ACS850 Product Presentation by Panapakorn Shinawatra

Petri Torniainen, October 2009

New ABB industrial drive module ACS850-04 overview ÂŠ ABB Group October 18, 2012 | 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:



Pulp & paper



Mining



Cement



Chemical, oil & gas

Examples of applications: 

Cranes



Winders



Mixers

New industrial drive modules For System Integrators and OEMs ACS850-04 is designed for fast, cost effective installation and integration into cabinets, therefore targeted for OEMs and System Integrators

ÂŠ ABB Group October 18, 2012 | Slide 3

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

New industrial drive modules Range

ÂŠ ABB Group October 18, 2012 | Slide 5

New industrial drive modules Frames A & B Dim. in mm



364

3 Kg

93.5

I2N (A)

PN (kW)

Type

1.1

ACS850-04-03A0-5

3.6

1.5

ACS850-04-03A6-5

4.8

2.2

ACS850-04-04A8-5

2.2

ACS850-04-06A0-5

ACS850-04-08A0-5

197 (219)*



380

Frame A, IP20

Frame B, IP20

I2N (A)

PN (kW)

Type

ACS850-04-010A-5

5.5

ACS850-04-014A-5

7.5

ACS850-04-018A-5

*Depth in brackets = with control panel 274 (297)*

New industrial drive modules Frames C & D Dim. in mm

567

276 (298)*



I2N (A)

PN (kW)

Type

ACS850-04-025A-5

ACS850-04-030A-5

18.5

ACS850-04-035A-5

ACS850-04-044A-5

ACS850-04-050A-5

16 Kg

166



567

276 (298)*

Frame C, IP20

Frame D, IP20

I2N (A)

PN (kW)

Type

ACS850-04-061A-5

ACS850-04-078A-5

ACS850-04-094A-5

*Depth in brackets = with control panel

New industrial drive modules Frames E & E0 Dim. in mm

602

354 (376)*

276

35 Kg



I2N (A)

PN (kW)

Type

103

ACS850-04-103A-5

144

ACS850-04-144A-5

*Depth in brackets = with control panel



700

67 Kg 312

Frame E0, IP20

Frame E, IP20 I2N (A)

PN (kW)

Type

166

ACS850-04-166A-5

202

110

ACS850-04-202A-5

225

110

ACS850-04-225A-5

260

132

ACS850-04-260A-5

290

160

ACS850-04-290A-5

New industrial drive modules Frame G Dim. in mm



1564

562

Frame G, IP00 I2N (A)

PN (kW)

Type

430

200

ACS850-04-430A-5

521

250

ACS850-04-521A-5

602

315

ACS850-04-602A-5

693

355

ACS850-04-693A-5

720

400

ACS850-04-720A-5

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

New industrial drive modules Ratings 

Currents are expressed in Amperes



I2N 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

ÂŠ ABB Group October 18, 2012 | Slide 12

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

New industrial drive modules Hardware Optimized for cabinet installation Bus cc



Compact, narrow design



Side-by-side mounting



DIN-rail mounting (frames A and B )



Power terminals on top (up to 45 kW) 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



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



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 C2 and C3 (1st and 2nd environment) 

C3 filter, frames A-B 



C3 filter, frames C – G 

Optional built-in EMC filter



In frames C and D possibility to retrofit afterwards (a separate “lid” in the cover)

C2 filter, frames A – D 



External filter connected directly to the power terminals

External filter

C2 filter, frames E0 & E 

Optional built-in EMC filter

New industrial drive modules Chokes for harmonic filtering



Frames A and B: optional, external, AC side



Frames C and D: standard, built-in, DC side



Frames E0,E and G: standard, built-in, AC side

New industrial drive modules Common DC bus



Standard ACS850 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 ACS850 to other ACS850 drives in the DC link



Supports the management of one or several braking choppers (integrated in the drive)

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

A-D

E0-G

Built-in braking chopper

Standard

Option (+D150)

Braking resistor

External option

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

New industrial drive modules Standard configuration Without control panel

ÂŠ ABB Group October 18, 2012 | Slide 22

New industrial drive modules Assistant control panel , option +J400 Assistant control panel



Option + J400



With real time clock



Incl. control panel holder in the unit



Can be attached either to the control unit cover or to the cabinet door

New industrial drive modules Control panel holder, option +J414 Control panel holder on the unit



Option +J414



Incl. control panel holder



No control panel



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 +J410 Control panel holder on the door



Includes control panel



Includes control panel holder



Includes IP54 kit



Includes 3 meter cable



No control panel holder in the unit

New industrial drive modules No control unit cover, option +0C168 No control unit cover



Option + 0C168



No control panel holder in the unit



No control panel

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

New industrial drive modules Safe Torque-Off  Safe

Torque-Off (STO) as standard 

SIL 3 (IEC 61508) / Safety category 4 (EN954-1)

ACS850-04

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

New industrial drive modules Operating conditions 



Temperature: 

-10°C to 55°C



G frame up to 50°C



Derating above 40°C

Relative humidity: 



Altitude: 

Up to 4000 m



At 500V up to 2000 m



1%/100 m derating above 1000m

Vibration: 



Max. 95%, no condensation allowed

Class 3M4 acc. to EN60721-3-3

Climatic / environmental conditions: 

Class 3K3, 3C2 acc. to EN60721-3-3

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

New industrial drive modules Cable lengths



Max. length of the STO cable is 25 m 



Longer cable can be made by using extra relays

Max. length of the D2D link is 50 m

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

New industrial drive modules Control board JCON-11 Pin XPOW

Name 1 24Vin 2 GND

XRO1

1 RO1NO 2 RO1COM 3 RO1NC

XRO2

4 RO2NO 5 RO2COM 6 RO2NC

XRO3

7 RO3NO 8 RO3COM 9 RO3NC

XD24

1 2 3 4

24VD 24VD DGND DGND

XDI

1 2 3 4 5 6 A

DI1 DI2 DI3 DI4 DI5 DI6 DIIL

XDIO

XAI

XAO

XD2D

1 DIO1 2 DIO2 1 VREF+ 2 VREF3 AGND 4 AI1+ 5 AI16 AI2+ 7 AI2AI SEL JUMPER AI1 AI2 1 AO1+ 2 AO13 AO2+ 4 AO2Term. Jumper 1B 2A 3 BGND

Control interface 1. Control voltage supply

External supply (24VDC) input for the control unit (to be used, if external power supply is required)

2. Digital I/O

6xDI (DI 6 can be used also as a thermistor input), 2xDI/O (can be used also for pulse train inputs or outputs, max 32 kHz; DI/O can be separated as separate group and used either as a npn/pnp input), 3xRO

3. Analog I/O

2xAI (mA or V), 2xAO (1xmA)

4. DIL input

Drive interlock input

5. RS-485 link

Galvanically isolated, can be used for D2D 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 (RJ45). Can be used also as a Modbus link for monitoring

ÂŠ ABB Group Removable October 18,8. 2012 | memory unit (RMU) Slide 35 XSTO

1 2 3 4

OUT1 OUT2 IN1 IN2

Complete drive configuration and settings are stored in the memory unit.

New industrial drive modules Drive to drive link 



Fast communication between drives 

Baud rate: 8 Mbit/s



Cable length: ~ 50 m



RS-485

Flexible data communication between drives 

Master/follower communication 



1 Master – several followers

Multicast communication 

Master/follower(s)



Follower/follower(s)

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

New industrial drive modules Option slots 1 and 2 Options

Data

Install in

Analogue & digital extension

FIO-01

4xDI/O, 2xRO

FIO-11

3xAI (mA/V), 1xAO (mA), 2xDI/O

FIO-21

1xAI (mA/V), 1xAO (mA), 1XDI, 2xRO

Slot 1 or 2

Feedback interface

ÂŠ ABB Group October 18, 2012 | Slide 38

FEN-01

2 inputs (TTL incremental encoder), 1 output *

FEN-11

2 inputs (SinCos 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

New industrial drive modules Option slot 3 Options

Data

Install in

Communication FPBA-01

PROFIBUS-DP, DPV0/DPV1

FCAN-01

CANopen

FDNA-01

DeviceNet

FENA-01

EtherNet/IP Modbus TCP Later on also PROFINET I/O

FSCA-01

Modbus

FLON-01

LONWorks (comes later)

Slot 3

ÂŠ ABB Group October 18, 2012 | Slide 39

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

New industrial drive modules Software - DTC DTC with enhanced features



Standard sw supports asynchronous motors and permanent magnet motors



Output frequency up to 500 Hz



Low motor noise mode



Improved stand still ID run

New industrial drive modules Software LOC

ASSISTANTS



Start-up Assistant

Easy start-up 

Macros: preprogrammed parameter settings



Start-up Assistant

Motor Set-up Application Speed control EXT1 

Speed control EXT2 EXIT

16:31

SEL



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

16:31

EDIT

Panel backup/restore functionality 

Creating and uploading the backup file from drive to panel



Showing backup file info 

LOC

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

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.



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 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 

P16.15: Load short/Load long

LOC

1601 1602 1603 1615

PARAMETERS

Local lock Parameter lock Pass code Menu set sel No request EXIT 16:31 EDIT

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 time1 2203 Dec time1 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

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. DI1) information about channel’s source is displayed.



When selecting parameter (e.g. 1002 Ext1 start in1) 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

ENTER

I/O SETTINGS

DI1 1002 Ext1 start in1 DI2 DI3 1010 reset sel LOC FaultI/O SETTINGS EXIT 16:31 EDIT DI1 1002 Ext1 start in1 DI2 DI3 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 Ext1 start in1 EXIT 16:31

DI1

[P.02.01.00] CANCEL 16:31

SEL

New industrial drive modules Software – Autotuning 



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 µs time level



Reference handling at 2 ms time level

500 µs

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. 

The data of the two loggers can be restored after a power failure as it is stored to non-volatile memory

Percentage of operating time



When the new peak value is detected, also some other actual signals (speed, current, dc voltage) are saved.

10 %

20 %

30 %

40 %

50 %

60 %

70 %

Amplitude logger range

80 %

90 %

100 %

New industrial drive modules Software – Maintenance assistance 

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 kWh



Total energy savings in euro or in other currency



Total energy savings in CO2

Energy optimizer 

Reduces motor magnetizing current at low mechanical loads

New industrial drive modules Software - Timers 

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 ÂŠ ABB Group April 2009 | Slide 54

New industrial drive modules DriveStudio Commissioning, tuning and monitoring tool



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 

Drive Solution Program composer 

For function block programming



PLC functions library



Interface to Drive functions and parameters

New industrial drive modules DriveSize

ÂŠ ABB Group October 18, 2012 | Slide 57

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

New industrial drive modules Documentation 



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