Driving forward issue 2 - draft - MKE Engineering Group | … · · 2016-03-24For the ACS800 this...

Driving Forward

Inside this issue

Welcome ……………..1

Flux optimisation …...2

Staff focus …………...3

Contact details ..…….3

Product spotlight …..4

Pull out and keep

ACS800 start up sheet

Pages 5 & 6

Print double sided for best result.

Motor economy from ABB SynRM motor and drive packages

Issue2Spring2016

MKEDriveSystems

MKEDriveSystemsisadivisionofMid-KentElectricalEngineeringCoLtd.www.mke.co.uk

MKEdriveSystems

Welcome to the second issue of our newsletter.

We did receive some good feed back from the first issue, the ACS550

start up sheet was popular or the “cheat sheet” as some prefer to call it.

The manuals that come with the ABB Drives contain a wealth of

information for all the various functions available to the diverse range of

industries that use ABB Drive Systems. However it seems that many of

our customers want a simple guide that gives the basic settings

required to get a motor running. To follow up on this we have included

an ACS800 start up sheet in this issue and plan to carry on building up

a set of start up sheets in future issues.

We have also had a request for a guide to setting up flux optimisation.

The diagram above shows the principal behind this and we have

included the “how to do it” information on page 2 of this issue.

Please keep the feedback coming and we will try to cover all the areas of

interest.

Flux optimisation

Flux optimization is a function available within

many ABB drive systems that enables the drive to

adjust motor flux so that only the minimum power

required to do the work is actually consumed.

This function is available in drives such as the

ACS600, ACS800, ACS550, ACH550.

For this function to work in the ACS600 and

ACS800 drives the drive must be set in to it’s DTC

mode, this is done from the “Motor control mode” parameter. For the ACS800 this is parameter

99.04, see the ACS800 start up sheet contained

in this news letter. For the ACS550 best results

are obtained if the drive is set to it’s vector speed

mode (the ACS550 does not have DTC), again

this is done from the “Motor control mode”

parameter. This is also parameter 99.04 in the

ACS550, see start up sheet in the previous issue

of this news letter.

You should check the basic motor parameters

have been set correctly before making the

change, i.e.

• Voltage

• Current

• Frequency

• Speed

• power

These are also in group 99 of the parameters and

need to be set according to the motor data plate.

When you change to DTC or Vector modes the

drive will carry out motor tests and if these motor

details are not correct the drive is likely to

generate a fault such as “ID run failed”, this is a

reasonably common occurrence and suggests

that the drive may not have been commissioned

correctly or perhaps a motor has been changed

but the motor details have not been updated in the

drive.

If the motor details are correct, and the motor

control mode is set as above, then the flux

optimization parameter can be switched on,

parameter 26.01.

Flux optimization is an active function. The drive

system will achieve the speed required of it and

Issue2Spring2016MKEdriveSystems


then start reducing the motor power. When the

drive detects that a reduction in speed is about to

occur the power will be increased again to ensure

the correct speed is maintained. The process of

reducing the power is repeated continually to

ensure that only the minimum power is consumed.

The applications that give the best savings are

centrifugal loads such as pumps and fans where

loads are not at 100% and a reduction in speed can be achieved. When pump system are being

considered, systems where friction head is high by

comparison to static head tend to give best results.

If a pump system is loaded very heavily, and

needs to run continually at its maximum speed, it

is unlikely that savings will be achieved.

Look for situations such as tanks which are being

filled or emptied. It is possible that the pumps may

have been sized to cope in worst case conditions.

At other times do the tanks need to be filled or

emptied at full speed?

Are pumps continually switching on and off with

short run times? Reduced speed running on these

applications, in conjunction with flux optimization,

can give large reductions in running costs.

An area to be aware of when changing the drive in

to the DTC or Vector mode, ready for flux

optimization, is that the drive will now be working based on actual motor RPM rather than output

frequency (Hz).

Default maximum output is 50Hz regardless of

motor rated speed, however default maximum

speed is 1500rpm. If you are running a two pole

motor, speed approximately 2900rpm, you will

need to adjust the maximum speed limit within

parameter group 20 to take account of this or you

may find that you are limited to half the normal

speed (e.g. set maximum speed in group 20 to

3000rpm to correct this).

To assess the effect of this function set a fixed

speed, e.g. 1200rpm for a four pole motor, let the

system run until stable first with Flux optimisation

off then again with it switched on.

If you see an unexpected result give us a call, we

are here to help.

Staff focus

In the previous issue of this news letter we featured our newest

apprentice for the staff focus, this time around the spot light is on

one of our more experience technicians.

Derek Millen has electrical engineering experience spanning 48 years. Derek started as

an apprentice with

Bowater Kemsley Mill in

1968. Since that time

Derek gained experience

of electrical engineering in a number of industries

before joining MKE in

2008.

Derek’s experience

covers the heavier side

of electrical engineering,

as expected from a mill

background, right

through to the

automation and controls

field. In fact Derek was

responsible for installing

the first PLC in

Sittingbourne Paper mill

in around 1978, a Square-D Sy-Max system. Also the first

SCADA system during the mid 1990s.

Derek has a particular strength when it comes to finding and

rectifying problems with control systems. Also putting together

solutions to adapt existing systems to new or modified

requirements.

Derek told me “I enjoy being part of the team at MKE, it’s the

people that make or break a work environment. In the case of

MKE Drive System it’s a good team to be part of.”



MKE Drive Systems:

Unit 3, D2 Trading Estate,

Castle Road, Sittingbourne,

Kent. ME10 3RH.

Telephone: 01795 438436

Email:

[email protected]

[email protected]

[email protected]

Website: www.mke.co.uk

MKE Industrial Electronics:

Unit B6/B8 Star Business Centre,

Fairview Industrial Estate,

Marsh Way,

Rainham,

Essex. RM13 8UP.

Telephone: 01708 520996

MKE Head Office:

Unit 15B & 15C Dolphin Park,

Upper Field Road,

Euro Link,

Sittingbourne,

Kent. ME10 3UP

Telephone: 01795 471089

Contact details

New ACS880 series drives

0.55KW

to

3200KW

Product spotlight



ABB AC500 PLC

The ABB AC500 PLC is available in ranges to suite most applications. Starting with the entry level

“eCo” range, shown in the photo above, then up

through the standard high performance range

which has variants such as the “XC” (eXtreme

Conditions) and the “S” (functional Safety).

The base level version of the of the eCo is in a

similar price to smart relays but offers full PLC

functionality along with modular expandability and

serial Modbus communications. There is also an Ethernet version of the eCo which

expands the Modbus communications to TCP/IP.

With the Ethernet version you also get an internal

web server which can be set up to offer the end

user a monitoring and control facility via standard

web browsers such as Internet Explorer or Mozilla

Firefox.

The web server facility has been used by one of

our customers to provide a commissioning tool for

their engineers during initial set up of equipment.

This means commissioning engineers can adjust

important values within the PLC code without the

need for PLC programming software or expertise.

Although PLCs are mainly found within industry.

The example opposite shows a screen shot from

internet explorer with an AC500-eCo in control of

an air handling system. With RS485 Modbus built

in to the ABB HVAC Variable Speed Drives (VSDs)

as standard these drives and PLCs are ideal for

this type of application within the Buildings

Management field.

Using the standard built in Modbus Facility all the

drive’s inputs and outputs are available to the PLC,

this can reduce hardwiring to a minimum.

Additionally all the information available from the

VSDs internal parameters is accessible and can be

displayed on the web pages.

We see numerous customer sites where their old

BMS systems are failing; due to the high cost of

upgrading to modern systems many are just

switched off or have equipment continually in hand

control. These ABB PLCs offer a cost effective

option for getting automated control back up and

running.

Another big bonus with these PLCs is the

programming software, it’s available free of charge!

*Note, the analogue inputs can be set to either voltage or current on the ACS550 by adjusting the J1 switches.

Unit 3, D2 Trading Estate, Castle Road, Sittingbourne, Kent.

ME10 3RH

Telephone: (01795) 438436

E-mail: [email protected]

E.G. setting motor voltage. ACS800, ABB Factory Macro

Description Par Setting

Motor control mode 99.04

Motor nominal voltage 99.05

Motor nominal current 99.06

Motor nominal frequency 99.07

Motor nominal speed 99.08

Motor nominal power 99.09

Start, stop & direction inputs 10.01

External reference 1 select 11.03

External reference 1 minimum 11.04

External reference 1 maximum 11.05

External reference 2 select 11.06

External reference 2 minimum 11.07

External reference 2 maximum 11.08

Minimum AI1 (voltage input) 13.01

Maximum AI1 (voltage input) 13.02

Minimum AI2 (current input) 13.06

Maximum AI2 (current input) 13.07

Constant speed inputs 12.01

Constant speed 1 value 12.02



Relay RO1 output 14.01



Analogue output 1 15.01

Minimum AO1 15.03

Scale AO1 15.05

Analogue output 2 15.06

Minimum AO2 15.08

Scale AO2 15.1

Parameter lock 16.02

Pass code 16.03

Local lock 16.06

Acceleration time 1 22.02

Deceleration time 1 22.03

Flux optimisation 26.01

If you are not at this

screen press “ACT” to get

there.

Then press “PAR” to arrive

at the parameter screen.

Use the double

triangle buttons to

scroll up or down

to group 99.

Then use the

single triangle

buttons to scroll up

or down to

parameter 05.

Press “ENTER” and

brackets should appear

around the

voltage.

Use triangle buttons to

make changes.

Large changes

Small changes

Then press enter

to remove the brackets

ABB ACS800 connections for the factory macro

Unit 3, D2 Trading Estate, Castle Road, Sittingbourne, Kent.

ME10 3RH

Telephone: (01795) 438436

E-mail: [email protected]

Remember to fit a

link between termi-

nals 8 & 11 if the

start interlock is not

used.

Driving forward issue 2 - draft - MKE Engineering Group | … · · 2016-03-24For the ACS800 this...

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