Petri Torniainen, October 2009
New ABB industrial drive module
ACS850-04 overview
© ABB Group
March 14, 2016 | 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
March 14, 2016 | Slide 2

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
© ABB Group
March 14, 2016 | Slide 3
New industrial drive modules
Range
© ABB Group
April 2009 | Slide 4
New industrial drive modules
Range
© ABB Group
March 14, 2016 | Slide 5
New industrial drive modules
Frames A & B
Dim. in mm

I2N
(A)
PN
(kW)
Type
3
1.1
ACS850-04-03A0-5
3.6
1.5
ACS850-04-03A6-5
4.8
2.2
ACS850-04-04A8-5
6
2.2
ACS850-04-06A0-5
8
3
ACS850-04-08A0-5
364
3 Kg
93.5
197 (219)*

380
5 Kg
Frame B, IP20
I2N
(A)
PN
(kW)
Type
10
4
ACS850-04-010A-5
14
5.5
ACS850-04-014A-5
18
7.5
ACS850-04-018A-5
*Depth in brackets = with control panel
101
© ABB Group
March 14, 2016 | Slide 6
Frame A, IP20
274 (297)*
New industrial drive modules
Frames C & D
Dim. in mm
567
276 (298)*

I2N
(A)
PN
(kW)
Type
25
11
ACS850-04-025A-5
30
15
ACS850-04-030A-5
35
18.5
ACS850-04-035A-5
44
22
ACS850-04-044A-5
50
22
ACS850-04-050A-5
16 Kg
166

567
22 Kg
276 (298)*
221
© ABB Group
March 14, 2016 | Slide 7
Frame C, IP20
Frame D, IP20
I2N
(A)
PN
(kW)
Type
61
30
ACS850-04-061A-5
78
37
ACS850-04-078A-5
94
45
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
55
ACS850-04-103A-5
144
75
ACS850-04-144A-5
*Depth in brackets = with control panel

700
443 (465)*
© ABB Group
March 14, 2016 | Slide 8
67 Kg
312
Frame E0, IP20
Frame E, IP20
I2N
(A)
PN
(kW)
Type
166
90
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
568
205 Kg
© ABB Group
March 14, 2016 | Slide 9
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
© ABB Group
April 2009 | Slide 10
New industrial drive modules
Ratings
© ABB Group
March 14, 2016 | Slide 11

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
© ABB Group
March 14, 2016 | 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
March 14, 2016 | Slide 14

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
© ABB Group
March 14, 2016 | 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
March 14, 2016 | 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 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
C2 filter, frames E0 & E

© ABB Group
March 14, 2016 | 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
March 14, 2016 | Slide 18

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
R
R
© ABB Group
March 14, 2016 | Slide 19
R
R

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)
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
March 14, 2016 | Slide 20
A-D
E0-G
Built-in braking chopper
Standard
Option
(+D150)
Braking resistor
External
option
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
March 14, 2016 | Slide 22
New industrial drive modules
Assistant control panel , option +J400
Assistant control panel
© ABB Group
March 14, 2016 | Slide 23

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
© ABB Group
March 14, 2016 | Slide 24

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
© ABB Group
March 14, 2016 | Slide 25

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
© ABB Group
March 14, 2016 | Slide 26

Option + 0C168

No control panel holder in the unit

No control panel
New industrial drive modules
Safe Torque-Off
© 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
© ABB Group
March 14, 2016 | Slide 28
New industrial drive modules
Operating conditions
© 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:


Max. 95%, no condensation allowed
Altitude:

Up to 4000 m
 At


Class 3M4 acc. to EN60721-3-3
Climatic / environmental conditions:

© ABB Group
March 14, 2016 | Slide 30
1%/100 m derating above 1000m
Vibration:


500V up to 2000 m
Class 3K3, 3C2 acc. to EN60721-3-3
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
March 14, 2016 | Slide 32
Longer cable can be made by using extra relays
Max. length of the D2D link is 50 m
New industrial drive modules
Interfaces
© 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
XSTO
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
1
2
3
4
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
8. Removable memory unit (RMU)
Complete drive configuration and settings are
stored in the memory unit.
OUT1
OUT2
IN1
IN2
© ABB Group
March 14, 2016 | Slide 35
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


© ABB Group
March 14, 2016 | Slide 36
1 Master – several followers
Multicast communication

Master/follower(s)

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
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
2
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
© ABB Group
March 14, 2016 | Slide 38
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
3
© ABB Group
March 14, 2016 | Slide 39
New industrial drive modules
Software
© ABB Group
April 2009 | Slide 40
New industrial drive modules
Software - DTC
DTC with enhanced features
© ABB Group
March 14, 2016 | Slide 41

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
2

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

© ABB Group
March 14, 2016 | 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
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
EXIT
© ABB Group
March 14, 2016 | 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
March 14, 2016 | 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
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
P16.15: Load short/Load long
PARAMETERS
Local lock
Parameter lock
Pass code
Menu set sel
No request
EXIT
16:31
EDIT
© ABB Group
March 14, 2016 | 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 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
© ABB Group
March 14, 2016 | 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. 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
© ABB Group
March 14, 2016 | Slide 47
ENTER
SEL
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



© ABB Group
March 14, 2016 | 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
23.05 Acc comp der time
23.06 Acc comp filt time
500 s
d
dt
03.05 Speed ref ramped
TAccCom
03.06 Speed ref used
20.01 Maximum speed
23.11 Speed win func
23.12 Speed win hi
23.13 Speed win low
03.08 Acc comp torq
PID
+
+
03.07 Speed error filt
23.01 Proport gain
23.02 Integration time
23.03 Derivation time
23.04 Deriv filter time
20.02 Minimum speed
23.08 Speed additive
0
06.02 bit 14 Ramp out zero
06.02 bit 12 Ramp in zero
23.15 PI adapt max sp
23.16 PI adapt min sp
23.17 Pcoef at min sp
23.16 Icoef at min sp
01.01 Speed act
23.07 Speed err ftime
x
23.14 Drooping rate
© ABB Group
March 14, 2016 | Slide 49
23.09 Max torq sp control
+
03.09 Torq ref sp control
23.10 Min torq sp control
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
© ABB Group
March 14, 2016 | Slide 50
80 %
90 %
100 %
New industrial drive modules
Software – Maintenance assistance
© ABB Group
March 14, 2016 | 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 kWh

Total energy savings in euro or in other
currency

Total energy savings in CO2
Energy optimizer

© ABB Group
March 14, 2016 | Slide 52
Reduces motor magnetizing current at low
mechanical loads
New industrial drive modules
Software - Timers

© ABB Group
March 14, 2016 | 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
DriveStudio
Commissioning, tuning and
monitoring tool
© ABB Group
March 14, 2016 | 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
March 14, 2016 | Slide 56
Drive Solution Program composer

For function block programming

PLC functions library

Interface to Drive functions and
parameters
New industrial drive modules
DriveSize
© ABB Group
March 14, 2016 | Slide 57
New industrial drive modules
Documentation
© ABB Group
April 2009 | Slide 58
New industrial drive modules
Documentation


© ABB Group
March 14, 2016 | 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