PIT Dewatering Capacitación ACS800

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


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


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


ACS800 single drive

BACKBACK


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


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


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


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


ACS800 single drive

ACS800 - 7, rev. 1

ACS 800

Copyright ABB Industry Oy

Application program example


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


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


ACS800 single drive ACS800-04 RPBA-01Profibus Connector

Address rotatory switches Status LEDs

Bus termination


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


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


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


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)


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


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


ACS800 single drive Protection examples

: overcurrent Fixed, automatic reset possibility: overvoltage Fixed , automatic reset possibility: undervoltage Fixed , automatic reset possibility: AI signal


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


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


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


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


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


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)


ACS800 single drive Troubleshooting: Warnings1 1242.8 rpmACS800*** WARNING ***ACS800 TEMP (4210)


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:


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.


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.


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


ACS800 single drive Motor Protection

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PIT Dewatering Capacitación ACS800