National Oilwell Varco RS

Technical College Course

AC Drive Fundamentals and Maintenance

Course (ABB)
VFD001E
Student Handbook

REFERENCE REFERENCE DESCRIPTION

This document contains proprietary and confidential information National Oilwell Varco
which belongs to National-Oilwell Varco, L.P., its affiliates or
subsidiaries (all collectively referred to hereinafter as "NOV"). It is Technical College and
loaned for limited purposes only and remains the property of NOV. Training Solutions
Reproduction, in whole or in part or use of this design or distribution 5200 N Sam Houston Pkwy W
of this information to others is not permitted without the express
written consent of NOV. This document is to be returned to NOV Suite 100
upon request and in any event upon completion of the use for Houston, TX 77086
which it was loaned. This document and the information contained Phone + 281.569.7800
and represented herein is the copyrighted property of NOV.
 National Oilwell Varco Fax + 281.569.7891
DOCUMENT NUMBER REV

2000004:8A/02 02

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REVISION HISTORY

02 Update to format and content

01 Initial document creation
Rev Date (dd.mm.yyyy) Reason for issue Prepared Checked Approved

CHANGE DESCRIPTION

Revision Change Description

01 First issue
02 Update to format and content

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NOV Training Solutions Disclaimer

This manual was developed by National Oilwell Varco as a training guide and while every effort was
made to insure its accuracy, this manual is only intended to be used as a training aid. Improvements
in equipment including, but not limited to, design, engineering, materials, production methods or
customer specifications may necessitate changes in the equipment that may result in inconsistencies
between the contents of this publication and the end product. National Oilwell Varco reserves the right
to make these changes without incurring any liabilities or obligations beyond those stipulated in a
signed purchase contract with its customer. The images, photographs, charts, diagrams, drawings,
verbal contents and specifications contained herein are not to be construed as giving rise to any
warranty, and are not to be regarded as approval or disapproval of any specific product or practice on
the part of National Oilwell Varco.

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TABLE OF CONTENTS

1 INTRODUCTION ........................................................................................................5
1.1 Electrical Safety ...............................................................................................7
1.2 Electrostatic Discharge (ESD) ..........................................................................8
1.3 AC Drive History............................................................................................. 10
1.4 Voltage Source Drive ..................................................................................... 17
1.5 AC Motor Theory ............................................................................................ 19
1.6 Inverter Overview ........................................................................................... 24
1.7 Torque Development Theory.......................................................................... 26
1.8 Direct Torque Control ..................................................................................... 27
2 AC DRIVE FUNDAMENTALS AND MAINTENANCE COURSE ABB.................... 38
2.1 R8i Inverter Module Overview ........................................................................ 38
2.2 Parallel Communications ............................................................................... 55
2.3 Firmware and Parameters .............................................................................. 63
3 AC DRIVE FUNDAMENTALS AND MAINTENANCE COURSE ABB..................... 67
3.1 Drive Windows ............................................................................................... 67
3.2 PID Controls Overview ................................................................................... 75
3.3 Drive Control Unit Overview ........................................................................... 78
3.4 Module Fault Indications ................................................................................ 90
4 AC DRIVE FUNDAMENTALS AND MAINTENANCE COURSE ABB..................... 92
4.1 Brake Chopper Overview ............................................................................... 92
4.2 Adaptive Programming Overview ................................................................... 95
4.3 Communications Overview............................................................................. 96
5 AC DRIVE FUNDAMENTALS AND MAINTENANCE COURSE ABB................... 107
5.1 Environmental Concerns .............................................................................. 107
5.2 Troubleshooting and Maintenance ............................................................... 110
5.3 Software ....................................................................................................... 115
5.4 System Drawings ......................................................................................... 116
5.5 Fan Replacement ......................................................................................... 120
5.6 Inverter Removal .......................................................................................... 123
5.7 IGBT Replacement....................................................................................... 126

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1 INTRODUCTION

Technical Support

Rig Solutions
24/7 Support

Technical Support Services

281.569.3050

houstonservicedept@nov.com

Course Objectives

After completing this course, the student will be able to:

Operate and utilize the ABB Interface Keypad

Describe the function of major components

Perform system diagnostics using Drive Windows and the Drive Simulator

Utilize software programs to backup, restore and troubleshoot system.

This will be done through the facilitation of lecture, video, simulators,

graphics/diagrams/flow charts, demonstration, question and answer, discussion, problem
solving, group work, identification, simulation, and homework; resulting in the student
possessing adequate ability to start-up and commission the ABB AC Drive.

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Safety

Personnel operating, installing, repairing, maintaining, or in the vicinity of rig equipment

should:
Wear appropriate Personal Protective Equipment (PPE)

Be trained in the areas of:

Rig safety
Tool operation
Maintenance

Be safety conscious at all times

Be aware of their surroundings

To help ensure safe work practices, safety tips regarding this piece of equipment will be
highlighted throughout this manual with the Safety 24/7 symbol.

Shop Safety

Stay with the group on shop tours and exercises.

Watch out for trip hazards.

This plant is a working manufacturing facility, so be watchful of heavy equipment

movement by overhead cranes and forklifts. Moving equipment has priority, so visitors
must clear from any path of movement.

PPE (safety hats, shoes, and eyewear) must be worn at all times while in the shop
facility.

Safety Information

This symbol indicates advisories for operational or servicing procedures

involving little or no risk of personnel injury or equipment damage.

This symbol indicates advisories involving a risk of equipment damage.

This symbol indicates advisories involving a definite risk of injury to rig

personnel.

This is specific to each piece of equipment. Refer to the O&M for correct
symbols and layout.

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1.1 Electrical Safety

Safety Issues

Never work alone

Use (1) Hand During Start-Up (As much as possible)

Remove all Loose-fitting Clothing, Jewelry, Metal Items

NO ESD straps are to be worn when power is applied

Approach Any Drive as if it were “Live” (Buss voltage discharge - check)

Output phase to ground voltage

phase to phase
phase to ground

Lock-Out procedures
Use the policies and procedures set forth by your company

Note: ALWAYS measure AC input power and DC buss voltage before working on
drives

Before Applying Power - Cautions

Ensure power source (690V), matches drive’s rating

If Drive uses EMF filters, ensure power source is a grounded source. If floating, remove
EMF capacitor ground. Contact ABB Tech Support for assistance if necessary.

Ensure drive’s internals are free from all foreign objects and debris.

Ensure Motor Leads Are Connected To Motor Terminals and Main Power Is Connected
To Input Terminals

Ensure the Motor Is Capable Of Rotating without interference.

Arc Flash Video

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1.2 Electrostatic Discharge (ESD)

Electrostatic Discharge Generation

Bringing Materials Together

Rubbing Materials Against Each Other
Rapid Separation Of Two Materials
Placing Materials Close To Each Other

Note: The size of the charge is dependent of the speed of separation, humidity and
materials used.

Means of Voltage Levels

Static Generation 10-20% Humidity 65-90% Humidity

Walking Across Carpet 35,000 1,500

Walking Across Vinyl Floor 12,000 250

Common Poly Bag Picked 20,000 1,200

Up From Bench

Common Sandwich Bag 20,000 1,200

Or Styrofoam Cup

Work Chair Padded With 18,000 1,500

Polyurethane Foam

Worker at Work Bench 6,000 100

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Electrostatic Discharge – Voltage Levels

Voltage level needed to feel & hear

3,000 VDC

Voltage level needed to damage printed circuit board

250 VDC

Voltage level needed to damage the gate lead of an IGBT

25 VDC

Types of ESD Failures

Catastrophic - The component fails completely

Latent - The component is stressed and functions some of the time and will stop
functioning in the future (after hours or when your on vacation)

ESD Prevention – Field Precautions

ESD Wrist Strap

• To be worn when ever installing or removing printed circuit boards from drive
with power disconnected.

• To be worn when ever handling components that have been shipped in black
conductive containers.

• Test your wrist strap regularly.

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1.3 AC Drive History

Definition

ABB = ASEA Brown Boveri

A = Avocado
N = Nectarine

Drive History

The basic function of a variable speed drive (VSD) is to control the flow of energy from the
mains to the process.

Initially, DC motors were used as VSD’s because they could easily achieve the required
speed and torque without the need for sophisticated electronics.

However, the evolution of AC variable speed drive technology has been driven partly by the
desire to emulate the excellent performance of the DC motor, such as fast torque response
and speed accuracy, while using rugged, inexpensive and maintenance free AC motors.

DC Motor Drives

In a DC motor, the magnetic field is created by the current through the field winding in the
stator. This field is always at right angles to the field created by the armature winding. This
condition, known as field orientation, is needed to generate maximum torque. The
commutator-brush assembly ensures this condition is maintained regardless of the rotor
position. Once field orientation is achieved, the DC motor’s torque is easily controlled by
varying the armature current and by keeping the magnetizing current constant.

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DC Motor Drives - Advantages

The advantage of DC drives is that speed and torque – the two main concerns of the
end-user - are controlled directly through armature current: that is the torque is the inner
control loop and the speed is the outer control loop.
Accurate and fast torque control
High dynamic speed response
Simple to control

Initially, DC drives were used for variable speed control because they could easily
achieve a good torque and speed response with high accuracy.

DC Motor Drives – Disadvantages

The main drawback of this technique is the reduced reliability of the DC motor; the fact
that brushes and commutators wear down and need regular servicing; that DC motors
can be costly to purchase; and that they require encoders for speed and position
feedback.

While a DC drive produces an easily controlled torque from zero to base speed and
beyond, the motor’s mechanics are more complex and require regular maintenance.

AC Drives – PWM Frequency Control

Unlike a DC drive, the AC drive frequency control technique uses parameters generated
outside of the motor as controlling variables, namely voltage and frequency.

Both voltage and frequency reference are fed into a modulator which simulates an AC sine
wave and feeds this to the motor’s stator windings. This technique is called Pulse Width
Modulation (PWM) and utilizes the fact that there is a diode rectifier towards the mains and
the intermediate DC voltage is kept constant. The inverter controls the motor in the form of
a PWM pulse train dictating both the voltage and frequency.

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Significantly, this method does not use a feedback device which takes speed or position
measurements from the motor’s shaft and feeds these back into the control loop.

Such an arrangement, without a feedback device, is called an “open-loop drive”.

PWM Frequency Control - Advantages

Because there is no feedback device, the controlling principle offers a low cost and
simple solution to controlling economical AC induction motors.

This type of drive is suitable for applications which do not require high levels of
accuracy or precision, such as pumps and fans.

PWM Frequency Control - Disadvantages

This technique, sometimes known as Scalar Control, the field orientation of the motor is
not used. Instead, frequency and voltage are the main control variables and are applied
to the stator windings. The status of the rotor is ignored, meaning that no speed or
position signal is fed back.

Therefore, torque cannot be controlled with any degree of accuracy. Furthermore, the
technique uses a modulator which basically slows down communication between the
incoming voltage and frequency signals and the need for the motor to respond to this
changing signal.

AC Drives – Flux Vector Control

To emulate the magnetic operating conditions of a DC motor, i.e. to perform the field
orientation process, the flux-vector drive needs to know the spatial angular position of
the rotor flux inside the AC induction motor.

With flux vector PWM drives, field orientation is achieved by electronic means rather
than the mechanical commutator/ brush assembly of the DC motor.

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Firstly, information about the rotor status is obtained by feeding back rotor speed and
angular position relative to the stator field by means of a pulse encoder. A drive that
uses speed encoders is referred to as a “closed-loop drive”.

Also the motor’s electrical characteristics are mathematically modeled with

microprocessors used to process the data. The electronic controller of a flux-vector
drive creates electrical quantities such as voltage, current and frequency, which are the
controlling variables, and feeds these through a modulator to the AC induction motor.
Torque, therefore, is controlled INDIRECTLY.

Flux Vector Control - Advantages

Flux vector control achieves full torque at zero speed, giving it a performance very close
to that of a DC drive.

Good torque response

Accurate speed control
Full torque at zero speed
Performance approaching DC drive

Flux Vector Control - Disadvantages

To achieve a high level of torque response and speed accuracy, a feedback device is
required. This can be costly and also adds complexity to the traditional simple AC
induction motor. Also, a modulator is used, which slows down communication between
the incoming voltage and frequency signals and the need for the motor to respond to
this changing signal. Although the motor is mechanically simple, the drive is electrically
complex.

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Cycloconverter – AC to AC Conversion

Pros
Power loss is minimal across the converter
Many types of switching devices

Cons
Severe electrical noise
Small operating output range – typically 50-100%
Only reduce the frequency never go above the base frequency

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SCR Inverter

+DC

Main Aux Main Aux Main Aux

Main Aux Main Aux Main Aux

- DC

Cɸ

Bɸ
Output Waveform Motor Windings
Aɸ

Pros
Created AC

Cons
Costly
Noise
Required Auxiliary SCRs to cutoff main SCRs

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Dual Converter

Rectifier Inverter

Stage Stage

DC Link

Dual Conversion Current Source

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1.4 Voltage Source Drive

Dual Stage Voltage Converter

Rectifier Inverter

DC Link

Stage Stage

Rectifier Stage

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DC Link

Inverter Stage

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1.5 AC Motor Theory

Horsepower

James Watt inventor of the steam engine needed a way to help sell his engines so he
calculated the work a horse could do in a minute and he did a lot of rounding.

( speed )(torque)
HP =
5252
Horsepower is defined as work done over time.

1 Horsepower = 32,572 ft·lbf /min.

Motor Theory

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Driving a Motor

The rotating magnetic field is of the stator is rotating at synchronous speed based on
the frequency and number of poles of the motor.

If the motor is too heavily loaded it can cause the rotor to slow. At this point the
difference of the speed in the magnetic field and the rotor is the slip frequency.

Note: Drive Frequency - Rotor Frequency = Slip Frequency

Synchronous Speed Formula

Speed = Frequency * 120 / Number of Poles

120 is a conversion factor – 60 * 2

“60” is to convert the Frequency Time in Seconds to the Minutes used in RPM
“2” is for the Poles – All poles come in sets of two

The Frequency of the AC power will affect the speed of the Rotor

Be aware that the formula is for Synchronous Speed

Half Wave Rectifier (Diode)

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Voltage Peak

Vpeak = Vrms 2
Full Wave Diode Rectifier

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Full Wave Diode Rectifier – H Configuration

Voltage Peak

Vdc = Vrms (2 ) 2
π
Three Phase AC Power

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Three Phase Full Wave Diode Rectifier

3 Phase Full Wave Rectifier

Vdc = Vrms (3) 2

π
Three Phase AC Power

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1.6 Inverter Overview

IGBT

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PWM Duty Cycle

PWM AC Output Waveform

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What the motor sees

1.7 Torque Development Theory

Lenz Law
(Video being shown in class)

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1.8 Direct Torque Control

AC Drives – Direct Torque Control

With DTC technology, field orientation is achieved without feedback using advanced
motor theory to calculate the motor torque directly and without using modulation.

The DTC controlling variables are

Motor Magnetizing Flux
Motor Torque.

With DTC there is no modulator and no requirement for a tachometer or position

encoder to feed back the speed or position of the motor shaft.

DTC uses the fastest digital signal processing hardware available and a more advanced
mathematical understanding of how a motor works.

The result is a drive with a torque response that is typically 10 times faster than any AC
or DC drive. The dynamic speed accuracy of DTC drives will be 8 times better than any
open loop AC drives and comparable to a DC drive that is using feedback.

DTC produces the first “universal” drive with the capability to perform like either an AC
or DC drive.

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Direct Torque Control

Complete Direct Torque Drive Control

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Basic Direct Torque Control Scheme

Keypad CDP312R

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Firmware Manual

Ref ABB Rev J Firmware Manual

Page 25 to 45 – Control Panel Review

User Controls

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Keypad – Actual Signals Display Mode

Keypad – Parameter Mode

Keypad - Function Mode

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Keypad – Drive Selection Mode

Keypad – Status Row

Keypad – Direction Selection

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Keypad – Speed Reference

Keypad – Actual Signal Entry

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Keypad – Actual Signals Display

Keypad – Reset Fault history

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Keypad – Reset Active Fault

Keypad – Fault History

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Keypad – Parameter Selection

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Keypad – Contrast Adjustment

Lab Exercise

Using the AC Drive Simulator Unit, perform the Control Panel Lab. This will familiarize
the student with operation of the AC Drive Control Panel.

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2 AC DRIVE FUNDAMENTALS AND MAINTENANCE COURSE ABB

2.1 R8i Inverter Module Overview

ABB AC Drive Inverter

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NOV Inverter Cubicle

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R8i Inverter Dimensions

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R8i Inverter Component Breakdown

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Circuit Diagram of Power Components (1/5)

Capacitor bank
and resistor
discharge

Capacitor Bank and Resistor Discharge

The capacitor bank is an energy storage which stabilizes the

intermediate circuit DC voltage

Discharging resistors are for discharging the capacitor energy

after power off

Circuit Diagram of Power Components (2/5)

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Busbars and CTs

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Circuit Diagram of Power Components (3/5)

Output
filter
inductor

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Circuit Diagram of Power Components (4/5)

Heat Sink,
IGBT+AGDR

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Circuit Diagram of Power Components (5/5)

Output

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Circuit Diagram of Power Components (R7i)

Output Filter (optional)

Charging Circuit (optional)

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Circuit Boards

Interface board and power supply boards

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System Block Diagram of 10 X R8i Drive

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R8i Inverter with Internal Fan Supply

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ABB Inverter Module

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Inside the Inverter

Gate Driver Board

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Firing Board Power Supply

Gate Firing Power Supply

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Interface Board

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2.2 Parallel Communications

Branching Unit

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APBU

APBU – Address Switches

APBU – Dip Switch Settings

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Inverter Fault Warnings

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Multi-Bridge Configuration

Redundancy

Built-in redundancy through parallel connected

modules

Each module is a complete three-phase inverter

Enables running with partial load if one module fails

Provides for higher drive availability and greater

process uptime

Unique in drives - not available in previous generation

ABB drives or in existing competitors’ drives

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Reduced Run Function with ACS800

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Controller Unit & APBU

RMIO Board
Fiber Optic with Auxiliary
Branching Unit I/O Boards

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Master Follower – Configuration

T = Transmitter
R = Receiver
NAMC = Application & Motor Control Board
Master Follower – Speed Follower

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Master Follower – Torque Follower

ABB Multidrive System

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2.3 Firmware and Parameters

Parameter Road Map

Firmware Manual
Ref ABB Rev J Firmware Manual

Actual Signals

Group 1 - Basic Signals for monitoring the Drive i.e. Speed, Frequency, Torque,
Current, Temperature

Group 2 - Speed and Torque reference monitoring signals

Group 3 - Data words for monitoring field bus communications (Each signal is a 16 bit
data word)

Group 4 - Signals for Adaptive Programming for faults

Group 9 - Signals for Adaptive Programming of Analog Signals

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Control Connection Parameters

Group 10 - The sources for external Start, Stop, and Direction Control

Group 11 - Panel reference type, external control location selection and external
reference and limits

Group 12 - Constant speed selection and value. An active constant overrides the drive
speed reference

Group 13 - Analog Inputs signal processing

Group 14 - Status information indicated through the relay outputs and the relay
operating delays

Group 15 - Selection of actual signals through analog outputs

Group 16 - Control Inputs Run enable

Drive Parameters

Group 20 - Drive operation limits.

Group 21 - Start and stop modes of the Motor

Group 22 - Acceleration and Deceleration Times

Group 23 - Speed control variables not visible in Scalar mode

Group 24 - Torque control variables only visible in DTC and Torque Control Macro

Group 25 - Speed bands within which the drive is not allowed to operate

Group 26 - Motor Control

Group 27 - Brake Chopper Control

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Protection Information

Group 30 - Fault functions Programmable protection

Group 31 - Automatic fault reset

Group 32 - Supervision limits a relay can be used to indicate when a value is

above/below the limit

Group 33 - Information program version and test date

Group 34 - Process Variable user variable and unit actual parameter 1.01

Group 35 - Motor temperature measurements

Application Parameters

Group 40 - PID control Macro

Group 42 - Brake Control controlling a mechanical brake

Group 50 - Encoder module visible only if set up in variable 98

Group 51 - Communications Module data visible only if set up in variable 98

Group 52 - Settings for standard mod bus

Group 60 - Master/Follower application

Group 70 - DDCS control settings for Channels 0, 1, & 3

Group 72 - User Load curve limit the amount of Torque with the load curve

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Adaptive Programming Parameter

Group 83 - Control of Adaptive program execution

Group 84 - Adaptive program selection

Group 85 - Adaptive program User Constants

Start up Data Parameters

Group 90 - Addresses were received field bus

Group 92 - Tells drive were to read transmitted data

Group 95 - Hardware configuration Fan speed control sine filter application

Group 96 - External Analog data output signal for analog extension module

Group 98 - Option module Activates selected option modules

Group 99 - Start up Data definition of motor set up data

Drive Programming

ID Run (first start, reduced, standard)

Auto Speed Tune

Customer’s Set Up – Verify that drive OL is “ON” if no dynamic braking

Option module programming (I/O, Comm., AP, etc.)

Upload to keypad & save to USER SAVE1 in par. 99.02

ID Run Lab Exercise

Perform the ID Run Lab Exercise

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3 AC DRIVE FUNDAMENTALS AND MAINTENANCE COURSE ABB

3.1 Drive Windows

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Drive Windows – Window Area

Drive Windows – Title Bar

Drive Windows – Menu Commands

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Drive Windows – Menu Commands

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Drive Windows – Tree Pane

Drive Windows – Tree Pane Drive Status

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Drive Windows – Monitor Menu Commands

Drive Window - Monitor

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Drive Windows - Datalogger

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Drive Windows – Datalogger Legend

Drive Windows – Trend Window

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Drive Windows – Trend Cursors

Drive Windows – Trend Zoom

Lab Exercise

Perform Drive Windows Lab Exercises.

Parameter Rescaling Lab
Drive Windows Lab

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3.2 PID Controls Overview

Proportional

Nominal Large P Small P

P

Proportional = Pgain * Error

(Ref/Fdbk)
Integral

Nominal I Small I Large I

Integral = Igain * ErrorAVG/Time * Time of

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Derivative

Derivative = Dgain * Errormeas. / TimeDuration of

Meas.

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Combined Terms

Desired Output Signal

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3.3 Drive Control Unit Overview

Drive with Control Panel

Simulator Drive Panel Shown

Drive Module – Modules Exposed

Simulator Drive Panel Shown

RDCU
RMIO Module
RPBU Module
RAIO Module
DDCS Module

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RDCU Layout

RDCU - Cover

RDCU Cover Shown

Many Styles for different applications.

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RMIO

RMIO-02 Circuit Card

Common Component
RDCU is made up of RMIO card and applicable cover

Control Wiring Connections

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RMIO Layout

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RPBA

RPBA ( Profibus Adapter)

Slot 1 of RDCU only
Securing screws also provide circuit and chassis
grounding
LED’s monitor health
Must be addressed

PROFIBUS is an open serial communication

standard that enables data exchange between all
kinds of automation components.

PROFIBUS-DP (Decentralized Periphery).

The RPBA-01 PROFIBUS DP Adapter module
supports the PROFIBUS DP protocol, including its
DP-V1 extension.

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RAIO

RAIO (Analog Input / Output)

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RAIO Programming

Note Node ID switch

RDCO / DDCS

The RDCO module is to be inserted into the position marked

“DDCS” on the drive. On installation, the signal and power
connection to the drive (RMIO board) is automatically made
through a 20-pin connector.

The module is held in place with plastic retaining clips and two
screws. The screws also provide the grounding of module,
and interconnect the GND signals of the module and the
RMIO board.

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DDCS

RTAC

Pulse Encoder Interface Adapter

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RTAC-01 Pulse Encoder Interface Module

RTAC - Terminal X1

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RTAC – Terminal X2

RTAC Programming

Node ID Selector
Grounding Terminal

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Parameter Set 50

Typical Encoder

TDS-11 Encoder Shown

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AC Drives for Drilling Applications

A Slots

B Slots

Z Slots

Encoder

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3.4 Module Fault Indications

RPBA Faults

RAIO Fault

There is one status LED (WD/INIT, yellow) on the

RAIO module. The LED is lit when the drive is
configuring the module at power-up.

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RTAC Faults

There are three diagnostic LED’s on the

RTAC-01module. The CHA (green) and
CHB (green) LED’s show the activity on
channels A and B. The WD/INIT (yellow)
LED shows the status of the module.

WD/INIT is lit when the drive is configuring

the module at power-up.

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4 AC DRIVE FUNDAMENTALS AND MAINTENANCE COURSE ABB

4.1 Brake Chopper Overview

If the power flow changes in a drilling operation due to the motor slowing or trying to
stop, the power fed by the process charges the DC capacitors and the DC bus voltage
starts to rise. If the motor is under a significant load such as drawworks applications,
this occurs at a much higher rate. The capacitance is a relatively low value in an AC
drive resulting in fast voltage rise, and the components of a frequency converter may
only withstand voltage up to a certain specified level.

The brake chopper limits DC bus voltage by leading the braking energy to a resistor.
The braking chopper is an electrical switch that connects DC bus voltage to a resistor
where the braking energy is converted to heat. The braking choppers are automatically
activated when the actual DC bus voltage exceeds a specified level depending on the
nominal voltage of the inverter.

Brake Chopper Resistors

Water Cooled
Air Cooled

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Brake Chopper Location in the AC Drive

Rectifier Inverter

Brake
Chopper
Cell

DC
Link

Stage Braking Stage

Resistor

Brake Chopper Function

Brake
Chopper
Cell

Braking
Resistor

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Types of Brake Choppers used by NOV

VACON

POWEREX ABB
Parameter Set 27 – Brake Chopper

Braking
Resistors

Braking Resistor
Thermistor Should Be
Measure Ohm Value, Wired To Input Contactor
(Required) Coil (hardware manual)
Refer To Hardware
Manual

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4.2 Adaptive Programming Overview

Parameter Set 83 – Adaptive Program Control

83.01 ADAPT PROG CM - Runs, Edits, or Stops the adaptive program
83.02 Edit Command - Makes changes to the Adaptive program block element
83.03 Edit Block - Defines the block location number to be edited
83.04 Time Level Set - Determines the cycle time of the Adaptive Program
83.05 Passcode - Defines the password to protect the adaptive program

Parameter Set 84 – Adaptive Program

84.01 Status - Nine bits to represent the status of the Adaptive Program
84.02 Faulted PAR - Indicates the parameter in the Adaptive Program
84.05 Block 1 - Sets the function of the Block
(ABS, ADD, AND, COMPARE, EVENT, MAX, MIN, MULDIV, NO, OR, PI, PI-
BAL, SR, SWITCH-B, SWITCH-I, TOFF, TON, TRIGG, and XOR)
84.06 Input 1 - First signal into the block
84.07 Input 2 - Second signal into the block
84.08 Input 3 - Third signal into the block
84.09 Output - Store the output in the first Block Parameter Set
84.79 Output - Store the output in the fifteenth Block Parameter Set

Parameter Set 85 – User Constants

85.01 Constant 1 - Sets the first constant of the adaptive program
85.02 Constant 2 - Sets the second constant of the adaptive program
85.03 Constant 3 - Sets the third constant of the adaptive program
85.04 Constant 4 - Sets the fourth constant of the adaptive program
85.05 Constant 5 - Sets the fifth constant of the adaptive program
85.06 Constant 6 - Sets the sixth constant of the adaptive program
85.07 Constant 7 - Sets the seventh constant of the adaptive program
85.08 Constant 8 - Sets the eighth constant of the adaptive program
85.09 Constant 9 - Sets the ninth constant of the adaptive program
85.10 Constant 10 - Sets the tenth constant of the adaptive program
85.11 String 1 - Stores a message to be used by the adaptive program
85.12 String 2 - Stores a message to be used by the adaptive program
85.13 String 3 - Stores a message to be used by the adaptive program
85.14 String 4 - Stores a message to be used by the adaptive program
85.15 String 5 - Stores a message to be used by the adaptive program

Lab Exercise

Perform the Adaptive Programming Lab Exercise

Reference ABB Application Guide for Adaptive Programming Information

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4.3 Communications Overview

Fieldbus
PLC protocol, typically Profibus DP in NOV systems.
Other PLC protocol can be used such as Device net, Control net, Modbus,
Canbus, etc…

ABB Drives
ABB standard protocol developed for their product lines.
Designed to talk to their Drive systems, PLC, HMI, etc…

Generic
Programmable for other Protocol that are not standardized
Will be setup by engineers, is not used by NOV.

Communications Board – Profibus DP

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Communications Board – Status LED’s

Error LED

On = Communications Error

Off = Normal

Offline LED

Off = The system is online with the Drive an is capable of
communicating with the PLC, the Profibus DB network is detected

On = The Board doesn’t detect the network

The Profibus Network cable is broken

The CPU Key switch of the PLC is in the Stop Position

The Terminations switch is not set properly

The Node Address is not set properly

Fieldbus Status LED

Off = No External Communications

On = Fieldbus module Active

Blinking Fast (Once per second) = Active with good communications

Blinking Slow (Once every five seconds) = No communications with
Profibus DP master (PLC CPU)

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RPBA – Profibus Termination

Termination Resistor Switch

RPBA = off
Use switch on Profibus connector
instead

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RPBA – Node Addressing

PPO Data - Field Structure

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Communications Board – PPO Structure

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Communications Board – PPO Structure

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Communications Board – Telegram Structure

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Communications Board – PKW Structure

Note:
Process data (PZD’s) cannot be stipulated via this
acyclical MSAC_C1 Channel

PPO Data - PLC Commands

Control Word Structure (Master to Slave)

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PPO Data – Inverter Information

Status Word Structure (Slave to Master)

Communications Board - References

Status Word Structure (Slave to Master)

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PPO Data - References

Reference Value One

Typically this is the Speed Reference
Range is from -10000 to +10000
-10000 is equal to 100.00% Reverse Speed
0 is equal to stop (0.00% Forward Direction
+10000 is equal to 100.00% Forward Direction

Actual Value One

Typically this is the Inverter Speed Feedback
Range is from -10000 to +10000
-10000 is equal to 100.00% Inverter Speed in Reverse
+10000 is equal to 100.00% Inverter Speed in Forward
The PLC will scale this accordingly for Display and control

PPO Data - Groups

Process Data – Master to Slave

PD1 – PD8 (Process Data words 1-8)
Control Information
Contains both Digital and Analog Values

Process Data – Slave to Master

PD1 – PD8 (Process Data words 1-8)
Status Information
Contains both Digital and Analog Values

Monitoring - Fieldbus Signals

All values displayed in hexadecimal format, DriveWindows 2.20 will allow number
format change.

Main Control words and Fault words are displayed

The auxiliary words (Fault, Status, and Limit) are determined by Parameter group 51
and the PLC Program.

All PLC data can be viewed in the Monitor and Data logger function of the
DriveWindows Program.

When viewing the values using the Keypad they will only be displayed in Hexadecimal
format.

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Profibus Monitoring

Parameter Group 3

All values displayed in hexadecimal format, Drive Windows 2.20 allows number
format change.

Main Control words and Fault words are displayed

The auxiliary words (Fault, Status, and Limit) are determined by Parameter group
51 and the PLC Program.

All PLC data can be viewed in the Monitor and Data logger function of the
DriveWindows Program.

When viewing the values using the Keypad they will only be displayed in
Hexadecimal format.

Lab Exercise

Perform Macro Sampler Lab Exercise

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5 AC DRIVE FUNDAMENTALS AND MAINTENANCE COURSE ABB

5.1 Environmental Concerns

Temperature
Altitude
Humidity
NEMA 1, 12
De-Ratings
Control Wiring

Temperature
In general, all drives are rated at 32 - 104 F (0-40 degree “C”)

Altitude
In general, all drives are rated up to 3300 ft. ASL

Humidity
In general, all drives are rated up to 95% relative humidity, non-condensing

NEMA Type 1 Rating - Enclosures constructed for indoor use to provide a degree of
protection to personnel against access to hazardous parts and to provide a degree of
protection of the equipment inside the enclosure against ingress of solid foreign objects
(falling dirt).

NEMA Type 12 Rating - Enclosures constructed (without knockouts) for indoor use to
provide a degree of protection to personnel against access to hazardous parts; to
provide a degree of protection of the equipment inside the enclosure against ingress of
solid foreign objects (falling dirt and circulating dust, lint, fibers, and flyings); and to
provide a degree of protection with respect to harmful effects on the equipment due to
the ingress of water (dripping and light splashing).

De-rating
All drives can be de-rated up to a maximum of 122 degrees “F” (50 degrees “C”)
All drives can be de-rated up to 13,123 ft.
Note: Reference Hardware Manual Pg. 70
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De-rating the Drive

The load capacity (current and power) decreases if the installation site altitude exceeds
3281 ft (1000 meters), or if the ambient temperature exceeds 104 °F (40 °C).

Altitude De-rating
At altitudes from 3281 to 13123 ft (1000 to 4000 m) (above sea level, the derating is 1%
for every 328 ft (100 m). For a more accurate derating, use the DriveSize PC tool.

Temperature De-rating
In the temperature range +104 °F (+40 °C) to +122 ° F (+50 °C ), the rated output
current is decreased1% for every additional 1.8 °F (1 °C ). The output current is
calculated by multiplying the current given in the rating table by the derating factor.

Control Wiring
Refer to the Hardware manual and connection diagrams for cabling
Note: Separate conduit for all control wiring (if indicated)
Use shielded Control cable

Braking Requirements

Cable distance between drive and resistors should be no more 10 meters

Safety control circuit, resistor temp sensors

Caution on surface temperature of resistor package

Turn off over voltage limit parameter in 20.05

Group 27 Brake Chopper must always be off

Note: Refer to braking manual for braking duty cycles, mounting and wiring
requirements

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Input Power Wiring

All drives require minimum 60C copper wire, size per NEC

All drives must have separate metallic conduit for input, control and output power wiring

Avoid parallel runs of power and control wiring. Input power wiring to cross control
wires at 90 degrees

When installing drives inside other enclosures, ensure 8” spacing between power and
control wires or use shielded power cable

When installing inside other enclosures, Ensure 20” spacing between motor and control
wires or use shielded motor cable.

Note: Refer to the Hardware manual for wire type and requirements

Output Power Wiring

Use minimum 60 C copper power wiring, size per NEC

Must use separate metallic conduit for input, control and output wiring

Output motor wiring can also be type MC continuous corrugated armor cable

For drive sizes 490 KVA and larger, MC continuous corrugated armor cable is highly
recommended

Be aware of long cable lengths and their effect on the motor’s insulation system

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5.2 Troubleshooting and Maintenance

Equipment Required and Readings

Megger
Multimeter
Clamp On Ammeter
Static Checks (Ohmmeter)

Static Measurements

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Megger Measurements

• Megger each motor lead to ground with leads

disconnected from drive. All (3) readings should
be in the high Megohm.

Note: Ensure motor leads are re-connected to motor output terminals !!!

Maintenance LED’s

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Faults and Warnings

When encountering drive warnings or faults during the start up, refer to the drive’s
Firmware Manual for evaluation

Drive’s fault memory

When running DTC, drive can not be run without a motor use Scalar mode

Before leaving the job site, ensure all warnings and faults have been deleted from
memory

Input Voltage Readings

With the drive running at full speed and full load,

measure AC input and motor output phases U-V,
V-W, W-U. All input readings should be within
approx. 2-3 % of each phase combination. Output
voltage should be within nominal motor name plate
level.

U
V
W

Note: Before applying power to drive, ensure voltage level is within drives
input voltage rating.
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Output Voltage Readings

With drive running at full speed and full load,

measure all (3) AC input and all (3) motor output
phases to ensure both drive and motor are
within their nameplate ratings. All phases
should be within approx. 5% of each other.

U
V
W

Maintenance Schedule

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Capacitor Maintenance

The drive intermediate circuit employs several electrolytic capacitors. Their lifespan is
from 45,000 to 90,000 hours depending on drive loading and ambient temperature.
Capacitor life can be prolonged by lowering the ambient temperature.

It is not possible to predict a capacitor failure. Capacitor failure is usually followed by a

mains fuse failure or a fault trip. Contact ABB if capacitor failure is suspected

Replacements are available from ABB. Do not use other than ABB-specified spare
parts.

Capacitor Reforming

Capacitor Reforming

Reform (re-age) spare part capacitors once a year according to ACS 600/800
Capacitor Reforming Guide (code: 64059629).

Note: Capacitor reforming data is provided on Student CD

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5.3 Software

Upload

Steps to Perform Upload

Set up drive as desired

Push keypad “Func” key
Use “Double Arrow” keys to select upload, download
Use “Single Arrow” keys to select “Upload” (blinking curser)
Push “Enter” button on keypad
Process complete

Download

Steps to Perform Application Download

Ensure keypad is in the “Local” mode

Ensure drive to be programmed is in same Macro (factory default)
Enter motor data into 99 group and option data in 98 group if required
Perform motor ID run
Push keypad “Func” key
Use “Double Arrow” keys to select “Download” (blinking cursor)
Push “Enter” button on keypad
Process complete

Download With Motor Data

Download With Motor Data

Place keypad on drive to be download to and put keypad into “Local” mode
In 99 group, select language and 98 group, select options if required
Press “PAR” key and using double arrow keys, go to 16 group, then use single
arrow keys, select parameter 16.03
Press “Enter” and using arrow keys, enter pass code (564), then press “Enter”
key
Press “Func” key, use double arrow keys to select upload/download, use single
arrow keys to select download
Press enter
After download is completed, turn power off for 10 seconds, then back on
Process complete

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5.4 System Drawings

Schematic Numbering System

Job Number / Series / Group

AC Drive Systems
####-201-0# = AC Drive Overview
####-203-0# = Incomer/Rectifier
####-210-0# = Inverter Bays
####-211-0# = Brake Choppers
####-212-0# = Bus Tie

SCR Drive Systems

####-010-0# = Mud Pump
####-012-0# = Drawworks
####-015-0# = RT/TD
####-021-0# = SCR
####-022-0# = Consoles

Generators/Miscellaneous
####-002-0# = System One Line
####-017-0# = Generator Control
####-015-0# = PLC Cubicle

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Schematic – Incomer / Rectifiers

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Schematic – Inverters

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Schematic – Choppers

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5.5 Fan Replacement

Cooling Fan Maintenance

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Schematic - Cooling Fan

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Fan Interface Board Location

Fan Power Supply Board Location

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5.6 Inverter Removal

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Inverter Removal

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Inverter Removal

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5.7 IGBT Replacement

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IGBT Replacement

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IGBT Replacement

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IGBT Replacement

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IGBT Replacement

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IGBT Replacement

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IGBT Replacement

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 Document Number 2000004:8A/02
Revision 02
Page 133

IGBT Replacement

Technical Support

NOV Technical Support

281-569-3050
houstonservicedept@nov.com

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