ABB ACS880 Series Use and care manual
—
ABB INDUSTRIAL DRIVES
ACS880 ESP control program (option
+N5600)
Firmware manual
Table of contents
1 Introduction to the manual
17What this chapter contains ....................................................................................
17Applicability ...............................................................................................................
17Licensing ....................................................................................................................
18Safety instructions ...................................................................................................
19Target audience ........................................................................................................
19Related manuals .......................................................................................................
20Terms and abbreviations ........................................................................................
21Cybersecurity disclaimer ........................................................................................
2 Using the control panel
3 Quick start-up guide
25Contents of this chapter .........................................................................................
25Before you start ........................................................................................................
25Safety ..........................................................................................................................
26Start-up ......................................................................................................................
36ESP application minimum configuration .............................................................
4 Control locations and operating modes
39What this chapter contains ....................................................................................
39Local control vs. external control ..........................................................................
40Local control .......................................................................................................
41External control .................................................................................................
41Using the control panel as an external control source ..................
42Operating modes of the drive ...............................................................................
42Speed control mode .........................................................................................
43Torque control mode ........................................................................................
43Frequency control mode ..................................................................................
43Special control modes ......................................................................................
5 ESP program features
45What this chapter contains ....................................................................................
46Overview of ESP control program .........................................................................
46Backspin supervision ...............................................................................................
46Restart delay ......................................................................................................
46Backspin speed observer .................................................................................
Table of contents 5
48Backspin speed observer constraints ...........................................................
49Settings and diagnostics ....................................................................
49Starting the motor ...................................................................................................
49Kick-start ............................................................................................................
50Settings and diagnostics ....................................................................
50Starting speed ...................................................................................................
50Current pulse-start ...........................................................................................
51Settings and diagnostics ....................................................................
51Acceleration assistance ...................................................................................
51Settings and diagnostics ....................................................................
51Pump impeller cleaning ...........................................................................................
52Settings and diagnostics ................................................................................
53ESP production mode ..............................................................................................
53Manual mode ......................................................................................................
53Automatic process control mode ..................................................................
55Settings and diagnostics ....................................................................
55Underload and overload protection .....................................................................
57Underload ride through recovery sequence ................................................
59Overload recovery sequence ...........................................................................
61Settings and diagnostics ....................................................................
61Sync loss function ....................................................................................................
62Settings and diagnostics ................................................................................
62Motor voltage control ..............................................................................................
63Settings and diagnostics ................................................................................
63Medium voltage direct settings ............................................................................
63Settings and diagnostics ................................................................................
63Automatic restart .....................................................................................................
64Settings and diagnostics ................................................................................
64Pump curves ..............................................................................................................
65Settings and diagnostics ................................................................................
65Diagnostics ................................................................................................................
65Signal supervision .............................................................................................
65Settings and diagnostics ....................................................................
6 Program features
67What this chapter contains ....................................................................................
68Drive configuration and programming ................................................................
68Programming via parameters ........................................................................
69Adaptive programming ....................................................................................
69Settings and diagnostics ....................................................................
69Application programming ...............................................................................
70Control interfaces ....................................................................................................
70Programmable analog inputs .........................................................................
70Settings and diagnostics ....................................................................
6 Table of contents
70Programmable analog outputs ......................................................................
70Settings and diagnostics ....................................................................
70Programmable digital inputs and outputs ..................................................
71Settings and diagnostics ....................................................................
71Programmable frequency input and output ................................................
71Settings and diagnostics ....................................................................
71Programmable relay outputs ..........................................................................
71Settings and diagnostics ....................................................................
71Programmable I/O extensions .......................................................................
72Settings and diagnostics ....................................................................
72Fieldbus control .................................................................................................
72Settings and diagnostics ....................................................................
72Master/follower functionality ........................................................................
72General ....................................................................................................
74Load share function with a speed-controlled follower .................
75Communication .....................................................................................
77Construction of the master/follower link ........................................
79Example parameter settings ..............................................................
80Specifications of the fiber optic master/follower link .................
80Settings and diagnostics ....................................................................
81External controller interface ...........................................................................
81General ....................................................................................................
81Topology .................................................................................................
82Communication .....................................................................................
83Motor control ............................................................................................................
83Direct torque control (DTC) ............................................................................
83Settings and diagnostics ....................................................................
84Reference ramping ...........................................................................................
84Special acceleration/deceleration ramps ........................................
84Settings and diagnostics ....................................................................
85Constant speeds/frequencies .......................................................................
85Settings and diagnostics ....................................................................
85Critical speeds/frequencies ...........................................................................
85Example ..................................................................................................
86Settings and diagnostics ....................................................................
86Critical speeds ...................................................................................................
86Example ..................................................................................................
87Settings and diagnostics ....................................................................
87Speed controller autotune ..............................................................................
88Before activating the autotune routine ...........................................
89Autotune modes ...................................................................................
89Autotune results ...................................................................................
90Warning indications .............................................................................
90Settings and diagnostics ....................................................................
Table of contents 7
90Oscillation damping .........................................................................................
91Tuning procedure for oscillation damping ......................................
91Settings and diagnostics ....................................................................
91Resonance frequency elimination ..................................................................
91Settings and diagnostics ....................................................................
92Rush control .......................................................................................................
92Settings and diagnostics ....................................................................
92Encoder support ................................................................................................
93Encoder echo and emulation ..............................................................
93Load and motor feedback ...................................................................
94Position counter ....................................................................................
95Encoder error handling ........................................................................
96Reading/writing position counter values through fieldbus ........
96Configuration of HTL encoder motor feedback .............................
97
Example 1: Using the same encoder for both load and motor
feedback .................................................................................................
97Example 2: Using two encoders .........................................................
98Example 3: ACS 600 / ACS800 compatibility ..................................
99Settings and diagnostics ....................................................................
99Jogging ...............................................................................................................
101Settings and diagnostics ....................................................................
101Scalar motor control .........................................................................................
102IR compensation for scalar motor control ......................................
102Settings and diagnostics ....................................................................
102Autophasing .......................................................................................................
104Autophasing modes .............................................................................
105Settings and diagnostics ....................................................................
105Flux braking ........................................................................................................
106Settings and diagnostics ....................................................................
106DC magnetization .............................................................................................
106Pre-heating .............................................................................................
106Pre-magnetization ................................................................................
106DC hold ....................................................................................................
107Post-magnetization ..............................................................................
107Continuous magnetization .................................................................
108Settings and diagnostics ....................................................................
108Motor temperature estimation ......................................................................
108Settings and diagnostics ....................................................................
109Application control ...................................................................................................
109Application macros ...........................................................................................
109Process PID control ...........................................................................................
109Quick configuration of the process PID controller ........................
110Sleep function for process PID control .............................................
111Tracking ..................................................................................................
111Settings and diagnostics ....................................................................
8 Table of contents
112Motor potentiometer .......................................................................................
112Settings and diagnostics ....................................................................
113Mechanical brake control ................................................................................
113Inputs of the brake control logic .......................................................
113Outputs of the brake control logic ....................................................
114Brake state diagram .............................................................................
116Timing diagram .....................................................................................
117Wiring example ......................................................................................
118Settings and diagnostics ....................................................................
118DC voltage control ....................................................................................................
118Overvoltage control ..........................................................................................
118Undervoltage control (power loss ride-through) .......................................
119Automatic restart .................................................................................
120Settings and diagnostics ....................................................................
121Voltage control and trip limits .......................................................................
121Settings and diagnostics ....................................................................
122Brake chopper ....................................................................................................
122Settings and diagnostics ....................................................................
122DC voltage boost ..............................................................................................
122Description of the DC voltage boost function ................................
123Use case examples ...............................................................................
124Limits .......................................................................................................
127Safety and protections ............................................................................................
127Emergency stop ................................................................................................
127Settings and diagnostics ....................................................................
128Motor thermal protection ...............................................................................
128Motor thermal protection model .......................................................
128Temperature monitoring using PTC sensors ..................................
130Temperature monitoring using Pt100 or Pt1000 sensors ............
130Temperature monitoring using KTY84 sensors .............................
131Motor fan control logic (parameters
35.100
…
35.106
) ..................
131Ex motor support (parameter
95.15
, bit 0) ......................................
131Settings and diagnostics ....................................................................
132Motor overload protection ..............................................................................
132Settings and diagnostics ....................................................................
133Thermal protection of motor cable ...............................................................
133Settings and diagnostics ....................................................................
133User load curve ..................................................................................................
134Settings and diagnostics ....................................................................
134Automatic fault resets .....................................................................................
135Settings and diagnostics ....................................................................
135Other programmable protection functions ................................................
135External events (parameters
31.01
…
31.10
) ......................................
135Motor phase loss detection (parameter
31.19
) ...............................
135Earth (Ground) fault detection (parameter
31.20
) .........................
Table of contents 9
135Safe torque off detection (parameter
31.22
) ..................................
135Swapped supply and motor cabling (parameter
31.23
) ................
136Stall protection (parameters
31.24
…
31.28
) .....................................
136Overspeed protection (parameter
31.30
) ........................................
136
Ramp stop supervision (parameters
31.32
,
31.33
,
31.37
and
31.38
).......................................................................................................
136Main cooling fan supervision (parameter
31.35
) ............................
136Custom motor current fault limit (parameter
31.42
) .....................
136Local control loss detection (parameter
49.05
) .............................
137Diagnostics ................................................................................................................
137Fault and warning messages, data logging ................................................
137Signal supervision .............................................................................................
137Settings and diagnostics ....................................................................
137Maintenance timers and counters .................................................................
137Settings and diagnostics ....................................................................
138Energy saving calculators ................................................................................
138Settings and diagnostics ....................................................................
138Load analyzer .....................................................................................................
138Peak value logger ..................................................................................
139Amplitude loggers ................................................................................
140Miscellaneous ............................................................................................................
140User parameter sets .........................................................................................
140Settings and diagnostics ....................................................................
140Parameter checksum calculation ...................................................................
141Settings and diagnostics ....................................................................
142User lock .............................................................................................................
142Settings and diagnostics ....................................................................
143Data storage parameters ................................................................................
143Settings and diagnostics ....................................................................
143Reduced run function .......................................................................................
144Activation of the reduced run function ............................................
145du/dt filter support ..........................................................................................
145Settings and diagnostics ....................................................................
145Sine filter support .............................................................................................
145Settings and diagnostics ....................................................................
146Router mode for BCU control unit .................................................................
147Settings and diagnostics ....................................................................
7 Application macros
149What this chapter contains ....................................................................................
149General ........................................................................................................................
150Factory macro ...........................................................................................................
150Default parameter settings for the Factory macro ...................................
150Default control connections for the Factory macro ..................................
10 Table of contents
152Hand/Auto macro ....................................................................................................
152Default parameter settings for the Hand/Auto macro .............................
153Default control connections for the Hand/Auto macro ............................
155PID control macro .....................................................................................................
155Default parameter settings for the PID control macro .............................
157Default control connections for the PID control macro ............................
159Sensor connection examples for the PID control macro ..........................
160Torque control macro ..............................................................................................
160Default parameter settings for the Torque control macro ......................
161Default control connections for the Torque control macro .....................
163Sequential control macro .......................................................................................
163Operation diagram ...........................................................................................
164Selection of constant speeds .........................................................................
164Default parameter settings for the Sequential control macro ................
165Default control connections for the Sequential control macro ...............
167Fieldbus control macro ...........................................................................................
8 Parameters
169What this chapter contains ....................................................................................
169Terms and abbreviations ........................................................................................
171Parameter group summary ....................................................................................
Table of contents 11
174Parameter listing ......................................................................................................
1741 Actual values ....................................................................................................
1793 Input references .............................................................................................
1814 Warnings and faults ......................................................................................
1895 Diagnostics .....................................................................................................
1916 Control and status words ............................................................................
2047 System info ......................................................................................................
2089 ESP signals ......................................................................................................
21110 Standard DI, RO ............................................................................................
21811 Standard DIO, FI, FO ....................................................................................
22412 Standard AI ....................................................................................................
23013 Standard AO ..................................................................................................
23614 I/O extension module 1 ...............................................................................
26415 I/O extension module 2 ..............................................................................
27016 I/O extension module 3 ..............................................................................
27619 Operation mode ...........................................................................................
27920 Start/stop/direction ..................................................................................
29021 Start/stop mode ..........................................................................................
30122 Speed reference selection ..........................................................................
31123 Speed reference ramp .................................................................................
31824 Speed reference conditioning ...................................................................
32625 Speed control ...............................................................................................
33826 Torque reference chain ...............................................................................
34728 Frequency reference chain .........................................................................
35730 Limits .............................................................................................................
36631 Fault functions ..............................................................................................
38032 Supervision ....................................................................................................
38933 Generic timer & counter ..............................................................................
39735 Motor thermal protection ..........................................................................
41236 Load analyzer ................................................................................................
41737 User load curve .............................................................................................
42040 Process PID set 1 ..........................................................................................
43541 Process PID set 2 ..........................................................................................
43843 Brake chopper ..............................................................................................
44144 Mechanical brake control ...........................................................................
44745 Energy efficiency .........................................................................................
45146 Monitoring/scaling settings .....................................................................
45647 Data storage .................................................................................................
45949 Panel port communication ........................................................................
46350 Fieldbus adapter (FBA) ...............................................................................
47251 FBA A settings ...............................................................................................
47452 FBA A data in .................................................................................................
47553 FBA A data out ..............................................................................................
47654 FBA B settings ..............................................................................................
47855 FBA B data in .................................................................................................
12 Table of contents
47956 FBA B data out ..............................................................................................
48058 Embedded fieldbus .....................................................................................
48960 DDCS communication ................................................................................
50561 D2D and DDCS transmit data ....................................................................
51062 D2D and DDCS receive data .......................................................................
51974 ESP control ....................................................................................................
52575 ESP reference setup ....................................................................................
53276 ESP automatic control ................................................................................
53779 Load protection ...........................................................................................
54680 Voltage control ............................................................................................
55281 Pump cleaning ..............................................................................................
55985 Q-H pump curves .........................................................................................
56590 Feedback selection .....................................................................................
57691 Encoder module settings ...........................................................................
58092 Encoder 1 configuration .............................................................................
58793 Encoder 2 configuration .............................................................................
58994 LSU control ...................................................................................................
59295 HW configuration ........................................................................................
60296 System ...........................................................................................................
61497 Motor control ................................................................................................
61898 User motor parameters ..............................................................................
62199 Motor data ....................................................................................................
631200 Safety ...........................................................................................................
632206 I/O bus configuration ...............................................................................
640207 I/O bus service ...........................................................................................
642208 I/O bus diagnostics ..................................................................................
644209 I/O bus fan identification ........................................................................
9 Fault tracing
649What this chapter contains ....................................................................................
649Safety ..........................................................................................................................
649Indications .................................................................................................................
649Warnings and faults ..........................................................................................
650Pure events .........................................................................................................
650Editable messages ............................................................................................
650Warning/fault history and analysis ......................................................................
650Event logs ...........................................................................................................
651Auxiliary codes .......................................................................................
651Factory data logger ..............................................................................
651Other data loggers ...........................................................................................
651User data logger ...................................................................................
651PSL2 data logger ...................................................................................
651Parameters that contain warning/fault information ................................
652Event word (parameters
04.40
…
04.72
) ...........................................
652QR Code generation for mobile service application .........................................
Table of contents 13
653Warning, fault and pure event messages ............................................................
697Auxiliary codes for line-side converter warnings ...............................................
700Auxiliary codes for line-side converter faults .....................................................
10 Fieldbus control through the embedded fieldbus interface (EFB)
705What this chapter contains ....................................................................................
706System overview .......................................................................................................
706Connecting the fieldbus to the drive ....................................................................
707Setting up the embedded fieldbus interface .....................................................
708Setting the drive control parameters ...................................................................
710Basics of the embedded fieldbus interface ........................................................
711Control word and Status word .......................................................................
712References ..........................................................................................................
712Actual values ......................................................................................................
712Data input/outputs ..........................................................................................
712Control of drive outputs through EFB ..............................................
713
Sending process PID feedback and setpoint values through
EFB ...........................................................................................................
713Register addressing .........................................................................................
713About the control profiles ......................................................................................
714The ABB Drives profile .............................................................................................
714Control Word ......................................................................................................
716Status Word .......................................................................................................
717State transition diagram .................................................................................
719References ..........................................................................................................
720Actual values ......................................................................................................
721Modbus holding register addresses .............................................................
721The Transparent profile ..........................................................................................
722Modbus function codes ..........................................................................................
723Exception codes .......................................................................................................
724Coils (0xxxx reference set) .....................................................................................
725Discrete inputs (1xxxx reference set) ...................................................................
726Error code registers (holding registers 400090…400100) .............................
11 Fieldbus control through a fieldbus adapter
729What this chapter contains ....................................................................................
729System overview .......................................................................................................
731Basics of the fieldbus control interface ...............................................................
732Control word and Status word .......................................................................
732Debugging the network words ..........................................................
733References ..........................................................................................................
733Debugging the network words ..........................................................
733Scaling of references ............................................................................
14 Table of contents
734Actual values ......................................................................................................
734Debugging the network words ..........................................................
734Scaling of actual values .......................................................................
735Contents of the fieldbus Control word (ABB Drives profile) ....................
737Contents of the fieldbus Status word (ABB Drives profile) ......................
738The state diagram (ABB Drives profile) ........................................................
739Setting up the drive for fieldbus control .............................................................
740Parameter setting example: FPBA (PROFIBUS DP) ....................................
12 Control chain diagrams
743What this chapter contains ....................................................................................
744Speed reference source selection I .......................................................................
745Speed reference source selection II ......................................................................
746Speed reference ramping and shaping ................................................................
747Motor feedback configuration ..............................................................................
748Load feedback and position counter configuration .........................................
749Speed error calculation ...........................................................................................
750Speed controller .......................................................................................................
751Torque reference source selection and modification .......................................
752Operating mode selection ......................................................................................
753Reference selection for torque controller ...........................................................
754Torque limitation ......................................................................................................
755Torque controller ......................................................................................................
756Frequency reference selection ...............................................................................
757Frequency reference modification ........................................................................
758Process PID setpoint and feedback source selection .......................................
759Process PID controller .............................................................................................
760Master/Follower communication I (Master) .......................................................
761Master/Follower communication II (Follower) ...................................................
Further information
Table of contents 15
16
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 the ACS880 ESP control program (option +N5600), ESP
application version 1.05 or later, and primary control version 3.4x or later.
You can see firmware and loading package versions in parameters.
Example:
Loading package versionParameter
AINFB or AINFC7.4 Firmware name
3.417.5 Firmware version
AESLB or AESLC7.6 Loading package name
1.09.0.07.7 Loading package version
This ESP application program is based on IEC standard 61131-3. It is an in-house
application, therefore the application code is locked and cannot be modified by
the user.
Licensing
The ESP control program (+N5600), version AESLx 1.00 or later comes with a license
key on the ZMU-02 memory unit. The program activates only after recognizing the
key and correspondingly registers itself with the ESP software.
1
Introduction to the manual 17
License keyDevice
N8019 MU Interlock key - Oil liftingZMU-02 memory unit license key
N8020 Licensed appl Oil liftingESP software (loading package)
You can see the license information in the Drive Composer PC tool or in the ACS-APx
control panel from System info →Licenses.
After the program is downloaded to the memory unit with the license key, the
program remains there unless you overwrite it by downloading new program or
program version. The license N8015 remains in the memory even if you overwrite
the program. This makes it possible for you to upgrade the tower crane application
later on a separate crane loading package.
If the program was loaded to the memory unit without the license key, then the
drive indicates a fault 64A5 Licensing fault. See the auxiliary fault code in the Event
logger to know the plus code of the missing license, in this case N8019. For further
assistance, contact your local ABB representative.
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 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 Parameter listing.
18 Introduction to the manual
Target audience
This manual is intended for people who design, commission, or operate the drive
system.
Related manuals
Note: A quick start-up sequence for a speed control application is provided by
ACS880 drives with primary control program, Quick start-up guide
(3AUA0000098062), delivered with the drive.
CodeName
Lists of hyperlinks to product manuals 1)
9AKK105408A7004ACS880-01 drives
9AKK105713A4819ACS880-04 drive modules (200 to 710 kW, 300 to 700 hp)
9AKK105408A8149ACS880-07 drives (45 to 710 kW, 50 to 700 hp)
9AKK105713A6663ACS880-07 drives (560 to 2800 kW)
9AKK107046A0239ACS880-07CLC drives hardware manual
9AKK107680A9275ACS880-07LC drives hardware manual
9AKK106930A9565ACS880-11 drives
9AKK107045A8023ACS880-14 drive modules (132 to 400 kW, 200 to 450 hp)
9AKK106930A3466ACS880-17 drives (45 to 400 kW, 60 to 450 hp)
9AKK106354A1499ACS880-17 drives (160 to 3200 kW)
9AKK107492A4721ACS880-17LC drives
9AKK106930A9564ACS880-31 drives
9AKK107045A8025ACS880-34 drive modules (132 to 400 kW, 200 to 450 hp)
9AKK106930A3467ACS880-37 drives (45 to 400 kW, 60 to 450 hp)
9AKK106354A1500ACS880-37 drives (160 to 3200 kW)
9AKK107492A4722ACS880-37LC drives
Other drive hardware manuals
3AXD50000025169ACS880-04XT drive module packages (500 to 1200 kW) hardware
manual
3AUA0000138495ACS880-04 single drive module packages hardware manual
3AXD50000022021ACS880-14 and -34 single drive packages hardware manual
3AUA0000104271ACS880-104 inverter modules hardware manual
3AXD50000045610ACS880-104LC inverter modules hardware manual
3AUA0000102519ACS880-107 inverter units hardware manual
3AXD50000196111ACS880-107LC inverter units hardware manual
Drive firmware manuals and guides
3AUA0000085967ACS880 primary control program firmware manual
3AUA0000098062ACS880 drives with primary control program, quick startup guide
3AXD50000028574Adaptive programming application guide
Introduction to the manual 19
CodeName
3AUA0000127808Drive application programming manual (IEC 61131-3)
3AUA0000103295ACS880 diode supply control program firmware manual
3AUA0000131562ACS880 IGBT supply control program firmware manual
3AXD50000126880CIO-01 I/O module for distributed I/O bus control user’s manual
Option manuals and guides
3AUA0000085685ACS-AP-I, -S, -W and ACH-AP-H, -W 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 ad-
apters, encoder interfaces, etc.
1) Available in the Document library.
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.
Terms and abbreviations
DescriptionTerm
Type of control unitBCU
Frequency converter for controlling AC motorsDrive
Electromagnetic compatibilityEMC
Electromagnetic interferenceEMI
Optional TTL incremental encoder interface moduleFEN-01
Optional TTL absolute encoder interface moduleFEN-11
Optional resolver interface moduleFEN-21
Optional HTL incremental encoder interface moduleFEN-31
Optional analog I/O extension moduleFIO-11
Optional thermistor protection moduleFPTC-01
Optional ATEX-certified thermistor protection module for potentially
explosive atmospheres
FPTC-02
Physical size of the drive or power moduleFrame, frame size
Optional functional safety modulesFSO-12, FSO-21
Insulated gate bipolar transistorIGBT
Inverter module(s) under control of one control unit, and related
components. One inverter unit typically controls one motor.
Inverter unit
Common term for drive module, inverter module, supply module,
brake chopper module etc.
Power module
Radio-frequency interferenceRFI
Submersible motor controlSMC
Safe torque off (IEC/EN 61800-5-2)STO
20 Introduction to the manual
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34
Table of contents
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