Petri Torniainen October 2009 New ABB industrial drive

Petri Torniainen, October 2009 New ABB industrial drive module ACS 850 -04 overview © ABB Group 04 November 2020 | Slide 1

New industrial drive modules Industrial drives § Very flexible drives that are easy to be configured to meet the needs of various industries and applications § Designed especially for process industry segments such as: § © ABB Group 04 November 2020 | Slide 2 § Pulp & paper § Mining § Cement § Chemical, oil & gas Examples of applications: § Cranes § Winders § Mixers

New industrial drive modules For System Integrators and OEMs ACS 850 -04 is designed for fast, cost effective installation and integration into cabinets, therefore targeted for OEMs and System Integrators © ABB Group 04 November 2020 | Slide 3

New industrial drive modules Range © ABB Group April 2009 | Slide 4

New industrial drive modules Range © ABB Group 04 November 2020 | Slide 5

New industrial drive modules Frames A & B Dim. in mm § 364 3 Kg 93. 5 I 2 N (A) PN (k. W) Type 3 1. 1 ACS 850 -04 -03 A 0 -5 3. 6 1. 5 ACS 850 -04 -03 A 6 -5 4. 8 2. 2 ACS 850 -04 -04 A 8 -5 6 2. 2 ACS 850 -04 -06 A 0 -5 8 3 ACS 850 -04 -08 A 0 -5 197 (219)* § 380 5 Kg Frame B, IP 20 I 2 N (A) PN (k. W) Type 10 4 ACS 850 -04 -010 A-5 14 5. 5 ACS 850 -04 -014 A-5 18 7. 5 ACS 850 -04 -018 A-5 *Depth in brackets = with control panel 101 © ABB Group 04 November 2020 | Slide 6 Frame A, IP 20 274 (297)*

New industrial drive modules Frames C & D Dim. in mm 567 276 (298)* § I 2 N (A) PN (k. W) Type 25 11 ACS 850 -04 -025 A-5 30 15 ACS 850 -04 -030 A-5 35 18. 5 ACS 850 -04 -035 A-5 44 22 ACS 850 -04 -044 A-5 50 22 ACS 850 -04 -050 A-5 16 Kg 166 § 567 22 Kg 276 (298)* 221 © ABB Group 04 November 2020 | Slide 7 Frame C, IP 20 Frame D, IP 20 I 2 N (A) PN (k. W) Type 61 30 ACS 850 -04 -061 A-5 78 37 ACS 850 -04 -078 A-5 94 45 ACS 850 -04 -094 A-5 *Depth in brackets = with control panel

New industrial drive modules Frames E & E 0 Dim. in mm 602 354 (376)* 276 35 Kg § I 2 N (A) PN (k. W) Type 103 55 ACS 850 -04 -103 A-5 144 75 ACS 850 -04 -144 A-5 *Depth in brackets = with control panel § 700 443 (465)* © ABB Group 04 November 2020 | Slide 8 67 Kg 312 Frame E 0, IP 20 Frame E, IP 20 I 2 N (A) PN (k. W) Type 166 90 ACS 850 -04 -166 A-5 202 110 ACS 850 -04 -202 A-5 225 110 ACS 850 -04 -225 A-5 260 132 ACS 850 -04 -260 A-5 290 160 ACS 850 -04 -290 A-5

New industrial drive modules Frame G Dim. in mm § 1564 568 205 Kg © ABB Group 04 November 2020 | Slide 9 562 Frame G, IP 00 I 2 N (A) PN (k. W) Type 430 200 ACS 850 -04 -430 A-5 521 250 ACS 850 -04 -521 A-5 602 315 ACS 850 -04 -602 A-5 693 355 ACS 850 -04 -693 A-5 720 400 ACS 850 -04 -720 A-5

New industrial drive modules Ratings © ABB Group April 2009 | Slide 10

New industrial drive modules Ratings © ABB Group 04 November 2020 | Slide 11 § Currents are expressed in Amperes § I 2 N rated current available continuously without overloading § ILd continuous current in light-duty use § IHd continuous current in heavy-duty use § IMax maximum output current

New industrial drive modules Ratings Supply voltage : 3 -phase 380 V to 500 V © ABB Group 04 November 2020 | Slide 12

New industrial drive modules Hardware © ABB Group April 2009 | Slide 13

New industrial drive modules Hardware Optimized for cabinet installation Bus cc © ABB Group 04 November 2020 | Slide 14 § Compact, narrow design § Side-by-side mounting § DIN-rail mounting (frames A and B ) § Power terminals on top (up to 45 k. W) enabling compact and EMC compliant installation § Motor connections at the bottom of the drive § Plug-in terminals § I/O § Power terminals (frames A and B )

New industrial drive modules Hardware © ABB Group 04 November 2020 | Slide 15 § 2 option slots for I/O extensions and encoders § 1 dedicated slot for fieldbus modules § Coated boards as standard § Fan supervision (frames A to D)

New industrial drive modules Hardware Removable memory unit © ABB Group 04 November 2020 | Slide 16 § Stores the complete software and parameter settings § Makes the recommissioning of the unit fast and easy § Gives a possibility for software and parameter configuration at e. g. ABB or OEM workshop before sending it to customer § Easy to install (only a screwdriver is needed !)

New industrial drive modules EMC filters C 2 and C 3 (1 st and 2 nd environment) § C 3 filter, frames A-B § § § C 3 filter, frames C – G § Optional built-in EMC filter § In frames C and D possibility to retrofit afterwards (a separate “lid” in the cover) C 2 filter, frames A – D § § External filter C 2 filter, frames E 0 & E § © ABB Group 04 November 2020 | Slide 17 External filter connected directly to the power terminals Optional built-in EMC filter

New industrial drive modules Chokes for harmonic filtering © ABB Group 04 November 2020 | Slide 18 § Frames A and B: optional, external, AC side § Frames C and D: standard, built-in, DC side § Frames E 0, E and G: standard, built-in, AC side

New industrial drive modules Common DC bus R R © ABB Group 04 November 2020 | Slide 19 R R § Standard ACS 850 feature § Allows energy savings due to the capability to use regenerated energy from a motor into another § Possibility to regenerate energy from one or several ACS 850 to other ACS 850 drives in the DC link § Supports the management of one or several braking choppers (integrated in the drive) R R

New industrial drive modules Dynamic braking options Braking choppers § In a common DC system several choppers can operate simultaneously Braking resistors § Available for different kind of pulse duty performance § Equipped with a thermal sensor as standard Option / Frame © ABB Group 04 November 2020 | Slide 20 A-D E 0 -G Built-in braking chopper Standard Option (+D 150) Braking resistor External option

New industrial drive modules Hardware configuration © ABB Group April 2009 | Slide 21

New industrial drive modules Standard configuration Without control panel © ABB Group 04 November 2020 | Slide 22

New industrial drive modules Assistant control panel , option +J 400 Assistant control panel © ABB Group 04 November 2020 | Slide 23 n Option + J 400 n With real time clock n Incl. control panel holder in the unit n Can be attached either to the control unit cover or to the cabinet door

New industrial drive modules Control panel holder, option +J 414 Control panel holder on the unit © ABB Group 04 November 2020 | Slide 24 n Option +J 414 n Incl. control panel holder n No control panel n The dummy control panel has 2 LEDs that indicate the status of the drive

New industrial drive modules Control panel and a door mounting kit, option +J 410 Control panel holder on the door © ABB Group 04 November 2020 | Slide 25 n Includes control panel holder n Includes IP 54 kit n Includes 3 meter cable n No control panel holder in the unit

New industrial drive modules No control unit cover, option +0 C 168 No control unit cover © ABB Group 04 November 2020 | Slide 26 n Option + 0 C 168 n No control panel holder in the unit n No control panel

New industrial drive modules Safe Torque-Off © ABB Group April 2009 | Slide 27

New industrial drive modules Safe Torque-Off n Safe Torque-Off (STO) as standard n SIL 3 (IEC 61508) / Safety category 4 (EN 954 -1) ACS 850 -04 © ABB Group 04 November 2020 | Slide 28

New industrial drive modules Operating conditions © ABB Group April 2009 | Slide 29

New industrial drive modules Operating conditions n n Temperature: n -10°C to 55°C n G frame up to 50°C n Derating above 40°C Relative humidity: n n n Altitude: n Up to 4000 m n At 500 V up to 2000 m n 1%/100 m derating above 1000 m Vibration: n n Class 3 M 4 acc. to EN 60721 -3 -3 Climatic / environmental conditions: n © ABB Group 04 November 2020 | Slide 30 Max. 95%, no condensation allowed Class 3 K 3, 3 C 2 acc. to EN 60721 -3 -3

New industrial drive modules Cables © ABB Group April 2009 | Slide 31

New industrial drive modules Cable lengths § Max. length of the STO cable is 25 m § § © ABB Group 04 November 2020 | Slide 32 Longer cable can be made by using extra relays Max. length of the D 2 D link is 50 m

New industrial drive modules Interfaces © ABB Group April 2009 | Slide 33

New industrial drive modules Control board JCON-11 Control interface © ABB Group 04 November 2020 | Slide 35 1. Control voltage supply External supply (24 VDC) input for the control unit (to be used, if external power supply is required) 2. Digital I/O 6 x. DI (DI 6 can be used also as a thermistor input), 2 x. DI/O (can be used also for pulse train inputs or outputs, max 32 k. Hz; DI/O can be separated as separate group and used either as a npn/pnp input), 3 x. RO 3. Analog I/O 2 x. AI (m. A or V), 2 x. AO (1 xm. A) 4. DIL input Drive interlock input 5. RS-485 link Galvanically isolated, can be used for D 2 D or Modbus 6. Safe Torque Off (STO) Designed for Safety Integrity Level 3 (SIL 3) acc. to IEC 61508 and Safety Category 3 acc. to EN 954 -1 7. User interface (HMI) PC-tools and control panel connection (RJ 45). Can be used also as a Modbus link for monitoring 8. Removable memory unit (RMU) Complete drive configuration and settings are stored in the memory unit.

New industrial drive modules Drive to drive link n n Fast communication between drives n Baud rate: 8 Mbit/s n Cable length: ~ 50 m n RS-485 Flexible data communication between drives n Master/follower communication n n © ABB Group 04 November 2020 | Slide 36 1 Master – several followers Multicast communication n Master/follower(s) n Follower/follower(s)

New industrial drive modules Optional I/O © ABB Group April 2009 | Slide 37

New industrial drive modules Option slots 1 and 2 Options Data Install in Analogue & digital extension 1 FIO-01 4 x. DI/O, 2 x. RO FIO-11 3 x. AI (m. A/V), 1 x. AO (m. A), 2 x. DI/O FIO-21 1 x. AI (m. A/V), 1 x. AO (m. A), 1 XDI, 2 x. RO Slot 1 or 2 Feedback interface 2 FEN-01 2 inputs (TTL incremental encoder), 1 output * FEN-11 2 inputs (Sin. Cos absolute, TTL incremental encoder), 1 output * FEN-21 2 inputs (Resolver, TTL incremental encoder), 1 output* FEN-31 1 input (HTL incremental encoder), 1 output Slot 1 or 2 * When this module is used, the lower part of the control unit cover cannot be used © ABB Group 04 November 2020 | Slide 38

New industrial drive modules Option slot 3 Options Data Install in Communication FPBA-01 PROFIBUS-DP, DPV 0/DPV 1 FCAN-01 CANopen FDNA-01 Device. Net FENA-01 Ether. Net/IP Modbus TCP Later on also PROFINET I/O FSCA-01 Modbus FLON-01 LONWorks (comes later) Slot 3 3 © ABB Group 04 November 2020 | Slide 39

New industrial drive modules Software © ABB Group April 2009 | Slide 40

New industrial drive modules Software - DTC with enhanced features © ABB Group 04 November 2020 | Slide 41 n Standard sw supports asynchronous motors and permanent magnet motors n Output frequency up to 500 Hz n Low motor noise mode n Improved stand still ID run

New industrial drive modules Software LOC ASSISTANTS 2 § Start-up Assistant Easy start-up § Macros: preprogrammed parameter settings § Start-up Assistant Motor Set-up Application Speed control EXT 1 § Speed control EXT 2 EXIT 16: 31 SEL § © ABB Group 04 November 2020 | Slide 42 Easy use § Intuitive parameter structure § Short/long parameter menus § I/O “mapping” § List of changed parameters Flexibility § Extensive parameter settings § Limited block programmability as standard

New industrial drive modules Software – Backup and restore LOC MAIN MENU PAR BACKUP I/O SETTINGS REF EDIT CANCEL LOC 16: 31 EDIT Panel backup/restore functionality § Creating and uploading the backup file from drive to panel § Showing backup file info § PAR BACKUP MAKE BACKUP TO PANEL § (1) Restoring all parameters § EXIT LOC 16: 31 SEL PAR BACKUP SHOW BACKUP INFO RESTORE PARS ALL RESTORE PARS NO-IDRUN RESTORE PARS IDRUN RESTORE ALL USER SETS EXIT © ABB Group 04 November 2020 | Slide 43 16: 31 SEL Versions etc. Incl. ID Run and motor data § (2) Restoring all parameters except ID Run and motor data § (3) Restoring only ID Run and motor data § (4) Restoring all user sets

New industrial drive modules Software – Fault loggers LOC FAULT LOGGER 36: LOCAL CTRL LOSS 06. 11. 08 09: 59: 27 15: SUPPLY PHASE 17: ID-RUN FAULT 31: SAFE TORQUE OFF EXIT 16: 31 DETAIL LOC § Fault logger can hold the information of 10 latest faults. § Fault information includes: LOCAL CTRL LOSS TIME 9: 59: 27 FAULT CODE 36 FAULT CODE EXTENSION EXIT LOC 16: 31 DIAG PAR BACKUP Check parameter ’ 30. 03 Local ctrl loss’ setting. Check PC tool or panel connection. EXIT © ABB Group 04 November 2020 | Slide 44 16: 31 OK § § Fault message + fault code § Time stamp § Fieldbus fault code § Status word § Output frequency, speed estimated, torque, current, DC voltage, torque limit status But no warnings

New industrial drive modules Software – Short/long parameter menus § Only the most important parameters for commissioning are shown as a default parameter set (21 parameter groups) § User can freely activate the long menus in order to see all parameters § LOC 1601 1602 1603 1615 P 16. 15: Load short/Load long PARAMETERS Local lock Parameter lock Pass code Menu set sel No request EXIT 16: 31 EDIT © ABB Group 04 November 2020 | Slide 45 LOC PAR EDIT 1615 Menu set sel Load long [2] CANCEL 16: 31 SAVE

New industrial drive modules Software – List of changed parameters LOC MAIN MENU CHANGED PAR FAULT LOGGER LOC CHANGED PAR 1616 Menu set active TIME & DATE 2005 Maximum current EXIT LOC 16: 31 ENTER 1. 70 A 2202 Acc time 1 2203 Dec time 1 EXIT 16: 31 List of changed parameters (panel view ”CHANGED PAR”) § List of parameters that have been changed from default § Parameter values in changed parameter list can be modified EDIT MAIN MENU PAR CHG LOG PARAMETERS LOC LAST CHANGES 2001 Maximum speed ASSISTANTS 1650 rpm EXIT § 16: 31 ENTER 28. 10. 08 13: 50: 16 EXIT © ABB Group 04 November 2020 | Slide 46 16: 31 § List of changed parameters (panel view ”PAR CHG LOG”) § List of 10 latest changes with date and time stamps § Parameter values in parameter changed log can be modified EDIT

New industrial drive modules Software – I/O mapping § I/O settings info in control panel shows usage of I/O § LOC The connections between I/O and different software functions are shown. § When selecting channel name (e. g. DI 1) information about channel’s source is displayed. § When selecting parameter (e. g. 1002 Ext 1 start in 1) parameter value can be changed. LOC MAIN MENU I/O SETTINGS REF EDIT LOC I/O SETTINGS DRIVE INFO Analog outputs EXIT 16: 31 Analog inputs Digital I/Os Digital inputs Relay outputs EXIT 16: 31 © ABB Group 04 November 2020 | Slide 47 ENTER SEL I/O SETTINGS DI 1 1002 Ext 1 start in 1 DI 2 DI 3 1010 reset sel LOC Fault. I/O SETTINGS EXIT 16: 31 EDIT DI 1 1002 Ext 1 start in 1 DI 2 DI 3 1010 Fault reset sel EXIT 16: 31 EDIT LOC I/O INFO NUM OF I/O ITEMS 1 SLOT NUMBER 0 LOC NUMBER PAR EDIT NODE 1002 Ext 1 start in 1 EXIT 16: 31 DI 1 [P. 02. 01. 00] CANCEL 16: 31 SEL

New industrial drive modules Software – Autotuning § § § © ABB Group 04 November 2020 | Slide 48 Autotuning updates automatically new tuning values for speed controller § Proportional gain § Integration time Four possible tuning modes : § Smooth (slow response) § Middle § Tight (fast response) § User (bandwidth, damping) Speed controller autotuning runs the specific speed curve for finding the tuning values

New industrial drive modules Software – Time levels Extended speed controller functionality § Speed controller at 500 s time level § Reference handling at 2 ms time level 500 s © ABB Group 04 November 2020 | Slide 49

New industrial drive modules Software – Load analyzer Consists of 2 independent loggers: 1) Amplitude logger (AL): 200 ms sampling time interval. 2) Peak value logger (PVL): records peak values of a selected signal. § § © ABB Group 04 November 2020 | Slide 50 When the new peak value is detected, also some other actual signals (speed, current, dc voltage) are saved. The data of the two loggers can be restored after a power failure as it is stored to non-volatile memory

New industrial drive modules Software – Maintenance assistance © ABB Group 04 November 2020 | Slide 51 § Reminds the user of the need of maintenance § 6 individual counters – parameter group 44 § Gives alarm for needs such as : cooling fan change, cabinet fan change, DC capacitor change, motor bearings…

New industrial drive modules Software – Energy efficiency counter Energy savings calculation § As an output you can get: § Total energy savings in k. Wh § Total energy savings in euro or in other currency § Total energy savings in CO 2 Energy optimizer § © ABB Group 04 November 2020 | Slide 52 Reduces motor magnetizing current at low mechanical loads

New industrial drive modules Software - Timers § © ABB Group 04 November 2020 | Slide 53 4 timers can be used to control the drive (like drive start/stop command) § Start/Stop daily § Start/Stop weekly

New industrial drive modules PC tools © ABB Group April 2009 | Slide 54

New industrial drive modules Drive. Studio Commissioning, tuning and monitoring tool © ABB Group 04 November 2020 | Slide 55 § Parameters setting and signal monitoring § Data logger and on-line signal monitoring § Backup and restore § Context sensitive helps § Start-up and Diagnostic Assistants

New industrial drive modules Drive SPC Programming tool § © ABB Group 04 November 2020 | Slide 56 Drive Solution Program composer § For function block programming § PLC functions library § Interface to Drive functions and parameters

New industrial drive modules Drive. Size © ABB Group 04 November 2020 | Slide 57

New industrial drive modules Documentation © ABB Group April 2009 | Slide 58

New industrial drive modules Documentation § § © ABB Group 04 November 2020 | Slide 59 Standard with every drive : § Quick installation and start-up guides § CD with full documentation Full paper format manuals available as an option § To be ordered as a separate item § Many customers are serial manufacturers or users and do not need / want piles of paper manuals