PIT Dewatering Capacitación ACS800
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Pit Dewatering_Capacitacin_ACS800.pptABB 11.2.2010 Slide 1 (22)
ACS800 single drive
Accionamiento Elctrico de SkidProyecto: SMCV Pit DewateringPlan de Capacitacin
Febrero 2010
Pit Dewatering_Capacitacin_ACS800.pptABB 11.2.2010 Slide 2 (22)
ACS800 single driveWhy to use VSD? Direct torque controlACS800 tools DriveWindowAdaptive programming SafetyACS800-04 Terminal Interface ACS800-04 RPBA-01 Connection diagram: Factory macroControl Panel CDP312RControl ModesControl Panel: Actual signal panel display and setting of referenceControl Panel: parameter display and changeControl Panel: Assistants in FUNC menuControl Panel: Drive change mode Protection examples Parameter groupsTroubleshooting: InstructionsTroubleshooting: Drive without the control panel Troubleshooting: Faults Troubleshooting: WarningsWarrantyDrive environmental limits and annual maintenanceMaintenance schedule for drive fans and capacitorsAfter sale check list Motor protection
Table of contents
Pit Dewatering_Capacitacin_ACS800.pptABB 11.2.2010 Slide 3 (22)
ACS800 single drive
Variable Speed Control saves a considerable amount of energy
Improved quality through better process controllability
Reduced process equipment wearand longer lifetime mean decreasedenvironmental loading
Soft Start and Stop reduces waste and saves raw material
Noise reduced in most cases Natural resources saved while
process efficiency improved
time
speed
Soft Start
Production rise
Energy saving
Best quality
Why to use VSD?...saves environment and has other benefits
Pit Dewatering_Capacitacin_ACS800.pptABB 11.2.2010 Slide 4 (22)
ACS800 single drive
BACKBACK
Pit Dewatering_Capacitacin_ACS800.pptABB 11.2.2010 Slide 5 (22)
ACS800 single drive
Torque step rise time
Accurate speed or torque control
Full torque at zero speed Direct control of torque - no
nuisance trips Power loss ride through
No unnecessary process interruptions
Fast control - better protection
Excellent motor control in all situations
DTC
Flux vector
Open loop PWM
< 5 msec.
10 to 20 msec.
> 100 msec.
0,00
0,50
1,00
Current
TorqueDTC
PWM
New Current level
New Torquelevel
Time
Pit Dewatering_Capacitacin_ACS800.pptABB 11.2.2010 Slide 6 (22)
ACS800 single drive
ACS 800 Tools
DriveSize Engineering Tool for dimensioning
drives and motors
DriveWindow Start- up and Maintenance Tool for
commissioning and monitoring
DriveAP Programming Tool for Adaptive
Programming
DriveOPC Integration Tool for integrating with
commercial software
Supporting the Lifecycle of Drives
Pit Dewatering_Capacitacin_ACS800.pptABB 11.2.2010 Slide 7 (22)
ACS800 single drive DriveWindow is Windows Application for commissioning and
maintaining ACS600, ACS800, ACS6000, and DCS600. Operating system Windows NT, Windows 2000, or Windows XP
DriveWindow is Windows Application for commissioning and maintaining ACS600, ACS800, ACS6000, and DCS600.
Operating system Windows NT, Windows 2000, or Windows XP
FunctionsControl operations (start, stop, references, etc.)Monitoring signals in numerical and graphical formatParameters (changing values)Datalogger (controls, display)Fault Logger (display faults, controls)Back-up & Restore (complete software back-up)All functions over network (control, monitoring, etc.)
FunctionsControl operations (start, stop, references, etc.)Monitoring signals in numerical and graphical formatParameters (changing values)Datalogger (controls, display)Fault Logger (display faults, controls)Back-up & Restore (complete software back-up)All functions over network (control, monitoring, etc.)
Required DriveWindow hardware:ISA card, orPCMCIA-card (PCMCIA-slot or PCI-slot with PCI/PCMCIA adapter)Network adapter when using remote connectionDDCS cabling
Required DriveWindow hardware:ISA card, orPCMCIA-card (PCMCIA-slot or PCI-slot with PCI/PCMCIA adapter)Network adapter when using remote connectionDDCS cabling
DriveWindow
Pit Dewatering_Capacitacin_ACS800.pptABB 11.2.2010 Slide 8 (22)
ACS800 single drive
ACS 800 Adaptive Programming
No extra software, hardware or tools needed
Creating and modifying I/O signals Speed or torque reference
Documentation Easy to create and understand One sheet is always enough
Built-in PLC - Programming Done in a Few Minutes
Pit Dewatering_Capacitacin_ACS800.pptABB 11.2.2010 Slide 9 (22)
ACS800 single drive
ACS800 - 7, rev. 1
ACS 800
Copyright ABB Industry Oy
Application program example
Pit Dewatering_Capacitacin_ACS800.pptABB 11.2.2010 Slide 10 (22)
ACS800 single drive Safety
The ACS800 adjustable speed AC drive should ONLY be installed by a qualified electrician..
Warning! Even when the motor is stopped, dangerous voltage is present at the Power Circuit terminals U1, V1, W1 , U2, V2, W2,UDC+ , UDC-, R-,R+.
Warning! Dangerous voltage is present when input power is connected. After disconnecting the supply, wait at least 5 minutes (to let the intermediate circuit capacitors discharge) before removing the cover.
Warning! Even when power is removed from the input terminals of the ACS800, there may be dangerous voltage (from external sources) on the terminals of the relay outputs R01R03.
When the control terminals of two or more drive units are connectedin parallel, the auxiliary voltage for these control connections must be taken from a single source which can either be one of the units or an external supply.
The ACS800 circuit boards are not a field repairable component. Never attempt to repair a malfunctioning unit with solderings; contact the factory or your local Authorized Service Center for component or the whole unit replacement.
Use only Components accepted by ABB for repair work.
Warning! The ACS800 will start up automatically after an input voltage interruption if the external run command is on.
Warning! There are several automatic reset functions in the ACS800. If selected, it resets the unit and resumes operation after a fault. These functions should not be selected if other equipment is not compatible with this kind of operation, or dangerous situations can be caused by such action.
Warning! The heat sink may reach a high temperature.
ACS800 needs lot of cooling air. Do not install ACS800 to any closed cabinet or space if there is not enough cooling air available.
Mark if read and understood
Pit Dewatering_Capacitacin_ACS800.pptABB 11.2.2010 Slide 11 (22)
ACS800 single drive Terminal Interface, module (ACS800-04)
U1 V1 W1 (Pover Supply)
U2 V2 W2 (Motor Connection)
Option slot 1
(RPBA connected)
X21 Analog Inputsand outputs
X22 Digital Inputs
X24 Relay Output 1
Control Panel Connector
X20 Voltage reference-10V
X23 Voltage reference +24V
X25 Relay Output 2
X26 Relay Output 3
Option slot 2
Option slot 3
(for RDCO)
Terminal blocks of the RMIO board:
FO Connector
Pit Dewatering_Capacitacin_ACS800.pptABB 11.2.2010 Slide 12 (22)
ACS800 single drive ACS800-04 RPBA-01Profibus Connector
Address rotatory switches Status LEDs
Bus termination
Pit Dewatering_Capacitacin_ACS800.pptABB 11.2.2010 Slide 13 (22)
ACS800 single drive Connection diagram: Factory macro
Analog outputs: Motor speed Output current
Voltage Reference (0-10V)
Note! This connection is example only.Made according to a Factory MacroMacro can be selected by parameter 99.02
Reference from a Current Source
5 AI 26 AI27 AI 38 AI 3
X21
0/(4)20mA
SCR
Analogue input configuration:AI1: Voltage input 10 - +10VAI2: Current input 0 20mAAI3: Current input 0 20mA
9
4Digital inputs: Wirings should be done according to application demand
DIL: +24V needed to prevent start interlock
X23: +24V output or external input
Pit Dewatering_Capacitacin_ACS800.pptABB 11.2.2010 Slide 14 (22)
ACS800 single drive Control Panel CDP 312R
Operation mode keys for:Drive selection modeFunction modeParameter modeActual signal display mode
The use of arrow keys and ENTER key depend on the operation mode of the panel
LOC/REM Changes between local and remote control of the drive. (L in the up left corner of the display when Local control is selected) STOP - Stops the drive
In local control
START- Starts the drive in local control
LCD Display
REF- Enables reference change in local control (reference change with arrow keys)
Direction keysof the local control: 1-Forward, 0-Reverse(when PAR 10.03=request)
RESET- Resets the fault in the local and remote control
Pit Dewatering_Capacitacin_ACS800.pptABB 11.2.2010 Slide 15 (22)
ACS800 single drive
1 1242.8 rpm 0FREQ 55.00 HzCURRENT 76 APOWER 55.0 %
1 L 1242.8 rpm 0FREQ 55.00 HzCURRENT 76 APOWER 55.0 %
Control modes
LOCAL control (CONTROL-PANEL or PC control) REMOTE control (control via I/O-terminals from CONTROL DESK or AUTOMATION SYSTEM)
LOCREM
Note! When local control is selected in the Control Panel or the PC, drive is immediately loosing the remote control
Note! When local control is selected in the Control Panel, Lindicates the control location. When local control is selected in the PC, PC Tool indicates the control location.
Normal operationCommissioning & Service operations
Pit Dewatering_Capacitacin_ACS800.pptABB 11.2.2010 Slide 16 (22)
ACS800 single drive
1 L [ 1242.8 rpm ] IFREQ 55.00 HzCURRENT 76 APOWER 55.0 %
Actual signal panel display and setting of reference
Frequency reference
Reference can be adjusted by pressing REF button => brackets around the reference value. When value is in the brackets the value can be changed with the arrow keys
LOCAL control(control from
CONTROL PANEL)
Drive ID number
(normally always 1)
Status row
Display rows
(actual signal display normally visible)
Drive Status information:
1=Running
0=Stopped
=No drive permission (run disabled, start interlock)
Pit Dewatering_Capacitacin_ACS800.pptABB 11.2.2010 Slide 17 (22)
ACS800 single drive Parameter display and changePress
Button:FUNCTION:Go to parameter mode:
Change the parameter group down:
Change the parameter up:
ENTERActivate the parameter value:
Change the parameter value:
ENTERAccept the newparameter value:
PAR Display:1 1242.8 rpm 010 START/STOP/DIR01 EXT1 STRT/STP/DIRDI1,2
Status row
Display rows:Param. GroupParam. numberParam. value
Display:1 1242.8 rpm 099 START-UP DATA01 LANGUAGEENGLISH
Display:1 1242.8 rpm 099 START-UP DATA02 APPLICATION MACROFACTORY
Display:1 1242.8 rpm 099 START-UP DATA02 APPLICATION MACRO[FACTORY]
Display:1 1242.8 rpm 099 START-UP DATA02 APPLICATION MACRO[HAND/AUTO]
Display:1 1242.8 rpm 099 START-UP DATA02 APPLICATION MACROHAND/AUTO
Pit Dewatering_Capacitacin_ACS800.pptABB 11.2.2010 Slide 18 (22)
ACS800 single drive Assistants in FUNC menuGuided Start-up procedure with assistantswill activated automaticly after power upthe drive, if one of the motor parametersis zero:
ASSISTANTS IN FUNC MENU:Language Selection Torque Control Motor Setup PID Control Application Macro Drive Protection Start/Stop Control OutputsOption Setup Speed Control EXT1Speed Control EXT2
Commission procedure can be done withassistant or with parameters (if FUNC is selected the commission can be donewithout manual with guided Start-upprocedure):
ORFUNC PAR
There are several assistants in the FUNC menu(execution order of the assistant is automatically selected in the Guided Start-up procedure)+:
Move between pages in FUNC menu withdouble arrow buttons:
Move between assistants in FUNC menu with single arrow buttons:
Start assistant and accept value withENTER button: ENTER
1 0.0 rpm 0*** INFORMATION ***Press FUNC to startLanguage selection
Pit Dewatering_Capacitacin_ACS800.pptABB 11.2.2010 Slide 19 (22)
ACS800 single drive Protection examples
: overcurrent Fixed, automatic reset possibility: overvoltage Fixed , automatic reset possibility: undervoltage Fixed , automatic reset possibility: AI signal
Pit Dewatering_Capacitacin_ACS800.pptABB 11.2.2010 Slide 20 (22)
ACS800 single drive
ACS800
Copyright ABB Oy
27 BRAKE CHOPPER
CONTROL CONNECTIONS
16 SYSTEM CTR INPUTS
15 ANALOGUE OUTPUTS
14 RELAY OUTPUTS
13 ANALOGUE INPUTS
12 CONSTANT SPEED
11 REFERENCE SELECT
10 START/STOP/DIR
DRIVE
26 MOTOR CONTROL
25 CRITICAL SPEEDS
24 TORQUE CONTROL
23 SPEED CONTROL
22 ACCEL/DECEL
21 START/STOP
20 LIMITS
Parameter Groups
Pit Dewatering_Capacitacin_ACS800.pptABB 11.2.2010 Slide 21 (22)
ACS800 single drive
ACS800
Copyright ABB Oy
35 MOT TEMP MEAS 60 MASTER/FOLLOWER
70 DDCS CONTROL
PROTECTION andINFORMATION
34 PROCESS VARIABLE
33 INFORMATION
32 SUPERVISION
31 AUTOMATIC RESET
30 FAULT FUNCTIONS
APPLICATION
Parameter Groups
51 COMM MODULE DATA
52 STANDARD MODBUS
42 BRAKE CONTROL
50 ENCODER MODULE
40 PID CONTROL
Pit Dewatering_Capacitacin_ACS800.pptABB 11.2.2010 Slide 22 (22)
ACS800 single drive
ACS800
Copyright ABB Oy
99 START-UP DATA
98 OPTION MODULES
START-UP and OPTION DATA
Parameter Groups
ADAPTIVE PROGRAMMING
85 USER CONSTANTS
84 ADAPTIVE PROGRAM
83 ADAPT PROG CTRL
96 EXTERNAL AO
90 D SET REG ADDR
92 D SET TR ADDR
Pit Dewatering_Capacitacin_ACS800.pptABB 11.2.2010 Slide 23 (22)
ACS800 single drive
If the faultcannot be resolved
by the given instructions, contact an ABB representative,
telephone:________________Before calling, following information
is good to be available:- serial number e.g. 2030700001- type of the units e.g. ACS800-01-0005-3- software revision (from drive menu)- description how and when fault/problem
occurs, how the unit is used and how often this fault comes.
Troubleshooting: Instructions
Caution! Do not attempt any measurement, parts replacement or other service procedures not described in these slides or product manuals. Such actions will void guarantee, endanger correct operation, and increase downtime and expense.
Warning! If an external source for start
command is selected and is still active, the ACS800 may start immediately after fault reset.
Warning! All electrical installation and maintenance work described in these slides should only be undertaken by a qualified electrician. The SafetyInstructions must be followed.
If there is no fault indication in the control panel or upper control system, check the external connections: Motor cable connections for possible short circuit. The supply voltage and cables. If digital/analogue input is used, check the input signals.
if read and understoodMark
ABB representative
fill in
Pit Dewatering_Capacitacin_ACS800.pptABB 11.2.2010 Slide 24 (22)
ACS800 single drive Troubleshooting: Drive without the control panel
Power LED (Green)
Fault LED (Red)
Green led ON:
Normal situation,power supply for the control panel and RMIO board is OK
Red led ON:
Drive in the Fault State
Pit Dewatering_Capacitacin_ACS800.pptABB 11.2.2010 Slide 25 (22)
ACS800 single drive Troubleshooting: Faults
Fault Resetting
To reset the drive for faults indicated by a red LED or fault in the Control Panel, correct the problem and reset the fault: From the control panel: Press RESET From the PC Tool (e.g.DriveWindow) From digital input signal From upper control system trough fieldbus Turn the power off for 5 minutes
Motor starting
Motor can be started when: Fault not exist anymore Fault is resetted Drive is ready for run Start signal is given for the drive
Fault Tracing
If the external connections of the drive is OK fault/warning message exist in the fault logger of the drive (fault history) and the message can be seen in the display of the Control panel or PC tool. Fault tracing instructions with Fault and warning tables can be found In the Firmware manual.
1 1242.8 rpmACS800*** FAULT ***ACS800 TEMP (4210)
Pit Dewatering_Capacitacin_ACS800.pptABB 11.2.2010 Slide 26 (22)
ACS800 single drive Troubleshooting: Warnings1 1242.8 rpmACS800*** WARNING ***ACS800 TEMP (4210)
Pit Dewatering_Capacitacin_ACS800.pptABB 11.2.2010 Slide 27 (22)
ACS800 single drive Warranty
The warranty period of the Manufacturer is 12 months from the date of commissioning or 24 months from the date of manufacturing*, whichever expires first.
The serial number has 10 digits. E.g. 1020100123: where 1 means place of manufacturing (1=Helsinki), 02 means manufacturing year (2002), 01 is manufacturing week 00123 running manufacturing number.
ACS800-04-0400-7
Serno *1020100123*
* Date of manufacturing is written to the serial number of the drive:
Pit Dewatering_Capacitacin_ACS800.pptABB 11.2.2010 Slide 28 (22)
ACS800 single drive Drive environmental limits and annual maintenanceWARNING! All maintenance work described in this document should only be undertaken by a qualified electrician.
WARNING ! Read "Safety" chapter from product manual before performing any maintenance on the equipment. Ignoring the safety instructions can cause injury or death.
Environmental Limits
Ambient operating temperature -15 - +40 C Max. ambient temperature 50 C if PN and I2 derated Installation altitude 0 - 1000 m Installation altitude 1000 - 2000 m if PN and I2 derated Relative humidity 5 - 95 % (non-condensing) Storage and transport temperature -40 C - +70 C
The ACS800 should be installed in clean and dry air (according to enclosure classification), free from water, corrosive materials and electrically conductive dust.
Heatsink
The heatsink fins accumulate dust from the dirty cooling air. Since a dusty heatsink is less efficient at cooling the drive, overtemperature warnings/faults become more likely. In a normalenvironment (not dusty) check the heatsink annually, in a dusty environment check more often.
Spare part drive modules
Modules stocked (non-operational) less than 2 years:Switch the power on to the converter for a 2 hour. The converter wakes upits capacitors by itself. Power the modules up ( 1 hour) once a year to keep the capacitors in operational condition.
Modules stocked (non-operational) more than 2 years:Follow the instructions of the ABB Capacitor reforming guide.
Pit Dewatering_Capacitacin_ACS800.pptABB 11.2.2010 Slide 29 (22)
ACS800 single drive Maintenance schedule for drive fans and capacitorsFan Replacement
Fan failure can be predicted by the increasing noise from fan bearings and the gradual rise in the heatsink temperature in spite of heatsink cleaning.
Pit Dewatering_Capacitacin_ACS800.pptABB 11.2.2010 Slide 30 (22)
ACS800 single drive After sale check list
Installation Check that ACS800 are vertically installed and there free space above and below the unit. Ensure that there is sufficient cool air in the cabinet to compensate for the power losses. Details about installation can be found from the HW Manual.In ACS800-01 units, if the supply network is floating (IT network) remove both grounding screws otherwise you may cause danger or damage the unit.
Cabling Check that local rules for cable cross-sections have been followed. Motor cable are three phase cables and shielded type. Route the motor cable away from control wires and the power supply cable to avoid electromagnetic interference, see HW Manual.
Motor Check that the motor is compatible. The motor must be a three-phase induction motor and suitable for frequency converter use. Check that insulation resistance of motor circuit have been measured.
Drawings Check that drawings correspond with the actual installation on the site.
Parameters Check that customer has copy of all parameters at least by paper. It is recommended to take parameter and backup -files with the DriveWindow 2 -program. Uploaded parameters in the control panel are not enough!!
Cleanliness Check that no packing material and surplus cables were left into the electrical room or inside drive after the installation.
Environmental Limits have been observed.
Mark if it have been done or/and figure out to the customer
Pit Dewatering_Capacitacin_ACS800.pptABB 11.2.2010 Slide 31 (22)
ACS800 single drive Motor Protection
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