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Introduction

The aim of this application note is to outline how to configure an ACSM1 drive to run with an ABB BSM series AC servo motor.

ACSM1 drives can control induction, synchronous and asynchronous servo and high torque motors with various feedback devices.

The compact hardware, different variants and programming flexibility ensure the optimum system solution.

The innovative memory unit concept enables flexible drive configuration.

The ACSM1 is available in different sizes from 0.75 to 355 kW / (1 to 450 HP) and is designed

for three-phase operation with a 230 to 480 V AC supply.

All units have an IP20 enclosure for cabinet installation (UL open) and are suitable

for single drive and multi-drive (common dc) configurations with integrated Safe Torque-Off (STO) as standard.

The ACSM1 also has different option cards that can be added at the point of order or can be added at a later date,

these include F series fieldbus option modules and FEN series motor feedback modules.

The ABB BSM series of AC servo motors provides a wide range of inertias and torques

and are designed for excellent performance response.

This series has a rugged, durable, industrial design.

Many of the BSM motors are capable of peak torques equal to four times their continuous rating,

which can be used to provide high acceleration torques in applications.

BSM motors are available with a wide variety of feedback devices to suit application needs.

IEC and NEMA configurations are available as well as stainless steel variants.

The ABB ACSM1 AC servo drive can provide basic speed or torque control modes as well as versatile

motion control features.

It also supports a wide variety of servo motors due to the flexible nature of the modular feedback

interface modules.

Introduction

The aim of this application note is to outline how to configure an ACSM1 drive to run with an ABB BSM

series AC servo motor.

ACSM1 drives can control induction, synchronous and asynchronous servo and high torque motors with

various feedback devices.

The compact hardware, different variants and programming flexibility ensure the optimum system

solution.

This series has a rugged, durable, industrial design.

Many of the BSM motors are capable of peak torques equal to four times their continuous rating,

which can be used to provide high acceleration torques in applications.

BSM motors are available with a wide variety of feedback devices to suit application needs.

IEC and NEMA configurations are available as well as stainless steel variants.

How to reset faults

The drive can be used in different configurations so, to answer this question we must first consider which

configuration we are using;

• In Analog Mode the user can set RESETINPUT(0) = [input] or in parameters group: “Error Handling >

Reset Input” to a Digital input.

• In Direct mode if the drive is running a mint program and it goes into an error state, it will automatically try

to call the ONERROR event.

• If configured as a DS402 RTE Slave, the drive is using the DS402 state machine so disabling and re

enabling the drive will reset any active error, though ts best to issue a reset first.

Error categories

Controllers use an error handling system that allocates a unique number for each error. This means that an

error code does not need to be deciphered to determine exactly which individual error has occurred.

Errors are recorded in two ways:

• Error List: This is designed to be manipulated by the Mint program. The controller’s error list can store up to

256 entries on MicroFlex e190 and MotiFlex e180.

• Error Log: This is a historical record of errors and is displayed in Mint WorkBench using the Error Log tool.

On MicroFlex e190 and MotiFlex e180. 5 KB of memory is reserved for the error log, where each error is

dynamically sized. This allows approximately 100 or more errors to be stored.

Entries in the error list can be viewed by type or sequentially, for which there are additional keywords (shown in

brackets in the following lists). Errors are arranged in several categories, with each error having a unique code.

Error categories

Controllers use an error handling system that allocates a unique number for each error. This means that

an error code does not need to be deciphered to determine exactly which individual error has occurred.

Errors are recorded in two ways:

• Error List: This is designed to be manipulated by the Mint program. The controller’s error list can store

up to 256 entries on MicroFlex e190 and MotiFlex e180.

• Error Log: This is a historical record of errors and is displayed in Mint WorkBench using the Error Log

tool.

On MicroFlex e190 and MotiFlex e180. 5 KB of memory is reserved for the error log, where each error is

dynamically sized. This allows approximately 100 or more errors to be stored.

Entries in the error list can be viewed by type or sequentially, for which there are additional keywords

(shown in brackets in the following lists). Errors are arranged in several categories, with each error having

a unique code.

Problem diagnosis

There are 3 ways to get information on the faults that have occurred;

• In Mint WorkBench, connect to the drive and use the Error Log tool to view recent errors, get the

descriptions and then check the help files for more information.

• The drive status display indicates errors and general status information. When an error occurs, the drive

displays a sequence starting with the symbol “E” or “b”, followed by the five-digit error code.

• The drive also has two Network status LEDs that indicate the status of a used RTE master. You can check

the drives hardware manual for more information on how to diagnose the LED status.

What this Document contains

If you have followed all the instructions in this manual in sequence, you should have few problems installing the

ABB Servo Drives. If you do have a problem, this document will help you to navigate then diagnose and resolve

the problem. The following pages contain information on how to understand and resolve issues that can occur.

Before we get to this it’s important to first discuss the fault diagnosis system used in ABB Motion products.

Problem diagnosis

There are 3 ways to get information on the faults that have occurred;

• In Mint WorkBench, connect to the drive and use the Error Log tool to view recent errors, get the descriptions

and then check the help files for more information.

• The drive status display indicates errors and general status information. When an error occurs, the drive

displays a sequence starting with the symbol “E” or “b”, followed by the five-digit error code.

• The drive also has two Network status LEDs that indicate the status of a used RTE master. You can check

the drives hardware manual for more information on how to diagnose the LED status.

In scalar control, some standard features are not available.

IR compensation for a scalar controlled drive IR stands for voltage.

I (current) × R (resistance) = U (voltage).

IR compensation is active only when the motor control mode is scalar.

When IR compensation is activated, the drive gives an extra voltage

boost to the motor at low speeds. IR compensation is useful in applications that

require a high break-away torque. In direct torque control (DTC) mode, IR

compensation is automatic and manual adjustment is not needed.

Sensors like absolute encoders and resolvers indicate the rotor position at all times

after the offset between the zero angle of rotor and that of the sensor has been

established. On the other hand, a standard pulse encoder determines the rotor

position when it rotates but the initial position is not known. However, a pulse

encoder can be used as an absolute encoder if it is equipped with Hall sensors,

albeit with coarse initial position accuracy. The Hall sensors generate so-called

commutation pulses that change their state six times during one revolution, so it is

only known within which 60° sector of a complete revolution the initial position is.

The drive monitors the motor status continuously, also during flux braking.

The other benefits of flux braking are:

• The braking starts immediately after a stop command is given. The function does

not need to wait for the flux reduction before it can start the braking.

• The cooling of the induction motor is efficient. The stator current of the motor

increases during flux braking, not the rotor current. The stator cools much more

efficiently than the rotor.

• Flux braking can be used with induction motors and permanent magnet

synchronous motors.

Two braking power levels are available:

• Moderate braking provides faster deceleration compared to a situation where flux

braking is disabled. The flux level of the motor is limited to prevent excessive

heating of the motor.

• Full braking exploits almost all available current to convert the mechanical braking

energy to motor thermal energy. Braking time is shorter compared to moderate

braking. In cyclic use, motor heating may be significant.

Autophasing

Autophasing is an automatic measurement routine to determine the angular position

of the magnetic flux of a permanent magnet synchronous motor or the magnetic axis

of a synchronous reluctance motor. The motor control requires the absolute position

of the rotor flux to control the motor torque accurately.

Sensors like absolute encoders and resolvers indicate the rotor position at all times

after the offset between the zero angle of rotor and that of the sensor has been

established. On the other hand, a standard pulse encoder determines the rotor

position when it rotates but the initial position is not known. However, a pulse

encoder can be used as an absolute encoder if it is equipped with Hall sensors,

albeit with coarse initial position accuracy. The Hall sensors generate so-called

commutation pulses that change their state six times during one revolution, so it is

only known within which 60° sector of a complete revolution the initial position is.

The drive monitors the motor status continuously, also during flux braking.

Therefore, flux braking can be used both for stopping the motor and for changing the

speed. 

Motor control features

Scalar motor control

It is possible to select scalar control as the motor control method instead of Direct

Torque Control (DTC). In scalar control mode, the drive is controlled with a frequency

reference. However, the performance of DTC is not achieved in scalar control.

It is recommended to activate the scalar motor control mode in the following situations:

• In multimotor drives: 1) if the load is not equally shared between the motors, 2) if

the motors are of different sizes, or 3) if the motors are going to be changed after

motor identification (motor ID run)

• If the nominal current of the motor is less than 1/6 of the nominal output current of the drive

• If the drive is used without a motor connected (for example, for test purposes)

• If the drive runs a medium-voltage motor through a step-up transformer.

Operation modes

The DriveSPC tool offers the following operation modes:

Off-line

When the off-line mode is used without a drive connection, the user can

• open a application program file (if exists).

• modify and save the application program.

• print the program pages.

When the off-line mode is used with a drive(s) connection, the user can

• connect the selected drive to DriveSPC.

• upload an application program from the connected drive (an empty template

which includes only the firmware blocks is available by default.)

• download the configured application program to the drive and start the program

execution. The downloaded program contains the function block program and the

parameter values set in DriveSPC.

• remove the program from the connected drive.

On-line

In the on-line mode, the user can

• modify firmware parameters (changes are stored directly to the drive memory)

• modify application program parameters (ie, parameters created in DriveSPC)

• monitor the actual values of all function blocks in real time.