Bakker Sliedrecht Electro Industrie

2011

1

JAN DE NULTraining

BASIC

ACS800drives

Content Training ACS800 drives

• SAFETY• Hardware Description

- ACS800-01, ACS800-02 - Options - Type coding

• Software Description - DTC - Standard software, system software

• Hands-on training

2

SAFETY INSTRUCTIONS

• Take care of clear general & local working instructions Especially :

• Always switch off the aux.- & main power• Verify that all systems are- & remain safe• Beware off charged capacitors• Mind your hands when handling very heavy drive

modules

3

Single - drive structure

4

DC linkRectifier

V1 V3 V5

V2V6V4

C

L +

-

U1V1W1

M 3 ~Ud

Control Electronicscontrol, monitoring and communication

L1

L2

L3

InverterMotor

Monitoring

Control

Supply

Uline UDC Uout

ABB Drives DTC concept

5

The DTC Concept

Speedcontrol

PID

REF

Torque Reference

TorqueReferenceController

Speed Reference

SwitchingLogic

=Torque

and FluxComparator

3~3~

Torqueand Flux

Calculated Speed

~

Switchpositions

Voltage

Current

Motor Model

DTC CORE

Measured Speed

Motor state calculation in every

25 s with a powerful digital signal

processor (DSP)

Fast and accurate control

Immediate response to load changes

Low audible noise and high motor loadability

Energy savings

Continuous production after pulse encoder failure

Flying restart of motors at network disturbances

Single - drive structure

6

3-phase supply

DC-BUS

SupplyUnit

InverterUnit

MOTOR

Multi-drive structure

7

...

3-phase supply

DC-BUS

SupplyUnit

InverterUnit

InverterUnit

InverterUnit

MOTOR 1 MOTOR NMOTOR 2

Multi-drive structure

8

...

3-phase supply

DC-BUS

SupplyUnit

InverterUnit

InverterUnit

InverterUnit

MOTOR

12-Pulse Single-drive structure

9

3-Phase Supply

DC-BUS

SupplyUnit

MOTOR

SupplyUnit 1

SupplyUnit 2

Y D

D

BRAKE RESISTOR

BrakeChopper

InverterUnit ....7

InverterUnit 1

InverterUnit 2

12 Pulse Multi-drive structure

103-Phase Supply

DC-BUS

Retractable Thruster

SupplyUnit 1

SupplyUnit 2

Brake ResistorTunnel Thruster

InverterUnit 1

InverterUnit 1

InverterUnit 2

BrakeChopper

Y D

D

ISU Inverter Supply Unit

G3~

G3~

Sharing Generator Real power :

=> Power control engine=> Frequency control

Sharing reactive Generator power

=> generator excitation control=> Voltage control

ISU Basics

12

2U1U

Lj I LULij

1U

I

genU

2

genI

2U

1

L

2

14

IGB

T

sup

ply

12 -

pu

lse

6 -

pu

lse

Network data

IHD=7,78

Current harmonics, 12-pulse rectifier

IHD=2,05

Current harmonics, IGBT Line converter

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

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

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

ISU-Voltage distortion UTHD

15

0

1.0

2.0

3.0

4.0

THD 3 5 7 9 11 13 15 20 25 30 35 40 45 50

UTHD[%] = f(Rsc)

0

1

2

3

4

5

10 20 30 40 50 60 70 80 90 100

Rsc

ISU current distortionis under 5 %

ISU voltage harmonics depend on short circuit ratio.This is =Ssc(kVA)/Sisu(kVA)

10kV, SSC=100MVA

1MVA, uk=6%

400V , Ssc= 1/(1/100MVA+0.06/1MVA)=14MVASisu=935kVA=>RSC=14/0.935=15Uthd=3%, safe value!

Calculation example:

ACS800-xx Single-drives

• ACS800-01 => 1.1 - 90 kW

• ACS800-02 => 90 - 500 kW

16

ACS800-xx Single-drives

• ACS800-04 => 1.1 - 90 kW

•

• ACS800-07 => 90 - 500 kW

17

ACS800-01 Construction

• Easy installation– Plug in option boards– Excellent wire bending

space because of cabling box

– Wide cable size range

• Easy to replace fan

• IP 55 as option

ACS800-01 Options

• Built-in options:– I/O extension modules– Fieldbus modules– Pulse encoder module– Fibre optic link module

(master-follower, PC connection etc.)

– EMC filter– Braking chopper

ACS800-01 R2-R6 SizeR2 R3 R4 R5 R6

Boards Motor Control and I/O Main circuit Filter (EMC or varistor)

Motor Control and I/O Main circuit Current measurement (R6) Filter (EMC or varistor)

Powersemiconduc-tors

Soldered PIM (includes braking IGBT) Rectifier (soldered) IGBT (soldered) As option: braking

IGBT (soldered)

Rectifier (screw) IGBT (screw) As option: braking IGBT (screw)

Charging Relay and charging resistor Half controlled input bridge, charging diode andresistor

Chokes DC-chokes AC-chokesMain circuitbusbars

Main circuit board (some of the busbars on the PCB may be reinforced) R5 400/500V: on main circuit board Others: busbars / on board

Fan 1*DC, intake side Internal fan in the

biggest rating of theframe

With IP 55 alsointernal fan

1 * DC, intake side Internal fan in the biggest rating of the frame With IP 55 also internal fan

1*DC, intake side With IP 55 also internal fan

Mechanics Injection moulded frame, heat sink in the cast Sheet metal frame Separate lamella aluminium profile heat sink Plastic deck, skeleton and cover

Changeableparts

Motor Control and I/O Board Filter (EMC or varistor) Board Control Panel Fan(s) DC-capacitors (R4 only)

All

ACS800-104LC

1730126010002 x R8i

1300940750R8i

630500R8i

250R7i

kVAkVAkVASize

520037703010 4 x R8i

3900283022603 x R8i

2600188015102 x R8i

690V500V400VFrame

310 430

870

ACS800-104LCCapacitor bank and Rdischarge

Heat exchanger

Bus bars and CTs

Output filter inductor

Heat sink, IGBT+AGDR, Rfilter

Control electronics

Control Panel (CDP-312R)

• Simple and powerful– Large display– Start-up Assistant– Adaptive Programming– Backward compatible– New display format to set

pointer parameters (Group/Index/bit)

– Version independent parameter up/download

ACS800-x Ratings

• Imax = maximum allowed current (absolute value, does not depend on the temperature)

• Icont.max = maximum continuous current at 40 deg. C

• IN = base current that allows 10% overloadability for 1 min. (calculated value)

• Ihd = base current that allows 50% overloadability for 1 min. (calculated value)

ACS800-01 Type Code Sheet 3 - 55 kW, Wall MountedUpdated on 20 Nov 2001

1…6 A C S 8 0 0 Product Series Industry Segment

7…9 - 0 1 Construction

Application Area

10…14 - SizeFrame Size R2 Frame Size R3 Frame Size R4 Frame Size R5

400V 0003 0004 0005 0011 0016 0020 0025 0030 0040 00500006 0009

500V 0004 0005 0006 0016 0020 0025 0030 0040 0050 0060 00700009 0011

15…16 - Voltage Rating

3 = 400 V 5 = 500 V

Industry Segments

Application Areas

01 = Wall Mounted, IP21, with control panel CDP312R, no EMC filter, Standard software, Cable connection box,

Braking chopper in frame sizes R2 and R3

ACS800-x Type Code 1/2

E.g. ACS800-01-0016-3

ACS800-x Type Code 2/2Option codes

I/O options

L500 Analogue I/O extension RAIO-01

L501 Digital I/O extension RDIO-01

L502 Pulse encoder interface RTAC-01

L503 DDCS Communication 3 RDCO-03

L509 DDCS Communication 2 RDCO-02

L508 DDCS Communication 1 RDCO-01

Fieldbus

K451 DeviceNet adapter RDNA-01

K454 Profibus-DP adapter RPBA-01

K458 Modbus adapter RMBA-01

Software

N650 PFC Macro

N651 Master/Follower Macro

N666 Extruder Application Check availability

N653 FCB Programmable Template Check availability

N654 Spinning Macro Check availability

Control panel

J405 No control panel

Protection class

B056 IP55

P901 Coated boards

Filters

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

Resistor braking

D150 Braking chopper

Cabling

H358 Cable conduit box (US & UK version)

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

Included as standard in frame sizes R2 and R3

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

ACS800 R8i parallel connection

APBU-42or

APBU-44

PPCS(8 Mbit/s)

APEB-84

AGPS-21

APOW-01 AINT-12

AFIN-01 AGDR-6X

FAN 3 x 6 x IGBT 3 x I

UDC

ASFC-01

INV 3

RCH1 RCH2 RCH3

SWITCHFUSE(OESL)

INV 3 ... 11

. . .

MAX12 pcs

3 x T

ASFC-01

. . .

PPCS(8 Mbit/s)

INV EN

UDC OK

AFPS-01

INVERTER 1

SAFETYSWITCH

AGPS-21

APOW-01 AINT-12

AFIN-01 AGDR-6X

AFPS-01

INVERTER 2

AGPS-21

APOW-01 AINT-12

AFIN-01 AGDR-6X

SPEEDAFPS-01

INVERTER 12

SAFETYSWITCH

SAFETYSWITCH

DDCS (PC)

SPEEDSPEED

FAN 3 x 6 x IGBT 3 x IUDC3 x T

FAN 3 x 6 x IGBT 3 x IUDC3 x T

from RMIO (PPCS)

* ASFC-01* APBU-42* APBU-44 * APEB-84* AINT-12* AGDR-6X* AGPS-21* APOW-01* AFIN-01* AFPS-01

Switch Fuse Controller (option MD)PPCS Branching UnitPPCS Branching & Datalogger UnitPPCS Extension BoardMain Circuit InterfaceIGBT Gate Driver BoardGate Driver Power SupplyInverter Power SupplyFan Inverter (option)Fan Power Supply (option)

AGDR AGDR AGDR

AINTAINTAINT

ACS800-02 Circuit Boards

T

M

RMIO AINT

Externaloptionmodules

Optionmodules

U V W

Optionmodules

+24V

RDCOoption

ACS 800-02

Pulse encoder, Fieldbus, Extended I/O

CDP312R

FAN~230

+ -

CH-3

CH-2

APOW

AGDR

AINP

AIBP

ADPI

+24V

CH-1

CH-0

RDCU => RMIO Board + I/O

29

Connection to drive modulewhen n x R8i true APBU44

Connection to Application Controllereg. AC80 or AC800M

Slot 1• Digital I/O Extension (RDIO)• Analogue I/O Extension (RAIO)• Pulse Encoder Interface (RTAC)• Fieldbus Interface

Slot 2• Digital I/O Extension (RDIO)• Analogue I/O Extension (RAIO)• Pulse Encoder Interface (RTAC)

Slot 3• DDCS Link (RDCO-0x)

DDCS4 Mbit/s

PPCS8 Mbit/s

DDCS4 Mbit/s

I/O-Module ExtensionDDCS4 Mbit/s

Master / Follower-connection

DDCS1 Mbit/s

PC-ToolDriveWindow

modbus19,2 kbit/s

Control Panel CDP312R

7 Digital inputs

2 Analog inputs2 Analog outputs

3 Digital outputs

Reference voltage(±10V max 10mA)

External power supply24VDC

Maximum I/O configuration with AIMA-01

30

212131322Sum

2NTAC-02Tacho interface

2RTACTacho interface

22RAIOAI/O EXT5

22RAIOAI/O EXT4

22RAIOAI/O EXT3

22RAIOAI/O EXT2

22RAIOAI/O EXT1

23RDIODI/O EXT5

23RDIODI/O EXT4

23RDIODI/O EXT3

23RDIODI/O EXT2

23RDIODI/O EXT 1

2337RMIOBasic-I/O

Tacho interface

Analog-

output

Analog-

input

Digital-

ouputDigital-input

I/O-Extension

PPCS Branching Unit APBU-44/84• Includes parallel connection support for 2-12 inverter modules.• Basic board APBU-44 supports 2-4 inverter modules and with

APEB-84C option board up to 12 inverter modules.• APBU-44 includes fast data logger. Data can be uploaded via

PPCS link to be analysed. This function can be used to find faulty component in the main circuit.

31

Motor Control and I/O Board (RMIO)3 programmable relay outputs

ACS800-02 Main Circuit Board (AINT)• Contains all the high voltage and internal measurement

components of the drive• Automatic current measurement scaling - no need for soldered

slots• Powers the AINP and AGDR boards (+ ABRK board)• Earth fault and short circuit

protections– Adjustable earth fault current

trip limit– Earth fault detection is based

on output phase currents• One type can be used with

all ACS800-02 types

ACS800-02 Gate Driver Board (AGDR)• Connected directly to the IGBT module

• Gate control, saturation feedback and the temperature measurement functions are linked via the board

ACS800-02 Power Supply Board (APOW)

• Feeds power directly to the RMIO and AINT board

• Supply for the AINP board is connected via AINT board

• Connected directly to the DC link

ACS800-02 Input Bridge Control Board (AINP)• Turns on the input bridge

thyristors

• Power supply via AINT

• Charging controlled by sw:– Input bridge is turned on,

when the DC-link voltage has reached 0.7 * 1.35 * 380 V and the voltage rise is < 0.01 * UN / 10 ms

ACS800-02 Input Bridge Protection Board (AIBP)

• Protects the input bridge from transients

ACS800-02 Brake Chopper Control Board (ABRK)

• Controls the chopper IGBT and measures its saturation voltage and temperature

• Control and power from AINT:– Turns the IGBT on, when the

DC-link voltage is > 1.21 * UN

– Braking chopper and resistor protections done by sw

Diagnostic and panel interface board (ADPI)

• Panel connectors, Red and Green indication leds located on the board

• Two boards connected parallel in every module (for flat and bookshelf assembly)

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

ACS800-02 Filter Boards (ARFC & NRFC)

• Used for 1st environment filter• Cannot be used in IT networks• Features

– Up to 100 m motor cable length– EN 61800-3

Differences base software RMIO Board

41DTC

APPLICATIE SOFTWARE

OVERRIDING SYSTEM

HARDWARE

RDCU =>

( RMIO )

Speed & Torque Control

42

M13~

SUPPLY

n

n1

Tn

N Ref.

T1

3 ~

T %

2 1

3 4

100

100

n %

Application program types

• Standard application program

• System application program

• Diode supply control program

• IGBT supply control program

• Brake chopper control program

• Multi Block application program

• Crane control program

• Template application program 43

PLC <=> Profibus <=> RMIO

44

Profibus Link

45

FBA DRIVE

FBI DDCS DDCS PAR

FIELDBUS

REQUEST

RESPONSE

OPTICAL LINKBAUDRATE: 4 Mbit/sINTERVAL: appr. 8 ms

FBA = Fieldbus AdapterFBI = Fieldbus InterfaceDDCS = Distributed Drive Communication SystemPAR = Parameter Table

Profibus PPO1 …PPO5

46

Parameter Identification Process Data

CW REF1 REF2 PD1 PD2 PD3 PD4 PD5 PD6 PD7ID IND VALUE SW ACT1 ACT2 PD1 PD2 PD3 PD4 PD5 PD6 PD7

PPO Type 1

PPO Type 2

PPO Type 3

PPO Type 4

PPO Type 5

Functions in ABB Drive Software

• Motor speed reference ramp

• Motor speed control

• Motor torque control

• Motor flux control

• Calculation actual motor data

• Fast limit loops for drive and motor

• Fast master / slave control47

Functions in SIEMENS PLC

• Analogue & digital interface

• Custom application software

• Calculation drive speed- & torque reference

• Detection, alarm & fault logics

• Control from drive touch panel

• Control & protection liquid cooling system

48