Welcome to ABB machinery drives training. This training module will introduce you to the ACS850-04, the ABB machinery drive module. 1
Upon the completion of this module, you will be able to describe the commissioning process of the ACS850-04, and describe what steps it requires. To commission an ACS850-04 safely and set it up for optimal performance, you must check that the equipment to be used with the drive is compatible, ensure that it is safe to run the drive, verify that the mechanical and electrical installation are done correctly, configure the drive, motor, and feedback and control interfaces, and tune the performance of the drive system. We present here a basic overview of the commissioning. Application-specific details, such as setting up the field-bus interface are not included in this module. 2
The commissioning process can be divided into nine steps. Most of the steps are generally the same regardless of what type of application the drive is used for. The last three steps regarding the set-up of the braking system, tuning the speed control and performing the test cycle depend more on the drive system configuration. 3
Before you do the commissioning, you have to check the equipment. You have to know what type of motor is driven, what its ratings are, and what kind of temperature measurement it uses. First determine the motor type. The supported motor types are listed here. The ACS850-04 drive supports a large variety of speed measurement options in case very high accuracy is needed. If the drive is controlled through a PLC, check that it has the correct fieldbus adapter. Different fieldbus protocols require different interface adapters. 4
Next, check that the environment is appropriate for the drive s ratings and protection class. For instance, the supply voltage has to be correct for the drive, the ambient temperature has to be within the allowed limits, the drive must be installed so that no contaminants endanger proper functioning, The drive must not be subjected to excess vibration, the cabinet must be in proper condition and the electrical installation must fulfill EMC requirements. Please refer to the hardware manual for technical details. 5
Check that the electrical installation is done safely. The power cables for the supply, motor and possibly the braking resistor must be properly connected. Also check their groundings. Measure that the insulation resistance is high enough. Check that no unexpected voltages can appear in the drive. For example, a rotating PM motor can make the drive live even when it is switched off. Always follow the safety instructions in the hardware manual. 6
Check that it is safe to rotate the motor. It must be able to turn in both directions. Check whether the rotational speed of the motor or the movement of the machine are limited in some way. When running the motor for the first time, it is important to make sure everyone in the vicinity is aware that the machine will be started. Ensuring the safety of others is always the first priority. 7
There are two ways of locally setting the drive start-up parameters. Parameters can be set either with the control panel or with a PC Tool such as DriveStudio. When using the control panel, start-up is limited to very basic settings. It should be noted that the start-up procedure includes actions which need to be performed only when the drive is powered up for the first time. After the first start-up, the drive can be powered up without using these start-up functions. Please refer to the appropriate Firmware manual to set the start-up parameters. 8
In order to control the motor, the ACS850-04 must first identify its characteristics. There are three identification alternatives. The normal method delivers the best motor control performance. During a normal ID run the load machine should be de-coupled from the motor. The second method is a reduced method that provides good motor control performance. Limited opposing loading is allowed. The third method is a standstill method, which offers moderate motor control performance. This method does not rotate the motor. Autophasing is a method to identify only the mechanical position difference between the poles of the permanent magnet and position feedback device, such as the resolver or absolute encoder. We will discuss this in more detail later in this training module. 9
As mentioned before, a normal ID run achieves the best motor-control performance. Use this mode whenever possible. It is especially recommended when the drive doesn t have speed feedback, and when the operating point is in the low-speed range. During a normal identification run, the drive accelerates the motor to about 80% - 100% of its nominal speed. An induction motor s magnetization level is varied between 50% - 110%. To do this type of ID run, you must ensure that the opposing-torque of the load is less than 20%. If the load is too high, or if the machinery can t withstand the torque that occurs, you must first decouple the machine from the motor. 10
The Reduced ID run mode is useful when the opposing load can t be decoupled from the motor. This ID run method accelerates the motor to the same speed as the normal ID run. As the motor is fully magnetized, the load s opposing-torque can be as high as 60%. Reduced ID run is suitable for conical motors because the rotor must be magnetized in order to open the mechanical brake. 11
This is an illustration of the speed and current profile during a normal or reduced ID run. Its duration depends on the inertia of the load. Typically it lasts about one or two minutes. Note that the auto-phasing routine may slightly turn the PM motor at the beginning of phase 2. 12
Sometimes you can t decouple the motor from the load, or run it at full speed. In such case you can use the standstill method to identify the motor without running it. In this mode, the motor is injected with DC current, but, for synchronous motors, the shaft doesn t rotate. Only phase 1 and 2 in the graph are done. For a PM motor, however, the shaft will rotate slightly during the autophasing process. The accuracy of this method is not as good as the previous methods and the control performance without speed feedback is limited. 13
This mode is visible only with long menus. Normally you do not have to change these parameter values. Motor model parameters can be entered directly without an ID run. These are in group 97. The core parameters can be given as SI or per-unit values. Note that you can also see the results of an ID run here. Please refer to the firmware manual for more information on this group. 14
The autophasing that was mentioned before is an automatic routine to determine the error in the alignment between the rotor magnets of a permanent magnet motor and the absolute-position measurement-device. If, for example, a resolver is manually replaced, you would need to do auto-phasing to ensure that it s aligned with the rotor. The error value will be stored in the drive's permanent memory. 15
For detailed instructions on how to use the control panel, see ACS850-04 Control Panel User s Guide. The parameters can be also set by using DriveStudio. It is often convenient to use DriveStudio s quick-help feature to get information about a certain parameter. The different assistants in the control panel are explained in the following slides. 16
When the drive is powered up, the start-up Assistant guides you through the set-up of the basic parameters. The start-up assistant is divided into separate assistants, each of which is responsible for the specification of a related parameter set. The assistants also check that the entered values are valid, that is, within the allowed limits. It is, of course, possible to adjust the drive parameters in the conventional way without using the assistant at all. There are four different firmware assistants: -Application Macro -Motor set-up -Start/Stop control, and -Reference select. The firmware assistants are routines that guide the user through the essential parameter settings. Application assistants are intended for specialized applications, such as crane and winch applications, which require additional features from the drive. 17
The next example shows, how the commissioning of an asynchronous motor is done. The start-up values for the motor are given in the name plate shown here. The motor s rating data which is needed in the ID run is represented in its name plate and in the motor catalogue. Example of an AM motor name plate is on the left side and PM motor name plate is on the right. 18
The motor setup assistant is used to set up the motor parameters. Press in the actual values in the soft key Menu. Motor setup assistant goes through the important parameters in group 99 and allows set up of the limits for safe operation. The motor nominal current, voltage, frequency, speed and other core values are taken directly from the nameplate. The allowed range of the nominal current depends on the motor control method used. With direct torque control (DTC), the nominal current can be set from one-sixth to two times the In value. If there are multiple motors connected to the inverter, the rules for the values are somewhat different, so refer to the firmware manual in those cases. The motor nominal frequency can be from 5 to 500 Hz. If the frequency is not given in the nameplate, it can be calculated from the nominal speed. 19
1) Motor start up assistant is selected from main menu view Assistants. The view changes to assistants view. Select Firmware assistants and then Motor set up. 2) First selection is for motor type, either AM for asynchronous motor or PMSM for permanent magnet synchronous motor. 3) Select motor control mode : Direct Torque Control DTC or Scalar control. DTC is suitable for most applications. Scalar control is recommended for - some multimotor drives - when nominal current of the motor is less than 1/6 of the nominal output current of the inverter. - when drive is used without a motor connected - when drive runs a medium voltage motor via a step-up transformer 4) Give motor nominal current value. If multiple motors are connected to the drive, enter the total current of motors 5) Motor nominal voltage. 6) Motor nominal frequency 7) Motor nominal speed 20
8) The motor nominal power must be given (in kilowatts or horsepower). If multiple motors are connected, enter the total power. 9) For permanent magnet motors, the cosphi value is not relevant. If this value is given, it should match the nameplate value. 10) Setting the nominal torque at the operation point will improve the accuracy of the motor torque estimation, but not the stability of the motor control itself. 11) Before the ID run, check that the maximum speed parameter 20.01 has at least the value of motor nominal speed, otherwise it will interfere with the ID run. 21
12) The motor setup assistant finishes by asking whether the motor id run should be performed or not. If yes, the final step is to select the id run mode. The drive must be in local mode. The id-run is performed when the drive is started. 22
Now we are ready to start the ID run. We select, for example, the normal ID run mode. At this point you must ensure that it s safe to run the motor at full speed. If applicable, the mechanical brake has to be released. Then we take control of the drive and start the run. It may take one or two minutes depending on the time required to accelerate the load. 23
Application macros are pre-defined parameter sets. When starting up the drive, the user typically selects one of the macros as a basis, makes the essential changes and saves the result as a user parameter set. The 5 different macros in the standard control program are: -Factory macro -Hand/Auto macro -PID control macro -Torque control macro, and -Sequential control macro The factory macro is suited to relatively straightforward speed control applications such as conveyors, pumps and fans. The hand/auto macro is used in speed control applications where two external control devices are used (potentiometer and PLC, for example). The PID control macro is suitable for process control applications, such as closed-loop pressure, level or flow control systems. The torque control macro is used in applications in which torque and or speed control of the motor is required. The sequential control macro is suited for speed control applications in which speed reference, multiple constant speeds, and two acceleration and deceleration ramps can be used. The last four macros have their own specific parameter value sets that differ from the factory macro values. Please refer to the appropriate Firmware manual for further information of the application macros. 24
The Start Stop control assistant will automatically set up, for instance: -the source for start and stop signals of the two external control locations -the Start Stop mode of the motor -the source of the external Run Enable signal and -the source of the emergency stop signal The Reference select assistant guides the user, for example: -to select the control mode for external control places -to select the speed or torque reference sources and to define other parameters related to them -to define analog input set-up if either is selected as speed or torque reference source 25
The ACS850-04 standard control program has six different maintenance counters that can be configured to generate an alarm when the counter reaches a pre-defined limit. In that sense the counters work as service reminders. A counter can be set to monitor any parameter. There are three types of counters: On time counter, Rising edge counter and Value counter. On time counter measures the time a digital source, for example a bit in a status word, is on. Rising edge counter is incremented whenever the monitored digital source changes state from 0 to 1. Value counter measures, by integration, the monitored parameter. An alarm is given when the calculated area below the signal peak exceeds a user-defined limit. Every counter has two selectable modes. In the Loop mode the counter is automatically reset after reaching the alarm limit and the alarm is active for 10 seconds and then disappears. The difference in the saturate mode is that the alarm remains active until the manual reset is given. 26
Here s a list of the most essential user configurable motor protections. The motor s thermal protection is based on its thermal protection model and on measurements either via the encoder module or the control board. The latter method results in a more accurate motor model. The motor s thermal protection is configured in parameter group 31. The speed limitation protection limits the maximum speed, and the torque limitation protection limits the maximum torque in both directions. Drive operation limits are found in parameter group 20. These limits must be set according to the application requirements. 27
The ACS850-04 contains both non-programmable and programmable protection functions. The most important protective supervisions which protect the drive hardware are non-programmable and cannot be disabled. The programmable protection functions can be set to trip the drive while it is running, display only a warning message or some of them can be totally disabled. 28
After commissioning the motor, setting its protective functions, and tuning its speed control, it's recommended to back up all the parameters and possibly the solution program. Recording backups and parameter copying can be done both with Control Panel and DriveStudio. The first action is to create a backup file and upload it to the panel by using MAKE BACKUP TO PANEL selection. When this is completed, the backup file information can be checked. There are four different ways to restore values back to drive. 29
DriveStudio backup/restore functionality has the same basic features as in control panel. Additionally it is possible to customize the restore of parameters and user sets. 30
For more information regarding commissioning, please see the ACS850 hardware manuals that are available online. In the manuals, focus on the chapters listed. 31
Thank you for viewing the presentation. 32