Tallinn Technical University

Department of Electrical Drives and Power Electronics

Valery Vodovozov, Dmitri Vinnikov, Tanel Jalakas

ACS800
Manual for Laboratory Works















Tallinn 2007


Content

Preface .........................................................................................................................................2
Safety Warnings ..........................................................................................................................2
Laboratory Setup Description......................................................................................................2
Laboratory Works Instructions....................................................................................................4
1 Commissioning the Power Converter...................................................................................4
1.1 Remote control the power converter from console .......................................................4
1.2 Control the power converter from the control panel .....................................................5
1.3 Data observing from the control panel ..........................................................................6
1.4 Taking measurements....................................................................................................6
Individual report contents....................................................................................................7
2 Power Converter Characteristics ..........................................................................................8
2.1 Voltage/frequency characteristics .................................................................................8
2.2 Critical speeds control ...................................................................................................8
2.3. IR-compensation...........................................................................................................8
2.4 Output characteristics ....................................................................................................9
Individual report contents....................................................................................................9
3 Computer Examining of Power Converter .........................................................................10
3.1 Acquaintance user interface of DriveWindow............................................................10
3.2 Control the drive..........................................................................................................10
3.3 Monitoring the drive acceleration................................................................................11
3.4 Saving and analyzing the results .................................................................................11
Individual report contents..................................................................................................12
Using Digital Oscilloscope TPS2000 Series .............................................................................13
1. Viewing a Signal ...............................................................................................................13
2. Taking Quick Measurements.............................................................................................13
3. Taking Cursor Measurements............................................................................................13
4. Taking Automatic Measurements......................................................................................14
Initial Settings of ACS800 for Laboratory Works ....................................................................15
2
Preface
The manual contains the instructions which the students must follow carrying out laboratory
works. The reader is expected to know electronic components, the standard electrical wiring, and
electrical schematic symbols. The brochure agrees with the curriculum and contents of
Advanced Course on Power Electronics. Read and understand the safety warnings prior to start
working with the laboratory setup.
Safety Warnings
1. Always remember that the laboratory setup is a dangerous device. Never apply the main
power and never run the motor if it may cause a danger or injury.
2. Before energize the laboratory setup, make sure that all equipment and measuring
instruments are suitable for operation throughout the speed, voltage, and current range
provided by the drives.
3. To avoid electric shock, never open the covers and do not touch with cables or motors
when the main power is applied or shafts rotate.
4. Do not control the motors by the device disconnecting; instead, use the control panels
keys or console buttons.
5. Do not run motors over the rated speed and do not allow their long-term overloading.
6. Remember that the STOP key on the control panel has no effect if the control location is
not set to LOCAL; to stop the drive in this mode press the STOP button on the console.
7. Remember that pressing the STOP key or the STOP button neither causes an emergency
braking of the motor nor instantly disconnects the drive from dangerous potential. Press
the EMERGENCY switch on the console to stall the drive in danger.
8. Remember that the maximum allowed number of power-ups is 5 in 10 minutes; this
exceeding may damage the capacitors and switching devices.
Laboratory Setup Description
The laboratory setup includes the two motor drives ACS800 series: the testing drive and the
loading drive. Each drive has the same structure and consists of:

induction motor
power converter
remote console
cabinet, housing, measuring, and cabling equipment

The motor shafts of the drives are mechanically coupled to each other to provide joint rotation.

Both power converters are wall-mountable low-harmonic units supplied the motors. Each
includes the line-side active rectifier and the motor-side inverter connected via the dc link.

The typical converter cabinet contains:

power converter
cooling fan under the top cover
control drive panel mounted on the front cover
heat sink on the back side
connection box under the bottom cover

3
The main circuit diagram of a single motor drive is shown in Fig. 1. Each converter involves two
modules coupled via dc link. Both the line-side rectifier and the motor-side inverter have six
IGBTs with freewheeling diodes. In the motoring mode, the line-side rectifier passes the three-
phase ac voltage into the intermediate dc link, which further supplies the motor-side inverter
running the motor. Instead, in the braking mode, the motor-side inverter passes energy back from
the motor to the supply lines through the dc link and the line-side rectifier. The line filter
suppresses the voltage and current harmonics. Electrolytic capacitors in the dc link serve for
energy buffering. By default, the converter dc link voltage reaches the peak value of the line-to-
line voltage and if necessary can be set also higher. The IGBT gating is based on the space
vector modulation principle further used for the scalar converter adjustment or direct torque
control (DTC). To calculate the switch turn on/off instants and fault protect, the line currents and
the dc link voltage are measured automatically by the converter sensors.

There are three sources for the drive control:

REM remote (external) control from the console coupled via input/output connections
(I/O) or fieldbus interface
LOC [1] local control from the control panel
LOC [2] local control from the computer DriveWindow software

Each source provides a user interface both the line-side and motor-side modules with essential
controls and parameter settings for the application programs.
Fig. 1
M
4
Laboratory Works Instructions
1 Commissioning the Power Converter
Objective: Commissioning is a system start-up that involves testing and adjusting to assure
proper functioning and understanding the principle of operation. The work aim is to learn how to
start, stop, change the rotation direction, adjust the converter from the console and the control
panel, and perform several ways to take the signals observing and measuring as well.
1.1 Remote control the power converter from console
Check the laboratory setup. Make sure that the loading drive is not powered.
Learn about the console using Fig. 2 and familiarize with the control panel in Fig. 3.
Power on the testing drive using the Main switch. Obtain information from the control
panel: panel identification data, drive identification data, and actual signals.
Press the ACT key on the control panel and explore the status row displayed there:

Module ID Control status Direction Reference Drive status
1 motor-side
2 line-side

L local
non or R remote
forward
reverse
Hz
V
I running
0 stopped
non disabled

Ensure the drive is in remote control mode (no L visible in control status); otherwise,
press LOC/REM key to change between the local and remote control.
Fig. 2
5
To run the motor press the Start button on the console. To adjust the speed, turn the
Speed reference knob. To change the direction of the motor shaft rotation, use the
Reverse switch. To turn off the motor press the Stop button.
Power off the laboratory setup.
1.2 Control the power converter from the control panel
Ensure the laboratory setup is not powered and the motors not rotate.
Observe the tested drive ratings before the further work by reading and recording the data
from converter and motor nameplates.
Power on the testing drive.
Ensure the motor-side inverter is currently being controlled; otherwise, press the DRIVE
and ENTER keys, scroll to ID number 1, and press the ENTER and ACT keys to verify
the change.
If a fault occurs during the control, display **FAULT** or **WARNING** by the ACT
key, and press the RESET key.
Learn about the following general parameter setting procedure of the control panel:
o to enter the Parameter Mode press the PAR key
o to scroll the parameter groups press the PAGEUP and PAGEDN keys
o to scroll parameters within a group use the UP and DOWN keys
o to activate the setting of a new value press the ENTER key
o change the parameter value by the UP and DOWN keys or fast change by the
PAGEUP and PAGEDN keys
o to fix your choice press the ENTER key
Follow this procedure, enter START-UP DATA (parameter group 99), then set given
APPLICATION MACRO and MOTOR CONTROL MODE, and further enter the motor
data from the motor nameplate: MOTOR NOMINAL VOLTAGE, CURRENT,
FREQUENCY, SPEED, POWER.
To change from Remote to Local control press the LOC/REM key (L visible on the
display).
No Name Function
1 LCD Display, 4 lines
2 ACT Actual Signals Mode
3 PAR Parameter Mode
4 FUNC Function Mode
5 DRIVE Drive Selection Mode
6 PAGEUP Large step up
7 UP Small step up
8 ENTER Set the choice
9 PAGEDN Large step down
10 DOWN Small step down
11 LOC/REM Local/Remote control
12 RESET Fault reset
13 REF Reference setting
14 START Run the motor
15 FORWARD Forward direction
16 REVERSE Reverse direction
17 STOP Stop the motor

Fig. 3
6
To set or change the frequency Reference press the REF key, then press the UP/DOWN
to slow reference change or the PGUP/PGDOWN keys to fast change. Press the ENTER
key to save the new reference in the memory until the power switch-off or further
changing.
To run the motor, press the START key on the control panel. To change the motor
direction of rotation, press the REVERSE or FORWARD key. To stop the motor press the
STOP key.
1.3 Data observing from the control panel
Run the drive in remote control mode to the given reference value.
Press the ACT key to enter the Actual Signals Mode (parameter group 01) where the LCD
displays three signals at a time. In the table below, some possible signals are listed:

Parameter Name Description
01.03 FREQUENC[Y] Inverter output frequency, Hz
01.04 CU[RRENT] Motor current, A
01.06 POWER Motor power, % of nominal
01.07 DC VOLTA[GE] Intermediate link voltage, VDC
01.08 MAINS VO[LTAGE] Supply rms voltage, V
01.09 MOTOR VO[LTAGE] Motor rms voltage, V
01.10 PP TEMPE[RATURE] Temperature of heat sink, C
01.37 MOTOR TE[MPERATURE] Estimated motor temperature, C

Read and record sequentially the motor-side inverter values from this list. To change a
signal, move the blinking cursor by the UP/DOWN keys and press the ENTER key in the
selected row, than select an actual signal by the UP/DOWN keys and press the ENTER
key again.
To obtain the line-side rectifier values, unacceptable in the motor-side wiring, press the
DRIVE key, scroll to ID number 2, and press the ACT key. Using the preceding
procedure, read and record the rectifier values accordingly the next table:

Parameter Name Description
01.05 FREQUENCY Line frequency, Hz
01.06 LINE CURRENT Line current, A
01.07 REACTIVE POWER Reactive power, kVAr
01.08 POWER Line-side power, kW
01.09 POWER Input power, % of nominal
01.10 DC VOLTAGE Intermediate link voltage, VDC
01.11 MAINS VOLTAGE Supply rms voltage, V
01.27 COSFII Power factor

1.4 Taking measurements
Employ the oscilloscope to view and measure ac voltages and currents using three
different ways.
Firstly, use the oscilloscope graticule to make a quick, visual estimate of a waveform,
count the major and minor divisions, and calculate the peak-to-peak voltage. Then, record
them and sketch the on-screen waveforms.
7
Secondly, switch on the amplitude and time cursors, move them along the measured
trace, read their numeric values from the display readouts, and record them.
Thirdly, take automatic measurements of the data pointed in the above tables, which are
more accurate and complete than the two preceding ones.
Attach the multimeter, measure, and record the same currents and voltages from its
readouts.
Stop and power off the drive.
Individual report contents
functional circuit and specification of the laboratory setup
converters and motors data including company, type, standard, degree of protection as
well as the electrical and mechanical ratings
measuring instruments data in the same scope as above
the given reference value of the testing drive
table of the signals, measured using the control panel, oscilloscope, and multimeter
scaled diagrams of the current and voltage waveforms sketched from the oscilloscope
traces
conclusions concerning the results estimation, comparison, and explanation

8
2 Power Converter Characteristics
Objective: Characteristics help to understand converter performance in the loading and adjusting
processes. The work aim is to observe and explain converter characteristics as well as to build
the corresponding diagrams.
2.1 Voltage/frequency characteristics
Voltage/frequency characteristic is the trace of a converter output voltage versus frequency. It
shows the converter linearity and the frequency and voltage range. When operated above a motor
field weakening point, the converter cannot reach the full required output voltage thus reducing
the load capacity.

Power on the testing drive. Set the zero reference frequency and define the motor voltage,
current, and power as the actual signals. Record the obtained frequency, voltage, and
power into the protocol table.
Run the drive. Smoothly changing the reference in the range 070 Hz, fill the measured
values into the protocol again.
Using the records, build the voltage/frequency and power/frequency diagram. Find the
field weakening border and the maximum motor voltage in the diagram.
Return the reference frequency to zero and stop the drive.
2.2 Critical speeds control
The critical speeds functions are useful for applications where it is required to avoid certain
motor speeds or speed bands because of mechanical resonance or supply oscillation problems.

To activate the functions set the parameter 25.01 CRIT SPEED SELECT to ON.
Define the minimum and maximum limits for the critical speed band by setting the
parameters 25.02 CRIT SPEED 1 LOW and 25.03 CRIT SPEED 1 HIGH to a given
values (1040 and 6090 Hz accordantly).
Run the drive. Smoothly changing the reference in the range 070 Hz, fill the measured
values into the protocol and build the voltage/frequency and power/frequency diagram.
Show the critical speed band in the diagram.
Return the reference frequency to zero, stop the drive, and set the parameter 25.01 to
OFF.
2.3. IR-compensation
When IR-compensation is activated, the converter gives extra voltage boost to the motor at low
frequencies. It is useful in applications that require high breakaway torque. Since voltage cannot
be fed to the converter at 0 Hz, full IR-compensation starts around the slip frequency.

To define the relative output voltage boost at zero speed, set the parameter 26.03 IR-
COMPENSATION to a given value (1030% of the motor nominal voltage).
Run the drive. Smoothly changing the reference in the range 070 Hz, fill the measured
values into the protocol and build the voltage/frequency and power/frequency diagram
again. Show the IR-compensation band in the diagram.
To define a frequency at which the IR-compensation reaches full value, set the parameter
26.04 IR STEP-UP FREQ to a given value (5...25 Hz) and repeat the experiment. Show
the new IR-compensation band in the diagram.
9
Return the reference frequency and the parameters 26.03 and 26.04 to zero and stop the
drive.
2.4 Output characteristics
Output characteristics collect a set of dependences of a converter output voltage versus current.
They describe the loading possibilities and steady properties of a converter.

Run the testing drive to a given reference frequency (20...30 Hz).
Power on the loading drive, set the reference torque to zero, and run it.
Record the loading torque and testing frequency, voltage, current, and power into the
protocol table.
Smoothly raising the loading torque from zero to the nominal current of the testing drive,
fill the same measured values into the protocol again. Unload the drive. Using the
records, build the output diagram for the given frequency.
Set other given reference frequency of the testing drive. Then, changing the loading
torque from zero to the motor nominal current fill the measured values into the protocol
and build the output diagram for the new frequency. Further, repeat the experiment in the
frequency range 0 to 70 Hz.
Set the previous value of IR-compensation and repeat the experiment in the low-
frequency region.
Unload and remove IR-compensation, stop and power off the drives.
Individual report contents
tables and diagrams of voltage/frequency characteristics without and with the critical
speed bands and IR-compensation
table and diagrams of output characteristics with IR-compensation band
conclusions concerning the results estimation, comparison, and explanation

10
3 Computer Examining of Power Converter
Objective: To maintain and learn ABB drives, the DriveWindow soft tool is intended. The work
aim is to master the converter remote control, its signal monitoring, working with parameters,
and graphical trending.
3.1 Acquaintance user interface of DriveWindow
The user interface shown in Fig. 4 includes the standard Windows areas handling from the
keyboard and mouse by user editing, moving, dragging, and resizing.

Power on the testing drive.
Connect DriveWindow to the drive by choosing ABB SMP string in the Select OPC
Server dialog box
Find the main parts of the user interface:
o title bar
o menu bar
o toolbars including Standard toolbar, Monitor toolbar, Logger toolbar, and Drive
panel at the bottom
o status bar along the bottom
o window area divided by four panels: Browse tree and Item sets on top as well as
Trend settings and Trend display below
3.2 Control the drive
To control the drive, either the Drive panel or the Drive menu can be used. The status bar
describes user actions.

Select the drive in the Browse tree pane.
Take the control by toggling the Take/Release Control button.
Examine the status image, name, and address of the currently controlled drive.
Fig. 4
11
Reset the fault and clear the fault logger if an error occurs.
Assign given reference frequency (30...70 Hz) into the edit field and click the Set
Reference button or press Enter to send it to the drive.
Run the drive, and then stop it.
Change the motor direction of rotation and run it again.
Execute the coast stop.
Release the control and ensure the drive is adjustable from the control panel.
3.3 Monitoring the drive acceleration
Control monitoring can be executed using the Monitor toolbar or the Monitor menu. Monitor runs
and collects data by reading cyclically the items from the drive in real time.

Take the control.
To learn the drive acceleration, choose Parameters in the Browse tree panel and set the
parameter 22.02 ACCEL TIME 1 to a given value (5...15 s) in the Item sets pane.
In the Trend Settings pane, set X-Axis Length above the given acceleration time.
To add the motor voltage, current, and frequency for monitoring, choose 01 ACTUAL
SIGNALS in the Browse tree pane and drag the required strings into the Trend Settings
pane. The numeric images appear in front of the added items. The Delete button lets to
remove unnecessary items from monitoring.
To start monitoring, click the Start or Continue Monitoring button in the Monitor toolbar
and right away run the drive to the given reference frequency.
Wait until the running comes to the end and press the Stop Monitoring button. Then stop
the drive also.
To scale the trends swing, use Adapt Y-Axis from the Axis submenu or Autoscale from the
Scaling submenu of the Monitor menu.
When viewing the stopped or paused trends, click the drawing area to display the graph
cursor, which measures the items.
3.4 Saving and analyzing the results
There are several ways to save trends. The currently displayed trends can be saved from File
menu into a DriveWindow graph file, exported to a text file, copied to the clipboard, or printed.

To process the data, select Export in the Graph submenu and assign a name of the created
.txt file. Later, open the file by Microsoft Excel, recalculate per-unit data into Volts,
Amperes, and Hertz, and build the required diagrams.
To save the trends for continuation the work, select Save As command and name and
comment the new .dwt file. Saved graphs are actually incomplete offline workspaces,
which contain just enough information to restore the graphs in the trend display. In the
future, by double clicking or selecting Open command in the Graph submenu the saved
file may be restored.
To use the trends in other applications, first copy them into the clipboard using Copy
Graph command in Edit menu and then paste in the required software.
To print the trends when the current printer is unavailable, use Microsoft Office Document
Image Writer.
After successful saving the monitor can be cleared by the Clear button and the parameter
22.02 ACCEL TIME 1 returned to 3 s.
12
Individual report contents
scaled diagrams of voltage, current, and frequency timing traces
mutual voltage/frequency diagram built using the voltage and frequency data
output voltage/current diagram built using the voltage and current data
conclusions concerning the results estimation and explanation
13
Using Digital Oscilloscope TPS2000 Series
1. Viewing a Signal
To quickly display a signal of unknown amplitude or frequency, follow these steps:

Power on the oscilloscope.
To connect the probe, align the slot in the probe connector with the key on the CH 1
BNC, push, and twist to the right to lock the probe in place.
Push the CH 1 MENU button.
Choose Probe.Voltage.Attenuation.500X and set the switch on the probe to the same
value.
Connect the Channel 1 probe tip to the signal and the reference lead to the circuit
reference point.
Push the AUTOSET button.
To view two signals, connect the second probe to CH 2 BNC and use the CH 2 MENU
button.

The oscilloscope sets the vertical, horizontal, and triggering controls automatically.
2. Taking Quick Measurements
To measure a time and amplitude, follow these steps:

Turn the SEC/DIV knob to display the starting edge of the waveform.
At the chosen channel, turn the VOLTS/DIV and VERTICAL POSITION knobs to set the
waveform amplitude to about five divisions.
Push the CH 1 MENU button.
Choose Volts/Div.Fine.
Turn the VOLTS/DIV knob to set the waveform amplitude to exactly five divisions.
Turn the VERTICAL POSITION knob to center the waveform; position the baseline of the
waveform 23 divisions below the center graticule.

Use readouts in the screen bottom area to know the vertical scale factors of the channels and the
main time base setting.
3. Taking Cursor Measurements
Cursors quickly take time and amplitude measurements on a waveform. To measure a time span,
follow these steps:

Push the CURSOR button to display the Cursor Menu.
Choose Type.Time.
Choose the channel, for example Source.CH1.
Choose the Cursor 1 option button to display the first cursor location.
Turn the multipurpose knob to change the cursor position.
Choose the Cursor 2 option button to display the second cursor location.
Turn the multipurpose knob to change the cursor position.
Time cursors display t (time difference between the cursors), 1/t (frequency), V (or
I, voltage/current difference), and the times at cursors relative to the trigger in the
Display Menu.

14
To measure amplitude, follow these steps:

If the Cursor Menu is not displayed, push the CURSOR button.
Choose Type.Amplitude.
Choose a channel if necessary.
Choose the Cursor 1 option button to display the first cursor location.
Turn the multipurpose knob to change the cursor position.
Choose the Cursor 2 option button to display the second cursor location.
Turn the multipurpose knob to change the cursor position.

Amplitude cursors display V (or I, voltage/current difference between the cursors), and the
signal values in the Display Menu.
4. Taking Automatic Measurements
There are eleven types of measurements available: Freq frequency, Period the time of the
first cycle, Mean the arithmetic mean amplitude over the entire period, Pk-Pk the absolute
difference between the maximum and minimum peaks of the waveform, Cyc RMS rms value of
the first complete cycle, Min and Max the minimum and the maximum values of the last 2500
points, Rise Time and Fall Time durations of the first rising and falling edges, Pos Width and
Neg Width the first positive and the first negative pulses widths at the waveform 50% level.
The oscilloscope can display up to five measurements at a time. To take a measurement, follow
these steps:

Push the MEASURE button to see the Measure Menu.
Choose the channel, for example Source.CH1.
Push another option button and choose the measurement type, for example, Type.Freq.
Push the Back option button to return to the Measure Menu and display the selected
measurement.

15
Initial Settings of ACS800 for Laboratory Works

Index Value
10.01 DI1,2
10.02 DI6,5
10.03 REQUEST
11.01 REF1(REF2*)
11.05 70
16.01 YES
Index Value
16.02 OPEN
20.01 -70 (-1500*)
20.02 70 (1500*)
22.02 3
25.01 OFF
25.02 0
Index Value
26.03 0
26.04 OFF
99.02 HAND/AUTO** (T-
CTRL*)
99.04 SCALAR
99.10 NO (ID MAGN*)

* Loading drive
** Application macro User 2