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ABB Advant Controller 80 User Manual

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  • Page 1 ABB Drives User’s Manual Advant Controller 80...
  • Page 3 User’s Manual Advant Controller 80 3BFE 64116487 R0125 REV A EFFECTIVE: 21.2.2000 SUPERSEDES: 1.6.1999 © 2000 ABB Industry Oy. All Rights Reserved.
  • Page 5 Safety Instructions General Safety Instructions WARNING! All electrical installation and maintenance work on the drive should be carried out by qualified electricians. Any installation work must be done with the power off, and power is not to be reconnected unless the installation work is complete. Dangerous residual voltages remain in capacitors when the disconnecting device is opened.
  • Page 6 Safety Instructions CAUTION! Fans may continue to rotate for a while after the disconnection of the electrical supply. CAUTION! Some parts like heatsinks of power semiconductors inside of cabinet remain hot for a while after the disconnection of the electrical supply.

  • Page 7: Table Of Contents

    Table of Contents Safety Instructions General Safety Instructions ............i Chapter 1 –...
  • Page 8 Chapter 3 – AC 80 Software Overview ..............3-1 AC 80 CPU System Program .
  • Page 9 S800 Digital Input Modules ..........4-19 S800 Digital Output Modules .
  • Page 10 AC 80 User’s Manual...

  • Page 11: Chapter 1 - Introduction

    Chapter 1 – Introduction Overview The Advant® Controller 80 (AC 80) is a high-performance programmable logic controller specially designed for drives. Here are a few basic functions of the AC 80: • Execution of fast drive control application programs • Communication with drives •...
  • Page 12 AC110 Series AC400 Series Controller Controller Advant Fieldbus 100 Tools Link Service Link (RS 232C) PC Tools (e.g. Drive Debu Fieldbus Link Fieldbus Adapter Panel/Printer Link (Modbus/RS-485) (e.g. PROFIBUS) Special I/O Link NMBC NMBC NAPI Special I/O Devices, NAPI DSU Supply Units Electrical ModuleBus S800 I/O Devices DriveBus...

  • Page 13: Terms, Abbreviations And Definitions

    A separate device which can be used for diagnostics and control, e.g. CDP 80, AOS. DDCS Distributed Drives Communication System; a communication protocol used in fibre optic links in ABB drives. Drive A single NAMC-based inverter, or several inverters each containing an NAMC board, connected to one line-up.

  • Page 14: Related Publications

    Firmware Manual for ACS 600 Standard Application Program (3AFY 61201441, English) Function Blocks for APC2 (3AFY 61281240, English) S800 I/O User’s Guide (3BSE 008 878, English) Use of PROFIBUS-DP Protocol in Advant Controller 80 (3BFE 64248260, English). AC 80 User’s Manual...

  • Page 15: Chapter 2 - Ac 80 Hardware And Connections

    Chapter 2 – AC 80 Hardware and Connections AC 80 Hardware The AC 80 is built in a ventilated plastic housing. It can be mounted onto a horizontal or vertical DIN 50022 rail. The module can be removed by pulling the locking spring (at the bottom of the unit) downwards e.g.

  • Page 16: Circuit Board Layout

    Chapter 2 – AC 80 Hardware and Connections Circuit Board Layout 1 – CPU board PM820-2 68360 2 – NCB board PM825-1 3 – Power supply PM820-1 4 – Terminal board TC820-1 Figure 2-2 The circuit boards of the AC 80. Block Diagram MAIN RS-232...

  • Page 17: Leds

    Chapter 2 – AC 80 Hardware and Connections LEDs The LEDs on the AC 80 can be divided into three groups, i.e. bus indicator LEDs, general purpose LEDs, and special purpose LEDs. (Further information on the LEDs is given in Chapter 5 – Diagnostics). Tx Rx Special Dbus...
  • Page 18 Chapter 2 – AC 80 Hardware and Connections General Purpose LEDs When the S7 LED is on, and the F LED is off, S0 to S6 indicate the AC 80 status as follows: AC 80 Status CPU in initial phase CPU in operational mode CPU has stopped after initialisation.

  • Page 19: The Init Button

    Chapter 2 – AC 80 Hardware and Connections Station Address The AC 80 is equipped with two address selection switches. They are Selection used for defining an exclusive station address for the AC 80 on the AF 100 bus. The address must be in the range of 1 to 79; setting the address outside this range renders the AC 80 unaccessible via AF 100.
  • Page 20 14.5 × 25 mm Tool* PC tools Fibre optic Protocol: DDCS 10 MBd optical (NCB CH3) (Drive Debug ) components DriveBus* ABB drives Fibre optic Protocol: DDCS, 10 MBd optical (NCB CH0) Branching units DDCSe components Special I/O* NBIO-21, NBIO-31,...

  • Page 21: Power Supply Connection

    Chapter 2 – AC 80 Hardware and Connections Power Supply The AC 80 is powered by a single or redundant 24 V d.c. (19.2 to 30 V) Connection supply. The table below gives the current consumption at three different voltages (without I/O modules). Current [mA] Voltage [V d.c.] Typical...

  • Page 22: Non-Redundant Power Supply Connection

    Chapter 2 – AC 80 Hardware and Connections Non-redundant Power Supply Connection Forwarded Power Electrical PM 820-1 ModuleBus L– DIN Rail +24 V AF100 – – L– L– +24 V Forwarded Power From +24 V Power Supply Figure 2-5 Non-redundant power supply connection. AC 80 User’s Manual...

  • Page 23: Redundant Power Supply Connection

    Chapter 2 – AC 80 Hardware and Connections Redundant Power Supply Connection Forwarded Power Electrical PM 820-1 ModuleBus X1B X1A L– DIN Rail Supervision POWER VOTER UNIT +24 V /A +24 V /B AF100 – – L– L– Power Supply B Monitor Power Supply A Monitor...

  • Page 24: Power-Up Procedure

    Chapter 2 – AC 80 Hardware and Connections Power-up Procedure 1. Measure that the voltages are correct on the power switch unit. 2. Switch on the circuit breakers on the power switch. 3. The AC 80 indicates the power-on status with the following LEDs: Function Colour Designation...

  • Page 25: Modulebus Connection

    Chapter 2 – AC 80 Hardware and Connections ModuleBus Connection ModuleBus is used for connecting I/O devices (or ABB drives) to the AC 80. It is divided into electrical and optical busses which are logically the same bus. Electrical ModuleBus The electrical ModuleBus link is made up of I/O devices installed side by side on the same mounting rail as the AC 80 itself.

  • Page 26: Electrical Modulebus

    Chapter 2 – AC 80 Hardware and Connections S800 I/O Devices (consisting of Module Termination Units [MTU] and I/O Modules) Extension Cable Connector TB807 Terminator Latch Electrical ModuleBus TB805 TB806 (max. length 2 m) AC 80 2 3 4 9 10 11 12 TB81x TK801V00x ModuleBus Optical Port...

  • Page 27: Drivebus Connection

    Chapter 2 – AC 80 Hardware and Connections DriveBus Connection The optical DriveBus link (Channel 0 on the NCB board) can be used for controlling 12 NAMC-based drives, inverter units or supply units. The connection of multiple drives requires the use of a branching unit (NDBU), which enables the construction of a logical bus with physical star topology.

  • Page 28: Panel/Printer Connection (Ch2)

    Chapter 2 – AC 80 Hardware and Connections Panel/Printer The panel/printer connector, labelled Ch2, is a Modbus-protocol Connection (Ch2) RS-485 interface for up to 8 devices. The panel/printer link can be operated in two modes (only one of which can be active at a time): Panelbus mode: for connection of Slave devices such as •...
  • Page 29 Chapter 2 – AC 80 Hardware and Connections N C P C - 3 0 C o n t r o l P a n e l C a b l e , A C 8 0 N M B C - 0 1 M O D B U S A C 8 0 T E R M I N A T I O N U N I T...
  • Page 30 Chapter 2 – AC 80 Hardware and Connections N C P C - 3 0 C o n t r o l N M B C - 0 1 P a n e l C a b l e , A C 8 0 M O D B U S A C 8 0 T E R M I N A T I O N U N I T...

  • Page 31: Af 100 Connection

    Chapter 2 – AC 80 Hardware and Connections AF 100 Connection The AC 80 is connected to the AC 400 series controller via an AF 100 bus. It is also possible to connect several AC 80 units together with an AF 100 bus (a bus administrator required).
  • Page 32 Chapter 2 – AC 80 Hardware and Connections First Station Last Station Terminal Header min. IBM Type 6A, Belden 1215 TC505/ TC506 min. 0.1 m BLUE S1 S2 GND S1 S2 GND TC501V150 TC501V150 BLUE max. cable length 750 m IBM Type 1, max.

  • Page 33: Special I/O Connection

    Chapter 2 – AC 80 Hardware and Connections Special I/O Connection This DDCS-protocol fibre optic link (Channel 1 on the NCB board) can be used for connecting up to eight I/O devices to the AC 80. The devices are addressed 1 to 8, and connected in a ring. The transmission speed of the Special I/O connection is 4 Mbit/s.
  • Page 34 Chapter 2 – AC 80 Hardware and Connections 2-20 AC 80 User’s Manual...

  • Page 35: Chapter 3 - Ac 80 Software

    Chapter 3 – AC 80 Software Overview The AC 80-related software can be divided into two parts: • AC 80 software – AC 80 CPU program – AC 80 NCB program • AC 80 software support on the PC. AC 80 CPU The CPU system program consists of the boot program, base software, and the application program.

  • Page 36: Ac 80 Ncb System Program

    Chapter 3 – AC 80 Software PARDAT handling on the AC 80 differs from that of the AC 70 or APC2. The actual PARDAT values are stored in a separate segment in non- volatile FLASH PROM. The application program is prepared by using the FCB (Function Chart Builder) tool.

  • Page 37: Ac 80 Software Support On Pc

    Chapter 3 – AC 80 Software AC 80 Software The AC 80 software support on the PC can be divided into CPU support and NCB support. Support on PC Follow the installation instructions included with each software package. AC 80 CPU Support CPU support requires an RS-232 serial cable between a COM port of the PC and the Service port of the AC 80.

  • Page 38: Ac 80 Ncb Support

    Chapter 3 – AC 80 Software Type circuits are made available to the application programs by copying them to the directory C:\TCLEV1. The user can also create type circuits using the Type Circuit Editor of the Application Builder. PC and DB element options are made available for application programming by selecting the respective option in the Application Builder.

  • Page 39: Chapter 4 - Programming The Ac 80

    Chapter 4 – Programming the AC 80 Overview This chapter gives information on writing the application program of the AC 80. It is assumed that the reader is familiar with the AdvaBuild for Windows software suite (especially the Function Chart Builder), as it is the principal tool for application programming.

  • Page 40: Af 100 Part Terminals

    Chapter 4 – Programming the AC 80 AF 100 Part Terminals CABLE AF 100 cable connection type. (S = Single cable; R = Redundant cabling) TIMESYNC Time synchronisation selector. One of the AF 100 stations should be set to MASTER, while all others should be set to SLAVE or NONE.

  • Page 41: Control Of Drives Through Optical Modulebus

    Chapter 4 – Programming the AC 80 Control of Drives ModuleBus has electrical and optical interfaces which are logically the same bus. A maximum of twelve I/O modules can be connected to the through Optical electrical ModuleBus. Further twelve I/O modules or drives can be ModuleBus connected to the optical ModuleBus link.

  • Page 42: Configuration Of Db Elements For Acs 600 Standard Drive

    Chapter 4 – Programming the AC 80 Configuration of DB Elements for ACS 600 Standard Drive DB Elements The ACS 600 Standard Drive requires two types of DB elements, DRIDS and DRISTD. The DRIDS DB element is used for the configuration of transmitted and received datasets.
  • Page 43 Chapter 4 – Programming the AC 80 The DRISTD element is used for addressing the drive, reading basic information from it, and connecting the DB elements of a drive (DRIDS and DRISTD) together. Figure 4-2 Settings of the DB element DRISTD. The DRISTD element has three different parts: Base, Parameter and Reference parts.
  • Page 44 Chapter 4 – Programming the AC 80 Essential Settings for Note that only the user-adjustable settings are represented here. ACS 600 Standard Drive DRIDS NAME Max. 20 characters, e.g. dataset_StdDrive DS_NO Dataset number (1 or 3) WR_ENA 1 (Must be forced by a connection from the PC section) DRISTD Base part: NAME...

  • Page 45: Configuration Of Db Elements For Acs 600 Multidrive

    Chapter 4 – Programming the AC 80 Configuration of DB Elements for ACS 600 MultiDrive DB Elements The ACS 600 MultiDrive requires two types of DB elements, DRIDS and DRIENG. The DRIDS DB element is used for the configuration of transmitted and received datasets.
  • Page 46 Chapter 4 – Programming the AC 80 DRIENG is used for addressing the drive, reading basic information from it, and connecting the DB elements (DRIDS and DRIENG) of the drive together. Figure 4-4 Settings of the DB element DRIENG. The DRIENG element has three different parts: Base, Parameter and Reference parts.
  • Page 47 Chapter 4 – Programming the AC 80 Essential Settings for Note that only the user-adjustable settings are represented here. ACS 600 MultiDrive DRIDS NAME Max. 20 characters, e.g. dataset_MultiDrive DS_NO Dataset number (10, 12, 14, ..., 32) WR_ENA 1 (Must be forced by a connection from the PC section) DRIENG Base part: NAME...

  • Page 48: Activation

    Chapter 4 – Programming the AC 80 Activation The DRIDS element is activated by setting the ACT and WR_ENA terminals to 1. (WR_ENA is set to 1 by a connection from the PC section.) The DRIENG and DRISTD elements do not need activation. Testing The DRISTD and DRIENG DB elements have two diagnostic terminals for checking the status of the link.

  • Page 49: Example: Acs 600 Multidrive On Optical Modulebus

    Chapter 4 – Programming the AC 80 Example: ACS 600 MultiDrive on Optical ModuleBus Figure 4-6 PC and DB sections of the application program. AC 80 User’s Manual 4-11...

  • Page 50: Control Of Drives Through Drivebus

    Control of Drives DriveBus has a fibre optic DDCS-protocol interface. A maximum of twelve drives (or other NAMC-based units) can be connected to through DriveBus DriveBus by using NDBU-85 or NDBU-95 branching units. DB Elements The DRB0L1 database element activates the drive node(s) and defines an area called the drive buffer for each.
  • Page 51 Figure 4-8 The ACSRX PC element. AC 80 User’s Manual 4-13...

  • Page 52: Essential Settings

    Essential Settings Each drive on the DriveBus link must have an individual address in the range of 1 to 12. The address – set with Parameter 70.01 – corresponds to the DRNR setting in the DB and PC elements below. For the DB and PC elements, the following settings are required: DRB00 DRTYPEx...

  • Page 53: Example: Acs 600 Multidrive On Drivebus

    Example: ACS 600 MultiDrive on DriveBus Figure 4-9 The DB elements library. Figure 4-10 The PC section. AC 80 User’s Manual 4-15...

  • Page 54: Configuring The Electrical Modulebus

    Configuring the As shown in Chapter 2, S800 I/O modules can be connected directly on the AC 80 Electrical ModuleBus, or in I/O clusters via Optical Electrical ModuleBus ModuleBus and TB820 ModuleBus modems. S800 I/O module configuration data is set up in DB elements. DB Elements for Each I/O module on the bus must have a dedicated DB element.
  • Page 55 Figure 4-12 Terminal value settings of a DI810 DB element. Figure 4-13 Terminal value settings of a subordinate element (DI810_1.11 depicted). Each subordinate element, i.e. input/output channel, can be given a descriptive instance name by the programmer. The input/output channel is active when the subordinate terminal ACT is set to 1 (default setting).
  • Page 56 In the figure below, five terminals have been named and connected to a MOVE element in the PC section. DB section PC section Figure 4-14 Connection of the subordinate elements of an S800 I/O module element to the PC section of the application program. 4-18 AC 80 User’s Manual...

  • Page 57: S800 Analogue Input Modules

    S800 Analogue Input The DB elements for controlling analogue inputs are shown in the table Modules below. AI Module DB Element Channels Type AI810 AI810 0 to 20 mA, 0 to 10 V AI820 AI820 ± 20 mA, ± 10 V, ± 5 V AI830RTD AI830 for PT100, Cu10, Ni100, Ni120...
  • Page 58 Essential Terminal Note that only the user-adjustable settings are represented. (The table Settings also includes the output terminals of the elements.) For more details, see the AC 80 PC Elements Reference Manual . Input Terminals for S800 I/O Database Elements (in Alphabetical Order) ACTive: 0=Spare, 1=Active Cold Junction Compensation (AI835) CONV_PAR...

  • Page 59: Control Of The Panel/Printer Link

    Control of the The elements to be used depend on the communication mode of the link. The mode is selected with the CH2TYP terminal in the Serial IF Panel/Printer Link part of the PM825 database element. See Chapter 2, section Panel/Printer Connection (Ch2), and this chapter, section The PM825 Element –...
  • Page 60 PC Elements Each device on the Panel/Printer link needs to be individually configured in the PC section of the application program. CDP 80 control panel communication is controlled by the PANC element. (The PANBUS element must have the following terminal values: SPEED: 19200;...
  • Page 61 Essential Settings Only the user-adjustable settings are represented. (The tables also include the information readable from the output terminals.) For more details, see the AC 80 PC Elements Reference Manual. PANBUS Base part: NAME Max. 20 characters 0 = Spare element 1 = Active element MASTER Communication:...
  • Page 62 MODR C1 (Call Parameter) Number of output pins (1 to 32). STATION Station number of device. REGADDR 0…9998 or 0…998 (See the AC 80 PC Elements Reference Manual). ACTIVE RESET MODW C1 (Call Parameter) Number of input pins (1 to 32). STATION Station number of device.

  • Page 63: Pc Elements

    Panel/Printer Link in The MultiVendor mode is selected by setting the CH2TYP terminal of MultiVendor Mode the PM825 DB element to MVC. Note: Use of the MultiVendor mode requires the installation of the optional Embedded Modbus elements. These elements can be installed along with AdvaBuild, or later on using the Application Builder.
  • Page 64 Each node is represented by a DB element of the type MVINODE. Figure 4-19 The terminals of the MVINODE element. The MVB (MVI Data Block) element specifies one MVI data block. It configures either data transmission or commands for the MVI protocol handler.

  • Page 65: Essential Settings

    Essential Settings Only the user-adjustable settings are represented. (The tables also include the information readable from the output terminals.) For more details, see the AC 80 PC Elements Reference Manual. MVICHAN Base part: NAME Max. 20 characters 0 = Spare element 1 = Active element Network number of MVI channel.

  • Page 66: Testing

    BLOCKED Cyclic data transmission: 0 = Not blocked 1 = Blocked MVI network number used for data block transmission. REMNODE Remote node number. In master mode: node number of slave. In slave mode: node number of master. CYCLETIM Defines the cycle time of the protocol command execution in multiples of 100 ms.
  • Page 67 Inside the PC section of the application program, it is possible to measure the value of a terminal by using the FCB tool. The diagnostic terminals of the DB element are connected to the PC section of the application program as shown below. Figure 4-21 Connecting the diagnostic terminals of the MVICHAN element to the PC section of the application program.

  • Page 68: Addressing

    Control of the The AF 100 link provides communication between multiple AC 80 stations. AF 100 is also used for connecting one or several AC 80 units AF 100 Link to an external system (such as the AC 110 controller), or for connecting the AC 80 to an APC2.

  • Page 69: Pc Elements

    PC Elements The AFTRA and MB90TRA elements are used for sending data cyclically over the AF 100. The data types are determined by the call parameters; the alternatives are I, IL and R. The transmitted data is updated to the AF 100 bus coupler memory each time the element is executed, and sent onto the bus as set with the SCAN terminal.

  • Page 70: Essential Settings

    Essential Settings Only the user-adjustable settings are represented. For more details, see the AC 80 PC Elements Reference Manual. PM825 AF 100 part: CABLE S (Single) or R (Redundant). EN_DTMO Enable Double Timeout: NO; YES TIMESYNC Time Synchronisation: NONE; MASTER; SLAVE BUSNO STNNO 1…79 (Must match AC 80 hardware address setting).

  • Page 71: Activation

    AFTRA/MB90TRA IDENT Dataset identification (1…50). SCAN Transmission interval in milliseconds (1…4096). AFREC/MB90REC IDENT Dataset identification (1…50). STATION Node number of the transmitter (1…79). Activation The AF 100 part of the PM825 database element does not need activation. The Base part of the DSP element is activated by setting the ACT terminal to 1.
  • Page 72 Example: AF 100 Communication between AC 80s PC Section of Node 1 PC Section of Node 2 = From Node 1 4-34 AC 80 User’s Manual...
  • Page 73 Control of the The Special I/O link is a DDCS-protocol fibre optic ring that can contain up to eight I/O devices. The sequence of the devices determines the Special I/O Link node numbers as shown below. AC 80 (NCB Board) NBIO-31 NPCT-01 NBIO-21...

  • Page 74: Db Elements

    DB Elements Each node (I/O device) on the Special I/O link is activated with the DB element NCBIO1. For each node, NCBIO1 defines a buffer containing the records that are used by the link to transmit and receive cyclic messages. The NCBIO1 element has to be defined in the application prior to any Special I/O link PC element.

  • Page 75: Essential Settings

    IORX(C1,C2,C3) NODE RESET CNTRL LINK ERRC Figure 4-34 The IORX PC element. Essential Settings IORX C1 (Call Parameter) Block number (1 to 8). C2 (Call Parameter) Number of datasets (1 to 2). (Note: 1 recommended for NDSC) C3 (Call Parameter) Data type (I or IL).

  • Page 76: Testing

    Figure 4-35 The DB and PC sections for communication with a Diode Supply Unit. Control of the The programming of the Fieldbus Adapter Link is detailed in the protocol-specific manuals, such as Use of PROFIBUS-DP Protocol in Fieldbus Adapter Link Advant Controller 80. 4-38 AC 80 User’s Manual...

  • Page 77: Chapter 5 - Diagnostics

    Chapter 5 – Diagnostics Overview There are various methods for finding out the reason for unexpected behaviour of the AC 80. These methods are: • Visual inspection (of the LEDs, for example) • Using the Function Chart Builder (FCB) tool and its diagnostic reports •...
  • Page 78 Chapter 5 – Diagnostics General Purpose LEDs When LED S7 is on, LEDs S0 to S6 display a status code (given in S0 to S7 Chapter 2). When the special purpose LED F is on and S7 is off, an error code is indicated by LEDs S0 to S6 as shown in the table below.
  • Page 79 Chapter 5 – Diagnostics Code Cause Remedy (Hex) User PROM error Restart the system in STOP MODE. Then reload the This indicates that the memory used for storing the application application program and try to save it again in PROM. program could be defective.

  • Page 80: Checking The System Status Using Fcb

    Chapter 5 – Diagnostics Checking the System Detailed AC 80 system status information is shown by FCB’s Option, System and Attribute reports. Essential revision identification data is Status Using FCB returned by the Option report (not the System report). The Attribute report is the only way of finding out which bus number was specified for the station as its application was created with AdvaBuild.

  • Page 81: Using Drivedebug

    Chapter 5 – Diagnostics There is also a possibility of registering ERRC occurrences in event loggers by connecting the ERRC output to the ERROR PC element, which adds a time stamp to the event and stores it in the event logger. From there, the time stamp and the ERRC value can be observed with Drive Window or the CDP 80 panel (first two digits of the error code are converted to descriptive text, the last two digits are shown numerically).
  • Page 82 Chapter 5 – Diagnostics AC 80 User’s Manual...
  • Page 84 ABB Industry Oy Drives P.O. Box 184 FIN-00381 Helsinki FINLAND Telephone: +358 10 222 000 Fax: +358 10 222 2681 Internet: http://www.abb.com/automation...

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