ABB Drive Features Energy Saving Calculator

ABB Low Voltage has released a drive module with an in-built energy saving calculator, embedded Modbus and drive-to-drive link, a user interface with a series of assistant wizards and integrated safety functions. It also features modular hardware and software along with a removable memory unit, and uses the latest motor control platform, Direct Torque Control (DTC). Targeted specifically at OEMs, panel builders and system integrators, the ABB industrial drive modules are designed for industrial machinery and applications such as extruders, cranes, mixers, pumps and fans, in the power range 1.1kW to 400kW, with voltages from 380V to 480V.

An on-board energy saving calculator indicates the amount of energy consumed and the amount of energy saved in kW hours and money, as well as showing the duration curve showing the load profile of the drive. It also has an automatic energy optimiser that provides for optimum drive efficiency. The drive's internal fan features an automatic on/off control, which provides even further energy savings by switching the cooling fan off when the drive is not active.

The same on/off control can control the additional fan used to cool the cabinet, saving more energy and reducing control room noise. The intelligent user interface with advanced assistants means there is no need to refer to manuals. Macros, predefined parameter settings for specific applications, provide for faster start-up. The settings can be changed later, if required. The start-up assistant complements the start-up assistant by guiding the user through the needed parameters during the drive start-up process, allowing a more precise parameter tuning.

There are several other features such as short/long parameter menus, I/O mapping and list of latest parameter changes that make the use of the drive easier. The drive also includes an embedded Modbus serial link that can be also configured as a high-speed drive-to-drive link for master/follower functionality. Fieldbus is also supported. The maintenance and diagnostics assistants help keep the process up and running and, in cases of disturbance, minimise the downtime.

The maintenance assistant gives an advanced warning for maintenance needs of the drive, motor or related components. The diagnostics assistant helps in locating the cause of a disturbance such as overload or overcurrent and in restoring the process operation, and gives sensible rectification advice. Safety is provided by an integrated Safe Torque Off (STO) feature, which removes the torque from the motor shaft. This safety feature conforms with the requirements of SIL 3/IEC 61508, Cat 4/EN 954-1, EN ISO 13849-1:PLe.

There are also solutions available for Safe Stop 1 (SS1), Safe Limited Speed (SLS), Safe Brake Control (SBC), Safe Speed Monitor (SSM) and Safe Direction (SDI). The performance and functionality of the drive module is based on the latest motor control technology as provided by the Direct Torque Control (DTC), with enhanced features such as improved performance close to zero speed without encoder, low motor noise mode, higher output frequency and improved motor identification at stand still.

This provides excellent process control for asynchronous and permanent magnet motors, yielding higher productivity and a high overall efficiency. These compact drive modules, with protection class IP20, are optimised for installation into cabinets. The smallest module width is 90mm. The modules can be installed side-by-side, which saves space as more drives can be placed into the same cabinet, also allowing smaller cabinets, and in turn, smaller control rooms. Removable I/O terminals provide for easy cabling and help save time in installation. The power cable terminals are located optimally for cabinet assembly (power in at the top, motor connections at the bottom).

The modularity of the product and a wide range of options such as fieldbus adapters, I/O extensions and various encoder interfaces increases the level of drive customisation. The large number of standard I/Os is sufficient for most applications but the modular hardware and software design provides OEMs, panel builders and system integrators with the ability to tailor a drive for a specific end-user application by only choosing the options and features required. In addition to the standard parameter settings, the drive can be customised with an in-built logic functionality programming using IEC 61131-3 function blocks.

This is supported by the user-friendly PC tools that can be connected to the drive. A removable memory unit increases the flexibility of the drive. The unit stores the complete firmware, including all user settings and motor data. If the power unit or control unit is replaced, the drive can be re-commissioned without any drive knowledge, by simply plugging the memory unit into the new drive. Moreover, the memory unit allows the application software and parameter configuration changes to be made at an OEM's own assembly plant before being sent to the end-user site, just-in-time for commissioning the drive.

The drive contains an extensive set of standard features that are programmed via parameters. Internal pointers allow for customisation, to produce end customer specific solutions. If further programmability is needed, then IEC 61131 programming is also available when using the Drivestudio PC tool.