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HELSINKI TRAINING CENTER | LOW-VOLTAGE AC DRIVES

ABB Industrial Drives

ACS880 Primary Control Program
G380X – ACS880 Operation, Start-up and Basic Maintenance, Hands-on_revB

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Common Firmware for ABB Industrial Drives

ACS800 ACS880
Standard control program Primary control program
Standard control program PMSM + Drive based IEC programming
System control program

System control program PMSM

Multiblock control program One common firmware over the whole ACS880
product family
Precise speed and torque control for all
+ applications
Benefits of ACS850 software
+
New functionality

2.8.2023 Slide 2 G380X - ACS880 Primary Control Program

The ACS880 product family has one common firmware.

The primary control program combines the ACS800 system functionality, the benefits of the
ACS850 software and new functionality. Compared to the ACS800, there no longer are separate
standard control programs and system control programs. There is only one software for the
basic applications. The ACS880 primary control program supports system functionality for
multidrives and standard functionality for single drives. The ACS880 firmware also supports IEC
61131 programming.

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Common Firmware for ABB Industrial Drives
Same firmware for different control units

Same firmware for different control units and target CPUs

– Control boards for single drives and low power inverters
– More capacity for parallel connected PUs and special
applications
One software loading package
– Automatic identification of control unit type
– Easy firmware update
• Important for applications with different control unit types
(e.g., multidrive).

2.8.2023 Slide 3 G380X - ACS880 Primary Control Program

The same firmware can be used in different control units and target CPUs. One loading package
can be used, simplifying firmware updates.

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ACS880 Direct Torque Control
Versatile motor control as standard

IM and PMSM motor control, including servo motors

– Both open and closed loop control
Accurate open loop performance
– High starting torque, good torque linearity
Enhanced control performance
IEC AC motors NEMA AC motors
– High output frequencies
– High switching frequencies (up to 16 kHz, depending on the
module used)
Improved motor identification, especially in standstill mode
– More measurements
– Better motor model
– Better control performance
Synchronous motors Synchronous reluctance motors

2.8.2023 Slide 4 G380X - ACS880 Primary Control Program

The ACS880 primary control program supports both asynchronous and permanent magnet
motors. The drive can also be ordered with an option to support ABB’s synchronous
reluctance motors (SynRM).
The ID run is improved to provide better motor identification, especially the standstill ID run.

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Examples of Functionalities
Motor phase inversion

Problem
– Incorrectly connected motor cables
– Incorrect direction of rotation U VW U VW

Solution: Motor phase inversion

– One parameter setting
– Included in basic start-up assistant
Benefit:
– Quickly correct rotation direction
– Useful with thick motor cables

2.8.2023 Slide 5 G380X - ACS880 Primary Control Program

The firmware supports motor phase inversion. If motor cables are accidentally connected
incorrectly, it is easy to invert the phases with one parameter. The feature is included in the basic
start-up assistant as a “direction test”.

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Parameter Harmonization
Similar interface

All basic parameters and functions of industrial and standard

drives are the same
– Learn one ABB drive → Use majority of ABB drives
Variable contents of parameters
– Parameter names and content can depend on other parameters
– Reduces number of parameters
– Useful for hardware configuration parameters such as extension
I/O, encoder and fieldbus

2.8.2023 Slide 6 G380X - ACS880 Primary Control Program

A major improvement is the harmonization of all parameters. All industrial and standard drives
share the same general parameter structure, names and numbers. If you learn the parameters
of the ACS880 primary control program, it is easy to learn any other ABB drive using this
architecture.
Parameters can now have dynamic content, meaning that changing one parameter can change
the name and content of other parameters. This reduces the number of parameters, and
simplifies the configuration of I/O, encoder and fieldbus modules.

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Versatile User Interface

Control panel
Versatile user interface and easy parameter
handling
– Favorites list and complete list
– Application macros
– Panel assistants

2.8.2023 Slide 7 G380X - ACS880 Primary Control Program

The user interface offers versatile ways to handle parameters. The control panel has
parameter views such as a favorites list. The firmware will support application macros and
assistants. The complete list of all parameters is also available (similar to previous
panels). You can also check which parameters have been modified.

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Visualization of Control Diagrams
In Drive Composer Pro version

2.8.2023 Slide 8 G380X - ACS880 Primary Control Program

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Visualization of Control Diagrams
In Drive Composer Pro version

2.8.2023 Slide 9 G380X - ACS880 Primary Control Program

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Parameter System Structure
Functionality Group numbers
General signal type parameter groups 1, 3, 4, 6, 7
Drive I/O systems 10, 11, 12, 13, 14, 15, 16
Drive logic and operation 19, 20, 21
Speed reference chain and speed control 22, 23, 24, 25
Torque reference chain 26
Frequency reference chain 28
Limits 30
Fault functions, maintenance counters, protections 31, 33, 35
Process PID 40, 41
Brake chopper and mechanical brake 43, 44
Energy saving configuration 45
Fieldbus configuration 50, 51, 52, 53, 54, 55, 56, 57, 58
DDCS and D2D Master/Follower comm. 60, 61, 62
Application specific parameters 74...89
Feedback device configuration 90, 91, 92, 93
HW and system configuration 95, 96
Motor control data 97, 98, 99
Safety 200

2.8.2023 Slide 10 G380X - ACS880 Primary Control Program

Regarding the parameter structure, these are the main functional groups. In this presentation,
we will review a few selected examples of the parameter groups.

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Energy Savings
Group 45: Energy savings configuration

Calculate saved energy compared to DOL or other control method

– Savings in kWh, MWh and GWh
Energy saving conversion factors
– Energy price (currency/kWh) and CO2 multiplier (kg/kWh)
• Saved money (by energy savings) in selected currency and
reduced CO2 emissions
Energy optimizer
– As “Flux optimization” in ACS800
• Function optimizes magnetizing current in partial loads

2.8.2023 Slide 11 G380X - ACS880 Primary Control Program

Energy savings has a dedicated parameter group. It includes an energy counter, showing how
much energy has been saved compared to a direct online motor. The difference can also be
calculated as currency or carbon dioxide values.
The energy optimization feature adjusts the motor flux in such a way that the drive runs with
lower energy consumption, maximizing the total efficiency, and thus saving energy.

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Encoder Modules
Speed and position feedback

FEN series encoder modules

– FEN-31 HTL pulse-encoder
– FEN-01 TTL encoder
– FEN-21 resolver
– FEN-11 absolute encoder
New features
– Possibility to have two same kind of encoder modules
connected at the same time
– In closed loop mode speed feedback is evaluated with speed
estimate
– Improvements to low-speed area calculation

2.8.2023 Slide 12 G380X - ACS880 Primary Control Program

ACS880 uses the FEN series encoder modules.

It is possible to have two encoder modules of the same type connected at the same time.
Closed loop speed feedback is evaluated with a speed estimate. Low-speed calculations
are improved.

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User Parameter Sets
All in one

User sets
Can contain all or a subset of drive parameters
– Motor data and ID run results included
Four (4) user sets supported
Can be edited in Drive composer

2.8.2023 Slide 13 G380X - ACS880 Primary Control Program

User parameter sets can contain any parameter subset, including motor data and ID run results.
It is possible to have 4 user specific parameter sets. An example is to have one parameter set
for one motor, and another set for two motors.
The user sets can be edited in Drive composer.

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Drive Diagnostics and Fault Tracing
Troubleshooting

Available tools
– To achieve maximum process uptime,
effective and easy to use diagnostics and fault
tracing tools are essential
• Both for drive and application
troubleshooting
– Basic firmware level diagnostic functions
– Event loggers
• Faults, warning and events
– Data loggers
– Diagnostics assistant
– Drive Composer Pro/Entry
• PC-tool data monitoring
• Support package “button”

2.8.2023 Slide 14 G380X - ACS880 Primary Control Program

Regarding facilities for diagnostics and fault tracing: The control program provides basic
firmware-level diagnostic functions, an event logging system, and support for data loggers.
The control panel and Drive composer will have a diagnostic assistant, indicating what to do in
fault situations (what to check, etc.)
Drive composer can also monitor data.

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Drive Diagnostics and Fault Tracing
Event loggers

Overview
– 5 primary faults, 20 secondary faults and
warnings
– Stored to FLASH
Content
– Time stamp, name, code and auxiliary code
– Operation data such as motor speed and
current
Parameters to indicate 5
– Simultaneous active faults/warnings
– Latest indicated faults/warnings

2.8.2023 Slide 15 G380X - ACS880 Primary Control Program

Event loggers record three types of events: faults, warnings and events.
Five active faults and warnings, and five latest faults and warnings are stored.
The duration of the storing time is 500 ms.

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Drive Diagnostics and Fault Tracing
Data loggers

All signals and parameters can be tracked (also Drive based IEC
programming variables)
Possibility to store data to non-volatile memory (FLASH)
Two data loggers
– 8 channels and 1000 samples per channel
– 0.5ms, 2ms or 10ms sampling interval
Data logger types
– User datalogger
• Fully user definable
• To help demanding commissioning or fault tracing
– Factory datalogger
• Preconfigured to catch data in case of first critical trip
• Saving of logger data for latest faults (history)
• Automatic re-starting of data logger, when drive started again

2.8.2023 Slide 16 G380X - ACS880 Primary Control Program

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Drive Diagnostics and Fault Tracing
Support package

Overview
– Collects automatically all the important data
to be sent to Drives support
• Data loggers
• Event logger
• All parameters
• Internal diagnostics data
– Helps fault tracing actions
– Easy for end users to provide information
• No pre-configuration needed
• One file to be sent to support via email
– Easy information handling at Drives support
• No special tools needed
• Language support

2.8.2023 Slide 17 G380X - ACS880 Primary Control Program

If there is a fault in the drive, the Support package feature can be used to easily gather and send
fault and diagnostics information to Drives support. The feature is available in the PC tool.
No pre-configuration is needed.
Clicking the button creates a file, which can be sent to Drives support by email.

The support package includes all the information needed in troubleshooting situations:
factory loggers, fault loggers, all parameters and internal diagnostics data

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Drive Diagnostics and Fault Tracing
Drive Composer PC-tool

Drive’s Control Panel

information

All-compatible
drive

Drive’s Drive Composer PC-tool: Support ABB Support

information Monitoring, Fault tracing, Package
Commissioning, etc.

2.8.2023 Slide 18 G380X - ACS880 Primary Control Program

The Drive composer PC tool has a diagnostics support function. It collects all the
important information from the drive when fault tracing is needed. The idea is to collect
data loggers, fault loggers, parameters and internal diagnostics data with a click of a
button in the PC tool. You can create a QR code that collects all data about the changed
parameters.

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Drive Programming
Two suitable options

Onsite fine-tuning and adaptation - AP New application development - DAB

– Customer / ABB – OEMs, System Integrators
commissioning and service and ABB software designers
personnel – Move PLC functionality to
– No suitable firmware Drive
function available – Create a new drive product
– Make a small function block for special applications
program

2.8.2023 Slide 19 G380X - ACS880 Primary Control Program

Regarding programming of ACS880, there are two main programming alternatives:

For on-site fine tuning and adaptation, small function block programs can be created with
adaptive programming.
For more advanced requirements, a development alternative is available for creating specialized
drive application programs.

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Adaptive Programming
For onsite fine tuning and adaptation

Overview
– Easy-to-use tool for limited programming
– Included in Drive composer pro and entry PC
tool
– Limited number of function blocks (20) in
primary control program firmware
– Other firmware versions: larger number of
blocks possible (e.g., Crane firmware)
– Input and output interfacing to firmware by
connector elements
– Available in Virtual Drives as well

2.8.2023 Slide 20 G380X - ACS880 Primary Control Program

Adaptive programming is part of Drive composer tool.

The programming is based on the block programming interface. Adaptive program files
can be handled by off line editing with the Composer pro tool. Files can be uploaded and
downloaded to the drive when on-line connection is used.

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Drive Application Builder
For new application development

Based on Driver Based IEC Programming

– Comprehensive software tool for industrial
automation technology
– IEC 61131 compatible
– Several programming languages
• Function Blocks, Ladder Diagrams,
Structured Text, Sequential Function Chart,
Instruction List
– Widely used by PLC and drive manufacturers
– PLC & drive IEC programming
• Configure drives, PLC, I/O system,
communication, safety
• Common project handling
– +N8010 licenses needed on ZMU

2.8.2023 Slide 21 G380X - ACS880 Primary Control Program

For more advanced programming requirements, drive based IEC programming can be
done with application Builder, which is an engineering framework for factory automation.
It is IEC 61131-3 compatible, which is widely used by PLC and drive manufacturers.
Automation Builder can be used to program a PLC and drive from within the same
environment.

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Configuration according to application needs
Your choice

– Primary control program (default firmware)

• Ready from ABB
• Configuration by parameters
• Adaptive programming
– Application specific control programs (e.g. cranes, winders)
• Ready from ABB
• Configuration by parameters
• Adaptive programming
– Developer primary and application specific control programs
• Base from ABB
• Configuration by parameters
• Drive based IEC programming (license required)
• Adaptive programming

2.8.2023 Slide 22 G380X - ACS880 Primary Control Program

The drive programming configurations are designed to accommodate different levels of

application needs.
With the default firmware, adaptive programming is available with the Drive composer pro tool.
Application-specific control programs for winches, cranes, etc., can be ordered as separate
options.
For the most advanced programming needs, application developers can purchase a
development license and create custom applications with Drive application builder.

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Backward Compatibility
Support for ACS800

AC80 and AC800M controllers supported via DDCS channels Drive composer for parameter handling and signal monitoring via
– Firmware supports “old” ABB drives profile via dataset interface DDCS tool network
– DDCS option board needed Built-in possibility for parameter remapping and rescaling table
enabling drive change with minimized changes in the automation
ACS800 master/follower link support system/PLC
– ACS880 can be a master or follower
– DDCS option board needed
Fieldbus support
– ABB drives profile
– Control word, references, actual values and status
– Parameter read/write not compatible due to different
parameter numbers
Support how to convert ACS600/ACS800 parameters to ACS880
– Conversion tool

2.8.2023 Slide 23 G380X - ACS880 Primary Control Program

Regarding backward compatibility with the ACS800:

The AC80 and the ACS800M controllers are supported via optical DDCS
communication. This requires an optional DDCS adapter. It is possible to use DDCS
communication between drives and over the control system.
The ACS800 master/follower link support: the ACS800 and the ACS880 can be in the
same system by using DDCS communication. The ACS880 can be a master or a
follower.
The ACS880 fieldbus supports the ABB drives profile (the basic communication profile).
Separate parameter read/write functions are not directly supported due to different
parameter numbers. In such cases, the PLC program may have to be modified.
The ACS600 and the ACS800 parameters can be converted to ACS880 parameters with
a conversion tool. There is a built-in possibility for parameter remapping and rescaling
table, which means you can change the drive with minimal changes in the automation
system.

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Backward Compatibility Support for ACS800
Conversion tool

2.8.2023 Slide 24 G380X - ACS880 Primary Control Program

Parameters of the ACS800 standard control program can be converted to ACS880 parameters.

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ACS880 Primary Control Program
Summary

Common firmware over the whole ACS880 product family

– Standard, system and PMSM functionality with one software
– Primary control program
Harmonized functionality and parameters
– Learn one firmware, manage easily different drive products
SynRM support
Easy and intuitive user interfaces
– Drive composer PC tool with interactive control diagrams
– Panel assistants for effective commissioning
– Drive support package for easily collecting diagnostic
information
High control performance with DTC
– AM and PM motors and low inductance PMSM servo motors
Common programming for ABB drives and PLCs according to IEC
61131-3
– Suits excellently for both OEM and ABB application development

2.8.2023 Slide 25 G380X - ACS880 Primary Control Program

To summarize:
The entire ACS880 product family will have a common firmware platform.
The parameters and functionality of the firmware have been harmonized. Learning one firmware
makes it easy to manage any drive product using the same architecture.
The user interfaces are easy to use and intuitive.
The control program offers high control performance with DTC.
A common programming environment is available for configuring both ABB drives and PLCs.

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