Bakker Sliedrecht Electro Industrie

JAN DE NUL Training

BASIC ACS800 drives

2011

Content Training ACS800 drives

SAFETY Hardware Description - ACS800-01, ACS800-02 - Options - Type coding Software Description - DTC - Standard software, system software Hands-on training
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SAFETY INSTRUCTIONS
Take care of clear general & local working instructions Especially : Always switch off the aux.- & main power Verify that all systems are- & remain safe Beware off charged capacitors Mind your hands when handling very heavy drive modules
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Single - drive structure

Uline UDC Uout

Rectifier L1 Supply L2 L3 Monitoring

DC link + L C Ud

Inverter Motor V1 V3 V5 U1 V1 W1

M3~

V4

V6

V2

Control

Control Electronics control, monitoring and communication

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ABB Drives DTC concept

The DTC Concept

Fast and accurate control

Immediate response to load changes Low audible noise and high motor loadability Energy savings Continuous production after pulse encoder failure Flying restart of motors at network disturbances

Motor state calculation in every 25 s with a powerful digital signal processor (DSP)

Torque Reference

Speed Speed control Referenc e

PID

Torque Reference Controller

Torque and Flux REF Comparator Torque and Flux Motor Model

Switching Logic

Switch positions Voltage Current

3~
Calculated Speed Measured Speed

DTC CORE

Single - drive structure

DC-BUS

Supply Unit

Inverter Unit

3-phase supply

MOTOR 6

Multi-drive structure
DC-BUS

Supply Unit

Inverter Unit

Inverter Unit

Inverter Unit

. . .

3-phase supply

MOTOR 1

MOTOR 2

MOTOR N

Multi-drive structure
DC-BUS

Supply Unit

Inverter Unit

Inverter Unit

Inverter Unit

. . .

3-phase supply

MOTOR

12-Pulse Single-drive structure

DC-BUS

Supply Unit 1

Supply Unit 2

Inverter Unit 1

Inverter Unit 2

Inverter Unit ....7

Brake Chopper

Y D

3-Phase Supply

MOTOR

BRAKE RESISTOR 9

12 Pulse Multi-drive structure

DC-BUS

Supply Unit 1

Supply Unit 2

Inverter Unit 1

Inverter Unit 2

Inverter Unit 1

Brake Chopper

Y D

3-Phase Supply

Retractable Thruster

Tunnel Thruster

10 Brake Resistor

ISU Inverter Supply Unit

Sharing Generator Real power : => Power control engine => Frequency control
G 3~ G 3~

Sharing reactive Generator power

=> generator excitation control => Voltage control

ISU Basics
j L j Li U I U
L

2 gen

U U1 U
2

1
1

L 2

gen

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Network data
6 pulse I THD = 30 % U THD RSC= 20 = 10 % U THD RSC=100 = 2 % cos total = 0,93...0,95

6 - pulse

Current harmonics, 12-pulse rectifier

IHD=7,78

12 pulse I THD = 12 % U THD RSC= 20 = 7 % U THD RSC=100 = 1,4 % cos total = 0,93...0,95

12 - pulse

Current harmonics, IGBT Line converter

IHD=2,05

IGBT Supply unit I THD = 4% U THD RSC= 20 = 3 % U THD RSC=100 = 0,8 % cos 1 =1 cos total = 0,99

IGBT supply

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ISU-Voltage distortion UTHD

4.0

ISU current distortion is under 5 % ISU voltage harmonics depend on short circuit ratio. This is =Ssc(kVA)/Sisu(kVA)
Calculation example: 10kV, SSC=100MVA 1MVA, uk=6% 400V , Ssc= 1/(1/100MVA+0.06/1MVA)= 14MVA Sisu=935kVA =>RSC=14/0.935=15 Uthd=3%, safe value!

3.0 2.0 1.0 0

THD 3 5 7 9 11 13 15

20

25

30

35

40

45

50

5 4 3 2 1 0

UTHD[%] = f(Rsc)

10

20

30

40

50

60

70

80

90

100

Rsc 15

ACS800-xx Single-drives
ACS800-01 => 1.1 - 90 kW

ACS800-02 => 90 - 500 kW

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ACS800-xx Single-drives

ACS800-04 => 1.1 - 90 kW

ACS800-07 => 90 - 500 kW

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ACS800-01 Construction
Easy installation
Plug in option boards Excellent wire bending space because of cabling box Wide cable size range

Easy to replace fan IP 55 as option

ACS800-01 Options
Built-in options:
I/O extension modules Fieldbus modules Pulse encoder module Fibre optic link module (master-follower, PC connection etc.) EMC filter Braking chopper

ACS800-01 R2-R6 Size

R2
Boards Motor Control and I/O Main circuit Filter (EMC or varistor) Soldered PIM (includes braking IGBT) Rectifier (soldered) IGBT (soldered) As option: braking IGBT (soldered)

R3

R4

R5

R6
Motor Control and I/O Main circuit Current measurement (R6) Filter (EMC or varistor) Rectifier (screw) IGBT (screw) As option: braking IGBT (screw) Half controlled input bridge, charging diode and resistor R5 400/500V: on main circuit board Others: busbars / on board 1*DC, intake side With IP 55 also internal fan

Power semiconductors Charging Chokes Main circuit busbars Fan

Relay and charging resistor DC-chokes AC-chokes Main circuit board (some of the busbars on the PCB may be reinforced)

Mechanics

Changeable parts

1*DC, intake side 1 * DC, intake side Internal fan in the Internal fan in the biggest rating of the frame biggest rating of the With IP 55 also internal fan frame With IP 55 also internal fan Injection moulded frame, heat sink in the cast Sheet metal frame Separate lamella aluminium profile heat sink Plastic deck, skeleton and cover Motor Control and I/O Board All Filter (EMC or varistor) Board Control Panel Fan(s) DC-capacitors (R4 only)

ACS800-104LC
Frame Size R7i R8i R8i
2 x R8i 2 x R8i 3 x R8i 4 x R8i

400V
kVA

500V
kVA

690V
kVA

250 500 750 1000 1510 2260 3010

310 630 940 1260 1880 2830 3770

430
870 1300 1730 2600 3900 5200

ACS800-104LC
Capacitor bank and Rdischarge
Bus bars and CTs Heat exchanger

Output filter inductor

Heat sink, IGBT+AGDR, Rfilter

Control electronics

Control Panel (CDP-312R)

Simple and powerful Large display Start-up Assistant Adaptive Programming Backward compatible New display format to set pointer parameters (Group/Index/bit) Version independent parameter up/download

ACS800-x Ratings
Imax = maximum allowed current (absolute value, does not depend on the temperature) Icont.max = maximum continuous current at 40 deg. C IN = base current that allows 10% overloadability for 1 min. (calculated value) Ihd = base current that allows 50% overloadability for 1 min. (calculated value)

ACS800-x Type Code 1/2

ACS800-01 Type Code Sheet
16

3 - 55 kW, Wall Mounted

Updated on 20 Nov 2001

A C S 8 0 0 - 0 1

Product Series

Industry Segment
Industry Segments

79

Construction 01 = Wall Mounted, IP21, with control panel CDP312R, no EMC filter, Standard software, Cable connection box, Braking chopper in frame sizes R2 and R3 Size
0005 Frame Size R3 0011 0016 0020 Frame Size R4 0025 0030

Application Area
Application Areas

1014

Frame Size R2 0004 400V 0003 0006 0009 500V 0004 0009 0005 0011

Frame Size R5 0040 0050

0006

0016 0020 0025

0030 0040

0050 0060 0070

E.g. ACS800-01-0016-3
1516

Voltage Rating
3 = 400 V 5 = 500 V

ACS800-x Type Code 2/2

Option codes
I/O options
L500 L501 L502 L503 L509 L508 Analogue I/O extension Digital I/O extension Pulse encoder interface DDCS Communication 3 DDCS Communication 2 DDCS Communication 1 RAIO-01 RDIO-01 RTAC-01 RDCO-03 RDCO-02 RDCO-01

2 slots available for I/O options or Fieldbus adapters. Communication board has always one dedicated slot. 2 digital I/O extension are supported.

Fieldbus
K451 K454 K458 DeviceNet adapter Profibus-DP adapter Modbus adapter RDNA-01 RPBA-01 RMBA-01

Software
N650 N651 N666 N653 N654 PFC Macro Master/Follower Macro Extruder Application FCB Programmable Template Spinning Macro Check availability Check availability Check availability

Control panel
J405 No control panel

E.g. ACS800-01-0016-3+E202+L500

Protection class
B056 P901 IP55 Coated boards

Filters
E202 EMC/RFI-filters, 1st Environment, Restricted (A-limits, Earthed Network)

Resistor braking
D150 Braking chopper

Included as standard in frame sizes R2 and R3

Cabling
H358 Cable conduit box (US & UK version)

ACS800 R8i parallel connection

fromR M IO (P PC S) PPC S (8 M bit/s) R C H 1R C H 2R C H 3 D D C S (PC )

ASFC -01

APBU -42 or -44 SW IT C H APBU APEB -84 FU SE (O ES L) ... PPC S (8 M bit/s) IN V 3 ... 11

* * * * * * * * * *

A S F C -0 1 A P B U -4 2 A P B U -4 4 A P E B -8 4 A IN T -1 2 A G D R -6 X A G P S -2 1 A P O W -0 1 A F IN -0 1 A F P S -0 1

S w itc hF u s eC o n tro lle r (o p tio nM D ) P P C SB ra n c h in gU n it P P C SB ra n c h in g&D a ta lo g g e rU n it P P C SE x te n s io nB o a rd M a inC irc u it In te rfa c e IG B TG a teD riv e rB o a rd G a teD riv e rP o w e rS u p p ly In v e rte rP o w e rS u p p ly F a nIn v e rte r (o p tio n ) F a nP o w e rS u p p ly (o p tio n )

IN V3

IN VE N SAFE TY SW IT C H U D CO K

SAFE TY SW IT C H IN VE R TER 2 AG PS -21

SAFE TY SW IT C H IN VE R TER 12 AG PS -21

AINT AIN T -12
S PE E D

ASFC -01

IN VE R TER 1 AG PS -21 APO W -01 AFPS -01 AFIN -01

AGDR AG D R -6X

AINT AIN T -12

S PE E D

APO W -01 AFPS -01 AFIN -01

... M AX 12 pcs

APO W -01 AFPS -01 AFIN -01

AINT AIN T -12

S PE E D

AGDR AG D R -6X

AGDR AG D R -6X

FAN 3 x 6 x IG BT 3 x I 3xT U D C

FAN 3 x 6 x IG BT 3xI U 3xT D C

FAN 3 x 6 x IG BT 3xI U 3xT D C

ACS800-02 Circuit Boards

RDCO option
CH-3

ACS 800-02
CDP 312R

FAN

~230

+24V

AIBP

ADPI

APOW
+24V

CH-2

AINP AINT

CH-1

RMIO

CH-0

Option modules
External option modules

Option modules

AGDR
V W

+ -

Pulse encoder, Fieldbus, Extended I/O

RDCU =>
modbus 19,2 kbit/s

RMIO Board + I/O

Slot 1 DigitalI/OExtension(RDIO) AnalogueI/OExtension(RAIO) PulseEncoderInterface (RTAC) FieldbusInterface Slot 2 DigitalI/OExtension(RDIO) AnalogueI/OExtension(RAIO) PulseEncoderInterface (RTAC) Slot 3 DDCSLink(RDCO-0x)
PPCS 8 Mbit/s

Control Panel CDP312R

External power supply 24VDC

Reference voltage
(10V max 10mA)

2 Analog inputs 2 Analog outputs

7 Digital inputs

3 Digital outputs

Connection to drive module when n x R8i true APBU44 Connection to Application Controller eg. AC80 or AC800M I/O-Module Extension

PC-Tool DriveWindow Master / Follower -connection

DDCS 1 Mbit/s

DDCS 4 Mbit/s

DDCS 4 Mbit/s

DDCS 4 Mbit/s

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Maximum I/O configuration with AIMA-01

I/OExtension RMIO Basic-I/O RDIO DI/O EXT 1 RDIO DI/O EXT2 RDIO DI/O EXT3 RDIO DI/O EXT4 RDIO DI/O EXT5 RAIO AI/O EXT1 RAIO AI/O EXT2 RAIO AI/O EXT3 RAIO AI/O EXT4 RAIO AI/O EXT5 RTAC Tacho interface NTAC-02 Tacho interface Sum Digitalinput 7 3 3 3 3 3 Digitalouput 3 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 22 13 13 12 2 Analoginput 3 Analogoutput 2 Tacho interface

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PPCS Branching Unit APBU-44/84

Includes parallel connection support for 2-12 inverter modules. Basic board APBU-44 supports 2-4 inverter modules and with APEB-84C option board up to 12 inverter modules. APBU-44 includes fast data logger. Data can be uploaded via PPCS link to be analysed. This function can be used to find faulty component in the main circuit.

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Motor Control and I/O Board (RMIO)

3 programmable relay outputs

ACS800-02 Main Circuit Board (AINT)

Contains all the high voltage and internal measurement components of the drive Automatic current measurement scaling - no need for soldered slots Powers the AINP and AGDR boards (+ ABRK board) Earth fault and short circuit protections Adjustable earth fault current trip limit Earth fault detection is based on output phase currents One type can be used with all ACS800-02 types

ACS800-02 Gate Driver Board (AGDR)

Connected directly to the IGBT module Gate control, saturation feedback and the temperature measurement functions are linked via the board

ACS800-02 Power Supply Board (APOW)

Feeds power directly to the RMIO and AINT board Supply for the AINP board is connected via AINT board
Connected directly to the DC link

ACS800-02 Input Bridge Control Board (AINP)

Turns on the input bridge thyristors
Power supply via AINT

Charging controlled by

sw:
Input bridge is turned on, when the DC-link voltage has reached 0.7 * 1.35 * 380 V and the voltage rise is < 0.01 * UN / 10 ms

ACS800-02 Input Bridge Protection Board (AIBP)

Protects the input bridge from transients

ACS800-02 Brake Chopper Control Board (ABRK)

Controls the chopper IGBT and measures its saturation voltage and temperature Control and power from AINT: Turns the IGBT on, when the DC-link voltage is > 1.21 * UN Braking chopper and resistor protections done by sw

Diagnostic and panel interface board (ADPI)

Panel connectors, Red and Green indication leds located on the board Two boards connected parallel in every module (for flat and bookshelf assembly)

Both control panels places plug & play - two panels cannot be used simultaneously

ACS800-02 Filter Boards (ARFC & NRFC)

Used for 1st environment filter Cannot be used in IT networks Features Up to 100 m motor cable length EN 61800-3

Differences base software RMIO Board

OVERRIDING SYSTEM

HARDWARE

RDCU => ( RMIO )

APPLICATIE SOFTWARE

DTC
41

Speed & Torque Control

n1
T1 SUPPLY n

N Ref.

T
3~

M1
3~

n%

100

2 3

1 4
100 T%

42

Application program types

Standard application program System application program Diode supply control program IGBT supply control program Brake chopper control program Multi Block application program Crane control program Template application program

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PLC <=> Profibus <=> RMIO

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Profibus Link
FIELDBUS

FBA
FBI DDCS

OPTICAL LINK
BAUDRATE: 4 Mbit/s INTERVAL: appr. 8 ms
REQUEST

DRIVE
DDCS PAR

RESPONSE

FBA FBI DDCS PAR

= Fieldbus Adapter = Fieldbus Interface = Distributed Drive Communication System = Parameter Table
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ProfibusPPO1PPO5
Parameter Identification
ID IND VALUE CW SW REF1 REF2 ACT1 ACT2 PD1 PD1

Process Data
PD2 PD2 PD3 PD3 PD4 PD4 PD5 PD5 PD6 PD6 PD7 PD7

PPO Type 1 PPO Type 2 PPO Type 3 PPO Type 4 PPO Type 5

46

Functions in ABB Drive Software

Motor speed reference ramp Motor speed control Motor torque control Motor flux control Calculation actual motor data Fast limit loops for drive and motor Fast master / slave control
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Functions in SIEMENS PLC

Analogue & digital interface Custom application software Calculation drive speed- & torque reference Detection, alarm & fault logics Control from drive touch panel Control & protection liquid cooling system
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