ABB ACS880 Series Owner's manual

—
ABB INDUSTRIAL DRIVES
ACS880 Cavitation detection control program
Supplement

ACS880 Cavitation detection control
program
Supplement
Table of contents
3AXD50000639199 Rev A
EN
EFFECTIVE: 2020-10-06

Table of contents
1 Introduction to the manual
7Contents of this chapter ...........................................................................
7Applicability .........................................................................................
7Safety instructions .................................................................................
7Target audience ....................................................................................
8Related manuals ...................................................................................
8Terms and abbreviations ..........................................................................
2 Program Features
9Contents of this chapter ...........................................................................
9Cavitation detection overview ....................................................................
9Cavitation detection function based on torque .................................................
10Settings and diagnostics ......................................................................
10Cavitation detection function based on speed .................................................
11Settings and diagnostics ......................................................................
11Cavitation detection function based on torque and speed ...................................
11Settings and diagnostics ......................................................................
11Autodetection function in normal conditions ...................................................
12Normal torque rms autodetection ............................................................
12Settings and diagnostics ...................................................................
12Normal speed rms autodetection ............................................................
13Settings and diagnostics ...................................................................
13Combination rms autodetection ..............................................................
14Settings and diagnostics ...................................................................
14Pump speed reference connection and control ...............................................
15Settings and diagnostics ......................................................................
15Enabling/disabling the Cavitation detection control program ................................
16Settings and diagnostics ......................................................................
16Cavitation protection ...............................................................................
20Settings and diagnostics ......................................................................
20End of tank function ...............................................................................
21Settings and diagnostics ......................................................................
3 Parameters
23Contents of this chapter ...........................................................................
23Terms and abbreviations ..........................................................................
23Parameter listing ...................................................................................
2307 System info ..................................................................................
2409 Application Signals .........................................................................
2586 Cavitation Protection .......................................................................
2687 Pump Mode and Reference Selection ...................................................
2888 Variable Variations Calculations ..........................................................
4 Fault tracing
31Contents of this chapter ...........................................................................
Table of contents 5

31Warning messages ................................................................................
32Fault messages ....................................................................................
Further information
6 Table of contents

Introduction to the manual
Contents of this chapter
This chapter contains general information on the manual. It also contains information on
the compatibility, safety and intended audience.
Applicability
This document is a supplement to ACS880 Primary control program firmware manual
(3AUA0000085967 [English]). This manual applicable to ACS880 Cavitation detection control
program (version 8.2.1.2 or later).
This supplement contains only information relevant to ACS880 Cavitation detection program.
For information on general firmware-related issues (parameters, faults, warnings etc.)
concerning ACS880 Primary control program, see ACS880 Primary control program firmware
manual (3AUA0000085967 [English]).
Safety instructions
Obey 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 ACS880 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 (page 23).
Target audience
This manual is intended for people who design, commission, or operate the drive system.
1
Introduction to the manual 7

Related manuals
CodeName
Drive hardware manuals
Drive hardware manual (varies depending on the drive type)
Drive firmware manuals and guides
3AUA0000085967ACS880 primary control program firmware manual
3AUA0000098062Quick start-up guide for ACS880 drives with primary control program
Option manuals and guides
3AUA0000085685ACX-AP-x assistant control panels user’s manual
3AUA0000094606Drive composer start-up and maintenance PC tool user’s manual
Manuals and quick guides for I/O extension modules, fieldbus adapters, encoder
interfaces, etc.
Terms and abbreviations
See ACS880 primary control program firmware manual (3AUA0000085967[English]).
8 Introduction to the manual

Program Features
Contents of this chapter
This chapter describes functions of the control program.
Cavitation detection overview
The Caviation detection control program is an IEC program loaded on ACS880 drive. The
program uses the drive torque, the drive speed or a combination of these two to detect high
variations of torque or speed in the pump motor. In most cases, these variations are caused
by cavitation or other mechanical issues.
The program detects cavitation by monitoring torque, speed or the combination of these
two. The user can select the most suitable monitoring method depending on the application.
It varies, case by case, which is the most suitable method.
Cavitation detection function based on torque
The Cavitation detection function based on the torque monitoring operates in these three
consecutive (and constantly repeated) phases:
2
Program Features 9

1. The function measures torque samples during a user-defined sample period (88.03), and
calculates:
•average torque (09.02),
• for each sample, the sample variation vs. the average torque,
•the effective (rms) value of all sample variation values (09.01).
2. The function compares the actual variation value (09.01) to the reference/normal variation
value (88.02) defined during the Autodetection period (88.08) by forming a relation
between theses two variation values (09.03).
3. The function compares the variation relation (09.03) to the allowed threshold value (88.04).
If the relation exceeds the threshold value for a time longer than the user-defined delay
(88.10), the program indicates cavitation (86.09).
Note: The indication is given only if the Cavitation detection control program is active (86.01),
87.08 Operation mode selection is set to value Torque and the selector for the cavitation
trigger signal (86.02) must point to torque.
If the Cavitation detection control program detects a change in speed reference, the Cavitation
detection function is temporarily disabled to avoid false signals caused by torque or speed
variations. The disabling only takes place if the change is in effect for a certain time period.
For calculating this time period, the function uses the change in speed reference, speed
scaling (46.01), acceleration/deceleration times (23.12/23.13) and a time coefficient (88.06).
￭Settings and diagnostics
Parameters: 09.01,86.01,86.02,87.08,88.01,88.02,88.03,88.04,88.05,88.06.
Events: E100 Cavitation fault,E200 Pump not started,E201 Pump does not reach speed,
E202 Cavitation alarm.
Cavitation detection function based on speed
The Cavitation detection function based on the speed monitoring operates in these three
consecutive (and constantly repeated) phases:
1. The function measures torque samples during a user-defined sample period (88.03), and
calculates:
•average speed (09.06),
• for each sample, the sample variation vs. the average speed,
•the effective (rms) value of all sample variation values (09.05).
2. The function compares the actual variation value (09.05) to the reference/normal variation
value (88.09) defined during the Autodetection period (88.08) by forming a relation
between theses two variation values (09.07).
3. The function compares the variation relation (09.07) to the allowed threshold value (88.11).
If the relation exceeds the threshold value for a time longer than the user-defined delay
(88.10), the program indicates cavitation (86.09).
Note: The indication is given only if the Cavitation detection control program is active (86.01),
87.08 Operation mode selection is set to value Speed and the selector for the cavitation
trigger signal (86.02) must point to speed.
If the Cavitation detection control program detects a change in speed reference, the Cavitation
detection function is temporarily disabled to avoid false signals caused by torque or speed
10 Program Features

variations. The disabling only takes place if the change is in effect for a certain time period.
For calculating this time period, the function uses the change in speed reference, speed
scaling (46.01), acceleration/deceleration times (23.12/23.13) and a time coefficient (88.06).
￭Settings and diagnostics
Parameters: 09.05,86.01,86.02,87.08,88.03,88.09,88.10,88.11,88.13
Events: E100 Cavitation fault,E200 Pump not started,E201 Pump does not reach speed,
E202 Cavitation alarm.
Cavitation detection function based on torque and speed
The Cavitation detection function based on monitoring torque and speed operates in these
three consecutive (and constantly repeated) phases:
1. The function measures torque and speed samples during a user-defined sample period
(88.03), and calculates:
•average speed (09.06) and average torque (09.02),
• for each sample, the sample variation vs. the average value (calculated separately
for torque and speed),
• the effective (rms) values of all sample variation values (calculated separately for
torque (09.01) and speed (09.05)).
2. The function calculates the sum of relative variation values (sum of 09.03 and 09.07).
This sum is shown in 88.16.
3. The function compares the sum 88.16 to the allowed threshold value (88.14). If the
relation exceeds the threshold value for a time longer than the user-defined delay (88.11),
the program indicates cavitation (86.09).
Note: The indication is given only if the Cavitation detection control program is active (86.01),
87.08 Operation mode selection is set to value Combination and the selector for the cavitation
trigger signal (86.02) must point to combination.
If the drive detects a change in speed reference, the Cavitation detection function is
temporarily disabled to avoid false signals caused by torque or speed variations. The
disabling only takes place if the change is in effect for a certain time period. For calculating
this time period, the function uses the change in speed reference, speed scaling (46.01),
acceleration/deceleration times (23.12/23.13) and a time coefficient (88.06).
￭Settings and diagnostics
Parameters: 86.01,86.02,87.08,88.03,88.06,88.14,88.15,88.16,88.17
Events: E100 Cavitation fault,E200 Pump not started,E201 Pump does not reach speed,
E202 Cavitation alarm.
Autodetection function in normal conditions
The Cavitation control program can calculate torque variation rms, speed variation rms or
a combination of both in normal conditions with the Autodetection functions. These reference
values are used when the program monitors cavitation.
Program Features 11

￭Normal torque rms autodetection
Normal torque rms autodetection calculates the torque rms variation value in normal
conditions. The function measures torque samples during a user-defined sample period
(88.08), and calculates:
•average torque (09.02),
• for each sample, the sample variation value vs. average torque,
•the effective (rms) value of all sample variation values (88.02).
Parameters of the Normal speed rms autodetection function are these:
•autodetection activation (88.07),
•autodetection time (88.08),
•variable selection (87.08) = Torque,
•average torque (09.02),
•normal torque variation rms value calculated by the autodetection (88.02),
•filter time for motor torque (46.13).
The autodetection calculates the normal torque variation rms value at one operation point
(speed reference value). Autodetection starts when:
•user has set the activation parameter (88.07) to value Run pump autotune,
•user has set the variable selection (87.08) = Torque,
• user has started the drive,
• the drive operates at its speed reference value.
Possible auto-detection failures are:
•User does not start the drive: Drive indicates warning E200 Cavitation alarm, and
autodetection (88.07) changes back to Done. Normal torque variation rms value (88.02)
remains unchanged.
• The control program detected a motor speed change (acceleration/deceleration), and
the change lasted too long: Drive shows a warning E201 Pump Does not reach speed
and autodetection (88.07) changes back to Done. Normal torque variation rms value
(88.02) remains unchanged.
Settings and diagnostics
Parameters: 09.02,87.08,88.02,88.07,88.08.
Events: E200 Pump not started,E201 Pump does not reach speed.
￭Normal speed rms autodetection
Normal speed rms autodetection calculates the speed variation rms value in normal
conditions. The function measures speed samples during a user-defined sample period
(88.08), and calculates:
•average speed (09.06),
• for each sample, the sample variation value vs. average speed,
•the effective (rms) value of all sample variation value (88.09).
Parameters of the Normal speed rms autodetection function are these:
12 Program Features

•autodetection activation (88.12),
•autodetection time (88.08),
•variable selection (87.08) = Speed,
•average speed (09.06),
•normal speed variation rms value calculated by the autodetection (88.09),
•filter time for motor speed (46.11).
The auto-detection calculates the normal speed variation rms value at one operation point
(speed reference value). Autodetection starts when:
•user has set the activation parameter (88.12) to value Run pump autotune
•user has set the variable selection (87.08) = Speed
• user has started the drive
• the drive operates at its speed reference value.
Possible autodetection failures are:
•User does not start the drive: Drive indicates warning E200 Pump not started, and
autodetection (88.12) changes back to Done. Normal speed variation rms value (88.09)
remains unchanged.
• The control program detected a motor speed change (acceleration/deceleration), and
the change lasted too long: Drive shows a warning E201 Pump Does not reach speed
and autodetection (88.12) changes back to Done. Normal speed variation rms value
(88.09) remains unchanged.
Settings and diagnostics
Parameters: 09.06,87.08,88.08,88.09,88.12.
Events: E200 Pump not started,E201 Pump does not reach speed.
￭Combination rms autodetection
The combined autodetection calculates both the torque variation rms value and the speed
variation rms value in the normal conditions. The sum value is then used in the Cavitation
detection function. See the corresponding sections in the section Cavitation detection.
Parameters of the Combination rms autodetection function are these:
•autodetection activation (88.18)
•autodetection time (88.08)
•variable selection (87.08) = Combination
•the sum of torque variation rms and speed variation rms in normal conditions (88.16)
•filter time for motor torque (46.13) and filter time for motor speed (46.11).
The autodetection calculates the normal torque and normal speed variation rms values at
one operation point (speed reference value). Autodetection starts when:
•user has set the activation parameter (88.18) to value Run pump autotune
•user has set the variable selection (87.08) = Combination
• user has started the drive
• the drive operates at its speed reference value.
Program Features 13

Possible autodetection failures are:
•User does not start the drive: Drive indicates warning E200 Cavitation alarm, and
autodetection (88.18) changes back to Done. Speed and torque combination indicator
(88.16) remains unchanged.
• The control program detected a motor speed change (acceleration/deceleration), and
the change lasted too long: Drive shows a warning E201 Pump Does not reach speed
and autodetection (88.18) changes back to Done. Speed and torque combination indicator
(88.16) remains unchanged.
Settings and diagnostics
Parameters: 87.08,88.07,88.08,88.09,88.15,88.16,88.18.
Events: E200 Pump not started,E201 Pump does not reach speed.
Pump speed reference connection and control
You can use the Cavitation detection control program in two ways:
1. To detect and indicate cavitation.
2. To detect and indicate cavitation, and to control the pump speed (Cavitation protection).
If you want that the Cavitation detection control program controls the pump speed, you must
set the speed reference output of the control program (09.04) as the speed reference source
for the drive (parameter 22.11 or 22.12). Make consistent selections in parameters 22.13
and 22.14. See the diagram below and the ACS880 Primary control program firmware
manual (3AUA0000085967 [English]).
When the pump operates normally, the output reference of the Cavitation detection control
program (09.04) is equal to its input reference (87.05). If the program detects cavitation, the
value of the output reference (09.04) changes as the control program decreases its speed
reference output by the pre-defined steps. See Cavitation protection (page 16).
14 Program Features

22.13
Ref1
22.14
1
0
MUL
SUB
ADD
MIN
MAX
0
AI
FB
…
Other
…
0
AI
FB
…
Other
…
Speed reference selection and handling
Cavitation detection control program
87.05
87.06
Zero Speed
FBA A Reference
Other
Internal Ref. Cavitation
detection
Drive
speed reference
03.05 09.04
Speed reference selection
Primary control program
22.11
22.12
22.81
22.82
22.83
￭Settings and diagnostics
Parameters: 22.11,22.12,22.13,22.14,87.05
Events: -
Enabling/disabling the Cavitation detection control program
The Cavitation detection control program is enabled by two signals:
1. 86.01 Cavitation Protection En/Dis must be set to Enable.
2. The mode selection parameters (87.04,87.02 and 87.03) must enable the operation
(bit 0 of 87.01 must be 1 (true)).
The Cavitation detection control program operates only when it is enabled with the
enable/disable parameter (86.01). In addition, there is also a separate function that you can
use for the enable/disable control, the Pump mode monitoring (87.01,87.02,87.03 and
87.04). This function monitors two user-defined signals, and on basis of their states, it forms
the additional enable/disable signal for the Cavitation detection control program. With this
function, you can, for example, enable the operation of the control program only in the
Program Features 15

external (remote) control mode of the drive, and disable it every time that user switches the
drive in local control mode (operates the drive with the panel). See the block diagram below.
87.03
87.02
86.01
FALSE
TRUE
Other
*
FALSE
TRUE
Other
Disable
Enable
87.01
87.04
Input1
In1 AND In2
In1 OR In2
Bit 0
Bit 1
Bit 2
(1
(2
(1
(2
AND
Enable/disable Cavitation protection
control program
*
￭Settings and diagnostics
Parameters: 86.01,87.01,87.02,87.03,87.04.
Events: -
Cavitation protection
In the Cavitation detection control program, the Cavitation detection function is active always
when the program is enabled. The program protects the pump only when the program
controls the motor speed in case of cavitation.
If the Cavitation detection control program detects a possible cavitation situation and the
program has been configured to control the drive speed (09.04 is set as the speed reference
source in 22.11 or 22.12), the program starts to decrease the speed by steps (86.05) in
order protect the pump. After each step, the program examines if there is still cavitation. If
cavitation continues, the drive reduces the speed more after a time delay (86.06) by a new
speed step.
If the program reduces the drive speed to the minimum protection speed (86.04) and
cavitation continues for a predefined time (86.07), the protection function generates a fault
or warning depending on the user selection (86.03).
At each speed step, if the drive does not detect cavitation for the pre-defined time (86.08),
the speed reference starts to increase by steps (86.05).
Cavitation detection and protection are inactive if:
16 Program Features

•the speed reference input (87.05) connected to the Cavitation detection control program
changes.
•Normal torque rms autodetection (88.07), Normal speed rms autodetection (88.12) or
Combination rms autodetection (88.18) is ongoing.
•Mode selection parameters disable the protection function (Bit 0 is False in 87.01). See
Enabling/disabling the Cavitation detection control program (page 15).
•the Cavitation detection control program is disabled (86.01).
Program Features 17

Examples of Cavitation protection:
• The program detects cavitation continuously and the pump is set to trip after 5 seconds
of running at minimum speed.
18 Program Features

• The drive detects cavitation occasionally and the speed goes up and down. At minimum
speed, the program detects cavitation for a time that is shorter than 86.07, so the drive
does not trip.
Program Features 19

•86.03 Cavitation Fault/Alarm is set to Alarm and 86.10 End of Tank Detection to Enabled.
The program does not increase speed after the drive has run for 3 seconds at minimum
speed although cavitation continues.
￭Settings and diagnostics
Parameters: 86.01,86.03,86.04,86.05,86.06,86.07,86.08,86.10,87.01,87.05,88.07,
88.12,88.18.
Events: E100 Cavitation fault,E200 Pump not started,E201 Pump does not reach speed,
E202 Cavitation alarm.
End of tank function
The End of Tank function (86.10) is suitable for applications in which a pump is used to
empty a tank, and it is essential to get the tank completely empty before a re-fill, despite of
the pump cavitation. If End of tank function is enabled (86.10), the counter of the End of
tank delay (86.11) starts when the drive reaches the minimum speed (86.04). If there is
cavitation throughout the whole delay time (86.11), the End of tank function starts. The End
of tank function prevents the program from increasing speed, even if cavitation is not detected
at some point, thus the drive runs at minimum speed until it is stopped (or the drive trips to
a fault). If the program does not detect cavitation during End of tank delay (86.11), the End
of tank function does not start and the drive can increase the speed again. If you enable
the End of tank function, you usually also set the fault/warning selection (86.03) to Warning
to prevent the cavitation fault trip during the End of tank period.
20 Program Features