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—ABB INDUSTRIAL DRIVES

ACS880 ESP control program (option +N5600)Firmware manual

—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.

*List of hyperlinks to product manuals CodeACS880-01 drives 9AKK105408A7004ACS880-04 drive modules (200 to 710 kW, 300 to 700 hp) 9AKK105713A4819ACS880-07 drives (45 to 710 kW, 50 to 700 hp) 9AKK105408A8149ACS880-07 drives (560 to 2800 kW) 9AKK105713A6663ACS880-11 drives 9AKK106930A9565ACS880-14 drive modules (132 to 400 kW, 200 to 450 hp) 9AKK107045A8023ACS880-17 drives (45 to 400 kW, 60 to 450 hp) 9AKK106930A3466ACS880-17 drives (160 to 3200 kW) 9AKK106354A1499ACS880-17LC drives 9AKK107492A4721ACS880-31 drives 9AKK106930A9564ACS880-34 drive modules (132 to 400 kW, 200 to 450 hp) 9AKK107045A8025ACS880-37 drives (45 to 400 kW, 60 to 450 hp) 9AKK106930A3467ACS880-37 drives (160 to 3200 kW) 9AKK106354A1500ACS880-37LC drives 9AKK107492A4722

Drive hardware manualsACS880-04XT drive module packages (500 to 1200 kW) hardware manual

3AXD50000025169

ACS880-04 single drive module packages hardware manual 3AUA0000138495ACS880-07CLC drives hardware manual 3AXD50000131457ACS880-14 and -34 single drive packages hardware manual 3AXD50000022021ACS880-104 inverter modules hardware manual 3AUA0000104271ACS880-104LC inverter modules hardware manual 3AXD50000045610ACS880-107 inverter units hardware manual 3AUA0000102519ACS880-107LC inverter units hardware manual 3AXD50000196111

Drive firmware manuals and guidesACS880 winch control program (option +N5100) firmware manual

3AXD50000021887

ACS880 drives with primary control program, quick start-up guide

3AUA0000098062

Adaptive programming application guide 3AXD50000028574Drive application programming manual (IEC 61131-3) 3AUA0000127808ACS880 diode supply control program firmware manual 3AUA0000103295ACS880 IGBT supply control program firmware manual 3AUA0000131562CIO-01 I/O module user’s manual 3AXD50000126880

Option manuals and guidesACX-AP-x assistant control panels user’s manual 3AUA0000085685Drive composer Start-up and maintenance PC tool user’s manual 3AUA0000094606Manuals and quick guides for I/O extension modules, fieldbus adapters, encoder interfaces, etc.

http://search.abb.com/library/ABBLibrary.asp?DocumentID=9AKK105408A7004&DocumentPartId=1&Action=LaunchDirecthttp://search.abb.com/library/ABBLibrary.asp?DocumentID=9AKK105713A4819&DocumentPartId=1&Action=LaunchDirecthttp://search.abb.com/library/ABBLibrary.asp?DocumentID=9AKK105408A8149&DocumentPartId=1&Action=LaunchDirecthttp://search.abb.com/library/ABBLibrary.asp?DocumentID=9AKK105713A6663&DocumentPartId=1&Action=LaunchDirecthttp://search.abb.com/library/ABBLibrary.asp?DocumentID=9AKK106930A9565&DocumentPartId=1&Action=LaunchDirecthttp://search.abb.com/library/ABBLibrary.asp?DocumentID=9AKK107045A8023&DocumentPartId=1&Action=LaunchDirecthttp://search.abb.com/library/ABBLibrary.asp?DocumentID=3AXD50000025169&LanguageCode=en&DocumentPartId=1&Action=LaunchDirecthttp://search.abb.com/library/ABBLibrary.asp?DocumentID=3AUA0000138495&DocumentPartId=1&Action=LaunchDirecthttp://search.abb.com/library/ABBLibrary.asp?DocumentID=3AXD50000131457&DocumentPartId=1&Action=LaunchDirecthttp://search.abb.com/library/ABBLibrary.asp?DocumentID=3AXD50000021887&LanguageCode=en&DocumentPartId=1&Action=LaunchDirecthttp://search.abb.com/library/ABBLibrary.asp?DocumentID=3AXD50000028574&DocumentPartId=1&Action=LaunchDirecthttp://search.abb.com/library/ABBLibrary.asp?DocumentID=3AUA0000127808&DocumentPartId=1&Action=LaunchDirecthttp://search.abb.com/library/ABBLibrary.asp?DocumentID=3AUA0000098062&DocumentPartId=1&Action=LaunchDirecthttp://search.abb.com/library/ABBLibrary.asp?DocumentID=3AUA0000085685&DocumentPartId=1&Action=LaunchDirecthttp://search.abb.com/library/ABBLibrary.asp?DocumentID=3AUA0000094606&DocumentPartId=1&Action=LaunchDirecthttp://search.abb.com/library/ABBLibrary.asp?DocumentID=3AXD50000022021&DocumentPartId=1&Action=LaunchDirecthttp://search.abb.com/library/ABBLibrary.asp?DocumentID=3AUA0000104271&DocumentPartId=1&Action=LaunchDirecthttp://search.abb.com/library/ABBLibrary.asp?DocumentID=9AKK106930A3466&DocumentPartId=1&Action=LaunchDirecthttp://search.abb.com/library/ABBLibrary.asp?DocumentID=9AKK106354A1499&DocumentPartId=1&Action=LaunchDirecthttp://search.abb.com/library/ABBLibrary.asp?DocumentID=9AKK107492A4721&DocumentPartId=1&Action=LaunchDirecthttp://search.abb.com/library/ABBLibrary.asp?DocumentID=9AKK106930A9564&DocumentPartId=1&Action=LaunchDirecthttp://search.abb.com/library/ABBLibrary.asp?DocumentID=9AKK107045A8025&DocumentPartId=1&Action=LaunchDirecthttp://search.abb.com/library/ABBLibrary.asp?DocumentID=9AKK106930A3467&DocumentPartId=1&Action=LaunchDirecthttp://search.abb.com/library/ABBLibrary.asp?DocumentID=9AKK106354A1500&DocumentPartId=1&Action=LaunchDirecthttp://search.abb.com/library/ABBLibrary.asp?DocumentID=9AKK107492A4722&DocumentPartId=1&Action=LaunchDirecthttp://search.abb.com/library/ABBLibrary.asp?DocumentID=3AXD50000045610&DocumentPartId=1&Action=LaunchDirecthttp://search.abb.com/library/ABBLibrary.asp?DocumentID=3AUA0000102519&DocumentPartId=1&Action=LaunchDirecthttp://search.abb.com/library/ABBLibrary.asp?DocumentID=3AXD50000196111&DocumentPartId=1&Action=LaunchDirecthttp://search.abb.com/library/ABBLibrary.asp?DocumentID=3AXD50000126880&DocumentPartId=1&Action=LaunchDirecthttp://search.abb.com/library/ABBLibrary.asp?DocumentID=3AUA0000131562&DocumentPartId=1&Action=LaunchDirecthttp://search.abb.com/library/ABBLibrary.asp?DocumentID=3AUA0000103295&DocumentPartId=1&Action=LaunchDirect

Firmware manualACS880 ESP control program (option +N5600)

3AXD50000041193 Rev BEN

EFFECTIVE: 2020-04-06

2020 ABB. All Rights Reserved.

Table of contents

Table of contents 5

Table of contents

1. Introduction to the manualWhat this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13Applicability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13Licensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14Target audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14Contents of the manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15Related documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15Terms and abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16Cybersecurity disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

2. Using the control panel

3. Control locations and operating modesWhat this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23Local control vs. external control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Local control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24External control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Operating modes of the drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26Speed control mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27Torque control mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27Frequency control mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27Special control modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

4. Quick start-up guideContents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29Before you start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29Drive start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30ESP application minimum configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

5. ESP program featuresWhat this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41Overview of ESP control program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41Backspin supervision . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Restart delay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42Backspin speed observer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42Backspin speed observer constraints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Starting the motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46Starting speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46Acceleration assistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46Kick-start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Safety

6 Table of contents

Current pulse-start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48ESP production mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Manual mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49Automatic process control mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Underload and overload protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52Underload ride through recovery sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54Overload recovery sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Motor voltage control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58Pump impeller cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59Pump curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

6. Program featuresWhat this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61Drive configuration and programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Programming via parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62Adaptive programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63Application programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Control interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64Programmable analog inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64Programmable analog outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64Programmable digital inputs and outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64Programmable relay outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65Programmable I/O extensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65Fieldbus control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67Master/follower functionality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68External controller interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75Control of a supply unit (LSU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Motor control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79Direct torque control (DTC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79Reference ramping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79Constant speeds/frequencies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80Critical speeds/frequencies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80Speed controller autotune . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81Oscillation damping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84Resonance frequency elimination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85Rush control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85Encoder support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86Jogging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92Scalar motor control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95Autophasing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96Flux braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99DC magnetization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100Hexagonal motor flux pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

Application control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103Application macros . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103Process PID control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103Motor potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106Mechanical brake control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

DC voltage control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112Overvoltage control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

Table of contents 7

Undervoltage control (power loss ride-through) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112Voltage control and trip limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113Brake chopper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

Safety and protections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115Emergency stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115Motor thermal protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116Thermal protection of motor cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119User load curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119Automatic fault resets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120Other programmable protection functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123Fault and warning messages, data logging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123Signal supervision . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123Maintenance timers and counters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123Energy saving calculators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124Load analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126User parameter sets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126Parameter checksum calculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126User lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127Data storage parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128Reduced run function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128du/dt filter support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129Sine filter support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130Router mode for BCU control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

7. Application macrosWhat this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133Factory macro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

Default parameter settings for the Factory macro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134Default control connections for the Factory macro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

Hand/Auto macro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136Default parameter settings for the Hand/Auto macro . . . . . . . . . . . . . . . . . . . . . . . . . . . 136Default control connections for the Hand/Auto macro . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

PID control macro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138Default parameter settings for the PID control macro . . . . . . . . . . . . . . . . . . . . . . . . . . . 139Default control connections for the PID control macro . . . . . . . . . . . . . . . . . . . . . . . . . . 140Sensor connection examples for the PID control macro . . . . . . . . . . . . . . . . . . . . . . . . . 141

Torque control macro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142Default parameter settings for the Torque control macro . . . . . . . . . . . . . . . . . . . . . . . . 142Default control connections for the Torque control macro . . . . . . . . . . . . . . . . . . . . . . . 143

Sequential control macro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144Operation diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144Selection of constant speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145Default parameter settings for the Sequential control macro . . . . . . . . . . . . . . . . . . . . . 145Default control connections for the Sequential control macro . . . . . . . . . . . . . . . . . . . . . 146

Fieldbus control macro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147

8 Table of contents

8. ParametersWhat this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149Terms and abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150Summary of parameter groups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151Parameter listing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154

01 Actual values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15403 Input references . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15804 Warnings and faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15905 Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16606 Control and status words . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16707 System info . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18209 ESP signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18510 Standard DI, RO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18611 Standard DIO, FI, FO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19312 Standard AI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19813 Standard AO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20214 I/O extension module 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20615 I/O extension module 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22516 I/O extension module 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22919 Operation mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23320 Start/stop/direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23521 Start/stop mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24422 Speed reference selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25123 Speed reference ramp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25924 Speed reference conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26525 Speed control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27026 Torque reference chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28128 Frequency reference chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28930 Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29731 Fault functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30532 Supervision . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31533 Generic timer & counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31935 Motor thermal protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32736 Load analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33737 User load curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34140 Process PID set 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34441 Process PID set 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35743 Brake chopper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35944 Mechanical brake control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36145 Energy efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36546 Monitoring/scaling settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36847 Data storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37249 Panel port communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37550 Fieldbus adapter (FBA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37751 FBA A settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38552 FBA A data in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38653 FBA A data out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38754 FBA B settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38755 FBA B data in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38856 FBA B data out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 389

Table of contents 9

58 Embedded fieldbus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38960 DDCS communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39761 D2D and DDCS transmit data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41062 D2D and DDCS receive data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41474 ESP control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42275 ESP reference setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42576 ESP automatic control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43079 Load protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43480 Voltage control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44281 Pump cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44685 Q-H pump curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45190 Feedback selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45691 Encoder module settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46592 Encoder 1 configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46893 Encoder 2 configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47494 LSU control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47695 HW configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47896 System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48597 Motor control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49598 User motor parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49999 Motor data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501200 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 508206 I/O bus configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 508207 I/O bus service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 508208 I/O bus diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 508209 I/O bus fan identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 508

9. Additional parameter dataWhat this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 509Terms and abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 509Parameter groups 1…9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 510Parameter groups 10…99 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 516

10. Fault tracingWhat this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 567Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 567Indications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 567

Warnings and faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 567Pure events . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 568Editable messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 568

Warning/fault history and analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 568Event logs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 568Other data loggers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 569Parameters that contain warning/fault information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 569

QR Code generation for mobile service application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 570Warning messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 571Fault messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 589Auxiliary codes for line-side converter warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 609Auxiliary codes for line-side converter faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 611

10 Table of contents

11. Fieldbus control through the embedded fieldbus interface (EFB)What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 615System overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 615Connecting the fieldbus to the drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 616Setting up the embedded fieldbus interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 617Setting the drive control parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 618Basics of the embedded fieldbus interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 621

Control word and Status word . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 622References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 622Actual values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 622Data input/outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 622Register addressing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 623

About the control profiles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 624The ABB Drives profile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 625

Control Word . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 625Status Word . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 627State transition diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 628References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 629Actual values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 630Modbus holding register addresses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 631

The Transparent profile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 632Modbus function codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 633Exception codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 634Coils (0xxxx reference set) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 635Discrete inputs (1xxxx reference set) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 636Error code registers (holding registers 400090…400100) . . . . . . . . . . . . . . . . . . . . . . . . . . 638

12. Fieldbus control through a fieldbus adapterWhat this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 639System overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 639Basics of the fieldbus control interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 641

Control word and Status word . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 642References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 642Actual values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 643Contents of the fieldbus Control word (ABB Drives profile) . . . . . . . . . . . . . . . . . . . . . . 645Contents of the fieldbus Status word (ABB Drives profile) . . . . . . . . . . . . . . . . . . . . . . . 646The state diagram (ABB Drives profile) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 647

Setting up the drive for fieldbus control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 648Parameter setting example: FPBA (PROFIBUS DP) . . . . . . . . . . . . . . . . . . . . . . . . . . . 649

13. Control chain diagramsWhat this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 651Speed reference source selection I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 652Speed reference source selection II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 653Speed reference ramping and shaping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 654Motor feedback configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 655Load feedback and position counter configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 656Speed error calculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 657

Table of contents 11

Speed controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 658Torque reference source selection and modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 659Operating mode selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 660Reference selection for torque controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 661Torque limitation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 662Torque controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 663Frequency reference selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 664Frequency reference modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 665Process PID setpoint and feedback source selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 666Process PID controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 667Master/Follower communication I (Master) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 668Master/Follower communication II (Follower) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 669

Further information

12 Table of contents

Introduction to the manual 13

1Introduction to the manual

What this chapter containsThis chapter describes the contents of the manual. It also contains information on the compatibility, safety and intended audience.

ApplicabilityThis manual applies to the ACS880 ESP control program (option +N5600), application version 1.04 or later, and primary control version 2.9x or later.

You can see firmware and loading package versions in parameters.

Example:

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.

Parameter Loading package version07.04 Firmware name AINFB or AINFC07.05 Firmware version 3.1007.06 Loading package name AESLB or AESLC07.07 Loading package version 1.07.0.0

14 Introduction to the manual

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.

You can see the license information in the Drive Composer PC tool or in the ACS-APx control panel from System info → Licenses.

If the program was loaded to a ZMU-02 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 instructionsFollow 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.

Target audienceThis manual is intended for people who design, commission, or operate the drive system.

Device License key ZMU-02 memory unit license key N8019 MU Interlock key - Oil lifting ESP software (loading package) N8020 Licensed appl Oil lifting


Contents of the manualThis 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.• Quick start-up guide contains the basic start-up sequence of the drive and

additional alternative checklists for starting up the drive with the control program.• ESP program features describes the program features specific to the ESP

application.• Program features describes the control locations and operation modes, as well as

the program features that are not specific to ESP applications.• 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 documentsA list of related manuals is printed on the inside of the front cover.


Terms and abbreviationsTerm/abbre-viation

Definition

AC 800M Type of programmable controller manufactured by ABB.

ACS800 A product family of ABB drivesACS-AP-I Types of control panel used with ACS880 drivesACS-AP-WAI Analog input; interface for analog input signalsAO Analog output; interface for analog output signalsBCU Type of control unit used in ACS880 drive systems, primarily those with

parallel-connected inverter or supply modules.CIO I/O module for controlling cabinet fansD2D Drive-to-drive; communication link between drives that is implemented by

application programming. See Drive application programming manual (IEC 61131-3) (3AUA0000127808 [English])

DC link DC circuit between rectifier and inverterDDCS Distributed drives communication system; a protocol used in communication

between ABB drive equipmentDI Digital input; interface for digital input signalsDIO Digital input/output; interface that can be used as a digital input or outputDO Digital output; interface for digital output signalsDrive 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 ACS880 primary control program is used to control the inverter part of the drive.

DriveBus A communication link used by, for example, ABB controllers. ACS880 drives can be connected to the DriveBus link of the controller. See page 78.

DTC Direct torque control. See page 82.EFB Embedded fieldbus interface. See page 615.

FAIO-01 Optional analog I/O extension moduleFBA Fieldbus adapterFCAN-01 Optional CANopen adapterFCNA-01 Optional ControlNet adapterFDCO-0x Optional DDCS communication moduleFDIO-01 Optional digital I/O extension module

FDNA-01 Optional DeviceNetTM adapterFEA-03 Optional I/O extension adapterFECA-01 Optional EtherCAT® adapterFEN-01 Optional TTL encoder interface module


FEN-11 Optional absolute encoder interface moduleFEN-21 Optional resolver interface moduleFEN-31 Optional HTL encoder interface moduleFENA-11 Optional Ethernet/IP, Modbus/TCP and PROFINET IO adapter

FENA-21 Optional dual-port Ethernet/IP, Modbus/TCP and PROFINET IO adapterFEPL-02 Optional POWERLINK adapterFIO-01 Optional digital I/O extension moduleFIO-11 Optional analog I/O extension moduleFPBA-01 Optional PROFIBUS DP adapterFPTC-01 Optional thermistor protection module.

FPTC-02 Optional ATEX-certified thermistor protection module for potentially explosive atmospheres.

FSCA-01 Optional Modbus/RTU adapter

FSO-xx Optional safety functions moduleHTL High-threshold logicID run Motor identification run. During the identification run, the drive will identify the

characteristics of the motor for optimum motor control.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. ACS880 drives

can be connected to the optical ModuleBus link of the controller.Motor-side converter

See inverter unit.

Term/abbre-viation

Definition


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 drivePID controller Proportional–integral–derivative controller. Drive speed control is based on

PID algorithm.PLC Programmable logic controllerPower unit Contains the power electronics and power connections of the drive (or inverter

module). The drive control unit is connected to the power unit.PSL2 Protocol used in communication between the drive control unit and the power

unit.PTC Positive temperature coefficientPU See power unit.RDCO-0x DDCS communication moduleRFG Ramp function generator.

RO Relay output; interface for a digital output signal. Implemented with a relay.SMC Submersible motor control.SSI Synchronous serial interfaceSTO Safe torque offSupply 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 logicUPS Uninterruptible power supply; power supply equipment with battery to

maintain output voltage during power failureZCU Type of control unit used in ACS880 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

www.odva.org


Cybersecurity disclaimerThis 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 131).

Using the control panel 21

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

22 Using the control panel

Control locations and operating modes 23

3Control locations and operating modes

What this chapter containsThis chapter describes the control locations and operating modes supported by the control program.

24 Control locations and operating modes

Local control vs. external controlThe ACS880 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) Extra inputs/outputs can be added by installing optional I/O extension modules (FIO-xx) in drive slots.2) Encoder or resolver interface module(s) (FEN-xx) installed in drive slots.

MOTOR

PLC

M3~

I/O 1)

Embedded fieldbus interface (EFB) or master/follower link

External control

Local control

Encoder

2)

ACS880

Control panel


External control

When the drive is in external control, control commands are given through• the I/O terminals (digital and analog inputs), or optional I/O extension modules• the embedded fieldbus interface or an optional fieldbus adapter module• the external (DDCS) controller interface• the master/follower link, and/or• the control panel.

Two external control locations, EXT1 and EXT2, are available. The user can select the sources of the start and stop commands separately for each location by parameters 20.01…20.10. The operating mode can be selected separately for each location (in parameter group 19 Operation mode), which enables quick switching between different operating modes, for example speed and torque control. Selection between EXT1 and EXT2 is done via any binary source such as a digital input or fieldbus control word (see parameter 19.11 Ext1/Ext2 selection). The source of reference is selectable for each operating mode separately.

The control location selection is checked on a 2 ms time level.

Using the control panel as an external control source

The control panel can also be used as a source of start/stop commands and/or reference in external control. Selections for the control panel are available in the start/stop command source and reference source selection parameters.

Reference source selection parameters (except PID setpoint selectors) have two selections for the control panel. The difference between the two selections is in the initial reference value after the reference source switches to the control panel.

The panel reference is saved whenever another reference source is selected. If the reference source selection parameter is set to Control panel (ref saved), the saved value is used as the initial reference when control switches back to the panel. Note that only one type of reference can be saved at a time: for example, attempting to use the same saved reference with different operating modes (speed, torque, etc.) causes the drive to trip on 7083 Panel reference conflict. The panel reference can be separately limited by parameters in group 49 Panel port communication.

With the reference source selection parameter set to Control panel (ref copied), the initial panel reference value depends on whether the operating mode changes with the reference source. If the source switches to the panel and the operating mode does not change, the last reference from the previous source is adopted. If the operating mode changes, the drive actual value corresponding to the new mode is adopted as the initial value.

The process PID setpoint selectors in parameter groups 40 Process PID set 1 and 41 Process PID set 2 only have one setting for the control panel. Whenever the control panel is selected as the setpoint source, operation resumes using the previous setpoint.


Operating modes of the driveThe drive can operate in several operating modes with different types of reference. The mode is selectable for each control location (Local, EXT1 and EXT2) in parameter group 19 Operation mode.

The following is a general representation of the reference types and control chains. The page numbers refer to detailed diagrams in chapter Control chain diagrams.

Motor feedback configuration

(p 671)

Speed reference

source selection I

(p 668)

Speed controller(p 674)

Speed reference source selection

II(p 669)

Speed reference ramping and

shaping(p 670)

Speed error calculation

(p 673)

Torque reference

source selection and modification

(p 675)

Reference selection for

torque controller(p 677)

Frequency reference

source selection and modification

(p 680)

Operating mode selection(p 676)

Torque controller

(p 679)

DTC motor control mode

Scalar motor control mode

Process PID setpoint and

feedback source selection(p 682)

Process PID controller(p 683)

Torque limitation(p 678)

Frequency reference

modification(p 681)

Load feedback and position

counter configuration

(p 672)


Speed control mode

The motor follows a speed reference given to the drive. This mode can be used either with estimated speed as feedback, or with an encoder or resolver for better speed control accuracy.

Speed control mode is available in both local and external control. It is also available both in DTC (Direct Torque Control) and scalar motor control modes.

Torque control mode

Motor torque follows a torque reference given to the drive. Torque control is possible without feedback, but is much more dynamic and accurate when used in conjunction with a feedback device such as an encoder or a resolver. It is recommended that a feedback device is used in crane, winch or lift control situations.

Torque control mode is available in DTC motor control mode for both local and external control locations.

Frequency control mode

The motor follows a frequency reference given to the drive. Frequency control is only available in scalar motor control mode.

Special control modes

In addition to the control modes mentioned above, the following special control modes are available:• Process PID control. For more information, see section Process PID control

(page 106).• Emergency stop modes Off1 and Off3: Drive stops along the defined deceleration

ramp and drive modulation stops.• Jogging mode: Drive starts and accelerates to the defined speed when the

jogging signal is activated. For more information, see section Jogging (page 95).

Quick start-up guide 29

4Quick start-up guide

Contents of this chapterThis chapter contains the basic start-up sequence of the drive and additional alternative checklists for starting up the drive with the ESP control program.

In this chapter, the drive is set up using ACS-AP-I control panel. You can also do the start-up sequence using the Drive composer PC tool.

Before you startMake sure that the drive has been mechanically and electrically installed as described in the appropriate Quick installation guide and/or Hardware manual.

Safety

WARNING! All electrical installation and maintenance work on the drive should be carried out by qualified electricians only.

Never work on the drive, the brake chopper circuit, the motor cable or the motor when power is applied to the drive. Always make sure by measuring that no voltage is actually present.

30 Quick start-up guide

WARNING! Make sure that the machinery into which the drive with brake control function is integrated fulfills the personnel safety regulations. Note that

the frequency converter (a Complete Drive Module or a Basic Drive Module, as defined in IEC 61800-2), is not considered as a safety device mentioned in the European Machinery Directive and related harmonized standards. Thus, the personnel safety of the complete machinery must not be based on a specific frequency converter feature (such as the brake control function), but it has to be implemented as defined in the application specific regulations.

Drive start-up

SafetyWARNING! Only qualified electricians are allowed to start up the drive.

Check the installation. See the installation checklist in the appropriate Hardware manual.

Check that the starting of the motor does not cause any danger. De-couple the driven machine if• there is a risk of damage in case of an incorrect direction of rotation, or• a Normal ID run is required during the drive start-up, when the load torque is higher

than 20% or the machinery is not able to withstand the nominal torque transient during the ID run.

1 – Power-up, date and time settingsPower up the drive.Note: It is normal that warning messages appear at various points along the start-up process. To hide a message and to resume the start-up process, press .Hide any warnings now to enter the Home view (shown on the right).The two commands at the bottom of the display (in this case, Options and Menu), show the functions of the two softkeys and located below the display. The commands assigned to the softkeys vary depending on the context.

Remote 0.0 rpm

0.000.00

Motor torque%% 0.0Motor currentA

Motor speed usedrpm

Options 12:34 Menu


In the Home view, press (Menu).The main Menu (right) appears.

Highlight Settings on the menu using and and press (Select).

In the Settings menu, highlight Date & time (if not already highlighted) and press (Select).

In the Date & time menu, highlight Date (if not already highlighted) and press (Select).

Remote 0.0 rpmMenu

Parameters

Assistants

Energy efficiency

Event log

Exit 12:34 Select

Remote 0.0 rpmSettingsLanguageDate & time

Back 12:34 Select

Edit textsDisplay settings

Next daylight saving start 28.03.

Remote 0.0 rpmDate & timeDate

Back 12:35 Edit

TimeShow date as

23.06.201612:34:56

day.month.yearShow time as 24-hourDaylight saving EU

Remote 0.0 rpmDate

Cancel 12:35 Save

Day Month Year

Thursday.06.201623


Set the correct date:• Use and to move the cursor left

and right.• Use and to change the value.• Press (Save) to accept the new

setting.Check/adjust all the remaining settings in the Date & time menu.The Show clock setting determines whether the time is shown at all times in the bottom pane of the display.After you have made the settings, press

(Back or Exit) repeatedly until the Home view (right) reappears.

2 – Electrical settingsSwitch to local control to ensure that external control is disabled by pressing the key. Local control is indicated by the text “Local” in the top pane.

Open the main Menu by pressing (Menu).

Remote 0.0 rpm

0.000.00


Motor speed usedrpm

Options 12:35 Menu

Loc/RemLocal 0.0 rpm

0.000.00


Motor speed usedrpm

Options 12:36 Menu

Local 0.0 rpmMenu

Parameters

Assistants

Energy efficiency

Event logExit 12:36 Select


Highlight Parameters and press (Select).

Highlight Complete list using and and press (Select).A listing of parameter groups is displayed.

Select motor type.Note: ESP control program supports Asynchronous and Permanent Magnet Synchronous motors.

99.03 Motor type

Verify used Motor control mode.Note: ESP application requires SMC control mode selection, DTC mode can be used only in cases where no step-up transformer is needed between drive and motor.

99.04 Motor control mode

Set motor nominal current.Note: If step-up transformer is in use, then nominal current setting in the drive is always calculated for the primary side of the transformer, i.e. 99.06 Motor nominal current = Motor plate nominal current * Transformer ratio.

99.06 Motor nominal current

Set motor nominal voltage.Note: For applications with sine filter and step-up transformer in use, the nominal voltage setting in the drive is calculated for the primary side of the transformer with consideration for the resistive and inductive losses along the circuit, i.e. 99.07 Motor nominal voltage = (Motor plate nominal voltage / Transformer ratio) + circuit voltage losses (typically ~10%).

99.07 Motor nominal voltage

Local 0.0 rpmParametersFavoritesBy function

Back 12:36 Select

Complete listModified

Local 0.0 rpmComplete list01 Actual values03 Input references04 Warnings and faults05 Diagnostics06 Control and status words07 System info

Back 12:36 Select


Set motor nominal frequency. 99.08 Motor nominal frequency

Set motor nominal speed. 99.09 Motor nominal speed

Set motor nominal power. 99.10 Motor nominal power

Set motor cos Φ.Note: This value is not mandatory, but can be entered to improve the control accuracy. If not known, enter the value as zero (0).

99.11 Motor nominal cos Φ

Set sine filter data. • Check 95.15 Special HW settings

• If ABB official filter is used, set bit1 ABB sine filter = 1.

• If sine filter is supplied by other vendor, set bit 3 Custom sine filter = 1.

• If no filter is used, make sure both bit1 and bit3 are set to 0.

• For filters other than ABB filter, it is also important to provide filter data using parameters 99.18 and 99.19.

95.15 Special HW settings99.18 Sine filter inductance99.19 Sine filter capacitance

Set used transformation ratio based on step-up transformer tapping.

95.40 Transformation ratio

3 – Drive control interface settingsSet desired drive control interface.Note: By default, the drive is configured to start/stop from I/O interface. Other options are available, including Fieldbus.

20.01 Ext1 commands

Set desired drive start trigger type. Drive will react on edge or level status of user start command based on this parameter setting.

20.02 Ext1 start trigger type

If default control interface is used, select the source for the drive control signal.Note: By default, the drive starts/stops according to the status of digital input DI1 (0 = Stop, 1 = Start).

20.03 Ext1 in1 source

Select desired motor stop mode: ramp or coast.

21.03 Stop mode


4 – Jumpers positionCheck the positions of jumpers J1 and J2 on the control unit of the drive. These jumpers determine whether analog inputs AI1 and AI2 are current or voltage. Check/adjust the following parameters.

Select the unit to either mA or V, corresponding to jumper J1 setting.

12.15 AI1 unit selection

Configure analog inputs if used for drive control:Parameters 12.17 and 12.18 – set the low and high limits of the analog input signal.Scaling parameters 12.19 and 12.20 – define the internal signal levels that correspond to the low and high limits. See graph below.

The corresponding parameters for analog input AI2 are 12.27…12.30.

12.17 AI1 min12.18 AI1 max 12.19 AI1 scaled at AI1 min 12.20 AI1 scaled at AI1 max12.27 AI2 min12.28 AI2 max 12.29 AI2 scaled at AI2 min 12.30 AI2 scaled at AI2 maxAI (scaled)

AI (mA/V)

12.20

12.1812.17

12.19


Configure analog outputs if used for drive control:Parameter 13.12 – select the source for analog output AO1 (by default, motor speed in rpm). Parameters 13.17 and 13.18 – set low and high source signal values that correspond to the actual analog output values defined in parameters 13.19 and 13.20.

13.12 AO1 source13.17 AO1 source min13.18 AO1 source max13.19 AO1 out at AO1 src min13.20 AO1 out at AO1 src max

Set desired source for the fault reset command.

31.11 Fault reset selection

4 – Scaling settingsSet the maximum frequency value used to define the acceleration ramp rate.The initial frequency value is used to define deceleration ramp rate (see parameter group 28 Frequency reference chain). The frequency acceleration and deceleration ramp times are therefore related to this value (not to parameter 30.14 Maximum frequency). Also defines the 16-bit scaling of frequency-related parameters. The value of this parameter corresponds to 20000 in fieldbus, master/follower etc. communication.

46.02 Frequency scaling

Source signal

AO (mA)

13.18

13.2013.19

13.17


Set the "at setpoint" limits for frequency control of the drive. When the absolute difference between reference and actual frequency (01.06 Output frequency) is smaller than 46.22 At frequency hysteresis, the drive is considered to be "at setpoint". This is indicated by bit 8 of 06.11 Main status word.

46.22 At frequency hysteresis


ESP application minimum configurationThis section contains the following alternative control schemes for starting up the drive with the ESP control program.

Note: For other ESP control program features, refer to the corresponding chapter of this manual.

ESP controlIn case Fieldbus is used as the primary control interface for the application, the ESP control word provides suitable access to all major functions of the ESP control program.

74.01 ESP control word

Configure restart delay function.The function prevent undesired pump start while fluid column is draining through the pump. Note: For further information on Backspin supervision function, see Backspin supervision (page 42).

74.20 Restart delay enable74.21 Restart delay time

ESP reference controlSelect the source for the production speed reference.

75.11 Pump speed ref source

Set the frequency reference if parameter 75.11 Pump speed ref source is selected as Fixed speed ref.

75.12 Fixed speed ref

Set the frequency reference scaler. Note: The used speed reference = 75.19 Maximum production speed * (75.11 Pump speed ref source / 75.13 Speed reference scaler.If 75.13 Speed reference scaler = 0, then there is no scaling: The used speed reference = 75.11 Pump speed ref source.

75.13 Speed reference scaler

Set starting speed at which drive will start modulating.

75.15 Starting speed

Set the desired acceleration time for ESP motor to speed up from zero to the value set in parameter 46.02 Frequency scaling.

75.21 Acceleration time

Set the desired deceleration time for ESP motor to slow down from the value set in parameter 46.02 Frequency scaling.

75.22 Deceleration time


Configure acceleration assistance function.• Set speed limit for the acceleration

assistance.• Set current boost to help motor to

accelerate high inertia.

75.40 Acceleration assistance enable75.42 Acceleration assistance speed limit75.46 Acceleration assistance current

Configure Kick start function.• Set time for the drive output frequency to

stay and wait for the motor to start spinning.

• Set the speed reference at which drive should be modulating at start.

• Set the current reference boost needed to produce higher starting torque necessary for the motor to start spinning.

75.50 Kick start enable75.51 Kick start hold time75.52 Kick start speed reference75.56 Kick start current ref

Load protectionConfigure underload and overload protection functions.• Choose fixed or dynamic type of limit.• Select supervision signal.• Define response delay.• Select the type of response event:

Warning, Fault or Recovery sequence.

79.09 Load limit speed scale79.10 Underload protection enable79.11 Underload limit type79.12 Underload supervision signal79.13 Underload limit79.18 Underload delay time79.19 Underload event reaction

Configure custom user load curve for dynamic load limit.• Choose five speed points.• Set five corresponding underload limit

points.• Set five corresponding overload limit

points.

79.01 Load curve speed point 179.02 Load curve speed point 279.03 Load curve speed point 379.04 Load curve speed point 479.05 Load curve speed point 579.21 Underload curve point 179.22 Underload curve point 279.23 Underload curve point 379.24 Underload curve point 479.25 Underload curve point 579.51 Overload curve point 179.52 Overload curve point 279.53 Overload curve point 379.54 Overload curve point 479.55 Overload curve point 5


Voltage controlConsider activating energy optimization in order to set drive automatically minimize current fed to the motor based on actual mechanical load conditions.

80.01 Energy optimization enable

Configure u/f curve settings. Note: Automatic energy optimization function should be disabled for the manual user u/f curve to have effect.

80.10 U/F Curve enable80.11 Frequency point 1...80.18 Frequency point 880.21 Additive value 1...80.28 Additive value 8.

ESP program features 41

5ESP program features

What this chapter containsThis chapter describes the functions within the control program that are specific to ESP application, how to use them and how to program them to operate.

Overview of ESP control programThe Electric submersible pump (ESP) control program is a drive application program used in oil pump stations and other related areas that require pumping of viscous liquids.

42 ESP program features

Backspin supervisionBackspin supervision set of functions can be used to monitor the status of pump-motor shaft after production operation is interrupted. The function prevents undesired premature restart of the pump before fluid column is sufficiently drained.

Restart delay

The Restart delay function prevents any new start command for a period of time set in parameter 74.21 Restart delay time after stop command is initiated. The function prevents accidental pump restart at least for the given amount of time. It is always recommended to enable restart delay and keep it active for several minutes even if the backspin speed observer function is enabled.

Backspin speed observer

Backspin speed observer function can be used to monitor the actual speed of the motor in real time, in case spinning passively due to fluid column drainage down through the pump.

The drive must be in stopped state during backspin speed observer operation. When enabled, it will automatically activate motor speed supervision after Restart delay time is elapsed. The function will ignore the user start command and prevent drive normal operation until passive motor speed reduces down to speed region defined as safe to restart.

Note: When Restart delay is active, the Backspin speed observer function cannot show motor speed estimate unless requested by the user Drive start command.


The figure below shows the control scenarios of Restart delay and Backspin speed observer functions.

The table below describes the control scenarios of Restart delay and Backspin speed observer functions.

Control scenario

Description

1 Parameter 74.20 Restart delay enable function activates as soon as the user drive start command is set to OFF.

1 - 2 New normal start command cannot accept for the period of time set in parameter 74.21 Restart delay time.

2 - 5 You can safely enable drive start command when restart delay is active. Backspin speed observer function will detect the actual motor speed without interfering the motor mechanically.

3 - 4 If the restart delay function is still active, it prevents drive from starting normal operation even if observer measured speed is in the speed region defined as safe to restart.

1 2 3 4 6 75

0

89 10 11 12 13 14 15

74.30 Speed observer enable

74.20 Restart delay enable

User Drive start command

74.21 Restart delay time

09.41 Restart delay remaining

06.16 Drive status word 1, bit 6

Start interlock

Speed measurement routine

74.39 Measurement delay

74.33 Observer speed check time

74.99 ESP start/stop sw, bit 6

74.99 ESP start/stop sw, bit 8

Actual speedMeasured speed

74.32 Restart speed limit high74.31 Restart speed limit low

Time

Time

Time

Time

Time

Time

Time

Time

Time

Time

Time


5 Drive stops measuring the actual pump-motor speed if Start command if OFF when parameter 09.41 Restart delay remaining timer is still counting.

6 Parameter 74.30 Speed observer enable is set ON, so that when restart delay time is elapsed, the speed measurement function starts automatically.

2-3, 7-8, 13-14

The time needed for the Backspin speed observer function to detect the actual motor speed is defined with parameter 74.39 Measurement delay.

7-9 When Backspin speed observer is active, the drive start command will have no effect until measured speed gets in to the safe-to-restart speed region defined with parameters 74.31 Restart speed limit low and 74.32 Restart speed limit high.

9-11 The speed observer function will trigger the speed check timer set in parameter 74.33 Observer speed check time when the measured speed is within the safe-to-restart speed region.

10 If the measured speed is outside safe-to-restart speed region, then the speed check timer will reset.

11-12 If the measured speed is within the safe-to-restart speed region defined in parameter 74.33 Observer speed check time, then the speed observer function routine is over. The drive stops modulating and parameter 74.99 ESP start/stop sw, bit 8 is set to TRUE.In case user drive start command is active, then immediately after speed check time is elapsed the flying start sequence is initiated and drive takes control over the pump-motor to go over the starting routines and then accelerate it to the production speed.

12-13 The drive is waiting for the user to initiate the drive start command.

13-14 As soon as the user drive start command is given, the drive repeats speed measurement routine to ensure that the actual speed is within the safe-to-restart speed region, then the drive will proceed to the normal starting routine without any speed check time delay.If the speed is outside the safe-to-restart speed region, then all the speed supervision procedure is repeated from point 8.

14-15 The drive gets in to normal production state through the starting routines.

Control scenario

Description


Backspin speed observer constraints

Backspin speed measurement is a special drive control mode that requires physical cable connection to the motor. Therefore, the motor contactor should be closed all the time for the function to work. If the contact to the motor gets impaired while monitoring, then manually restart after the connection is restored.

Backspin speed measurement sensitivity has its limitations at slow speeds. The lowest detectable speed varies (not the same) depends on motor size and can be as low as 1Hz with 900kW motor. With small motors (1-10kW), the speed detection routine cannot produce accurate measurement below 4Hz. The general guideline for the function set up to test speed measurement capacity with each type of motor in use to assess the lowest feasible speed measurement.

Backspin speed measurement cannot always reliably detect zero-speed crossing from positive to negative speed and vice versa. The general guideline is to always have the Restart delay function enabled and active for several minutes after process is interrupted. It delays the Backspin Speed Observer function to engage, thus giving system some time to transit from production state to the state of fluid drainage (typically, being the primary reason for motor to passively back-spin).

With permanent magnet type of motors, backspin speed observer function could sustain passive monitoring of speeds not greater than half of the motor nominal speed.

Settings

Parameter group 74 ESP control (page 429).


Starting the motorIn some cases pump motor can be difficult to restart. This might be caused by solids and/or sedimentation clogging the pump. Thus, it requires higher starting torque to break through the blockage. Another difficulty occurs with a complex electric circuit between drive and motor, typical for the step-up systems which makes accurate torque production.

ACS880 ESP control program contains advanced current controller that allows user to set directly a desired motor current reference instead of manipulating voltage output. This enables user to achieve more accurate control over the motor starting torque but avoid excessive voltage. The number of starting routines are available for the user to take full advantage of the current controller benefits that improve motor starting procedure.


Kick-start

Kick-start refers to pre-magnetization of the motor before start, in the ESP systems with step-up transformers. This is used where standard DC pre-magnetization does not work.

Kick-start function provides sometime to motor to develop starting torque sufficient to start spinning. The fast acceleration rate settings create risk for the motor to pull out before it gets to follow the frequency reference. Instead, the function gives current boost to motor at low speed for a set amount of time sufficient to develop starting torque and eventually break through the static friction.

The function allows user to set desired speed and current reference for the motor applied for a defined period of time. After the starting routine is completed, the drive will automatically transit to accelerate to production speed with additional help of the Acceleration assistance (if enabled). Kick-start function increases the efficiency of starting routines such as Starting speed (page 75.15), Current pulse-start (page 75.60), and Acceleration assistance (page 75.40).

Settings

Parameter group 75 ESP reference setup (page 433).

Starting speed

Starting speed defines the frequency at which the drive begins modulating upon receiving start-command. In the ESP systems, where AC transformer is used to step-up voltage from low voltage drive to medium voltage motor. This function assists efficient power transmission and prevent undesirable transformer saturation at start.

Speed reference

Time

Time

75.42 Acceleration assistance speed limit

75.52 Kick start speed reference


75.56 Kick startcurrent ref

75.46 Acceleration assistance current

75.51 Kick start hold time

Kick-start routine Acceleration assistance

Motor current

0

0

Regular current


Current pulse-start

Current pulse-start function enables when regular starting routines are not enough to accelerate the motor. The most common reason can be pump waxing or sedimentation. The function produces a series of thrusts to the pump impeller by sending short high-current impulses.

You can adjust speed, magnitude and frequency of thrusts applied. After the Current pulse-start routine is competed, the control is given to Kick-start function (if enabled) and then proceed to production speed with additional help of the acceleration assistance (if enabled).

Note: Current pulse-start is applicable only for AC induction motors. For permanent magnet motors, it is recommended use acceleration assistance (75.40) and kick start feature (75.50), when regular starting routines are not enough to accelerate the motor.

Settings

Parameter group 75 ESP reference setup (page 433).

Acceleration assistance

Acceleration assistance function enables the user to set motor current reference used during acceleration. This setting makes drive to extremely develop energy in the motor that is necessary to accelerate high load at fast ramp rate. The function will work until motor accelerate to a desired speed and then continue with energy efficiency settings set by the user in group 80 Voltage control.

Speed reference

75.61 Current pulse speed reference


75.62 Current pulse start current ref

Time

Time

0

0

Regular current

Pulse-start cycle 1 Pulse-start cycle 2 Last cycle

75.69 Current pulse cycle time

75.69 Current pulsecycle time


Settings

Parameter group 80 Voltage control (page 450).

Pump impeller cleaningThe Pump impeller cleaning procedure consists of a programmable sequence of motor running forward and reverse for the defined number of cycles. The cleaning function removes the solids stuck to impeller blades and thus reduces the friction and inertial losses during normal operation.

The function can be triggered using:

1. Explicit command trigger - provided by the user through Fieldbus or digital input.

2. On schedule - repeated regularly based on user timer setting.

The ongoing cleaning operation can be interrupted either manually or automatically based on actual load supervision. • Supervision high function can be used to abort currently running cleaning cycle to

avoid motor overheating in case of abnormal load peaks.• Supervision low function can be used to abort the whole cleaning sequence if load

detected i

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