ACS800 Firmware Manual - Motion Control Rev C

 

ACS800

Firmware Manual ACS800 Motion Control Application Program 7.x

 

 ACS800 Motion Control Application Program 7.x

Firmware Manual

3AFE68373026 REV C DRAFT EN EFFECTIVE: 28.02.2007

! 2006

ABB Oy. All Rights Reserved.

 

5 

Table of Contents

Table of Contents Introduction to the manual 

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Reader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Start-up

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 How to start-up the drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 How to control the drive d rive through the I/O interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 How perform the ID. Run 20 IDto Run Procedure . . . . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 20 Control panel 

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Overview of the panel pan el . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Panel operation operatio n mode keys and displays displa ys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Status row . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Drive control with the panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 How to start, stop and change cha nge direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 How to set speed reference referen ce . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24  Actual signal display d isplay mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 How to select actual signals signa ls to the display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 How to display the full name of the actual signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 How to view and reset the fault history . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 How to display and reset r eset an active fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27  About the fault history hi story . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Parameter mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 How to select a parameter and change the value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 How to adjust a source selection (pointer) parameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Function mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 How to upload data d ata from a drive to the pa panel nel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 How to download data from the panel to a drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 How to set the contrast of the display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Drive selection mode mod e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 How to select a drive and change its panel link ID number . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Reading and entering packed boolean boole an values on the display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 34

Table of Contents

 

6 

Basic program features

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Local control vs. external control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Local control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . External control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

35 35 35 36 36

Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Block diagram: start, stop source for EXT1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reference types and processing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Programmable analogue anal ogue inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Update cycles in the Motion Control Application Applica tion Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Speed control through RAIO analogue analogu e extension module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Basic checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Settings of the analogue extension module and the drive . . . . . . . . . . . . . . . . . . . . . . . . . .  Analogue input signal conversion to a speed spe ed value in rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . Programmable analogue outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

36 37 38 40 40 41 41 41 41 42 42 42 42 43

Update cycles Applica Settings . . . . .in. the . . . .Motion . . . . . Control . . . . . . .Application . . . . . .tion . . .Program . . . . . . . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Programmable digital inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Update cycles in the Motion Control Application Applica tion Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Programmable relay outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Update cycles in the Motion Control Application Applica tion Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  Actual signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Motor identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power loss ride-through . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  Automatic Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DC Magnetising . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Flux Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Flux Optimisation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  Acceleration and deceleration dece leration ramps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Speed controller tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

43 43 43 44 44 44 44 45 45 45 45 46 46 46 47 47 47 48 48 48 48 48 49 49 49 50 50 50 51

Table of Contents

 

7 

Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Speed control performance p erformance figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Torque control performance figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Hexagonal motor flux . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Programmable protection functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53  AI 0.0 rpm O SPEED 0.0 RPM TORQUE 0.00 % MODE ACK SPEED

…after which the display suggests starting the Language Selection.

1  

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

->

0.0 rpm

O

The drive is now ready for the start-up.

Start-up

 

16 

Press ACT to remove the suggestion on starting the language selection. The drive is now ready for the limited start-up.

1 -> 0.0 rpm O SPEED 0.0 RPM TORQUE 0.00 % MODE ACK SPEED

ST TART-UP DAT DATA ENTERING ENTER ING (parameter group 99) MANUAL S

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

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

O

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

O

- Press PAR  PAR  to  to select the Parameter Mode of the panel. - Pre Press ss the dou double ble-ar -arrow row key ( - Pre Press ss the arrow arrow key (

or

or

) to scroll scroll the pa param ramete eterr groups groups..

) to scroll scroll par parame ameter ters s wit within hin a gro group. up.

- Activate the setting of a new value by ENTER . - Cha Change nge the value value by the arrow arrow key ( arrow key ( or ).

or

), fas fastt change change by the double double--

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

Enter the motor data from the motor nameplate:

Note: Set the motor data Note: to exactly the same value as on the motor nameplate.

 ABB Motors 3

motor 

V 690 Y 400 D 660 Y 380 D 415 D 440 D Cat. no

M2AA 200 MLA 4

IEC 200 M/L 55 No Ins.cl. F Hz kW r/min A cos 1475 32.5 0.83  30 50 56 1475 50 0.83  30 50 1470 34 0.83  30 1470  30 59 0.83 50 1475 50 54 0.83  30  35 59 0.83 1770 60 3GAA 202 001 - ADA

6312/C3

IP 55 IA/IN t E/s

6210/C3

380 V mains voltage

180 IEC 34-1

- motor nominal voltage  Allowed range: 1/2 · U N  … 2 · U N of ACS800. (U  (U N refers to the highest voltage in each of the nominal voltage ranges: 415 VAC for 400 VAC units, 500 VAC for 500 VAC units units and 690 VAC for 600 V VAC AC units.)

- motor nominal current  Allowed range: approx. 1/6 · I 2hd  2hd 

O

1 -> 0.0 rpm O 99 START-UP DATA 04 MOTOR NOM CURR [ ]

- motor nominal frequency Range: 8…300 Hz

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

- motor nominal speed

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

Range: 1…18000 rpm

Start-up

… 2 · I 2hd  2hd of ACS800

 1 -> 0.0 rpm 99 START-UP DATA 03 MOTOR NOM VOLT [ ]

 

17 

-motor nominal power  Range: 0…9000 kW

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

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

 1 ->  ACS800

0.0 rpm

O

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

Select the motor identification method. The default value ID MAGN (ID Magnetisation) is suitable for most applications. It is applied in this basic start-up procedure. If your selection is ID Magnetisation, move to next step without pressing any key. The ID Run (STANDARD or REDUCED) should be selected if 

 1 -> 0.0 rpm 99 START-UP DATA 08 ID RUN [ ]

O

- the operation point is near zero speed, and/or  - operation at torque range above the motor nominal torque within wi thin a wide speed range and without any measured speed feedback is required. If your selection is ID Run, continue by following the separate instructions given a few pages ahead in subsection How to perform the ID Run. IDENTIFICATION MAGNETISATION MAGNETISATION (with Motor ID Run selection ID MAGN)

Press the LOC/REM  key  key to change to local control (L shown on the first row). Press to start the Identification Magnetisation. The motor is magnetised at zero speed for 20 to 60 s. Three warnings are displayed: The first warning is displayed when the magnetisation starts. The second warning is displayed while the magnetisation is on. The third warning is displayed after the magnetisation is completed.

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

I

 1 L-> 0.0 rpm ** WARNING ** ID MAGN

I

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

O

DIRECTION OF ROT ROTA ATION OF THE MOTOR

Check the direction of rotation of the motor. - Press ACT  to  to get the status row visible. - Increase the speed reference from zero to a small value (e.g. 50 rpm) rpm) by pressing pressing REF  and and then then the the arr arrow key ( , , or ). - Press

1 -> 0.0 rpm O SPEED xx RPM TORQUE xxx % MODE ACK SPEED

to start the motor.

- Check that the motor is running in the desired direction. - Stop the motor by pressing

.

Start-up

 

18 

To change the direction of rotation of the motor: - Disconnect mains power from the drive, and wait 5 minutes min utes for the intermediate circuit capacitors to discharge. Measure the voltage between each input terminal (U1, V1 and W1) and earth with a multimeter to ensure that the frequency converter is discharged. - Exchange the position of two motor cable cabl e phase conductors at the motor terminals or at the motor connection box.

forward direction

reverse direction

- Verify your work by applying mains power and repeating the check che ck as described above. ENCODER SETTINGS (if used)

Set encoder interface parameters. Check the functioning of the encoder interface: Set parameter 19.02 SPEED 19.02 SPEED ACT FB SEL to INTERNAL and compare signals 03.06 SPEED 03.06 SPEED MEAS ENC1 and 03.05 03.05 SPEED  SPEED ESTIMATED. If signal values differ  - check encoder interface parameters (group 50 ENCODER MODULES)) MODULES - check that the sign of signal 03.06 SPEED 03.06 SPEED MEAS ENC1 matches the rotation direction. The sign is affected by cable phasing. Check the encoder hardware configuration. (See the encoder Hardware Manual.) The drive is now ready for use.

Start-up

See group 50 ENCODER MODULES

 

19

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 •

th the e mot motor or sta start rt-u -up p is perf perfor ormed med,, and

•

the de defaul faultt (factor (factory) y) pa param rameter eter settings settings are valid. valid. PRELIMINARY SETTINGS

Ensure the Factory macro is active.

See parameter 99.02 99.02..

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

See chapter Application chapter Application macros.. macros

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

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

STARTING AND CONTROLLING THE SPEED OF THE MOTOR

Start by switching digital input DI1 on.

1 -> SPEED TORQUE

0.0 rpm I 0.0 RPM 0.00 %

MODE ACK SPEED

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

1 I ->1242.0 rpm SPEED 1242.00 rpm TORQUE 10.00 % MODE ACK SPEED

STOPPING THE MOTOR

Switch off digital input DI1.

1 -> 500.0 rpm O SPEED 0.0 RPM TORQUE 0.00 % MODE ACK SPEED

Start-up

 

20 

How to perform the ID Run The drive performs the ID Magnetisation automatically at the first start. In most applications there is no need to perform a separate ID Run. The ID Run (Standard or Reduced) should be selected if  • the oper operatio ation n point point is near near zer zero o speed speed,, and/or  and/or  • operation operation at torque range above above the the motor motor nominal nominal torque torque within within a wide speed speed range and without any measured speed feedback is required. The Reduced ID Run is to be performed instead of the Standard if it is not possible to disengage the driven machine from the motor. ID Run Procedure Note: If parameter values (Group 10 to 98) are changed before the ID Run, check Note: that the new settings meet the following conditions:

• 20.01 MIN 20.01 MIN SPEED < 0 rpm • 20.02 20.02 MAX  MAX SPEED > 80% of motor rated speed • 20.05 20.05 MAX  MAX CURRENT > 100% · I hd 20.07 TORQ  TORQ MAX LIM > 50% • 20.07 • Ensure that that the panel panel is in in the local local control control mode (L displayed displayed on the status status row). row). Press the LOC/REM  key  key to switch between modes. • Change Change the ID Run Run select selection ion to to STANDA STANDARD RD or REDUCED. REDUCED. • Press ENTER  to  to verify selection. The following message will be displayed on the control panel: 1 L ->1242.0 rpm

O

 ACS800 **WARNING** ID RUN SEL

• To start start the ID ID Run, start the drive. drive. The The Run Enable Enable signal signal must be active active (see parameter 10.07 RUN 10.07 RUN ENABLE). Control panel warnings Warning when the ID Run is started 1 L -> 1242.0 rpm  ACS800 **WARNING** MOTOR STARTS

I

Warning during the ID Run 1 L -> 1242.0 rpm  ACS800 **WARNING** ID RUN

I

Warning after a successfully completed comp leted ID Run 1 L -> 1242.0 rpm  ACS800 **WARNING** ID DONE

I

In general it is recommended not to press any control panel keys during the ID run. However: • The Motor Motor ID Run Run can can be be stoppe stopped d at any time. time. Start-up