Category: ABB DRIVES

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Debugging of ABB VFD for ACS800 Enhancement

A. Motor Auto-tuning (Quick Debugging Steps)

  1. Power On: Ensure the system is powered on.
  2. Input Initialization:
    • Press PAR to select the language. Set 99.1 to ENGLISH.
    • Choose the application macro. Set 99.2 to CRANE.
    • Determine if parameters should be reset to factory defaults. Set 99.3 to YES or NO.
    • Select the motor control mode in 99.4: DTC (Direct Torque Control) or SCALAR.
    • Enter the rated voltage in 99.5 V.
    • Input the rated current in 99.6 A.
    • Specify the rated frequency in 99.7 HZ.
    • Set the motor’s rated speed in 99.8 RPM.
    • Define the motor’s rated power in 99.9 KW.
  3. Motor Identification Run:
    • Proceed to motor identification by selecting 99.10.
    • Generally, choose ID MAGN (the motor won’t rotate).
    • For STANDARD mode (motor rotates), the motor must be disconnected from the equipment.
    • In REDUCED identification mode (motor rotates), the motor remains connected.
    • After selecting the identification mode, a “WARNING” signal may appear.
    • Press the start button to begin motor identification. This process can be stopped at any time using the stop button.
    • Once the motor identification is complete, press RESET to enter actual signal display mode.
  4. Motor Direction Check: Verify the motor’s rotation direction using the control panel.
  5. Input Speed Limits and Acceleration/Deceleration Times: Enter the necessary parameters.

B. Parameter Configuration – Optimized for Google SEO

  1. Set parameter 10.1 to DI1 for brake acknowledgment digital input.
  2. Leave parameter 10.2 as NOT SEL for zero-position digital input.
  3. Parameter 10.3 remains NOT SEL for deceleration digital input.
  4. Parameter 10.4 is NOT SEL for rapid stop digital input.
  5. Parameter 10.5 is NOT SEL for power-on acknowledgment digital input.
  6. Keep parameter 10.6 as NOT SEL for synchronization request digital input.
  7. Set parameter 10.7 to EXT DI1.1 for chopper fault digital input.
  8. Configure parameter 10.8 to DI2 for the second speed level digital input.
  9. Set parameter 10.9 to DI5 for the third speed level digital input.
  10. Parameter 10.10 is set to DI6 for the fourth speed level digital input.
  11. Parameters 10.11 to 10.15 and 10.17, 10.18 remain NOT SEL.
  12. Set parameter 10.16 to DI-1L for fault reset digital input.
  13. Parameter group 13 deals with analog input signals. No need for modification.
  14. Set parameter 14.1 to BRAKE LIFT for relay output 1.
  15. Configure parameter 14.2 to WATCHDOG-N for relay output 2.
  16. Parameter 14.3 is set for relay output 3 to indicate a FAULT-N signal. When a fault occurs, the relay releases, and during power-on, the fault relay engages.
  17. Parameter group 15 covers analog output signals. No modifications required.
  18. Parameter group 16 deals with password settings. No need to change.
  19. Parameter group 20 defines limit values:
    • Parameter 20.1: Minimum speed for the operating range.
    • Parameter 20.2: Maximum speed for the operating range.
    • Parameter 20.3: Maximum output current.
    • Parameter 20.4: Maximum positive output torque.
    • Parameter 20.5: Maximum negative output torque.
    • Parameter 20.6: DC overvoltage controller.
    • Parameter 20.7: DC undervoltage controller.
    • Parameter 20.8: Minimum frequency for the operating range.
    • Parameter 20.9: Maximum frequency for the operating range.
    • Parameters 20.10 to 20.13 relate to analog inputs but are not detailed here.
  20. Parameter 21.1 is not to be changed.
  21. Set parameter 21.2 for the field excitation time, approximately 4 times the motor’s rated KW (in milliseconds).
  22. Parameter group 23 covers speed control gains, integral and derivative times, motor slip, etc. Generally left unchanged.
  23. Parameter group 24 deals with torque build-up time. Typically not modified.
  24. Parameter group 26 allows compensation voltage setting for the motor (only in SCALAR mode).
  25. Parameter group 27 configures the braking chopper:
    • Set parameter 27.1 to ON for brake chopper control.
    • Parameter 27.2 is set to FAULT to activate overload protection for the braking resistor.
    • Enter the actual value for the braking resistor in parameter 27.3.
    • Set the time constant for the braking resistor in parameter 27.4 to 300S.
    • Define the maximum continuous braking power for the resistor in parameter 27.5.
    • Set the control mode for the brake chopper control to AS GENERATOR in parameter 27.6.
  26. Parameter group 28 deals with motor modeling. Typically not modified.
  27. Parameter group 30 covers fault functions. Generally left unchanged.
  28. Parameter group 50 configures encoder values:
    • Set the number of encoder pulses in parameter 50.1.
    • Define the calculation method for encoder pulses in parameter 50.2.
    • Parameter 50.3 is set to FAULT for encoder fault action.
    • Set the encoder monitoring delay time in parameter 50.4 (avoid setting to 0).
    • Parameter 50.5 determines the encoder feedback usage, typically set to TRUE.
  29. Parameter group 60 handles the switch between local and external operation.
  30. Parameter groups 61 and 62 deal with speed monitoring. Generally not modified.
  31. Parameter group 63 covers torque monitoring. Typically left unchanged.
  32. Parameter group 64 is for crane mode:
    • Set parameter 64.1 to TRUE for STAND ALONE mode.
    • Parameter 64.10 is configured to STEPJOYST or STEPRADIO.
    • Parameters 64.13 to 64.16 define the speeds for the four speed levels (as a percentage of rated speed).
  33. Parameter group 65 deals with motor field current settings. Generally not modified.
  34. Parameter group 66 covers torque verification, typically left unchanged.
  35. Parameter group 67 configures brake control:
    • Set the brake application time to 0.5S in parameter 67.1.
    • Define the brake fault delay as 0.5S in parameter 67.2.
    • Parameters 67.3 to 67.10 are not detailed but can be set as needed.
  36. Parameter group 68 is for power optimization, typically not modified.
  37. Parameter group 69 defines the maximum speed and acceleration/deceleration times.
  38. Parameter group 98 activates optional modules.
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ACS800 Variable Speed Drive (VSD) Debugging Steps

I. Basic Local Control Process for ACS800 VSD

Ensure that the air switch is closed and the contactor is energized.
Press the LOC/REM key to switch to local control mode.
Press the FAR key to enter the parameter setting interface. Use the double arrow keys to navigate to the 99 parameter group, then use the single arrow keys to select item 04. Press ENTER to confirm. Here, you can choose between DTC mode (suitable for most cases) or SCALA mode. After selecting, press ENTER to save or ACT to exit.
Press the ACT key to return to the main operation interface.
Press the REF key, use the up/down arrow keys to input the desired parameter value, and then press ENTER to confirm.
Press the start key to begin operating the VSD.
To replace the displayed actual signal, follow these steps:
a. Press the ACT key to enter signal display mode.
b. Select the row you want to change and press ENTER.
c. Use the arrow keys to browse and select a new signal (such as actual motor speed – SPEED, transmission output frequency – FREQ, etc.).
d. Press ENTER to confirm the change or ACT to exit.

II. Data Upload and Download Operations

To upload set motor parameters to the CDP-312 panel:

Verify that item 98.02 is set to FIELDBUS and item 98.07 is set to ABB DRIVES.
Switch to local control mode (LOC).
Press the FUNC key to access the function menu.
Use the arrow keys to navigate to the UPLOAD function and press ENTER to execute the upload.
If you need to move the control panel, ensure it is in remote control mode first.
To download data from the control panel to the drive unit:

Connect the control panel containing the uploaded data.
Ensure you are currently in local control mode.
Press the FUNC key to access the function menu.
Navigate to the DOWNLOAD function and press ENTER to execute the download.
III. Achieving PLC and VSD PROFIBUS-DP Communication

After confirming that the communication module is installed and the DP network cable is correctly connected, follow these steps to set the parameters:

In local mode, use FAR and the arrow keys to enter parameter settings.
Set 98.02 to FIELDBUS to activate the RPBA-01 communication module.
Set 98.07 to ABB DRIVES to determine the communication protocol.
Configure items 10.01, 10.02, and 10.03 as needed to define the external control source.
Set 16.01 to YES to allow operation.
Select the fault reset signal source for 16.04.
From 11.01 to 11.08, set the source of the control word and given value.
In items 22.01 to 22.03, define acceleration/deceleration time and stop function.
For the 51 group of parameters, configure according to the fieldbus adapter module’s settings.
Adjust the actual signal transmission content in the 92 group as needed.
IV. Additional Parameter Setting Reference (Not Currently Used)

This section provides guidance on setting speed limits, protection functions, and parameter locking for future reference.

Note: Before making any parameter changes, ensure you fully understand their impact and consult a professional if necessary.

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Adjusting the Power Rating of ABB VFDs: A Step-by-Step Guide

Adjusting the Power Rating of ABB VFDs: A Step-by-Step Guide

When it comes to flexibility in power rating adjustments, ABB’s ACS510/ACS550/ACS350/ACS355/ACH550 Variable Frequency Drives (VFDs) offer a seamless solution. Whether you need to upgrade from a 1.1KW to a 5.5KW VFD or make any other power adjustment, these drives provide the capability to adapt to your specific requirements. This is especially beneficial in scenarios where you have a limited number of VFD main boards, like the SMIO-01C, and need to utilize them across different power ranges. Below is a detailed guide on how to access and modify the power rating parameters of these VFDs.

Accessing and Modifying Parameters

  1. Open the Parameter Table:
    • Navigate to the deepest level of parameters, which may include numbers like 0102 or any other displayed values.
    • If you see 9905, for instance, hold the UP (arrow up), DOWN (arrow down), and RETURN (button next to LOC on the upper left) buttons simultaneously for 3 seconds.
    • You will observe a flash on the screen, and the top line should display “PARAMETERS+”.
  2. Expand Parameter Groups:
    • Exit and re-enter the parameter groups.
    • Notice that the number of parameter groups has increased from 99 to a maximum of 120.
    • Navigate to parameter group 105.

Modifying Power Capacity

Follow these precise steps to adjust the power capacity:

  1. Find and Modify Parameter 10509:
    • Change 105.09 to the desired current value.
    • Ensure the corresponding power value matches the VFD label. For example:
      • For ACS510-01-017A-4, change to 0174H.
      • For ACS510-01-031A-4, change to 0314H.
  2. Set 10502 to 1 and confirm.
  3. Set 10511 to 4012 and confirm.

Note: The order of these modifications is crucial. Any mistake may require you to restart the process.

Verifying Parameter Changes

  • Re-enter the parameter table.
  • Check if parameter 3304 (transmission capacity) reflects the correct modifications.

Important Considerations

  • The process outlined above modifies the power rating on the ABB drive motherboard (SMIO-01C). It does not alter the power of the drive board itself.
  • Despite the appearance of expanded power capabilities, the actual output power of the VFD remains unchanged unless the power board is also modified.
  • This guide is specific to ACS510/ACS550/ACS350/ACS355/ACH550 VFDs and is not applicable to the ACS800 series.

For assistance with power modification methods for ACS800 inverters, please reach out to us directly. Our team is here to help you navigate the intricacies of VFD power adjustments and ensure your equipment operates at its optimal capacity.