Debugging of ABB VFD for ACS800 Enhancement

A. Motor Auto-tuning (Quick Debugging Steps)

1. Power On: Ensure the system is powered on.
2. Input Initialization:
   • Press PAR to select the language. Set 99.1 to ENGLISH.
   • Choose the application macro. Set 99.2 to CRANE.
   • Determine if parameters should be reset to factory defaults. Set 99.3 to YES or NO.
   • Select the motor control mode in 99.4: DTC (Direct Torque Control) or SCALAR.
   • Enter the rated voltage in 99.5 V.
   • Input the rated current in 99.6 A.
   • Specify the rated frequency in 99.7 HZ.
   • Set the motor’s rated speed in 99.8 RPM.
   • Define the motor’s rated power in 99.9 KW.
3. Motor Identification Run:
   • Proceed to motor identification by selecting 99.10.
   • Generally, choose ID MAGN (the motor won’t rotate).
   • For STANDARD mode (motor rotates), the motor must be disconnected from the equipment.
   • In REDUCED identification mode (motor rotates), the motor remains connected.
   • After selecting the identification mode, a “WARNING” signal may appear.
   • Press the start button to begin motor identification. This process can be stopped at any time using the stop button.
   • Once the motor identification is complete, press RESET to enter actual signal display mode.
4. Motor Direction Check: Verify the motor’s rotation direction using the control panel.
5. Input Speed Limits and Acceleration/Deceleration Times: Enter the necessary parameters.

B. Parameter Configuration – Optimized for Google SEO

1. Set parameter 10.1 to DI1 for brake acknowledgment digital input.
2. Leave parameter 10.2 as NOT SEL for zero-position digital input.
3. Parameter 10.3 remains NOT SEL for deceleration digital input.
4. Parameter 10.4 is NOT SEL for rapid stop digital input.
5. Parameter 10.5 is NOT SEL for power-on acknowledgment digital input.
6. Keep parameter 10.6 as NOT SEL for synchronization request digital input.
7. Set parameter 10.7 to EXT DI1.1 for chopper fault digital input.
8. Configure parameter 10.8 to DI2 for the second speed level digital input.
9. Set parameter 10.9 to DI5 for the third speed level digital input.
10. Parameter 10.10 is set to DI6 for the fourth speed level digital input.
11. Parameters 10.11 to 10.15 and 10.17, 10.18 remain NOT SEL.
12. Set parameter 10.16 to DI-1L for fault reset digital input.
13. Parameter group 13 deals with analog input signals. No need for modification.
14. Set parameter 14.1 to BRAKE LIFT for relay output 1.
15. Configure parameter 14.2 to WATCHDOG-N for relay output 2.
16. Parameter 14.3 is set for relay output 3 to indicate a FAULT-N signal. When a fault occurs, the relay releases, and during power-on, the fault relay engages.
17. Parameter group 15 covers analog output signals. No modifications required.
18. Parameter group 16 deals with password settings. No need to change.
19. Parameter group 20 defines limit values:
    • Parameter 20.1: Minimum speed for the operating range.
    • Parameter 20.2: Maximum speed for the operating range.
    • Parameter 20.3: Maximum output current.
    • Parameter 20.4: Maximum positive output torque.
    • Parameter 20.5: Maximum negative output torque.
    • Parameter 20.6: DC overvoltage controller.
    • Parameter 20.7: DC undervoltage controller.
    • Parameter 20.8: Minimum frequency for the operating range.
    • Parameter 20.9: Maximum frequency for the operating range.
    • Parameters 20.10 to 20.13 relate to analog inputs but are not detailed here.
20. Parameter 21.1 is not to be changed.
21. Set parameter 21.2 for the field excitation time, approximately 4 times the motor’s rated KW (in milliseconds).
22. Parameter group 23 covers speed control gains, integral and derivative times, motor slip, etc. Generally left unchanged.
23. Parameter group 24 deals with torque build-up time. Typically not modified.
24. Parameter group 26 allows compensation voltage setting for the motor (only in SCALAR mode).
25. Parameter group 27 configures the braking chopper:
    • Set parameter 27.1 to ON for brake chopper control.
    • Parameter 27.2 is set to FAULT to activate overload protection for the braking resistor.
    • Enter the actual value for the braking resistor in parameter 27.3.
    • Set the time constant for the braking resistor in parameter 27.4 to 300S.
    • Define the maximum continuous braking power for the resistor in parameter 27.5.
    • Set the control mode for the brake chopper control to AS GENERATOR in parameter 27.6.
26. Parameter group 28 deals with motor modeling. Typically not modified.
27. Parameter group 30 covers fault functions. Generally left unchanged.
28. Parameter group 50 configures encoder values:
    • Set the number of encoder pulses in parameter 50.1.
    • Define the calculation method for encoder pulses in parameter 50.2.
    • Parameter 50.3 is set to FAULT for encoder fault action.
    • Set the encoder monitoring delay time in parameter 50.4 (avoid setting to 0).
    • Parameter 50.5 determines the encoder feedback usage, typically set to TRUE.
29. Parameter group 60 handles the switch between local and external operation.
30. Parameter groups 61 and 62 deal with speed monitoring. Generally not modified.
31. Parameter group 63 covers torque monitoring. Typically left unchanged.
32. Parameter group 64 is for crane mode:
    • Set parameter 64.1 to TRUE for STAND ALONE mode.
    • Parameter 64.10 is configured to STEPJOYST or STEPRADIO.
    • Parameters 64.13 to 64.16 define the speeds for the four speed levels (as a percentage of rated speed).
33. Parameter group 65 deals with motor field current settings. Generally not modified.
34. Parameter group 66 covers torque verification, typically left unchanged.
35. Parameter group 67 configures brake control:
    • Set the brake application time to 0.5S in parameter 67.1.
    • Define the brake fault delay as 0.5S in parameter 67.2.
    • Parameters 67.3 to 67.10 are not detailed but can be set as needed.
36. Parameter group 68 is for power optimization, typically not modified.
37. Parameter group 69 defines the maximum speed and acceleration/deceleration times.
38. Parameter group 98 activates optional modules.