ACS600

Prepared by: Rajmohan Jha Page 1 of 21

ABB’s ACS 600 DTC Drive

ABB’s DTC industrial drives are designed for industrial applications, and especially for applications in process industries such as the pulp & paper, metals, mining, cement, power, chemical, and oil & gas industries. These industrial drives are highly flexible AC drives that can be configured to meet the precise needs of these applications. These drives cover a wide range of power and voltages, including voltages up to 690 V. These industrial drives come with a wide range of inbuilt options. A key feature of these drives is programmability, which makes adaptation to different applications easy. Drive modules The heart of the drive is DTC, Direct Torque Control, that provides high performance and significant benefits: e.g. accurate static and dynamic speed and torque control, high starting torque and long motor cables. Inbuilt drive options make the installation work fast and easy. One of the most significant design criteria of these industrial drives has been the long lifetime. Wearing parts such as fans and capacitors have been selected accordingly. Extensive protection features result in excellent reliability in the demanding Industrial market. _________________________ _________________________

Prepared by Approved by Rajmohan Jha Mr. S. Bhowmik Manager, EDR Group Head - EEI



Contents:

Sl. No. Topic Page #

1. What is Drive, Application & Advantage 3-5

2. Comparison of different speed control techniques 5

3. What is DTC, Principle & Block Diagram 5-7

4. Power circuit & electronic PCB of ACS600 8-9

5. Description & operation of CDP 10-15

6. List of Tasks & relevant drive parameters 16

7. Motor ID run 17

8. Faults, Cause, Remedies, Maintenance 17-20

9. Questions for self evaluation, Book References 21



1. What is the main function of a Drive? A motor drive controls a) The speed, b) Torque, c) Direction d) Resulting horsepower of a motor. . 2.Application of Drive in steel Industry

• Drives for all rolling mills, including • Foil mills • Skin-pass mills • Two-stand mills • Tandem mills (TCM) • Rod and bar mills • Wire rod mills • Section mills • Tube mills • Conventional hot strip mills • Compact mills based on thin slab • All types of Blower & fan Applications including

1. Sinter Plant 2. Blast Furnace Blowers 3. ID Fan in Power plant 4. FD Fan in Power Plant 5. Boiler Feed Pump in Power Plant

3.Advantage of using Drive

• Optimized production quality • Optimized production output • Minimized Scrap • Increased process reliability • Minimized wear and tear of equipment • Energy saving





4.Advantage of using AC Drive • They use conventional low cost 3 phase AC SQIM motor for most application • These motors require virtually no maintenance. • AC motors are smaller, lighter, more commonly available. • AC motors are better suited for high speed (Over 2500 RPM). • AC motors can operate in adverse atmospheric & ambient conditions • Modern AC drives have high degree of accuracy & dynamic response.

Direct Torque control =Control of stator flux +Control of Torque • Zero voltage vector to maintain present value of stator flux • Other voltage vectors to alter flux to desired direction



Speed reference and the speed feedback from motor model are compared. Error is fed to speed controller which generates torque reference. Flux reference is generated from flux reference controller. Torque reference and flux reference are compared with their actual values which is calculated by adaptive motor model. Based on the result of these torque comparator and flux comparator optimum pulse selector decides the voltage vector required to be produced Accordingly group of switches inside the inverter are made on & output of inverter is fed to the motor to get the desired speed as demanded by the process.



5. Power circuit of ACS600 DTC Drive 5.1 R2-R4 frame size

Power circuit comprises of:-

• Balanced three phase supply • AC choke to deal with line transients • Input Bridge either diode(in R4 frame size) or Thyristor /Diode(inR5…. frame size)

to rectify AC to DC • Charging Contactor for capacitor precharging (in R4……frame size) • Charging resistance to limit capacitor charging current • Capacitor Bank for filtering ripples in dc • Discharging Resistor for capacitor discharging • Power Plates containing IGBT blocks • Hall effect sensors to measure current • Fan for cooling the ACS600 module • EMC filters for Electromagnetic compatibility

Electronic Boards:- • NAMC (Application and motor control) contains the memory, Digital signal

processor, circuits for motor status calculation and communication inside the unit. • NIOC (Input/output control) contains circuit responsible for communication with

standard I/O terminals



R5-R9 Frame size

Electronic boards………(contd)

• NINT (Main circuit interface) is responsible for IGBT control, protection and making measurements for the motor status calculation.

• NGDR (Gate driver) is used to provide driving signal to gate-emitter of IGBT. • NPOW (Power supply)board provides power for the control circuit. • NINP (Input bridge control)board is used in frame R5….. For controlling the

Thyristor - diode rectifier bridge.



Operation & Parameterization through control panel Description of CDP:-

The LCD type display has 4 lines of 20 characters. The language is selected at start-up (parameter 99.01). The control panel has four operation modes: - Actual Signal Display Mode (ACT key) - Parameter Mode (PAR key) - Function Mode (FUNC key) - Drive Selection Mode (DRIVE key) The use of single arrow keys, double arrow keys and ENTER depend on the operation mode of the panel. The drive control keys are: 1 Start 2 Stop 3 Activate reference setting 4 Forward direction of rotation 5 Reverse direction of rotation 6 Fault reset 7 Change between Local / Remote (external) control









How to Display faults:-







Motor Identification Run:- • The performance of Direct Torque Control is based on an accurate motor model.

• This is determined during the motor start-up.

• A motor Identification Magnetization is automatically done the first time the start

command is given.

• During this first start-up, the motor is magnetized at zero speed for several seconds to allow the motor model to be created.

• This identification method is suitable for most applications.

• In demanding applications a separate Identification Run can be performed.

• Parameter for ID Run 99.10 Types of ID Run:- • Standard :- Performed when no load is connected-Results in most accurate motor

model. • Reduced:-Can be performed with load also.

Table- The ACS 600 Fault messages

FAULT CAUSE REMEDY

ACS 600 TEMP The ACS 600 internal temperature is excessive. The trip level of inverter module temperature is 125 0C

Check ambient conditions Check air f low and fan operation. Check heatsink f ins for dust pick-up Check motor power against unit power.

OVERCURRENT Output current is excessive.

Check motor load. Check acceleration time. Check the the motor and motor cable. Check there are no power factor correction capacitors or surge absorbers in the motor cable.

SHORT CIRCUIT Output current is excessive.

Check the motor and motor cable. Check there the no power factor correction capacitors of surge absorbers in the motor cable.

LINK OR HWC The fibre optic link to the power plate is faulty or the change rate of the output current has exceeded the hardware

Check the fibre optic cable connected to the power plates. Check thee are no power factor correction capacitors or



overcurrent limit. surge absorbers in the motor cable.

DC OVERVOLT Intermediate circuit DC voltage is excessive.

Check mains for static or transient overvoltages. Check braking chopper and Resistor (if used). Check deceleration time. Use Coasting To Stop function (if applicable). Retrofit the frequency converter with a Braking Chopper and Braking Resistor.

SUPPLY PHASE Intermediate circuit DC voltage is oscillating. This can be caused by a missing mains phase, a blown fuse or a rectif ier bridge internal fault.

Check mains supply and fuses

OVERFREQ Motor is turning faster than the highest allowed speed. This can be caused by an incorrectly set minimum/maximum speed, insufficient braking torque or changes in the load when using torque reference.

Check the minimum/maximum speed settings. Check the adequacy of motor braking torque. Check the applicability of torque control. Check the need for a Braking Chopper and Braking Resistor.

EARTH FAULT (Programmable Fault Function 30.17)

The load on the incoming mains system is out of balance. This can be caused by a fault in motor, motor cable or an internal malfunction.

Check motor. Check motor cable. Check there are no power factor correction capacitors or surge absorbers in the motor cable.

Al<MIN FUNC (programmable Fault Function 30.1)

An analogue control signal is below minimum allowed value. This can be caused by incurred signal level or a failure in the control wiring.

Check for proper analogue control signal levels. Check the control wiring. Check A1 < (MIN FUNC Fault Function parameters .

PANEL LOSS (Programmable Fault Function 30.2)

A control Panel selected as active control location for the ACS 600 has ceased communicating.

Check Control Panel connector. Replace Control Panel in the mounting platform. Check PANEL LOSS Fault Function parameters.

EXTERNAL FLT (Programmable Fault Function 30.3)

There is fault in one of the external devices. (This information is configured through one of the programmable digital inputs).

Check external devices for faults. Check EXT FAULT Fault Function parameters.

MOTOR TEMP Motor temperature is too Check motor ratings and load



(programmable Fault Function 30.4..30.9)

high (or appears to be too high). This can be caused by excessive load, insufficient motor power, inadequate cooling or incorrect start-up data.

Check start-up data. Check MOTOR TEMP Fault Function parameters.

THERMISTOR (programmable Fault Function 30.4 … 30.5)

Motor thermal protection mode selected as THERMISTOR and the temperature is excessive.

Check motor ratings and load. Check start-up data. Check thermistor connects for digital input D16. Check thermistor cabling.

I/O COMM There is an internal fault on the I/O Control board (NIOC) in the ACS 600

Check for loose connectors between NIOC board and the Application and Motor Control board (NAMC).

AMBIENT TEMP I/O Control board temperature is lower than 5…0 *C or exceeds +73….83 *C

Check air f low and fan operation.

USER MACRO There is no User Macrosaved or the file is detective

Create the User Macro again.

MOTOR STALL (Programmable Fault Function 30.10…. 30.12

Motor is operating in the stall region. This can be caused by excessive load or insufficient motor power.

Check motor load and the ACS 600 ratings. Check MOTOR STALL Fault Function parameters

UNDERLOAD (programmable Fault Function 30.13 … 30.15)

Motor load is too low. This can be caused by a release mechanism in the driven equipment.

Check for a problem in the driven equipment. Check UNDERLOAD Fault Function parameters

MOTOR PHASE LOSS (programmable Fault Function 30.15)

One of the motor phases is lost. This can be caused by a fault in the motor, the motor cable, a thermal relay (if used) or an internal fault.

Check motor and motor cable. Check thermal relay (if used). Check MOTOR PHASE Fault Function parameters. Passivate this protection.

NO COMMUNCATION

There is no Bus Administrator connected to the link The selected drive is not present on the link. The link does not work because of hardware malfunction or problem in cabling.

Check from the Drive Selection Mode if there is a Bus Administrator connected if not, Check the cabling.



Maintenance

The ACS 600 requires minimum maintenance. It is recommended that the unit

be kept under more close monitoring after the start-up. There is only need for

the routine check-up once operations have stabilized.

The following safety instruction should be followed in the maintenance work.

WARNING! The maintenance work should only be undertaken by a qualif ied

electrician. No measurements, parts replacements or other service

procedures not described in this manual should be attempted.

Disconnect mains power if fault tracing involves work inside the frame, the

motor or the motor cable. Wait 5 minutes for the intermediate circuit

capacitors to discharge. The ACS 600 can contain dangerous voltage from

external control circuits. Exercise appropriate care when working on the unit.

Neglecting these instructions can cause physical injury and death.

WARNING! The printed circuit boards contain integrated circuit that are

extremely sensitive to electrostatic discharge. Exercise appropriate care

when, working on the unit to avoid permanent damage to the circuits.

Heatsink

The heatsink f ins pick up dust from the cooling air. The rate of pick-up

depends on the frequency converter usage and the amount and type of

contamination in the ambient air. The heatsink needs regular cleaning to

ensure heat dissipation. The ACS 600 can run into over temperature

Warnings and Fault if the heatsink is not cleaned regularly.

In normal environment, the heatsink should be checked and cleaned

annually, Frequency converters operating in extreme conditions will need to

be cleaned more often. The best cleaning frequency must be tried out

experimentally.

The dust should be removed gently with a soft brush if the cleaning is carried

out in the same room where the unit is normally operated Compressed air

should not be used for cleaning unless the installation can be taken apart and

the cleaning is carried out in another room (or outdoors), Fan rotation should



be prevented (in order to prevent bearing wear) when using compressed air

for heatsink cleaning.

Fan

The cooling fan minimum lifespan is calculated at about 60 000 hours, but in

an average installation the fan is l ikely to operate considerably longer. The

actual lifespan depends on the frequency converter usage and ambient

temperature.

The fan is completely sealed and its lifespan cannot be prolonged with

cleaning or lubrication. Fan rotation must be prevented when compressed air

is used for cleaning heatsink f ins.

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. If

the frequency converter is operated in a critical part of a process, fan

replacement is recommended once these symptoms start appearing.

Fan failure will be self-evident due to the overtemperature Warnings and

Fault. After the heatsink has cooled it is possible to reset the Warning/Fault

and briefly operate the motor in a critical application.

A replacement fan is available from ABB. Do not attempt operation with other

than ABB specified spare spare parts. The fan can be withdrawn by removing

the bottom of the frame.

Capacitors

The ACS 600 intermediate circuit employs several electrolytic capacitors. The

minimum lifespan of these capacitors in calculated at about 100 000 hours,

but in an average installation the capacitors are likely to operate

considerably longer. The actual lifespan depends on the frequency converter

loading and the ambient temperature.

Capacitor failure is usually followed by a mains fuse failure or a Fault trip,

Contact ABB if capacitor failure is suspected. Replacements are available

from ABB. Do not attempt operation with other than ABB specified spare

parts.



Questions for self evaluation

1. What is drive? What does it do?

2. What is the advantage of using AC Drive?

3. What are the different power circuit components of ACS 600 DTC

Drive?

4. What are the functions of different electronic PCB in ACS 600 Drive?

5. How to start, reference, change direction of the drive from CDP?

6. How to see the stored faults in CDP?

7. How to change actual signal display through CDP?

8. How to select a parameter and change the value?

9. What is the purpose of ID run?

10. How to do ID run?

11. What is the signif icance of different fault messages?

12. How and what to maintain in ACS 600 DTC Drive?

Book References

1. Firmware Manual ABB’s ACS 600 DTC Drive

2. Sensorless Vector and Direct Torque Control: P. VAS (Oxford Science

Publications, 1998

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ACS600

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