ABB ACS860 Use and care manual

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ABB INDUSTRIAL DRIVES
ACS860 primary control program
Firmware manual

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List of related manuals
You can find manuals and other product documents in PDF format on the Internet. See
section
Document library on the Internet on the inside of the back cover. For manuals not
available in the Document library, contact your local ABB representative.
*Available in the Document library.
Other drive hardware manuals
ACS860-104 inverter modules hardware manual 3AXD50000034054
ACS860-107 inverter units hardware manual 3AXD50000034048
Drive firmware manuals and guides
ACS860 primary control program firmware manual 3AXD50000034052
ACS860 drives with primary control program, quick start-
up guide
3AXD50000034105
Option manuals and guides
ACX-AP-x assistant control panels user’s manual 3AUA0000085685
Drive composer Start-up and maintenance PC tool user’s
manual
3AUA0000094606
Manuals and quick guides for fieldbus adapters, encoder
interfaces, etc.

Firmware manual
ACS860 primary control program
3AXD50000034052 Rev B
EFFECTIVE: 2019-12-06
 2019 ABB Beijing Drive Systems Co. Ltd.
All Rights Reserved.
Table of contents

Table of contents 5
Table of contents
1. Introduction to the manual
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Applicability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Target audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Contents of the manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Related documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Terms and abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Cybersecurity disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2. Using the control panel
3. Control locations and operating modes
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Local control vs. external control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Local control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
External control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Operating modes of the drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Speed control mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Torque control mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Frequency control mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Special control modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4. Program features
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Drive configuration and programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Programming via parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Adaptive programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Control interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Programmable analog inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Programmable analog outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Programmable digital inputs and outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Programmable relay outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Fieldbus control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Master/follower functionality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
External controller interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Motor control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Vector control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Reference ramping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Constant speeds/frequencies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Critical speeds/frequencies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Speed controller autotune . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Oscillation damping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Safety

6 Table of contents
Resonance frequency elimination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Rush control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Encoder support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Jogging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Scalar motor control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Flux braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
DC magnetization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Application control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Application macros . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Motor potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Mechanical brake control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
DC voltage control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Overvoltage control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Undervoltage control (power loss ride-through) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Voltage control and trip limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Brake chopper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Safety and protections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Emergency stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Motor thermal protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Automatic fault resets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Other programmable protection functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Fault and warning messages, data logging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Signal supervision . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Maintenance timers and counters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Energy saving calculators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Load analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
User parameter sets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Parameter checksum calculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
User lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Data storage parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Reduced run function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
du/dt filter support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
5. Application macros
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Factory macro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Default parameter settings for the Factory macro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Default control connections for the Factory macro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Hand/Auto macro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Default parameter settings for the Hand/Auto macro . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Default control connections for the Hand/Auto macro . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Torque control macro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Default parameter settings for the Torque control macro . . . . . . . . . . . . . . . . . . . . . . . . . 84
Default control connections for the Torque control macro . . . . . . . . . . . . . . . . . . . . . . . . 85
Sequential control macro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Operation diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Selection of constant speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

Table of contents 7
Default parameter settings for the Sequential control macro . . . . . . . . . . . . . . . . . . . . . . 87
Default control connections for the Sequential control macro . . . . . . . . . . . . . . . . . . . . . . 88
Fieldbus control macro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
6. Parameters
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Terms and abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Summary of parameter groups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Parameter listing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
01 Actual values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
03 Input references . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
04 Warnings and faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
05 Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
06 Control and status words . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
07 System info . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
10 Standard DI, RO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
11 Standard DIO, FI, FO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
12 Standard AI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
13 Standard AO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
19 Operation mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
20 Start/stop/direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
21 Start/stop mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
22 Speed reference selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
23 Speed reference ramp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
24 Speed reference conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
25 Speed control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
26 Torque reference chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
28 Frequency reference chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
30 Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
31 Fault functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
32 Supervision . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
33 Generic timer & counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
35 Motor thermal protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
36 Load analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
44 Mechanical brake control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
45 Energy efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
46 Monitoring/scaling settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
47 Data storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
49 Panel port communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
50 Fieldbus adapter (FBA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
51 FBA A settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
52 FBA A data in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
53 FBA A data out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
58 Embedded fieldbus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256
60 DDCS communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
61 D2D and DDCS transmit data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
62 D2D and DDCS receive data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
90 Feedback selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278
91 Encoder module settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284
92 Encoder 1 configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285

8 Table of contents
95 HW configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287
96 System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
97 Motor control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
98 User motor parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304
99 Motor data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305
7. Additional parameter data
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311
Terms and abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311
Parameter groups 1…9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312
Parameter groups 10…99 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316
8. Fault tracing
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343
Indications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343
Warnings and faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343
Pure events . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344
Editable messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344
Warning/fault history and analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344
Event logs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344
Other data loggers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345
Parameters that contain warning/fault information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345
QR Code generation for mobile service application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346
Warning messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 347
Fault messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 362
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 381
9. Fieldbus control through the embedded fieldbus interface (EFB)
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 383
System overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 383
Connecting the fieldbus to the drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 384
Setting up the embedded fieldbus interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 385
Setting the drive control parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 386
Basics of the embedded fieldbus interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 389
Control word and Status word . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 390
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 390
Actual values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 390
Data input/outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 390
Register addressing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 391
About the control profiles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 392
The ABB Drives profile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 393
Control Word . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 393
Status Word . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 395
State transition diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 396
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 397
Actual values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 398
Modbus holding register addresses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 399

Table of contents 9
The Transparent profile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 400
Modbus function codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
Exception codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
Coils (0xxxx reference set) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
Discrete inputs (1xxxx reference set) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
Error code registers (holding registers 400090…400100) . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
10. Fieldbus control through a fieldbus adapter
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407
System overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407
Basics of the fieldbus control interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409
Control word and Status word . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
Actual values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411
Contents of the fieldbus Control word (ABB Drives profile) . . . . . . . . . . . . . . . . . . . . . . 413
Contents of the fieldbus Status word (ABB Drives profile) . . . . . . . . . . . . . . . . . . . . . . . 414
The state diagram (ABB Drives profile) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415
Setting up the drive for fieldbus control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 416
Parameter setting example: FPBA (PROFIBUS DP) . . . . . . . . . . . . . . . . . . . . . . . . . . . 417
11. Control chain diagrams
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419
Speed reference source selection I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 420
Speed reference source selection II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 421
Speed reference ramping and shaping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 422
Motor feedback configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 423
Load feedback and position counter configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 424
Speed error calculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 425
Speed controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 426
Torque reference source selection and modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 427
Operating mode selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 428
Reference selection for torque controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 429
Torque limitation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 430
Torque controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 431
Frequency reference selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 432
Frequency reference modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 433
Master/Follower communication I (Master) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 434
Master/Follower communication II (Follower) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 435
Further information

10 Table of contents

Introduction to the manual 11
1
Introduction to the manual
What this chapter contains
This chapter describes the contents of the manual. It also contains information on the
compatibility, safety and intended audience.
Applicability
This manual applies to ACS860 primary control program version 2.9x or later.
The firmware version of the control program is visible in parameter 07.05 Firmware
version, or the System info in the main menu on the drive control panel.
Safety instructions
Follow all safety instructions delivered with the drive.
• Read the complete safety instructions before you install, commission, or use
the drive. The complete safety instructions are delivered with the drive as either
part of the Hardware manual, or, in the case of ACS860 multidrives, as a
separate document.
• Read the firmware function-specific warnings and notes before changing
parameter values. These warnings and notes are included in the parameter
descriptions presented in chapter Parameters.
Target audience
This manual is intended for people who design, commission, or operate the drive
system.

12 Introduction to the manual
Contents of the manual
This manual contains the following chapters:
•Using the control panel provides basic instructions for the use of the control panel.
•Control locations and operating modes describes the control locations and
operating modes of the drive.
•Program features contains descriptions of the features of the ACS860 primary
control program.
•Application macros contains a short description of each macro together with a
connection diagram. Macros are pre-defined applications which will save the user
time when configuring the drive.
•Parameters describes the parameters used to program the drive.
•Additional parameter data contains further information on the parameters.
•Fault tracing lists the warning and fault messages with possible causes and
remedies.
•Fieldbus control through the embedded fieldbus interface (EFB) describes the
communication to and from a fieldbus network using the embedded fieldbus
interface of the drive.
•Fieldbus control through a fieldbus adapter describes the communication to and
from a fieldbus network using an optional fieldbus adapter module.
•Control chain diagrams showing the parameter structure within the drive.
Related documents
Note: A quick start-up sequence for a speed control application is provided by
ACS860 drives with primary control program, Quick start-up guide
(3AUA0000034053), delivered with the drive.
A list of related manuals is printed on the inside of the front cover.

Introduction to the manual 13
Terms and abbreviations
Term/abbre-
viation Definition
AC 800M Type of programmable controller manufactured by ABB.
ACS800 A product family of ABB drives
ACS-AP-I Types of control panel used with ACS860 drives
ACS-AP-W
AI Analog input; interface for analog input signals
AO Analog output; interface for analog output signals
BCU Type of control unit used in ACS860 drive systems, primarily those with
parallel-connected inverter or supply modules.
DC link DC circuit between rectifier and inverter
DDCS Distributed drives communication system; a protocol used in communication
between ABB drive equipment
DI Digital input; interface for digital input signals
DIO Digital input/output; interface that can be used as a digital input or output
DO Digital output; interface for digital output signals
Drive Frequency converter for controlling AC motors. The drive consists of a rectifier
and an inverter connected together by the DC link. In drives up to
approximately 500 kW, these are integrated into a single module (drive
module). Larger drives typically consist of separate supply and inverter units.
The ACS860 primary control program is used to control the inverter part of the
drive.
DriveBus A communication link used by, for example, ABB controllers. ACS860 drives
can be connected to the DriveBus link of the controller. See page 34.
Vector Control See page 36.
EFB Embedded fieldbus interface. See page 383.
FBA Fieldbus adapter
FCAN-01 Optional CANopen adapter
FDCO-0x Optional DDCS communication module
FDNA-01 Optional DeviceNet™ adapter
FEN-01 Optional TTL encoder interface module
FEN-31 Optional HTL encoder interface module
FENA-11 Optional Ethernet/IP, Modbus/TCP and PROFINET IO adapter
FENA-21 Optional dual-port Ethernet/IP, Modbus/TCP and PROFINET IO adapter
FEPL-02 Optional POWERLINK adapter
FPBA-01 Optional PROFIBUS DP adapter
FSCA-01 Optional Modbus/RTU adapter
HTL High-threshold logic
ID run Motor identification run. During the identification run, the drive will identify the
characteristics of the motor for optimum motor control.

14 Introduction to the manual
IGBT Insulated gate bipolar transistor; a voltage-controlled semiconductor type
widely used in inverters and IGBT supply units due to their easy controllability
and high switching frequency
INU-LSU Type of optical DDCS communication link between two converters, for
example the supply unit and the inverter unit of a drive system.
Inverter unit The part of the drive that converts DC to AC for the motor.
I/O Input/Output
ISU An IGBT supply unit; type of supply unit implemented using IGBT switching
components, used in regenerative and low-harmonic drives.
Line-side
converter
See supply unit.
LSU See supply unit.
ModuleBus A communication link used by, for example, ABB controllers. ACS860 drives
can be connected to the optical ModuleBus link of the controller.
Motor-side
converter
See inverter unit.
Network
control
With fieldbus protocols based on the Common Industrial Protocol (CIPTM),
such as DeviceNet and Ethernet/IP, denotes the control of the drive using the
Net Ctrl and Net Ref objects of the ODVA AC/DC Drive Profile. For more
information, see www.odva.org, and the following manuals:
• FDNA-01 DeviceNet adapter module User’s manual (3AFE68573360
[English]), and
•FENA-01/-11 Ethernet adapter module User’s manual (3AUA0000093568
[English]).
Parameter User-adjustable operation instruction to the drive, or signal measured or
calculated by the drive
PID controller Proportional–integral–derivative controller. Drive speed control is based on
PID algorithm.
PLC Programmable logic controller
Power unit Contains the power electronics and power connections of the drive (or inverter
module). The drive control unit is connected to the power unit.
PTC Positive temperature coefficient
PU See power unit.
RDCO-0x DDCS communication module
RFG Ramp function generator.
RO Relay output; interface for a digital output signal. Implemented with a relay.
SSI Synchronous serial interface
DIL Drive interlock
Supply unit The part of the drive that converts AC to DC. An IGBT supply unit (ISU) is also
capable of feeding regenerative energy back into the supply network.
TTL Transistor-transistor logic
Term/abbre-
viation Definition

Introduction to the manual 15
UPS Uninterruptible power supply; power supply equipment with battery to
maintain output voltage during power failure
ZCU Type of control unit used in ACS860 drives (primarily in drive modules, or
inverter/supply units consisting of a single power module). Consists of an I/O
board built into a plastic housing.
Depending on the type of hardware, the control unit may be integrated into or
fitted onto the drive/inverter module, or installed separately.
Term/abbre-
viation Definition

16 Introduction to the manual
Cybersecurity disclaimer
This product is designed to be connected to and to communicate information and
data via a network interface. It is Customer's sole responsibility to provide and
continuously ensure a secure connection between the product and Customer network
or any other network (as the case may be). Customer shall establish and maintain
any appropriate measures (such as but not limited to the installation of firewalls,
application of authentication measures, encryption of data, installation of anti-virus
programs, etc) to protect the product, the network, its system and the interface
against any kind of security breaches, unauthorized access, interference, intrusion,
leakage and/or theft of data or information. ABB and its affiliates are not liable for
damages and/or losses related to such security breaches, any unauthorized access,
interference, intrusion, leakage and/or theft of data or information.
See also section User lock (page 75).

Using the control panel 17
2
Using the control panel
Refer to ACX-AP-x assistant control panels user’s manual (3AUA0000085685
[English]).

18 Using the control panel

Control locations and operating modes 19
3
Control locations and
operating modes
What this chapter contains
This chapter describes the control locations and operating modes supported by the
control program.

20 Control locations and operating modes
Local control vs. external control
The ACS860 has two main control locations: external and local. The control location
is selected with the Loc/Rem key on the control panel or in the PC tool.
Local control
The control commands are given from the control panel keypad or from a PC
equipped with Drive composer when the drive is set to local control. Speed and
torque control modes are available for local control; frequency mode is available
when scalar motor control mode is used (see parameter 19.16 Local control mode).
Local control is mainly used during commissioning and maintenance. The control
panel always overrides the external control signal sources when used in local control.
Changing the control location to local can be prevented by parameter 19.17 Local
control disable.
The user can select by a parameter (49.05 Communication loss action) how the drive
reacts to a control panel or PC tool communication break. (The parameter has no
effect in external control.)
Control panel or Drive
composer PC tool (optional)
Fieldbus adapter (Fxxx)
or DDCS communication
module
1) Encoder or resolver interface module(s) (FEN-xx) installed in drive slot 1.
MOTOR
PLC
M
3~
Embedded fieldbus
interface (EFB) or
master/follower link
External control
Local control
Encoder
1)
ACS860
Control panel