action Press key Display To enter the Drive Selection Mode. ACS800 DRIVE AQCCXXXX xxxxxx ID NUMBER 1 To select the next drive/view. ACS800 The ID number of the station is changed by first pressing...
Page 51: Reading And Entering Packed Boolean Values On The Display
Reading and entering packed boolean values on the display Some actual values and parameters are packed boolean, that is, each individual bit has a defined meaning (explained at the corresponding signal or parameter). On the control panel, packed boolean values are read and entered in hexadecimal format. In this example, bits 1, 3 and 4 of the packed boolean value are ON: Bit 15 Bit 0...
Page 52 Control panel...
Page 53: Program Features
See page for a screenshot of DriveWindow connected to an ACS800 drive with the Crane control program. Note: The crane drive is not ready for start if the drive status displayed in the upper right corner of the control panel is not “0”.
Page 54: Local Control
Local control External control ACS800 Standard I/O Slot 1 Control panel Fieldbus adapter Slot 1 or Slot 2 RTAC/RDIO/RAIO module RDCO Fieldbus adapter module Nxxx (DDCS) DriveWindow (DDCS) Advant controller (eg AC 80, AC 800M) RTAC/RDIO/RAIO AIMA-01 I/O module (DDCS)
Page 55: External Control
External control When the drive is in external control, the commands are given through standard I/O terminals (digital and analogue inputs), optional I/O extension modules and/or the fieldbus interface. In addition, it is also possible to set the control panel as the source for the external control.
Page 56: Settings
Settings Panel key Additional information LOC/REM Selection between local and external control Parameter 11.02 Selection between EXT1 and EXT2 10.01 Start, stop, direction source for EXT1 11.03 Reference source for EXT1 10.02 Start, stop, direction source for EXT2 11.06 Reference source for EXT2 Group 98 OPTION Activation of the optional I/O and serial communication...
Page 57: Block Diagram: Reference Source For Ext1
Block diagram: reference source for EXT1 The figure below shows the parameters that select the interface for the speed reference of external control location EXT1. AI1 / Std IO Select AI1, AI2, AI3, DI3, DI4 AI2 / Std IO AI3 / Std IO EXT1 AI5, AI6 DI3 / Std IO...
Page 58: Zero Position Of The Joystick
Zero position of the joystick The function supervises a 10.16 ZERO POSition PTR input in case of a stop or a trip. The input can be used either as a NO contact or as an NC contact depending on the configuration selected in the pointer value. The drive will check for a 1 -> 0 edge of this input before it activates the next start.
Page 59: Reference Types And Processing
Reference types and processing In addition to the conventional analogue input signal and control panel signals, the drive can accept a variety of references. • The drive reference can be given with two digital inputs: One digital input increases the speed and the other decreases it. •...
Page 60: Programmable Analogue Inputs
Programmable analogue inputs The drive has three programmable analogue inputs: one voltage input (0/2 to 10 V or -10 to 10 V) and two current inputs (0/4 to 20 mA). Two extra inputs are available if an optional analogue I/O extension module is used. Each input can be inverted and filtered, and the maximum and minimum values can be adjusted.
Page 61: Programmable Analogue Outputs
Programmable analogue outputs Two programmable current outputs (0/4 to 20 mA) are available as standard, and two outputs can be added by using an optional analogue I/O extension module. Analogue output signals can be inverted and filtered. The analogue output signals can be proportional to motor speed, process speed (scaled motor speed), output frequency, output current, motor torque, motor power, etc.
Page 62: Programmable Digital Inputs
Programmable digital inputs The drive has seven programmable digital inputs as a standard. Nine extra inputs are available if optional digital I/O extension modules are used. Update cycles in the Crane control program Input Cycle DI / standard 6 ms DI / extension 20 ms Settings...
Page 63: Additional Information For Digital Inputs And Pointers Ptr
The Crane control program supports programmable digital inputs with a (PTR) logic with sign.group.index.bit (+.000.000.00). Additional information for Digital Inputs and Pointers PTR +001.017.00 Values of standard Digital Inputs on RMIO board DIL D16-1 STATUS RMIO DI1 = +001.017.00 RMIO DI2 = +001.017.01 RMIO DI3 = +001.017.02 RMIO DI4 = +001.017.03 RMIO DI5 = +001.017.04...
Page 64: Programmable Relay Outputs
Programmable relay outputs As standard there are three programmable relay outputs. Six outputs can be added by using the optional digital I/O extension modules. By means of a parameter setting, you can choose which information to indicate through the relay output: ready, running, fault, warning, motor stall, etc.
Page 65: Actual Signals
Actual signals Several actual signals are available: • Drive output frequency, current, voltage and power • Motor speed and torque • Mains voltage and intermediate circuit DC voltage • Active control location (Local, EXT1 or EXT2) • Reference values • Drive temperature •...
Page 66: Motor Identification
Motor identification The performance of Direct torque control is based on an accurate motor model determined during the motor start-up. A motor identification magnetisation is automatically done the first time the start command is given. During this first start-up, the motor is magnetised at zero speed for several seconds to allow the motor model to be created.
Page 67: Flux Braking
Flux braking The drive can provide greater deceleration by raising the level of magnetisation in the motor. By increasing the motor flux, the energy generated by the motor during braking can be converted to motor thermal energy. This feature is useful in motor power ranges below 15 kW.
Page 68: Flux Optimisation
Flux optimisation Flux optimisation reduces the total energy consumption and motor noise level when the drive operates below the nominal load. The total efficiency (motor and the drive) can be improved by 1% to 10%, depending on the load torque and speed. Settings Parameter 26.01.
Page 69: Acceleration And Deceleration Ramps
Acceleration and deceleration ramps Two user-selectable acceleration and deceleration ramps are available. It is possible to adjust the acceleration/deceleration times and the ramp shape. Switching between the two ramps can be controlled via a digital input. speed Motor The available ramp shape alternatives are Linear and S-curve.
Page 70: Step Referencing
Step referencing It is possible to predefine four step references. The step references are selected with digital inputs. Step reference activation overrides the external speed reference. This function operates on a 6 ms time level. The four step references are based on a combination of three digital inputs, for example, DI3, DI4 and DI5.
Page 71: Speed Controller Tuning
Speed controller tuning During the motor identification, the speed controller is automatically tuned. It is, however, possible to manually adjust the controller gain, integration time and derivation time, or let the drive perform a separate speed controller Autotune Run. In Autotune Run, the speed controller is tuned based on the load and inertia of the motor and the machine.
Page 72: Speed Control Performance Figures
Speed control performance figures The table below shows typical performance figures for speed control when Direct torque control is used. load Speed control No pulse With pulse encoder encoder Static speed error, + 0.1 to 0.5% + 0.01% % of n (10% of nominal slip) t (s)
Page 73: Scalar Control
Scalar control It is possible to select Scalar control as the motor control method instead of Direct torque control (DTC). In the Scalar control mode, the drive is controlled with a frequency reference. The outstanding performance of the default motor control method, Direct torque control, is not achieved in Scalar control.
Page 74: Hexagonal Motor Flux
Hexagonal motor flux Typically, the drive controls the motor flux in such a way that the rotating flux vector follows a circular pattern. This is ideal in most applications. When operated above the field weakening point (FWP, typically 50 or 60 Hz), it is, however, not possible to reach 100% of the output voltage.
Page 75: Motor Thermal Protection
Motor thermal protection The motor can be protected against overheating by activating the Motor thermal protection function and by selecting one of the Motor thermal protection modes available. The Motor thermal protection modes are based either on a motor temperature thermal model or on an overtemperature indication from a motor thermistor.
Page 76: Stall Protection
Stall protection The drive protects the motor in a stall situation. It is possible to adjust the supervision limits (torque, frequency, time) and choose how the drive reacts to a motor stall condition (warning indication / fault indication & stop the drive / no reaction). The torque and current limits, which define the stall limit, must be set according to the maximum load of the used application.
Page 77: Earth Fault Protection
Earth fault protection The Earth fault protection detects earth faults in the motor or motor cable. The protection is based on sum current measurement. • An earth fault in the mains does not activate the protection. • In an earthed (grounded) supply, the protection activates in 200 microseconds. •...
Page 78: Preprogrammed Faults
Preprogrammed faults Overcurrent The Overcurrent trip limit is 3.5 * I (nominal motor current for heavy duty use). There are several sources of the overcurrent trip: • Software trip (time level 100 ms, level = 97% of measurement scale) • Hardware level trip (97% of measurement scale for 35 ms) •...
Page 79: Drive Temperature
Figure: DC voltage control and trip limits. HIGH VOLTAGE TRIP LIMIT: 130% HIGH VOLTAGE CONTROL LIMIT: 124% BRAKE CHOPPER LIMIT: 120% LOW VOLTAGE CONTROL LIMIT: 82% CHARGING LIMIT: 79% LOW VOLTAGE TRIPPING LIMIT: 60% According to the above figure, for a 400 V drive unit the voltage level at the intermediate circuit in the overload area should be 560 V DC corresponding to U 1max (415 V), while in the underload area it should be 513 V DC corresponding to U...
Page 80: Input Phase Loss
(Scalar control active). Internal fault If the drive detects an internal fault, the drive is stopped and a fault indication is given. Operation limits ACS800 has adjustable limits for speed, current (maximum), torque (maximum) and DC voltage. Settings Parameter group LIMITS.
Page 81: Parameter Lock
Parameter lock You can prevent parameter adjustment by activating the parameter lock. Settings Parameters 16.02 and 16.03. Motor temperature measurement through the standard I/O interface This section describes the temperature measurement of one motor when the RMIO drive control board is used as the connection interface. WARNING! According to IEC 664, the connection of the motor temperature sensor to the RMIO board requires double or reinforced insulation between motor live parts and the sensor.
Page 82: Settings
Settings Parameter Additional information 15.01 Analogue output in a motor 1 temperature measurement. Set to M1 TEMP MEAS. 35.01…35.03 Settings of motor 1 temperature measurement Other Parameters 13.01 13.05 (AI1 processing) and 15.02 15.05 (AO1 processing) are not effective. At the motor end, the cable shield should be earthed through a 10 nF capacitor. If this is not possible, the shield is to be left unconnected.
Page 83: Motor Temperature Measurement Through An Analogue I/O Extension
Motor temperature measurement through an analogue I/O extension This section describes the motor temperature measurement of one motor when an optional analogue I/O extension module RAIO is used as the connection interface. WARNING! According to IEC 664, the connection of the motor temperature sensor to the RAIO module requires double or reinforced insulation between motor live parts and the sensor.
Page 84: Settings
Settings Parameter Additional information 35.01 … 35.03 Settings of motor 1 temperature measurement 98.12 Activation of optional analogue I/O for motor temperature measurement Other Parameters 13.16 13.20 (AI1 processing) and 96.01 96.05 (AO1 signal selection and processing) are not effective. At the motor end, the cable shield should be earthed through a 10 nF capacitor.
Page 85: External Speed Limitation
External speed limitation The External speed limitation function limits the speed reference to a predefined value when an external speed limit signal is activated. You can define the speed limits in parameters 20.22 MAX EXT LIM SPD and 20.23 MIN EXT LIM SPD, while the external speed limit signal has to be configured in parameter 10.20 EXT SPD...
Page 86: Speed Monitor (Internal Overspeed Protection)
Speed monitor (internal overspeed protection) The Speed monitor function is an internal overspeed protection function. It supervises the speed of the motor and trips the drive at motor overspeed. The function defines the motor overspeed level in percentage of the minimum (Par. 20.01) or maximum speed (Par.
Page 87: Speed Matching (Internal Overload Protection)
Speed matching (internal overload protection) The Speed matching function is an internal overload protection function. It supervises the motor torque. The function checks that the motor follows the speed reference during acceleration and deceleration, and does not have an excessive speed error during acceleration, deceleration and when running at the constant speed.
Page 88: Settings
Settings Parameter Additional information 75.01 Activation of the function 75.02 Speed deviation limit 75.03 Delay for the fault trip 75.04 Speed change per second Diagnostics Actual signal Additional information 03.33 bit 1 Speed match fault bit Faults SPD MATCH FLT Excessive speed error when running at set point or rate of change of actual speed is low Torque proving (Crane system check)
Page 89: Settings
• The torque proving sequence can start when the input signal RUNNING (B3 of actual signal 03.02) is ”1”, in other words, when the converter is in operation. After a successful sequence, the output signal TORQ PROV OK changes to “1”. •...
Page 90: Power On Acknowledge And Internal Fault Reset
Power ON acknowledge and internal fault reset The Power ON Ack signal (usually from the main contactor auxiliary contact) is, by default, programmed to the DIL input on the RMIO board. For more information, see section Programmable digital inputs on page Additional information for Digital Inputs and Pointers PTR on page 63.
Page 91: Actual Position Configuration Based On A Motor Encoder Signal
Actual position configuration based on a motor encoder signal Position The Position function calculates the actual position of the hook. The Shaft synchro function uses the hook position when synchronising the Master and Follower drives. In addition, the position is used in anti-sway controlled trolley drives and long travel drives.
Page 92: Settings
Settings Parameter Additional information 78.04 Settings of the position scale Diagnostics Actual signals Additional information 02.21 Actual Position Actual position reset You can reset the actual position value (02.21 POS ACT PPU) by using the Homing sequence or manually through parameters. Homing sequence The Homing function is used to calibrate the actual position value 02.21...
Page 93: Settings
Settings Parameter Additional information 10.15 Homing acknowledge selection 10.21 Homing signal selection 10.22 Homing acknowledge signal selection 11.14 Homing reference to be used in homing sequence 78.10 Homing position value for initializing the actual position on completion of homing sequence. Diagnostics Actual signals Additional information...
Page 94: Master/Follower Use Of Several Drives (Only In Ext2 Control)
Master/Follower use of several drives (Only in EXT2 Control) In a Master/Follower application, the system is run by several drives, the motor shafts of which are coupled to each other. The Master and Follower drives communicate via a fibre optic link. For the Master/Follower configuration to work, the drive has to be in EXT2 control.
Page 95 Note: Only the ring topology is supported. T = Transmitter; R = Receiver; RMIO = I/O and Control Board Please note that channels CH0/CH2/CH3 are located on the optional RDCO-0x board. Master Follower Follower ACS800 ACS800 ACS800 RMIO-XX RMIO-XX RMIOXX...
Page 96 The figure below illustrates the data transmission from Master to Follower on channel 2 communication. Master Follower n DATA SET 41 Command Word Par. 10.02 = COMM Command Word Speed reference 6 ms Par. 11.06 = COMM Speed reference Torque reference Torque reference Position error Master position...
Page 97: Master/Follower Interlock Words
Master/Follower interlock words Data set 43 is used for transmission of Master Interlock Word from Master drive to Follower drive. Data set 43 is updated on 100 ms. Data set word 44.1 is used for transmission of Follower Interlock Word from Follower drive to Master drive.
Page 98: Speed Reference Scaling Between The Master And The Follower
Speed reference scaling between the Master and the Follower When a Master/Follower and Synchro control application is used, the Follower usually needs to have a speed buffer for correcting the position error between the Master and the Follower. The Follower speed buffer needs to have +5 or +10% higher speed limit settings than the Master.
Page 99 The following figures illustrate two basic application types. Master and Follower with a common drum and separate motors (Load Sharing) START/STOP MASTER DIRECTION TO MASTER DRIVE COMMAND SPEED REF TO FOLLOWER SPEED TORQUE REFER- TORQUE REFER- INVERTER CONTROLLER ENCE SELECTOR ENCE CONTROL CONTROL SPEED...
Page 100: Settings And Diagnostics
Master and Follower with separate drums and separate motors (Shaft synchro) START/STOP DIRECTION MASTER TO MASTER COMMAND DRIVE SPEED REF SPEED TORQUE REFER- TORQUE REFER- INVERTER TO FOLLOWER CONTROLLER ENCE SELECTOR ENCE CONTROL CONTROL SPEED SPEED REF 3 TORQUE 2.02 Inverter 2.09 2.10...
Page 101: Shaft Synchro (Only In Ext2 Control)
Shaft synchro (Only in EXT2 Control) The Shaft synchro function synchronises the Master and Follower drives when the drives are in the Master/Follower mode (see section Master/Follower use of several drives (Only in EXT2 Control) on page 94). However, the synchronisation is in use only when the drives are set to the speed mode.
Page 102 The Master position will be transferred at 6 ms intervals using data sets 41.1 and 41.2. Both data sets are required since the data set words are of integer type which limits the position value to -32767 mm to 32767 mm. Hence, for a wider position, range some of the unused bits in the Follower Control Word (signal 03.11) are combined together and used as the multiplying factor for position value in terms of 32767.
Page 103: Defining The Basic Data For Speed Correction
Defining the basic data for speed correction Example: If parameter 78.02 SYNCRO GAIN is set to 0.1, the speed correction in the Follower drive is (0.1 × 78.08 SYNC CORR SCALE) rpm if the position error between the Master and Follower drive is 1 unit. Calculating the linear rope speed The linear rope speed can be calculated as follows.
Page 104 The position can be moved to a predefined value using the Homing sequence. An initial position value in mm can be entered in Par. 78.10 HOME POSITION to initialize the actual position to the predefined value. The actual position is initialized in the respective drives on completion of the homing sequence.
Page 105 Figure: Control diagram for Shaft synchronisation executed in 20 ms Program features...
Page 106: Settings
Settings Parameter Additional information Group 60 Settings for the Master/Follower application. To be adjusted in the Master and Follower drives. 78.01, 78.03 Activation of the Shaft synchro function. To be adjusted in the Master and Follower drives. 78.01, 78.02, 78.03, Settings of the Shaft synchro function.
Page 107 Example: The following example shows the parameter configuration for a Master/Follower Synchro control application. Master in speed mode Follower in speed/synchro mode EXT1 = stand-alone mode EXT1 = stand-alone mode EXT2 = MF + synchro EXT2 = MF + synchro Program features...
Page 108: External Speed Correction
External speed correction When the Synchro function is not used, you can use External speed correction. Parameter 97.16 SPD CORR PTR defines the correction by writing it to signal 03.35 SPEED CORR BUFF. This speed correction bypasses internal ramps. The speed correction value is added to the speed controller.
Page 109: Synchro Error Blocking
Synchro error blocking For special cases (for example, external disturbances), it is possible to block speed correction signal 03.35 SPEED CORR BUFF with parameter 97.19 SYNC ERR BLK LVL. If the change in 02.23 SYNC POS ERROR is bigger than the value of 97.19 SYNC ERR BLK LVL, signal 03.35...
Page 110: Service Counter
297. Note: If you use and/or change the AP blocks used in the Crane control program made by ABB, you are responsible for the software and the application. DriveAP DriveAP is a Windows-based tool for Adaptive Programming. With DriveAP it is possible to upload the Adaptive Program from the drive and edit it with PC.
Page 111: Examples Of Crane Functionalities Created With Driveap
Using Adaptive Programming (AP), you can create a main contactor control logic for the 3-phase power supply of the ACS800 drive. With the help of the main contactor control logic, the power supply of the drive is disabled when the crane is not used (the standby energy-efficiency mode).
Page 112: Control Of A Mechanical Brake
Control of a mechanical brake The mechanical brake (a disk or drum brake) is used for holding the motor and driven machinery at zero speed when the drive is stopped, or not powered. Example The figure below shows a brake control application example. WARNING! Make sure that the machinery into which the drive with brake control function is integrated fulfils the personnel safety regulations.
Page 113: Operation Time Scheme
Operation time scheme The time scheme below illustrates the operation of the brake control function. See also State shifts on page 114. Start command External speed reference Inverter modulating Motor magnetised extmt trqpv Torque proved Open brake command Internal speed reference (actual motor speed) Torque reference...
Page 114: State Shifts
State shifts From any state (rising edge) MODULATION 0/0/1 OPEN 1/1/1 BRAKE RELEASE RFG 1/1/0 INPUT RFG INPUT 1/1/1 TO ZERO CLOSE 0/1/1 BRAKE RFG = Ramp Function Generator in the speed control loop (reference handling). BRAKE 0/0/1 ACK FAULT State (Symbol X/Y/Z - NN: State name...
Page 115 As seen in the state diagram, the brake Open command is triggered when the drive comes to the run mode after the motor gets magnetised. The drive waits for the Torque proving ok signal and then releases the brake Open command, which switches on the brake open relay output.
Page 116: Settings
The (42.16) BRK REOPEN DELAY can be used for a safety purpose in the event of a frequent Start -> Stop -> Start sequence. This parameter delays the opening of the brake when a Start command is issued immediately after a stop sequence. Settings Parameter Additional information...
Page 117: Settings
Settings Parameter Additional information 95.03 Number of existing parallel connected inverters Diagnostics Actual signal Additional information 04.01 INT board fault Faults INT CONFIG Number of inverter modules is not equal to original number of inverters Safety functions External 24 V supply of RMIO board In crane applications, external voltage is typically connected to the RMIO board to keep the software running even if the main power supply is disabled.
Page 118: Settings
Settings Parameter Additional information 10.09 Selection for Slowdown 11.12 Speed limit during Slowdown Diagnostics Actual signal Additional information 03.32 bit 0 Slowdown enabled bit Warnings SLOW DOWN UP Slowdown activated in up direction SLOW DOWN DOWN Slowdown activated in down direction Fast stop This function is used to ramp down to zero speed according to a predefined deceleration time (parameter...
Page 119: High-End And Low-End Limits
High-end and Low-end limits This function releases an Emergency command to the drive if any of the end limits are active. Two separate end limits, 10.12 HIGHEND PTR and 10.13 LOWEND PTR can be configured to be used in the forward (up) and reverse (down) direction, respectively.
Page 120: Settings
Figure: Slowdown and End limit ROOF HIGHEND INPUT (Par. 10.12) NC SLOW DOWN (Par. 10.09) NC Forward (Up) Reverse (Down) SLOW DOWN (Par. 10.09) NC LOWEND INPUT(Par. 10.13) NC FLOOR Speed Ref = Drive speed ref Speed Ref = Drive speed ref limited to Slowdown ref Par.
Page 121: Start High Logic
Start high logic Warning START HIGH (FFB3) may be caused by the following conditions: • Prevention of start during power-on sequence. The Crane control program includes prevention of the crane start when the mains power is switched on. If the crane start signal is TRUE during mains power switch-on, the drive indicates warning START HIGH...
Page 122: Inverter Limit
Inverter limit This function is a safety protection from the drive operation point. The function checks for the following limits when the drive is running in the generating mode with generating power greater than 10% of the motor nominal power and the speed greater than 5% of the maximum speed.
Page 123: Load Speed Control
Load speed control This function is used for running the motor above the base speed if the motor is able to provide a sufficient torque with respect to the load condition. The function allows you to run the motor at a higher speed above the base speed according to the motor current at the base speed with the load.
Page 124 Example: Consider that the motor nominal current is 10 A corresponding to the base speed of 1500 rpm. Then the parameters are to be configured in the following sequence. Note: The values defined below are only used to define the sequence, and the actual parameter values have to be entered according to the actual motor details and the load.
Page 125 Par. 77.17 REF Y3 REV ------- 1300 rpm Par. 77.18 CURR X4 REV ------- 25 A Par. 77.19 REF Y4 REV ------- 1300 rpm In this example, the empty hook current is considered in the range 10 … 12 A, both in the forward and reverse direction.
Page 126 The figures below show speed limits according to different load conditions. Program features...
Page 127: Settings
Settings Parameter Additional information 77.01 Selection of Load speed control 77.03 Setting of time period for holding the speed reference at base speed 77.04…77.19 Setting of speed limits according to motor current at the base speed Diagnostics Actual signal Additional information 03.32 bit 10 Load speed control error bit 03.32 bit 5...
Page 128 Program features...
Page 129: Application Macros, Control Location Ext1/Ext2
Application macros, control location EXT1/EXT2 Chapter overview This chapter describes the intended use, operation and the default control connections of the standard application macros. It also describes how to save a user macro, and how to recall it. Overview of macros Application macros are preprogrammed parameter sets.
Page 130: Control Locations And Control Modes
Control locations and control modes Stand-alone mode Control location EXT1 is used for the stand-alone mode when the crane motion is working alone. For more information, see Stand-alone mode (EXT1) on page 56. The homing control mode is used in the stand-alone state. For more information, see section Homing sequence on page 92.
Page 131: Default Control Connections
Default control connections The figure below shows the external control connections for the Crane macro. The markings of the standard I/O terminals on the RMIO board are shown. Parameter 10.03 should be REQUEST. VREF Reference voltage -10 V DC 1 kohm < R <...
Page 132: User Macros
User macros In addition to the standard application macros, it is possible to create two user macros. User macro 1 EXT1 Stand-alone speed control 16.05 USER MACRO IO CHG EXT2 Master/Follower and Synchro control User macro 2 EXT1 Stand-alone speed control EXT2 Master/Follower and Synchro control...
Page 133 To recall the user macro: • Change the parameter 99.02 APPLICATION MACRO to USER 1 LOAD. • Press ENTER to load. The user macro can also be switched via digital inputs (see parameter 16.05 USER MACRO IO CHG). Note: The user macro load also restores the motor settings in group 99 START-UP DATA and the results of the motor identification.
Page 134: Control Schemes
Control schemes This section describes the different control schemes which can be used to control the drive and the parameters to be set accordingly. Control using digital inputs and Potentiometer Reference Name Description Set parameters Parameter value Start/Stop Control Selecting the source for start and stop signals of the two external control locations, EXT1 and EXT2 for EXT1 Selecting between EXT1 and EXT2...
Page 135 See figures below for control connection for control using digital inputs and Potentiometer Reference. See the wiring diagram on page if used as power ON ackn signal. VREF Reference voltage -10 V DC To be configured using respective 1 kohm < R <...
Page 136: Rdio-01 Digital I/O Extension
RDIO-01 digital I/O extension Considering the function pointer is configured with an inverted signal 24 - 230 V AC 1) * To be configured using respective DI1A High-end limit (0 = Emergency stop) DI1B High-end limit pointer parameters 1) * DI2A Low-end limit (0 = Emergency stop) DI2B...
Page 137 Name Description Set parameters Parameter value Referencing EXT2 Selecting the source for the speed/ torque reference (If 11.06 AI1/JOYSTICK unipolar) Selecting the source for the speed / torque reference (If 11.06 AI1 BIPOLAR Bipolar) (If AI1 is used: Setting analogue input AI1 limits, scale, (13.01, 13.02, 13.03, inversion) 13.04, 13.05, 30.01)
Page 138 See figures below for control connection using Joystick in Unipolar configuration See the wiring diagram on page if used as power ON ackn signal. Considering the function pointer is VREF Reference voltage -10 V DC 1 kohm < R < 10 kohm configured with an inverted signal VREF Reference voltage 10 V DC...
Page 139 See figures below for control connection using Joystick in Bipolar configuration See the wiring diagram on page if used as power ON ackn signal. VREF Reference voltage -10 V DC 1 kohm < R < 10 kohm VREF Reference voltage 10 V DC 1 kohm <...
Page 140: Rdio-01 Digital I/O Extension
RDIO-01 digital I/O extension Considering the function pointer is configured with an inverted signal 24 - 230 V AC 1) * DI1A High-end limit (0 = Emergency stop) To be configured using respective DI1B High-end limit pointer parameters 1) * DI2A Low-end limit (0 = Emergency stop) DI2B...
Page 141: Control Using Motorized Potentiometer
Control using motorized potentiometer Name Description Set parameters Parameter value Start/Stop Control Selecting the source for start and stop signals of the two external control locations, EXT1 and EXT2 for EXT1 Selecting between EXT1 and EXT2 11.02 EXT 1 Defining Start/Stop selection 10.01 DI1 F, DI2 R Defining the direction control...
Page 142 See figures below for control connection using motorized potentiometer See the wiring diagram on page if used as power ON ackn signal. VREF Reference voltage -10 V DC To be configured using respective 1 kohm < R < 10 kohm pointer parameters VREF Reference voltage 10 V DC...
Page 143: Rdio-01 Digital I/O Extension
RDIO-01 digital I/O extension Considering the function pointer is 24 - 230 V AC configured with an inverted signal 1) * DI1A High-end limit (0 = Emergency stop) To be configured using respective DI1B High-end limit pointer parameters 1) * DI2A Low-end limit (0 = Emergency stop) DI2B...
Page 144 See figures below for control connection using step reference See the wiring diagram on page if used as power ON ackn signal. VREF Reference voltage -10 V DC Considering the function pointer is 1 kohm < R < 10 kohm configured with an inverted signal VREF Reference voltage 10 V DC...
Page 145: Rdio-01 Digital I/O Extension Module -1
RDIO-01 digital I/O extension module -1 Considering the function pointer is 24 - 230 V AC configured with an inverted signal 1) * DI1A High-end limit (0 = Emergency stop) To be configured using respective DI1B High-end limit pointer parameters 1) * DI2A Low-end limit (0 = Emergency stop)
Page 146: Control Using Fieldbus
Control using fieldbus Name Description Set parameters Parameter value Start/Stop Control Selecting the source for start and stop signals of the two external control locations, EXT1 and EXT2 for EXT1 Selecting between EXT1 and EXT2 11.02 COMM.CW Defining Start/Stop selection 10.01 COMM.CW Defining the direction control...
Page 147 See figures below for control connection in fieldbus mode See the wiring diagram on page if used as power ON ackn signal. VREF Reference voltage -10 V DC Considering the function pointer is 1 kohm < R < 10 kohm configured with an inverted signal VREF Reference voltage 10 V DC...
Page 148: Rdio-01 Digital I/O Extension
RDIO-01 digital I/O extension Considering the function pointer is configured with an inverted signal 24 - 230 V AC 2) * DI1A High-end limit (0 = Emergency stop) DI1B High-end limit 2) * DI2A Low-end limit (0 = Emergency stop) DI2B Low-end limit DI3A...
Page 149 Communication Interface 11.02 COMM.CW 10.01 03.01 MAIN CW COMM.CW 10.02 MAIN REFERENCE DATA SET 01.11 COMM.REF EXT REF1 11.03 REF1 REF2 01.12 COMM.REF EXT REF2 11.06 AUXILLARY 1 Fieldbus REFERENCE DATA SET Communication PARAMETER REF 3 90.01 TABLE REF 4 REF 5 10.01 90.02...
Page 150 Application macros, control location EXT1/EXT2...
Page 151: Actual Signals And Parameters
Actual signals and parameters Chapter overview The chapter describes the actual signals and parameters and gives the fieldbus equivalent values for each signal/parameter. More data is given in chapter Additional data: actual signals and parameters. Terms and abbreviations Term Definition Absolute Maximum Value of 20.08, or 20.07...
Page 152: Actual Signals
Calculated supply voltage. 1 = 1 V 01.09 OUTPUT VOLTAGE Calculated motor voltage. 1 = 1 V 01.10 ACS800 TEMP Calculated IGBT temperature. 1 = 1 °C 01.11 EXTERNAL REF 1 External reference REF1 in rpm. (Hz if value of parameter 99.04...
Page 153: Actual Signals
FAN ON-TIME Running time of the drive cooling fan. 1 = 10 h Note: Resetting of the counter is recommended when the fan is replaced. For more information, contact your local ABB representative. 01.45 CTRL BOARD TEMP Control board temperature.
Page 154: Actual Signals
Name/Value Description FbEq 02.18 SPEED MEASURED Measured motor actual speed (zero when no encoder is used). 100% 20000 = 100% corresponds to the Absolute Maximum Speed of the motor. 02.19 MOTOR ACCELERATIO Calculated motor acceleration from signal 01.02 SPEED. 1=1 rpm/s. 02.21 POS ACT PPU Actual position measurement value, which is scaled with Par.
Page 155 Name/Value Description FbEq 03.16 ALARM WORD 4 A 16-bit data word. See section 03.16 ALARM WORD 4 in chapter Fieldbus control. 03.17 FAULT WORD 5 A 16-bit data word. See section 03.17 FAULT WORD 5 in chapter Fieldbus control. 03.18 ALARM WORD 5 A 16-bit data word.
Page 156: Actual Signals
95.09 LCU PAR2 SEL. A 16-bit data word. 1) Percent of motor maximum speed / nominal torque / maximum process reference (depending on the ACS800 macro selected). 2) The contents of these data words are detailed in chapter Fieldbus control.
Page 157: Parameters
Parameters Index Name/Selection Description FbEq 10 START/STOP/DIR The sources for external start, stop and direction control 10.01 EXT1 STRT/STP/DIR Defines the connections and the source of the Start, Stop and Direction commands for external control location 1 (EXT1). Note: In M/F configuration, EXT2 should be used for M/F mode and EXT1 for stand-alone mode.
Page 158 Index Name/Selection Description FbEq 10.04 EXT1 STRT PTR Defines the source or constant for value Par. 10.04 EXT1 STRT PTR of parameter 10.01 EXT1 STRT/STP/DIR. -255.255.31 … Parameter index or a constant value: +255.255.31 / C.- - Parameter pointer: Inversion, group, index and bit fields. The bit number is 32768 …...
Page 159 Index Name/Selection Description FbEq 10.10 FAST STOP PTR Defines the source or constant for the Fast Stop command. The command can be a normally open (if the bit selection is not inverted) or normally closed (if the bit selection is inverted) logic according to the selection in the pointer value. When the command is active, the drive decelerates according to the parameter 22.10 value.
Page 160 Index Name/Selection Description FbEq 10.16 ZERO POS PTR Defines the source or constant for Zero position input. Checks for this signal before the drive can be started in case the drive has stopped in a fast stop or fault condition. -255.255.31 …...
Page 161: Reference Select
Index Name/Selection Description FbEq 11 REFERENCE Panel reference type, external control location selection and external reference sources and limits SELECT 11.01 KEYPAD REF SEL Selects the type of the reference given from panel. REF1 (rpm) Speed reference in rpm. (Frequency reference (Hz) if parameter 99.04 SCALAR.) REF2 (%)
Page 162 Index Name/Selection Description FbEq AI1/JOYST Unipolar analogue input AI1 as joystick. The minimum input signal runs the motor at the maximum reference in the reverse direction, the maximum input at the maximum reference in the forward direction. Note: Parameter 10.03 REF DIRECTION must have the value REQUEST.
Page 163 Index Name/Selection Description FbEq DI11U,12D See selection DI3U,4D. PARAM 11.10 Source selected with Par. 11.10 EXT1 REF PTR. AI1 BIPOLAR Bipolar analogue input AI1 (-10 … 10 V). The figure below illustrates the use of the input as the speed reference. Operation Range scaled maxREF1...
Page 164 Index Name/Selection Description FbEq 11.04 EXT REF1 MINIMUM Defines the minimum value for external reference REF1 (absolute value). Corresponds to the minimum setting of the source signal used. 0 … 18000 rpm Setting range in rpm (Hz if parameter 99.04 is SCALAR).
Page 165 Index Name/Selection Description FbEq See parameter 11.03. AI5/JOYST See parameter 11.03. AI6/JOYST See parameter 11.03. DI11U,12D(R) See parameter 11.03. DI11U,12D See parameter 11.03. PARAM 11.11 Source selected with Par. 11.11 EXT2 REF PTR. AI1 BIPOLAR See parameter 11.03 EXT REF1 SELECT.
Page 166: Step Referencing
Index Name/Selection Description FbEq 11.14 HOMING REF Defines the speed reference in homing sequence. Value in rpm. The speed reference sign is not considered if the Start command used defines the direction also (For example, Par. 10.01 EXT1 STRT/STP/DIR configured as DI1F, DI2R).
Page 167: Analogue Inputs
Index Name/Selection Description FbEq 12.07 STEP DI2 PTR Defines the source or constant for value Par. 12.07 of parameter 12.01. -255.255.31 … Parameter index or a constant value. See parameter 10.04 EXT1 STRT PTR +255.255.31 / C.- for information on the difference. 32768 …...
Page 168 Index Name/Selection Description FbEq 13.03 SCALE AI1 Scales analogue input AI1. Example: The effect on speed reference REF1 when: - REF1 source selection (parameter 11.03) = AI1 - REF1 maximum value setting (parameter 11.04) = 0 rpm - REF1 maximum value setting (parameter 11.05) = 1500 rpm - Minimum AI1 setting (parameter 13.01) = 0 V - Maximum AI1 setting (parameter 13.02) = 10 V - Actual AI1 value = 4 V (40% of the full scale value)
Page 169 Index Name/Selection Description FbEq 13.07 MAXIMUM AI2 See parameter 13.02. 20 mA See parameter 13.02. TUNED VALUE See parameter 13.02. TUNE See parameter 13.02. 13.08 SCALE AI2 See parameter 13.03. 0 … 1000% See parameter 13.03. 0 … 32767 13.09 FILTER AI2 See parameter 13.04.
Page 170: Relay Outputs
Index Name/Selection Description FbEq 13.20 INVERT AI5 See parameter 13.05. See parameter 13.05. See parameter 13.05. 65535 13.21 MINIMUM AI6 See parameter 13.01. Note: If RAIO-01 is used with voltage input signal, 20 mA corresponds to 10 V. 0 mA See parameter 13.01.
Page 171: Analogue Outputs
Index Name/Selection Description FbEq 14.11 RO PTR5 Defines the source or constant for value. -255.255.31 … Parameter index or a constant value. See parameter 10.04 for information on +255.255.31 / C.- the difference. 32768 … C.32767 14.12 RO PTR6 Defines the source or constant for value. -255.255.31 …...
Page 172: Syst Ctrl Inputs
Index Name/Selection Description FbEq 15.05 SCALE AO1 Scales the analogue output AO1 signal. 10 … 1000% Scaling factor. If the value is 100%, the reference value of the drive signal 100 … corresponds to 20 mA. 10000 Example: The nominal motor current is 7.5 A and the measured maximum current at maximum load 5 A.
Page 173 Index Name/Selection Description FbEq 16.02 PARAMETER LOCK Selects the state of the parameter lock. The lock prevents parameter changing. OPEN The lock is open. Parameter values can be changed. LOCKED Locked. Parameter values cannot be changed from the control panel. The lock can be opened by entering the valid code to parameter 16.03.
Page 174: Limits
Index Name/Selection Description FbEq 16.07 PARAMETER SAVE Saves the valid parameter values to the permanent memory. Note: A new parameter value of a standard macro is saved automatically when changed from the panel but not when altered through a fieldbus connection. DONE Saving completed SAVE..
Page 175 Index Name/Selection Description FbEq 20.03 MAXIMUM CURRENT Defines the allowed maximum motor current. 0.0 … x.x A Current limit 0 …10·x.x 20.04 TORQ MAX LIM1 Defines the maximum torque limit 1 for the drive. 0.0 … 600.0% Value of limit in percent of motor nominal torque. 0 …...
Page 176 Index Name/Selection Description FbEq See selection AI1. See selection AI1. PARAM 20.19 Limit given with 20.19 20.15 TORQ MIN LIM1 Defines the minimum torque limit 1 for the drive. -600.0 … 0.0% Value of limit in percent of motor nominal torque. -60000 …...
Page 177: Start/Stop
START FUNCTION Selects the motor starting method. In special crane applications like slew-motion cranes, its possible to enable the auto start function mode. For more information, contact your local ABB representative. CNST DC MAGN In the crane applications, this parameter is fixed to CNST DC MAGN. Constant...
Page 178 Index Name/Selection Description FbEq 21.04 DC HOLD Activates/deactivates the DC hold function. DC hold is not possible if parameter 99.04 = SCALAR. When both the reference and the speed drop below the value of parameter 21.05, the drive will stop generating sinusoidal current and start to inject DC into the motor.
Page 179 Index Name/Selection Description FbEq 21.08 SCALAR FLY START Activates the flying start feature in the Scalar control mode. See parameters 21.01 and 99.04. Inactive Active 65535 21.09 START INTRL FUNC Defines how the Start Interlock input on the RMIO board affects the drive operation.
Page 180: Accel/Decel
Index Name/Selection Description FbEq 22 ACCEL/DECEL Acceleration and deceleration times. 22.01 ACC/DEC SEL Selects the active acceleration/deceleration time pair. ACC/DEC 1 Acceleration time 1 and deceleration time 1 are used. See parameters 22.02 and 22.03. ACC/DEC 2 Acceleration time 2 and deceleration time 2 are used. See parameters 22.04 and 22.05.
Page 181 OFF3 (see parameter 21.07). The emergency Stop command can be given through a fieldbus or an Emergency Stop module (optional). Consult the local ABB representative for more information on the optional module and the related settings of the Standard Application Program.
Page 182: Speed Ctrl
Index Name/Selection Description FbEq 22.08 ACC PTR Defines the source or constant for value PAR 22.08&09 of parameter 22.01. -255.255.31 … Parameter index or a constant value. See parameter 10.04 EXT1 STRT PTR 100 = 1 s +255.255.31 / C.- for information on the difference.
Page 183 Index Name/Selection Description FbEq 23.02 INTEGRATION TIME Defines an integration time for the speed controller. The integration time defines the rate at which the controller output changes when the error value is constant. The shorter the integration time, the faster the continuous error value is corrected.
Page 184: Torque Ctrl
Index Name/Selection Description FbEq 23.04 Defines the derivation time for acceleration/(deceleration) compensation. In COMPENSATION order to compensate inertia during acceleration a derivative of the reference is added to the output of the speed controller. The principle of a derivative action is described for parameter 23.03.
Page 185: Motor Control
Index Name/Selection Description FbEq 26 MOTOR CONTROL 26.01 FLUX OPTIMIZATION Activates/deactivates the Flux optimisation function. See section Flux optimisation on page 68. Note: The function cannot be used if parameter 99.04 = SCALAR. Note: The function should generally not be activated for crane application. Inactive Active 65535...
Page 186 (Hz) 26.04 IR STEP-UP Field weakening FREQ point (FWP) For more information, see Sine Filters User’s Manual for ACS800 Drives [3AFE68389178 (English)]. 0...50 Hz Frequency 26.05 HEX FIELD WEAKEN Selects whether motor flux is controlled along a circular or a hexagonal pattern in the field weakening area of the frequency range (above 50/60 Hz).
Page 187: Brake Chopper
Index Name/Selection Description FbEq 27 BRAKE CHOPPER Control of the brake chopper. 27.01 BRAKE CHOPPER Activates the brake chopper control. Inactive Active. Note: Ensure the brake chopper and resistor are installed and the 65535 overvoltage control is switched off (parameter 20.05). 27.02 BR OVERLOAD Activates the overload protection of the brake resistor.
Page 188 Index Name/Selection Description FbEq 30.03 EXTERNAL FAULT Selects an interface for an External fault signal. NOT SEL Inactive PAR 30.24 External fault indication is given through pointer value in Par. 30.24. 0: Fault trip. Motor coasts to stop. 1: No External fault. 30.04 MOTOR THERM Selects how the drive reacts when the motor overtemperature is detected by...
Page 189 Index Name/Selection Description FbEq THERMISTOR Motor thermal protection is activated through digital input DI6. A motor thermistor, or a break contact of a thermistor relay, must be connected to digital input DI6. The drive reads the DI6 states as follows: DI6 Status (Thermistor resistance) Temperature 1 (0 …...
Page 190 Index Name/Selection Description FbEq 30.06 MOTOR THERM Defines the thermal time constant for the user-defined thermal model (see the TIME selection USER MODE of parameter 30.05). Motor Load 100% Temperature 100% Motor thermal time constant 256.0 … 9999.8 s Time constant 256 …...
Page 191 Index Name/Selection Description FbEq 30.10 STALL FUNCTION Selects how the drive reacts to a motor stall condition. The protection wakes up - the drive is at stall limit (defined with parameters 20.03, 20.13 and 20.14) - the output frequency is below the level set with parameter 30.11 - the conditions above have been valid longer than the time set with parameter 30.12...
Page 192 Index Name/Selection Description FbEq 30.16 MOTOR PHASE Activates the Motor phase loss supervision function. LOSS Inactive FAULT Active. The drive trips on a fault. 65535 30.17 EARTH FAULT Selects how the drive reacts when an earth fault is detected in the motor or the motor cable.
Page 193: Information
Note: You cannot change the parameter setting. Decoding key: AQCR716x Product Series A = ACS800 Product Q = ACS800 Crane Firmware Version 716x = Version 7.16x 33.02 APPL SW VERSION Displays the type and the version of the application program.
Page 194: Mot Temp Meas
Index Name/Selection Description FbEq 34.05 TORQ ACT FILT TIM Defines a filter time for the actual signal torque (actual signal 01.05). Affects also on the torque read through an analogue output. 0 … 20000 ms Filter time constant 0 … 20000 Unfiltered signal -t/T O = I ·...
Page 195 Index Name/Selection Description FbEq 1...3 PTC The function is active. The temperature is supervised using one to three PTC sensors. Analogue output AO1 feeds constant current through the sensor(s). The resistance of the sensor increases sharply as the motor temperature rises over the PTC reference temperature (T ), as does the voltage over the resistor.
Page 196: Brake Control
Index Name/Selection Description FbEq 35.06 MOT 2 TEMP FLT L Defines the fault trip limit for the motor 2 temperature measurement function. The fault indication is given when the limit is exceeded. -10 … 5000 ohm/°C See 35.03. -10 … 5000 (PTC/Pt100) 35.07 MOT MOD...
Page 197 Index Name/Selection Description FbEq 42.06 BRAKE FAULT FUNC Defines how the drive reacts in case the status of the optional external Brake Acknowledge signal does not meet the status presumed by the brake control function. FAULT The drive trips on a fault: fault indication and drive stops the motor. WARNING The drive generates a warning.
Page 198 Index Name/Selection Description FbEq 42.10 LOW REF BRK HOLD Activates a brake hold function and defines the hold delay for it. The function stabilises the operation of the brake control application when the motor operates near zero speed. 0.0 … 60.0 s 0.0 s = inactive.
Page 199 Index Name/Selection Description FbEq 42.11 MOTOR SLIP SPD Defines the motor slip speed allowed during brake opening. If the motor speed exceeds this level during brake opening, a brake slip fault will be generated. This function performs a mechanical system check of the brake during the Torque proving sequence, ensuring that the brake does not slip during the Torque proving sequence with the brake closed.
Page 200: Encoder Module
Index Name/Selection Description FbEq 50 ENCODER MODULE Encoder connection. Visible only when a pulse encoder module (optional) is installed and activated with parameter 98.01. The settings will remain the same even though the application macro is changed. 50.01 PULSE NR States the number of encoder pulses per one revolution.
Page 201: Comm Module Data
Index Name/Selection Description FbEq 50.07 ENC CABLE CHECK Selects the drive operation when encoder signal is missing. Note: Monitoring is only for RTAC-03. For more information, see RTAC-03 TTT Pulse Encoder Interface Module User’s Manual [3AFE68650500 (English)] DISABLED Not active WARNING Drive generates warning ENC CABLE.
Page 202 Index Name/Selection Description FbEq FOLLOWER 4 Follower drive STANDBY Follower drive which reads the control signals through a fieldbus interface, not from the Master/Follower link as usual. 60.02 TORQUE SELECTOR Selects the reference used in motor torque control. Typically, the value needs to be changed only in the Follower station(s).
Page 203 Index Name/Selection Description FbEq 60.03 WINDOW SEL ON Activates the Window control function. The Window control, together with selection ADD at parameter 60.02, forms a speed supervision function for a torque-controlled drive. The parameter is visible only when Master/Follower is active (See Par.
Page 204 Index Name/Selection Description FbEq 60.06 DROOP RATE Defines the droop rate. The parameter value needs to be changed only if both the Master and the Follower are speed-controlled: - External control location 1 (EXT1) is selected (see parameter 11.02 - External control location 2 (EXT2) is selected (see parameter 11.02) and parameter 60.02 is set to SPEED.
Page 205: Ddcs Control
The setting needs to be changed when a master station is connected to channel 0 and it does not automatically change the address of the slave. Examples of such masters are an ABB Advant Controller or another drive.
Page 206: Speed Matching
Index Name/Selection Description FbEq 75 SPEED MATCHING Settings for Speed matching. See section Speed matching (internal overload protection) on page Note: When Shaft synchronisation is active, avoid using this function as the speed correction from synchronisation block can do step speed corrections after the speed ramp.
Page 207: Load Speed Ctrl
Index Name/Selection Description FbEq 77 LOAD SPEED CTRL Settings for Load speed control. See section Load speed control on page 123. Note: The Base speed versus Motor current graph is plotted using the parameters 77.04 … 77.19. These parameters have to be configured in the correct sequence and if the sequence of values in these parameters are not correct, the speed will be limited to Par.
Page 208 Index Name/Selection Description FbEq 77.10 CURRENT X4 FWD Defines the current in amps expected at the base speed in forward direction for limiting the speed reference to the value in parameter 77.11 REF Y4 FWD. This current can be the current at the base speed with maximum load when running in the forward direction.
Page 209: Shaft Syncro
Index Name/Selection Description FbEq 77.20 BASE SPEED Defines the base speed in rpm. This value is used to check for the actual motor current when the motor speed crosses this value. The motor current when the actual speed crosses this base speed in either forward or reverse direction is checked for a period of Par.
Page 210: Service Counter
Index Name/Selection Description FbEq 0 ... 100.0 rpm Setting range in rpm 0 … 1000 78.09 Defines the Synchro error limit which will be used if configured as Follower SYNC ERR LIM drive for the SYNC FAULT fault generation. See Par. 78.07. 0 ...
Page 211 Index Name/Selection Description FbEq EDIT Stop to edit mode. Program can be edited. 83.02 EDIT COMMAND Selects the command for the block placed in the location defined with parameter 83.03. The program must be in the editing mode (see parameter 83.01).
Page 212: Adaptive Program
Index Name/Selection Description FbEq 83.05 PASSCODE Sets the passcode for the Adaptive Program protection. The passcode is needed at activation and inactivation of the protection. See parameter 83.02. 0 … Passcode. The setting restores to 0 after the protection is activated/inactivated. Note: When activating, write down the passcode and store it in a safe place.
Page 213: User Constants
Index Name/Selection Description FbEq TOFF TRIGG 84.06 INPUT1 Selects the source for input I1 of Block Parameter Set 1. -255.255.31 … Parameter index or a constant value: +255.255.31 / C.- - Parameter pointer: Inversion, group, index and bit fields. The bit number is 32768 …...
Page 214: Set Rec Addr
Index Name/Selection Description FbEq 85.09 CONSTANT9 Sets a constant for the Adaptive Program. -8388608 to 8388607 Integer value 1 = 1 85.10 CONSTANT10 Sets a constant for the Adaptive Program. -8388608 to 8388607 Integer value 1 = 1 85.11 STRING1 Stores a message to be used in the Adaptive Program (EVENT block).
Page 215 Index Name/Selection Description FbEq 92.03 MAIN DS ACT2 Selects the address from which the Actual signal 2 is read to the Main Data Set. 0 … 9999 Parameter index 92.04 AUX1 DS ACT3 Selects the address from which the Actual signal 3 is read to the Auxiliary Data Set.
Page 216: Hardware Specif
DC switch exists. The default setting (ON or OFF) for each unit is set accordingly at the factory as default. ACS800 IGBT pulses are always blocked when the program detects that the DC switch is opened or inverter charging is ongoing (at power switch on). The application program generates alarm INV DISABLED if the DC switch is opened when the inverter is stopped.
Page 217 Index Name/Selection Description FbEq 95.06 LCU Q PW REF Defines the reference value for the line-side converter reactive power generation. Line-side converter can generate reactive power to the supply network. This reference is written into line-side converter unit parameter 24.02 Q POWER REF2.
Page 218: External Ao
Index Name/Selection Description FbEq 96 EXTERNAL AO Output signal selection and processing for the analogue extension module (optional). The parameters are visible only when the module is installed and activated with parameter 98.06. 96.01 EXT AO1 PTR Defines the source or constant for value. 1000 = 1 mA -255.255.31 …...
Page 219: Motor Model
Index Name/Selection Description FbEq 96.06 EXT AO2 PTR Defines the source or constant for value. 1000 = 1 mA -255.255.31 … Parameter index or a constant value. See parameter 10.04 for information on +255.255.31 / C.- the difference. 32768 … C.32767 96.07 INVERT EXT AO2 Activates the inversion of analogue output AO2 of the analogue I/O extension...
Page 220: Option Modules
Index Name/Selection Description FbEq Application message blocking on page 127. 97.18 PWRON STRTINT PowerON start interlock pointer. Power ON start interlock pointer can be programmed for another use. Default: DI_IL (+.001.017.06) (start interlock input on the RMIO board). If you need to use DIL input for some other purpose than Power ON acknowledge, set parameter 97.18 to 0 (= +.000.000.00) to disable Power ON acknowledge.
Page 221 CH0 on the RDCO board. See also parameter group 51 COMM MODULE DATA. ADVANT The drive communicates with an ABB Advant OCS system via CH0 on the RDCO board (optional). See also parameter group 70 DDCS CONTROL. STD MODBUS The drive communicates with a Modbus controller via the Modbus Adapter Module (RMBA) in option slot 1 of the drive.
Page 222 Visible only when fieldbus communication is activated with parameter 98.02. ABB DRIVES ABB Drives profile GENERIC Generic drive profile. Typically used with the fieldbus modules that have the type designation of form Rxxx (installed in the option slot of the drive).
Page 223 Index Name/Selection Description FbEq 98.12 AI/O MOTOR TEMP Activates the communication to the analogue I/O extension module and reserves the module for the use of the motor temperature measurement function. The parameter also defines the type and connection interface of the module.
Page 224: Start-Up Data
Index Name/Selection Description FbEq 98.13 AI/O EXT AI1 FUNC Defines the signal type for input 1 of the analogue I/O extension module (AI5 in the drive application program). The setting must match the signal connected to the module. Note: The communication must be activated with parameter 98.06. UNIPOLAR AI5 Unipolar BIPOLAR AI5...
Page 225 Index Name/Selection Description FbEq 99.02 APPLICATION Selects the application macro. See chapter Application macros, control MACRO location EXT1/EXT2 for more information. Note: When you change the default parameter values of a macro, the new settings become valid immediately and stay valid even if the power of the drive is switched off and on.
Page 226 Note: Correct motor run requires that the magnetizing current of the motor does not exceed 90 percent of the nominal current of the inverter. 0 … 2 · I Allowed range: approx. 1/6 … 2 · I of ACS800 (parameter 99.04 = DTC). 1 = 0.1 A Allowed range: approx.
Page 227 Index Name/Selection Description FbEq 99.10 MOTOR ID RUN Selects the type of the motor identification. During the identification, the drive MODE will identify the characteristics of the motor for optimum motor control. The ID run procedure is described in chapter Start-up and control through the I/O interface.
Page 228 Actual signals and parameters...
Page 229: Fieldbus Control
The following diagram shows the control interfaces and I/O connections of the drive. Fieldbus controller Fieldbus Other ACS800 devices Advant controller Fieldbus adapter Controller (Eg AC 800M,...
Page 230: Redundant Fieldbus Control
• Type Rxxx fieldbus adapter module (not RMBA-01) is installed in drive slot 1. • RMBA-01 Modbus Adapter module is installed in drive slot 2. Eg PROFIBUS Modbus ACS800 RMIO board RPBA-01 adapter PROFIBUS-DP link Slot 1 RMBA-01 adapter std.
Page 231: Setting Up Communication Through A Fieldbus Adapter Module
Initialises communication between drive and FIELDBUS fieldbus adapter module. Activates module set-up ADVANT parameters (Group 51). STD MODBUS CUSTOMISED 98.07 ABB DRIVES ABB DRIVES Selects the communication profile used by the GENERIC GENERIC or drive. See section Communication profiles on page CSA 2.8/3.0...
Page 232 Parameter Alternative Setting for Function/Information settings fieldbus control 51.29 FILE xyz (binary coded – Displays the fieldbus adapter module configuration CONFIG ID* decimal) file identification stored in the memory of the drive. This information is drive application program- dependent. 51.30 FILE xyz (binary coded –...
Page 233: Setting Up Communication Through The Standard Modbus Link
FIELDBUS (Standard Modbus Link) and Modbus-protocol ADVANT controller. Activates communication parameters STD MODBUS in group 52. CUSTOMISED 98.07 ABB DRIVES ABB DRIVES Selects the communication profile used by the GENERIC drive. See section Communication profiles CSA 2.8/3.0 page 249. COMMUNICATION PARAMETERS 52.01...
Page 234: Modbus Addressing
Modbus addressing In the Modbus controller memory, the Control Word, the Status Word, the references, and the actual values are mapped as follows: Data from fieldbus controller to drive Data from drive to fieldbus controller Address Contents Address Contents 40001 Control Word 40004 Status Word...
Page 235: Setting Up Communication Through Advant Controller
For more information, see AC 800M Controller Hardware Manual [3BSE027941 (English)], AC 800M/C Communication, Protocols and Design Manual [3BSE028811 (English),] ABB Industrial Systems, Västerås, Sweden. • AC 80 Advant Controller Optical ModuleBus connection: TB811 (5 MBd) or TB810 (10 MBd) Optical ModuleBus Port Interface required.
Page 236 FIELDBUS (fibre optic channel CH0) and Advant ADVANT controller. The transmission speed is STD MODBUS 4 Mbit/s. CUSTOMISED 98.07 ABB DRIVES ABB DRIVES Selects the communication profile used by GENERIC the drive. See section Communication CSA 2.8/3.0 profiles on page 249.
Page 237: Drive Control Parameters
Drive control parameters After the fieldbus communication has been set up, the drive control parameters listed in the table below must be checked and adjusted where necessary. The Setting for fieldbus control column gives the value to use when the fieldbus interface is the desired source or destination for that particular signal.
Page 238 Parameter Setting for Function/Information fieldbus control SYSTEM CONTROL INPUTS 16.01 COMM.CW Enables the control of the Run Enable signal through fieldbus 03.01 Main Control Word bit 3. Note: Must be set to YES when the Generic Drive communication profile is selected (see Par.
Page 239 Parameter Setting for Function/Information fieldbus control 90.06 0 … 8999 Defines the drive parameter into which the value of fieldbus reference REF8 is written. Format: see parameter 90.01. 90.07 1 (Standard) or This parameter selects the source from which the drive reads the Main 10 (Multidrive) Reference data set (comprising the fieldbus Control Word, fieldbus reference REF1, REF2, REF3, REF4 and REF5).
Page 240 Parameter Setting for Function/Information fieldbus control 92.12 -255.255.31…+255.255.31 Selects the address from which the 03.02 Main Status Word bit 14 is read / C.-32768 … C.32767 from. 92.13 2 (Standard) or This parameter selects the source to which the drive writes the Main Status 11 (Multidrive) data set (comprising the Status Word, Actual Signal1, Actual Signal2, and the Auxillary signals.
Page 241: The Fieldbus Control Interface
The fieldbus control interface The communication between a fieldbus system and the drive employs data sets. One data set (abbreviated DS) consists of three 16-bit words called data words (DW). The Crane control program supports the use of four data sets, two in each direction.
Page 242: The Control Word And The Status Word
The following diagrams illustrate how group 10 parameters and the sign of the fieldbus reference interact to produce the reference REF1/REF2. Notes: • With the ABB Drives communication profile, 100% reference is defined with parameters 11.05 (REF1) and 11.08...
Page 243 For information on the scaling of the fieldbus reference, see section Fieldbus reference scaling on page (for ABB Drives profile) or Fieldbus reference scaling on page (for Generic Drive profile). *Direction determined by the sign of Direction determined by digital command, COMM.
Page 244: Actual Values
*Direction is determined by the sign of COMM. REF when Par. 10.01 / 10.02 EXTx STRT/STP/DIR is set to COMM.CW Par. 11.03 / 11.06 EXT REFx SELECT is set to FAST COMM. Actual Values Actual Values (ACT) are 16-bit words containing information on selected operations of the drive.
Page 245: Block Diagram: Control Data Input From Fieldbus When A Type Rxxx Fieldbus Adapter Is Used
… … … … Fieldbus control...
Page 246: Block Diagram: Actual Value Selection For Fieldbus When A Type Rxxx Fieldbus Adapter Is Used
Fieldbus control...
Page 247: Block Diagram: Control Data Input From Fieldbus When A Type Nxxx Fieldbus Adapter Is Used
Fieldbus control...
Page 248: Block Diagram: Actual Value Selection For Fieldbus When A Type Nxxx Fieldbus Adapter Is Used
Fieldbus control...
Page 249: Communication Profiles
The ABB Drives communication profile is active when parameter 98.07 is set to ABB DRIVES. The Control Word, Status Word, and reference scaling for the profile are described below. The ABB Drives communication profile can be used through both EXT1 and EXT2.
Page 250: Main Control Word
03.01 MAIN CONTROL WORD The upper case boldface text refers to the states shown in the State Machine for the ABB Drives communication profile on page 252. Name Value Enter STATE/Description OFF1 CONTROL 1 Enter READY TO OPERATE. Stop along currently active deceleration ramp (22.03/22.05). Enter OFF1 ACTIVE;...
Page 251: Main Status Word
03.02 MAIN STATUS WORD The upper case boldface text refers to the states shown in the State Machine for the ABB Drives communication profile on page 252. Name Value STATE/Description RDY_ON READY TO SWITCH ON. NOT READY TO SWITCH ON.
Page 252: State Machine For The Abb Drives Communication Profile
State Machine for the ABB Drives communication profile SWITCH-ON MAINS OFF INHIBITED ABB Drives (SW Bit6=1) Communication Power ON (CW Bit0=0) Profile NOT READY TO SWITCH ON (SW Bit0=0) A B C D CW = Control Word SW = Status Word...
Page 253: Fieldbus Reference Scaling
Fieldbus reference scaling With the ABB Drives communication profile active, fieldbus references REF1 and REF2 are scaled as shown in the table below. Note: Any correction of the reference is applied before scaling. See section References on page 242. Ref.
Page 254: Start/Stop Sequence Using Communication Bits
This section describes the sequence of the 03.01 MAIN CONTROL WORD bits used for starting, stopping and restarting after a fault condition or an abnormal stop, when the drive is configured in the ABB Drives communication profile. For the flow sequence of the communication bits, see...
Page 255: Flow Chart For Main Control Command Bit Sequence
Fault condition/abnormal stop and restarting After a drive fault condition or an abnormal stop, the drive can be restarted through the controlling device by giving the following main command word bit sequence: • Enable Bit 7 (Bit 7 = 1) to issue the fault reset command if the drive has tripped on a fault.
Page 256: Fieldbus References In A Master/Follower Configuration
Fieldbus references in a Master/Follower configuration When the ABB Drives communication profile is active, the fieldbus interface uses the following references in the Master drive: • When the Master is in control location EXT1 (stand-alone, speed-controlled), the fieldbus interface uses REF1 for the speed reference.
Page 257: Generic Drive Communication Profile
Generic Drive communication profile The Generic Drive communication profile is active when parameter 98.07 is set to GENERIC. The Generic Drive profile realises the device profile for drives – speed control only – as defined by specific fieldbus standards such as PROFIDRIVE for PROFIBUS, AC/DC Drive for DeviceNet, Drives and Motion Control for CANopen, etc.
Page 258: Drive Commands Supported By The Generic Drive Communication Profile
Drive commands supported by the Generic Drive communication profile Name Description STOP The drive decelerates the motor to zero speed according to the active deceleration ramp (parameter 22.03 or 22.05). START The drive accelerates to the set reference value according to the active acceleration ramp (Par. 22.02 or 22.04).
Page 259: Fieldbus Reference Scaling
Fieldbus reference scaling With the Generic Drive communication profile active, the speed reference value received from the fieldbus and the actual speed value received from the drive are scaled as shown in the table below. Note: Any correction of the reference (see section References on page 242) is applied before scaling.
Page 260: Csa 2.8/3.0 Communication Profile
No active faults WARNING A warning is active. No active warnings LIMIT Drive at a limit Drive at no limit 11 … 15 Reserved The reference and actual scaling is equal to that of the ABB Drives profile. Fieldbus control...
Page 261: Diverse Control, Status, Fault, Alarm And Limit Words
Diverse control, status, fault, alarm and limit words 03.03 AUXILIARY STATUS WORD Name Description Reserved OUT OF WINDOW Speed difference is out of the window (in speed control)*. Reserved MAGNETIZED Flux has been formed in the motor. Reserved SYNC RDY Position counter synchronised.
Page 262: Limit Word 1
Name Description SHORT CIRC For the possible causes and remedies, see chapter Fault tracing. OVERCURRENT DC OVERVOLT ACS800 TEMP EARTH FAULT THERMISTOR MOTOR TEMP SYSTEM_FAULT A fault is indicated by the System Fault Word (Actual Signal 03.07). UNDERLOAD For the possible causes and remedies, see chapter Fault tracing.
Page 263: Fault Word 2
03.06 FAULT WORD 2 Name Description SUPPLY PHASE For the possible causes and remedies, see chapter Fault tracing. NO MOT DATA DC UNDERVOLT Reserved Not Used For the possible causes and remedies, see chapter Fault tracing. ENCODER ERR I/O COMM CTRL B TEMP EXTERNAL FLT OVER SWFREQ...
Page 264: System Fault Word
For the possible causes and remedies, see chapter Fault tracing. Reserved THERMISTOR For the possible causes and remedies, see chapter Fault tracing. MOTOR TEMP ACS800 TEMP ENCODER ERR T MEAS ALM 7 … 11 Reserved COMM MODULE For the possible causes and remedies, see chapter Fault tracing.
Page 265: Alarm Word 2
03.09 ALARM WORD 2 Name Description Reserved UNDERLOAD For the possible causes and remedies, see chapter Fault tracing. 2, 3 Reserved ENCODER For the possible causes and remedies, see chapter Fault tracing. 5, 6 Reserved POWFAIL FILE (FFA0) Error in restoring POWERFAIL.DDF ALM (OS_17) Error in restoring POWERDOWN.DDF MOTOR STALL...
Page 266 Name Description INCHING_1 Not in use (Inching function is not available in crane control) INCHING_2 Not in use (Inching function is not available in crane control) REMOTE_CMD Fieldbus control enabled (Set to "1") START REQ Start request status in the Master. Used to check whether the Master drive has an active start request.
Page 267: Auxiliary Status Word 3
03.13 AUXILIARY STATUS WORD 3 Name Description REVERSED Motor rotates in reverse direction. EXT CTRL External control is selected. REF 2 SEL Reference 2 is selected. STEP REF A Step reference (1 … 4) is selected. STARTED The drive has received a Start command. USER 2 SEL User Macro 2 has been loaded.
Page 268: Alarm Word 4
03.16 ALARM WORD 4 Name Description Reserved MOTOR 1 TEMP For the possible causes and remedies, see chapter Fault tracing. MOTOR 2 TEMP BRAKE ACKN 4 … 15 Reserved 03.17 FAULT WORD 5 Name Description BR BROKEN For the possible causes and remedies, see chapter Fault tracing.
Page 269: Alarm Word 5
This signal is active with AINT board. Fault codes 03.20...03.24 Code Description Application/Fault Word Status Bit 4210 ACS800 TEMP 03.05 FAULT WORD 1 bit 3 4210 ACS TEMP xx y 03.05 FAULT WORD 1 bit 3 and 04.01 FAULTED INT INFO 8110 AI <...
Page 270 Code Description Application/Fault Word Status Bit 7114 BC OVERHEAT 03.17 FAULT WORD 5 bit 4 7113 BC SHORT CIR 03.17 FAULT WORD 5 bit 2 FF74 BRAKE ACKN 03.15 FAULT WORD 4 bit 3 FFF3 BRAKE SLIP FLT 03.33 CRANE FAULT WORD bit 3 7110 BR BROKEN...
Page 271 Code Description Application/Fault Word Status Bit FF51 LINE CONV FFF0 MOTOROVER SPD FF56 MOTOR PHASE 03.06 FAULT WORD 2 bit 15 4310 MOTOR TEMP 03.05 FAULT WORD 1 bit 6 4312 MOTOR 1 TEMP 03.15 FAULT WORD 4 bit 1 4313 MOTOR 2 TEMP 03.15 FAULT WORD 4...
Page 272: Warning Codes
USER MACRO 03.07 SYSTEM FAULT WORD bit 1 Warning codes 03.25...03.29 Code Description Application/Fault Word Status Bit 4210 ACS800 TEMP 03.08 ALARM WORD 1 bit 4 8110 AI < MIN FUNC 03.09 ALARM WORD 2 bit 10 FFA3 BACKUP USED...
Page 273 Code Description Application/Fault Word Status Bit FF30 ID MAGN REQ FF68 ID N CHANGED FF35 ID RUN FF33 ID RUN SEL FF81 IN CHOKE TEMP 03.18 ALARM WORD 5 bit 4 2212 INV CUR LIM 03.18 ALARM WORD 5 bit 8 3200 INV DISABLED 03.18 ALARM WORD 5...
Page 274: Limit Word Inv
Current limit at inverter overcurrent trip limit. OVERLOAD CUR Maximum inverter overload current limit. See par. 20.03. CONT DC CUR Continuous dc-current limit. CONT OUT CUR Continuous output current limit (I cont.max 11 … 15 Reserved *Not active with ACS800 Default settings. Fieldbus control...
Page 275: Alarm Word 6
03.31 ALARM WORD 6 Name Description INV OVERTEMP For the possible causes and remedies, see chapter Fault tracing. 1 … 15 Reserved 03.32 CRANE STATUS WORD Name Description SLOW DOWN ENABLED Slow down enabled by the activation of the configured input.
Page 276: Crane Fault Word
03.33 CRANE FAULT WORD Name Description MOTOR OVER SPD For the possible causes and remedies, see chapter Fault tracing. SPD MATCH FLT For the possible causes and remedies, see chapter Fault tracing. TRQ PROVE FLT For the possible causes and remedies, see chapter Fault tracing.
Page 277: Fcw With Pos
11 … 15 Reserved 04.01 FAULTED INT INFO The FAULTED INT INFO Word includes information on the location of faults PPCC LINK, OVERCURRENT, EARTH FAULT, SHORT CIRCUIT, ACS800 TEMP, TEMP DIF and POWERF INV (see 03.05 FAULT WORD 03.06 FAULT WORD 03.17 FAULT WORD 5...
Page 278: Int Sc Info
Name Description PBU FLT PBU board fault Used only with parallel connected inverters. Inverter Block Diagram RMIO Motor Control and I/O Board Upper-leg IGBTs Main Circuit Interface Board RMIO PPCS Link Branching Unit Lower-leg IGBTs Inverter Unit Block Diagram (2 to 12 parallel inverters) RMIO INT3 INT1 INT2...
Page 279: Fault Tracing
A warning or fault message on the panel display indicates an abnormal drive status. Most warning and fault causes can be identified and corrected using this information. If not, you must contact an ABB representative. If the drive is operated with the control panel detached, the red LED in the panel mounting platform indicates the fault condition.
Page 280: Warning Messages Generated By The Drive
Warning messages generated by the drive WARNING CAUSE WHAT TO DO ACS800 TEMP Drive IGBT temperature is excessive. Fault trip Check ambient conditions. limit is 100%. (4210) Check air flow and fan operation. 3.08 AW 1 bit 4 Check heatsink fins for dust pick-up.
Page 281 Fault Function motor cable. inverter module number. 30.17) If no earth fault can be detected, contact your local ABB representative. DC BUS LIM Drive limits torque due to too high or too low Informative alarm intermediate circuit DC voltage. (3211) Check Fault Function parameters.
Page 282 WARNING CAUSE WHAT TO DO FAST STOP Fast Stop Signal 10.10 activated. Deactivate the Fast Stop signal. (FFF8) FLWR1 LIM/FLT Follower 1 has gone into a fault or has hit any See Follower 1 drive for more detailed of the limits. This message is displayed in the description of fault of limit.
Page 283 WARNING CAUSE WHAT TO DO ID RUN SEL Motor identification run is selected, and drive is Press Start key to start identification run. ready to start ID run. This warning belongs to (FF33) ID run procedure. IN CHOKE TEMP Excessive input choke temperature Stop drive.
Page 284 WARNING CAUSE WHAT TO DO LOAD SP DW LIM The speed reference is limited in the reverse Check motor current settings and group 77 direction according to the Load speed control settings. (FFB9) function. 3.32 CSW bit 6 MACRO CHANGE Macro is restoring or user macro is being Wait until drive has finished task.
Page 285 WARNING CAUSE WHAT TO DO MOT POW LIM Drive limits motor power according to limits Informative alarm defined with parameters 20.11 and 20.12. (FF86) Check parameter 20.11 P MOTORING LIM 20.12 P GENERATING LIM settings. 3.18 AW 5 bit 12 Check Fault Function parameters.
Page 286 WARNING CAUSE WHAT TO DO START HIGH The Start command is active when the drive is Start command should be made OFF and then powered ON. The Start command remains ON can be made ON for a start sequence. (FFB3) after a fault or fast stop has occurred and a reset is done.
Page 287: Warning Messages Generated By The Control Panel
Download function of panel has failed. No data Make sure panel is in local mode. FAILED has been copied from panel to drive. Retry (there might be interference on link). Contact ABB representative. DRIVE IS Downloading is not possible while motor is Stop motor. Perform downloading. RUNNING running.
Page 288: Fault Messages Generated By The Drive
Fault messages generated by the drive FAULT CAUSE WHAT TO DO ACS800 TEMP Drive IGBT temperature is excessive. Fault trip Check ambient conditions. limit is 100%. (4210) Check air flow and fan operation. 3.05 FW 1 bit 3 Check heatsink fins for dust pick-up.
Page 289 30.17) If no earth fault can be detected, contact your local ABB representative. DC HIGH RUSH Drive supply voltage is excessive. When Check supply voltage level, drive rated voltage supply voltage is over 124% of unit voltage and allowed voltage range of drive.
Page 290 Fault Function motor cable. 30.17) If no earth fault can be detected, contact your local ABB representative. ENCODER A<>B Pulse encoder phasing is wrong: Phase A is Interchange connection of pulse encoder connected to terminal of phase B and vice phases A and B.
Page 291 FAULT CAUSE WHAT TO DO FLWR1 COM FLT Follower 1 Communication error . Check CH2 communication, communication settings. (FFBA) FLWR2 COM FLT Follower 2 Communication error . Check CH2 communication, communication meetings. (FFBB) FLWR3 COM FLT Follower 3 Communication error . Check CH2 communication, communication meetings.
Page 292 FAULT CAUSE WHAT TO DO INV OVERTEMP Converter module temperature is excessive. Check ambient temperature. If it exceeds 40°C, ensure that load current does not (4290) exceed derated load capacity of drive. See 3.17 FW 5 bit 13 appropriate hardware manual. Check that ambient temperature setting is correct (parameter 95.10).
Page 293 FAULT CAUSE WHAT TO DO MOTOR 1 TEMP Measured motor temperature has exceeded Check value of fault limit. fault limit set with parameter 35.03. (4312) Let motor cool down. Ensure proper motor cooling: Check cooling fan, clean cooling 3.15 FW 4 bit 1 surfaces, etc.
Page 294 3.06 FW 2 bit 11 ensure that supply is on. See parameter 16.09 CTRL BOARD SUPPLY. Check signal 03.19. Contact ABB representative if any of faults in signal 3.19 are active. PPCC LINK xx INT board fibre optic connection fault in...
Page 295 3.05 FW 1 bit 0 and 4.02 Output bridge of converter unit is faulty. Contact ABB representative. SLOT OVERLAP Two option modules have the same connection Check connection interface selections in group interface selection.
Page 296 FAULT CAUSE WHAT TO DO THERMISTOR Motor temperature is excessive. Motor thermal Check motor ratings and load. protection mode selection is THERMISTOR. (4311) Check start-up data. 3.05 FW 1 bit 5 Check thermistor connections to digital input DI6. (programmable Fault Function 30.04 …...
Page 297: Adaptive Programming Examples For Crane Control
Using the Adaptive Programming (AP), you can create a main contactor control logic for the 3-phase power supply of the ACS800 drive. With the help of the main contactor control logic, the power supply of the drive is disabled when the crane is not used (the standby energy-efficiency mode).
Page 298 The following figures show the main circuit and control circuit diagrams for the main contactor control logic. Adaptive Programming examples for crane control...
Page 299 Adaptive Programming examples for crane control...
Page 300 Create an AP file for the automatic control of opening and closing the main contactor according to the following example. BLOCK 1 BLOCK 2 BLOCK 3 BLOCK 4 BLOCK 5 TRIGG TRIGG 84.05 84.10 84.15 84.20 84.25 +1.17.5 -1.17.5 +84.09 -3.02.2 +84.24 +84.34...
Page 301: Brake Match
Brake match Brake match detects mechanical brake slips and downward movement of the load when Mechanical brake control is in use, the operator has given the stop command and the target is to close the brake. The slip detection is based on the motor encoder position signal, and the function works only if an encoder is used.
Page 302 Adaptive Programming examples for crane control...
Page 303 Adaptive Programming examples for crane control...
Page 304: Redundancy In Master/Follower Crane Control
For more information, see the Application Guide for Adaptive Program (3AFE64527274 [English]) and DriveAP User’s Manual (3AFE64540998 [English]). When you use a spare unit, the ACS800 motor output must be provided with an interlock power switch. The spare unit must be connected to the Master/Follower optical fibre ring network (communication channel 2).
Page 305 Adaptive Programming examples for crane control...
Page 306 Note: Only the ring topology is supported. T = Transmitter; R = Receiver; RMIO = I/O and Control Board Please note that channels CH0/CH2/CH3 are located on the optional RDCO-0x board. Master Follower Standby ACS800 ACS800 ACS800 RMIO-XX RMIO-XX RMIOXX...
Page 307 Adaptive Programming examples for crane control...
Page 308 After switching the link mode, the RMIO +24 V DC must be switched OFF/ON before restarting the crane. In the following example: • Drive 01 {0}-{1} is the Master and it is running. • Drive 02 {0}-{2} is a Follower and it is running. •...
Page 309 In the following example: • Drive 01 {0}-{1} in the standby mode and ready. • Drive 02 {0}-{2} is the Master and it is running. • Drive 03 {0}-{3} is a Follower and it is running. Adaptive Programming examples for crane control...
Page 310: Scaling Actual Encoder Position Signal (Mm) To Analogue Output As Ma
Scaling actual encoder position signal (mm) to analogue output as mA The actual encoder position signal 02.21 POS ACT PPU (mm) can be scaled to 4 … 20 mA for analogue outputs and sent to other systems as an mA signal, for example, for supervision or protection purposes.
Page 311: Slack Rope Torque Detection
Slack rope torque detection Using Adaptive Programming (AP), you can create a function for detecting slackness of the ropes on the drum. The slack rope detection is done by monitoring the actual motor torque and comparing it with a slack-rope-detection torque level. When the actual torque of the motor falls below the defined level and the slack rope detection delay has passed, the drive trips on "SLACK FLT".
Page 312 The following figures show the previous example enlarged. Adaptive Programming examples for crane control...
Page 313: Conical Rotor Motors
Conical rotor motors Using the Adaptive Programming (AP), you can create a file for handling brake control of conical rotor motors that do not have an external brake. With the help of Adaptive Programming, the conical rotor motors can be used together with the Crane control program.
Page 314 The following figures show the previous example enlarged. Adaptive Programming examples for crane control...
Page 315: Analogue Extension Module
Analogue Extension Module Chapter overview The chapter describes the use of analogue extension module RAIO as the speed reference interface of an ACS800 drive equipped with the Crane control program. Speed control through the analogue extension module Two variants are described: •...
Page 316: Parameter Settings: Bipolar Input In Basic Speed Control
Parameter settings: bipolar input in basic speed control The table below lists the parameters that affect the handling of the speed reference received through the extension module bipolar input AI1 (AI5 of the drive). Parameter Setting 98.06 AI/O EXT MODULE RAIO-SLOT1 98.13 AI/O EXT AI1 FUNC BIPOLAR AI5...
Page 317: Parameter Settings: Bipolar Input In Joystick Mode
Parameter settings: bipolar input in joystick mode The table below lists the parameters that affect the handling of the speed and direction reference received through the extension module bipolar input AI1 (AI5 of the drive). Parameter Setting 98.06 AI/O EXT MODULE RAIO-SLOT1 98.13 AI/O EXT AI1 FUNC BIPOLAR AI5...
Page 318 Analogue Extension Module...
Page 319: Additional Data: Actual Signals And Parameters
Additional data: actual signals and parameters Chapter overview This chapter lists the actual signal and parameter lists with some additional data. For the descriptions, see chapter Actual signals and parameters. Terms and abbreviations Term Definition Profibus equivalent for drive parameters communicating through the NPBA-12 Profibus Adapter.
Page 320: Actual Signals
1 = 1 V 01.08 MAINS VOLTAGE MAINS V 1 = 1 V 01.09 OUTPUT VOLTAGE OUT VOLT 1 = 1 V 01.10 ACS800 TEMP ACS TEMP 1 = 1°C °C 01.11 EXTERNAL REF 1 EXT REF1 1 = 1 rpm 01.12 EXTERNAL REF 2...
Page 321 Index Name Short name FbEq Unit Range 02.09 TORQUE REF 2 T REF 2 0 = 0% 10000 = 02.10 TORQUE REF 3 T REF 3 100% of motor 02.13 TORQ USED REF T USED R nominal torque 02.14 FLUX REF FLUX REF 0 = 0% 10000 = 100%...
Page 322 Index Name Short name FbEq Unit Range 03.22 3.LATEST FAULT 3.FAULT 0...65535 (Decimal) 03.23 4.LATEST FAULT 4.FAULT 0...65535 (Decimal) 03.24 5.LATEST FAULT 5.FAULT 0...65535 (Decimal) 03.25 LATEST WARNING LAST WRN 0...65535 (Decimal) 03.26 2.LATEST WARNING 2.WARN 0...65535 (Decimal) 03.27 3.LATEST WARNING 3.WARN 0...65535 (Decimal)
Page 323 1) Percent of motor max. speed / nominal torque / max. process reference (depending on the ACS800 macro selected). 2) The contents of these data words are detailed in chapter Fieldbus control. For the contents of Actual Signal 03.11, see the Master/Follower Application Guide [3AFE64590430 (English)].
Page 324: Parameters
Parameters Index Name/Selection User Default START/STOP/DIR 10.01 EXT1 STRT/STP/DIR DI1 F, DI2 R 10.02 EXT2 STRT/STP/DIR NOT SEL 10.03 REF DIRECTION REQUEST 10.04 EXT 1 STRT PTR 10.05 EXT 2 STRT PTR 10.07 NET CONTROL 10.08 NET REFERENCE 10.09 SLOW DOWN INPUT NOT SEL 10.10 FAST STOP PTR...
Page 325 Index Name/Selection User Default 13.12 MAXIMUM AI3 20 mA 13.13 SCALE AI3 100% 13.14 FILTER AI3 0.10 s 13.15 INVERT AI3 13.16 MINIMUM AI5 0 mA 13.17 MAXIMUM AI5 20 mA 13.18 SCALE AI5 100% 13.19 FILTER AI5 0.10 s 13.20 INVERT AI5 13.21...
Page 326 Index Name/Selection User Default 20.11 P MOTORING LIM 300% 20.12 P GENERATING LIM -300% 20.13 MIN TORQ SEL NEG MAX TORQ 20.14 MAX TORQ SEL MAX LIM1 20.15 TORQ MIN LIM1 0.0% 20.16 TORQ MIN LIM2 0.0% 20.17 TORQ MAX LIM2 300.0% 20.18 TORQ MIN PTR...
Page 327 Index Name/Selection User Default 27.04 BR THERM T CONST 27.05 MAX CONT BR POWER 0 kW 27.06 BC CTRL MODE COMMON DC FAULT FUNCTIONS 30.01 AI<MIN FUNCTION FAULT 30.02 PANEL LOSS FAULT 30.03 EXTERNAL FAULT NOT SEL 30.04 MOTOR THERM PROT 30.05 MOT THERM P MODE DTC/USER MODE...
Page 328 Index Name/Selection User Default 42.16 BRK REOPEN DLY ENCODER MODULE 50.01 PULSE NR 1024 1001 50.02 SPEED MEAS MODE A --- B --- 1002 50.03 ENCODER FAULT FAULT 1003 50.04 ENCODER DELAY 1000 1004 50.05 ENCODER DDCS CH CH 1 1005 50.06 SPEED FB SEL...
Page 329 Index Name/Selection User Default 77.15 REF Y2 REV 0 rpm 77.16 CURRENT X3 REV 77.17 REF Y3 REV 0 rpm 77.18 CURRENT X4 REV 77.19 REF Y4 REV 0 rpm 77.20 BASE SPEED 1500 rpm SHAFT SYNCRO 78.01 SYNCRO CONTROL 1519 78.02 SYNCRO GAIN...
Page 330 Index Name/Selection User Default 90.03 AUX DS REF5 1737 90.04 AUX DS REF6 1738 90.05 AUX DS REF7 1739 90.06 AUX DS REF8 1740 90.07 START DS REC 1741 D SET TR ADDR 92.01 MAIN DS STATUS WORD 1771 92.02 MAIN DS ACT1 1772 92.03...
Page 331 MOTOR NOM SPEED 2900 rpm 1933 99.09 MOTOR NOM POWER 0.0 kW 1934 99.10 MOTOR ID RUN MODE ID MAGN 1935 99.11 DEVICE NAME ACS800 CRANE 1936 CONTROL 99.12 OEM SIGNAL ACS800 CRANE 1937 CONTROL Additional data: actual signals and parameters...
Page 332 Additional data: actual signals and parameters...
Page 333: Drivewindow
DriveWindow DriveWindow connected to the ACS800 RMIO/RDCO board and channel CH3. DriveWindow...
Page 334 DriveWindow...
Page 335: Control Block Diagrams
Control block diagrams Control block diagrams...
Page 336 Control block diagrams...
Page 337: Control Block Diagrams
Control block diagrams...
Page 338: Control Block Diagrams
Control block diagrams...
Page 339: Further Information
Product and service inquiries Address any inquiries about the product to your local ABB representative, quoting the type designation and serial number of the unit in question. A listing of ABB sales, support and service contacts can be found by navigating to www.abb.com/drives...
Page 340 Contact us www.abb.com/drives www.abb.com/drivespartners...

ABB ACS800 Firmware Manual

Table of Contents

Introduction to the Manual

Start-Up and Control through the I/O Interface

Quick Start-Up Guide

Control Panel

Program Features

Application Macros, Control Location EXT1/EXT2

Actual Signals and Parameters

Quick Links

Related Manuals for ABB ACS800

Summary of Contents for ABB ACS800