© ABB DC drivesSlide 1

DCS800Firmware Structure Diagram

Wiwiet Yuniarto

© ABB GroupMarch 17, 2014 | Slide 2

Drive controlCurrent and speed controller

Torque-reference

Current (actual)

Torque-selector

Armature currentcontroller

Speedreference

TG

M

X

EMF voltagecontroller

Mux

Voltage referenceRated motor voltage

AC - Line

Rampgenerator

SpeedController Flux

Field currentController

11.12

11.06

ACW B6

Pulse encoder 1

Analog tacho

EMF

M1BaseSpeedM1NomVolt

Ref1Sel0

=op

en

SpeedRefExt1

2.17

Spee

dRef

Used

2.18

23.15

ACW1 B4

M1EncMeasMode

M1EncPulseNo

M1TachAdjust

M1TachoVolt1000

SpeedActEnc

DirectSpeedRef

SpeedRef3 SpeedRef4

DroopRate 24.02

TorqAccCompRef

Accelerationcompensation

AccCompDerTime

AccCompFiltTime

24.1424.15

SpeedCorr23.04

2.02

TorqRef1

TorqMinAll

HoldSpeedCtrl

SpeedStep

ACW B8

D23.10

TorqRef2

BalSpeedCtrl

BalRef

PI

24.11

PID -controller

TorqDerRef

TorqPropRef

Limiter

TorqMaxSPC

TorqMinSPC

TorqIntegRef

2.08

2.20

KpSValMinSpeedTiSValMinSpeed

DerivTime

DerivFiltTime

TorqRef2 (2.09)

24.17

24.1024.09

24.0624.0524.0424.03 KpS

KpSMinKpSWeakp

KpSValMinSpeed (24.19)

KpSTiSMinSpeed (24.17)

KpSWeakpFiltTime

TiSTiSInitValue

KpSTiSMinSpeed

24.1324.1224.2024.1924.18

p-part, i-part

TiSValMinSpeed (24.20)

speed

KpSTiSMaxSpeed (24.18)

KpSTiSMaxSpeed

p-partKpS (24.03)

KpSMin (24.04)

KpSWeakp

KpSValMinSpeedTiSValMinSpeed

DerivTime

DerivFiltTime

TorqRef2 (2.09)

KpS

KpSMinKpSWeakp

KpSWeakpFiltTime

TiSTiSInitValue

KpSTiSMinSpeedKpS (24.03)TiS (24.09)

p-part, i-part

speed

KpSTiSMaxSpeed

p-part

KpSWeakp (24.05)

+

-

20.0220.01

SpeedRef2301AuxSpeedRefAI1…AI6FixedSpeed1FixedSpeed2MotPotAuxRef-AI1reservedMinAI2AI4MaxAI2AI4

Ref1Mux

OpenCloseDI1…DI8MCW Bit11…Bit15ACW Bit12…Bit15

2.30

Ref2Sel

0 = openSpeedRefExt2

SpeedRef2301AuxSpeedRefAI1…AI6FixedSpeed1FixedSpeed2MotPotAI2-AI3AI2+AI3AI2*AI3MinAI2AI4MaxAI2AI4

Ref2Mux

Invert1102OpenCloseDI1, …, DI8MCW Bit11…Bit15ACW Bit12…Bit 15

2.16

00 00

2.01

Hold

Ramp

RampTimeScale

Jog

Ramp

JogDecTime

JogAccTime22.12

22.13

23.02

23.03

2.32

FixedSpeed1

FixedSpeed2

SpeedRef2

E StopRamp

ShapeTime

VarSlopeRate

BalRampOut

RampBypass

BalRampRef

dv_dt

Acc/Dec/ShapeSpeed

RampOut

SpeedActEMF

SpeedActTach

internal scaling:SpeedScaleAct (2.29) == 20000

MotSpeed

1 second

Filter

MotSpeedFilt

WinderScale

ProcSpeed

SpeedErrFilt

WinIntegOnWinWidthPosWinWidthNeg

WinCtrlMode

Window control

2.03SpeedErrNeg

23.06

-1

-

23.12

23.0723.0823.09

Speed measurement

External

M1SpeedFbSel

+

20.0120.02

50.06

Filter

SpeedFiltTime

Acceleration

Deceleration

TorqMaxAll2.19

-

Torque selector = Add-

Speed reference selectionSpeed reference selection Speed ramp

Speed actual selection

Speed controllerSpeed controller

SPEED REFERENCE CHAIN SPEED CONTROL

DCS800_Fw_structure_diagram_rev_e.dsf

2.31

Local

ACWB2

UMCW B4

UMCW B6

UMCW B5

22.0322.04

22.05

22.07

22.08

22.0122.09

ACWB3

23.0123.1323.0223.03

23.0123.1323.0223.03

Limiter

M1SpeedMax

M1SpeedMin

Limiter

M1SpeedMinM1SpeedMax

+

2.07

2.05

2.04

2.0620.07

20.08

2.09

50.04

50.02

99.0299.04

50.12

50.13

1.031.02

1.05

50.03

1.04

50.17

1.01

1.41

Filter

AI1Direct+AI2Direct+

+

11.03

11.02

10.02Direction

-1

Jog2 (10.18)Jog1 (10.17)

ACW2 B10

UMCW B8, B9

24.13

2.19

24.13

Signal

Parameter

Parameter is usually written to by Adaptive Program,application program or overriding control

Attention:The firmware structure diagrams show thestandard firmware

Legend

Pulse encoder 2

Enc2MeasMode

Enc2PulseNo50.19

50.18

SpeedActEnc21.42

Enc2Direct+

Encoder2

³Panel

³DWDWL

³

EMF VoltActRel1.17

UMCW B4UMCW B6 ³

0

Min

MaxAccTime1

AccTime2

22.0222.10

DecTime1

DecTime2

22.11Ramp2Select

SpeedFbMonLev30.14EMF FbMonLev30.15SpeedFbFltSel30.17

ArmVoltAct1.14

F522 SpeedFb

M1OvrSpeed30.16

F532 MotOverSpeed

M1ZeroSpeedLim20.03M1ZeroSpeedDly42.04M1BrakeStopDly42.13

Drive logic

DynBrakeDly50.11

SpeedErrFilt223.11

MCW B10 7.04

20.19

20.13M1CurLimBrdg2

Min

TorqUsedMaxSel

TorqMax20.05AI1, …, AI6

TorqUsedMax

TorqUsedMin

Lim 6

6

TorqLimAct

TorqRefA2501AI1…AI6

TorqRefA Sel

+

+

0

0123 4 5

Torque selector

Min 3

Max 4

TorqRefExt2.24

TorqGenMax

TorqRampUp

TorqRampDown

Torque ramp

Limiter

TorqMaxTref

TorqMinTref

LoadComp

Torque limiter

TorqMaxAll

TorqMinAll

Gear backlashcompensation

TorqMaxAll

TorqMinAll

26.01TorqSel

25.01

TorqRef4

25.02

Filter

TorqRefA FTC

25.03

LoadShare

TorqRefB

Add 5

Speed 1

Torque 2 TorqRef3 GearStartTorq

GearTorqTime

GearTorqRamp

TorqUsedMinSel

TorqMin20.06AI1, …, AI6Negate 2.23 =

2.22 * (-1)

M1CurLimBrdg1

FluxRefFldWeak

Max

TorqRef2

TorqRef1

NotUsedDI1, …, DI11MCW Bit 11, …, MCW Bit15ACW Bit 12, …, ACW Bit 15

TorqMuxTorqSel2601 (0…6)Speed/Torq (1 or 2)Speed/Min (1 or 3)Speed/Max (1 or 4)Speed/Limit (1 or 6)

TorqMuxMode

+

+

TorqCorr

TorqRefUsed

NotUsedAI1, …, AI6

TorqCorrect

+

Torque reference and torque selection Torque limitation

TORQUE CONTROL CHAIN

25.04

25.05

25.06

20.09

20.10

2.19

2.20

2.09

2.082.10

26.02

20.05

20.12

3.24

2.11

26.08

26.09

26.10

2.22

20.22

2.19

2.20

2.26

2.14

2.13

20.06

2.23

Panel

OnOff1

CommandSel 10.01Hand/Auto

Off2

E Stop

StartStop

&

UsedMCW (UMCW)

Bit0 On (Off1N)

Bit1 Off2N (Coast Stop)

Bit2 Off3N (E -Stop)

Bit3 Run

Bit4 RampOutZero

Bit5 RampHold

Bit6 RampInZero

Bit7 Reset

Bit8 Inching1

Bit9 Inching2

Bit10 RemoteCmd

Bit11…Bit15 reserved

MainCtrlWord (MCW)

Bit0 On (Off1N)

Bit1 Off2N (Coast Stop)

Bit2 Off3N (E -Stop)

Bit3 Run

Bit4 RampOutZero

Bit5 RampHold

Bit6 RampInZero

Bit7 Reset

Bit8 Inching1

Bit9 Inching2

Bit10 RemoteCmd

Bit11…Bit15 aux. control

ABB Drive profile control

10.15

10.08

10.09

10.16

Local

Local

Local

Local

10.08

10.09

Off2

E Stop

10.07

AuxCtrlWord2 (ACW2)AuxCtrlWord (ACW1)

Bit0 RestartDataLogBit1 TrigDataLogBit2 RampBypassBit3 BalRampOutBit4 LimSpeedRef4Bit5 reservedBit6 HoldSpeedCtrlBit7 WindowCtrlBit8 BalSpeedCtrlBit9 SyncCommandBit10 SyncDisableBit11 ResetSyncRdyBit12 aux. controlBit13 aux. controlBit14 aux. controlBit15 aux. control

Bit0 reservedBit1 reservedBit2 reservedBit3 reservedBit4 DisableBridge1Bit5 DisableBridge2Bit6 reservedBit7 reservedBit8 DriveDirectionBit9 reservedBit10 DirectSpeedRefBit11 reservedBit12 ForceBrakeBit13 reservedBit14 reservedBit15 ResetPIDCtrl

Drive Logic

FaultsAlarmsMotSpeedOff1ModeStopModeE StopModeFlyStartFanDlyMainContCtrlModeFldHeatSel

CurCtrlStat1

Bit0 FansOn Cmd.Bit1 reservedBit2 reservedBit3 motor heatingBit4 field directionBit5 FieldOn Cmd.Bit6 dynamic brakingBit7 MainContactorOn CmdBit8 DynamicBrakingOn CmdBit9 drive generatingBit10 reservedBit11 firing pulsesBit12 continuous currentBit13 zero currentBit14 DC-breaker trip cmdBit15 DC-breaker trip cmd

MainStatWord (MSW)

Bit0 RdyOnBit1 RdyRunBit2 RdyRefBit3 TrippedBit4 Off2NStatusBit5 Off3NStatusBit6 OnInhibitedBit7 AlarmBit8 AtSetpointBit9 RemoteBit10 AboveLimitBit11 reservedBit12 reservedBit13 reservedBit14 reservedBit15 reserved

AuxStatWord (ASW)

Bit0 DataLogReadyBit1 OutOfWindowBit2 E-StopCoastBit3 User1Bit4 User2Bit5 SyncRdyBit6 Fex1ActBit7 Fex2AckBit8 BrakeCmdBit9 LimitingBit10 TorqCtrlBit11 ZeroSpeedBit12 EMFSpeedBit13 FaultOrAlarmBit14 DriveDirectionNegBit15 AutoReclosing

1.0421.0121.0321.0421.1021.1421.1621.18

97.01TypeCode=2-Q

0%

25.10

26.05 26.04

TorqRef22.09

20.18

26.15

-1

7.02 7.03 7.01

&

Reset 10.03 Local³ ³

6.03 8.01 8.02

Local

DCS800_Fw_structure_diagram_rev_e.dsf

³³DW

DWL

Panel³DW

DWL

21.0221.0321.0430.2730.2830.3042.1049.40

³

Off1ModeStopMode

E StopModeLocalLossCtrlComLossCtrl

FaultStopModeM1TorqProvTimeM2TorqProvTime

26.03&

TorqSelMod

1

1

1

0

0

1

70.0570.15

Ch0 ComLossCtrlCh2 ComLossCtrl

ParChange

M1FldHeatRef

FldHeatSel

M1FldRefMode

Fieldcurrentmeasurement

Mot1FldCurRel

Mot1FldCur

1.29

1.30

Motor 1 fieldcurrent controller

M1KpFex

M1TiFex

M1FldRefExt

FldCurRefM1

internal scaling:Ifnom

== 10000

M1PosLimCtrl

Field current control Motor 1 Fieldcurrent measure-ment and motordata

44.0445.06

10.1021.1845.05

44.02

44.03

3.30

45.02

M1NomFldCur

M1 field data

99.12

99.11

M1UsedFexType

Fieldreversal(group 45)

OptiTorque

Bridge

44.0944.1044.0744.08

is set to maximum flux ifFldCtrlMode (44.01) = Fix

43.17

43.18

43.19

43.20

43.21

43.221.04

M1ArmL

M1ArmR

SelBridge M1NomFldCur

M1UsedFexType

M1BaseSpeed

If M1SpeedFbSel (50.03) = External,then MotSpeed (1.04) can be written to.

OperModeSel = FieldConv

CurRefSlope

di/dt limitation

20.12 M1CurLimBrdg1

20.13 M1CurLimBrdg2

1.15

EMF -calculation

ArmAlpha

Firing unit

RevDly

M1NomVolt

M1NomCur

Mainsvoltagemeasurement

Convertercurrentmeasurement.

NomMainsVolt

MainsVoltActRel

MainsVoltAct

ConvCurActRel

ConvCurAct

1.111.12

1.151.16

M

Motor 1

FldCurFlux40

FldCurFlux70

FldCurFlux90

Flux linearization

EMF VoltActRel

1.17

EMF controller

KpEMF

TiEMF

Flux control

M1BaseSpeed

MotSpeed

internal scaling:M n == 10000M max = 3.25 * M n

FluxRefFldWeak

3.24

FluxRefSumCurCtrlStat1

FluxRefEMF

VoltCorr

VoltRefSlope

V refmodification

VoltRef2

FldWeakDyn

is set to zero ifFldCtrlMode (44.01) = Fix

EMF InternalVoltRefExtAI1, …, AI6

EMF RefSel

EMF CtrlPosLim

EMF CtrlNegLim

97.09

FilterFilter

MainsCompTime

MaxCurLimSpeed

MotSpeed

ArmCurLimSpeed1

ArmCurLimSpeed2

ArmCurLimSpeed3

ArmCurLimSpeed4

ArmCurLimSpeed5

MainsVoltActRel

Language

Motor data

EMF ActFiltTime

44.25

44.26

Armaturecurrentmeasurement

ConvCurActRel

FluxCorr

+

+

++

ArmVoltAct ArmVoltActRel

Current limitation Bridge

FIELD CURRENT CONTROL(one field exciter)

MainsVoltActRel-

RevVoltMargin

Min

M1NomVolt

B9=1

B 9=0

VoltRef1

Armature current control

EMF and flux control

ARMATURE CURRENT CONTROL

Armature currentmeasurement andmotor data

ConvNomVolt4.04

ConvNomCur4.05

1.11

43.13

43.1220.15

20.14

3.13

99.02

99.03

99.1199.12

99.04

99.10

99.01

1.14 1.13

43.09

43.10

97.25

44.21

1.11

99.0244.22

3.25

1.04

99.0444.15

3.263.27 3.28

44.1244.1344.14

44.27

43.04

43.01

Limiter

ArmAlphaMin

ArmAlphaMax

Uk

FiringLimMode

44.236.03 B9

CurRef311CurRefExtAI1…AI6FexCurRefFluxRefEMF

CurSel

FluxRefFldWeak

Scale

n

3.2443.03

3.11

43.02

3.303.27

12-pulse master

Local

43.01

DCS800_Fw_structure_diagram_rev_e.dsf

Panel³DW

DWL

³

6.0543.14

CurCtrlStat2

6.04

OperModeSel

PwrSupplyRefExt

CurRefUsedCurrent controller

ControlModeSel

M1KpArmCur

M1TiArmCur

M1DiscontCurLim

MotCur

-

internal scaling:Imot nom == 10000

Imax= 3.25 * I mot nom

3.12

1.06

43.01

43.05

43.0643.0743.0843.24

0

CurCtrlStat2

6.04

ArmAlpha

3.13

CurCtrlStat2

6.04

43.17

43.18

43.19

43.20

43.21

43.221.04

OperModeSel

M1ArmL

M1ArmR

SelBridge M1NomFldCur

M1UsedFexType

M1BaseSpeed

OperModeSel = FieldConv

PwrSupplyRefExt

CurRefSlope

di/dt limitation

20.12 M1CurLimBrdg1

20.13 M1CurLimBrdg2

CurRefUsedCurrent controller

ControlModeSel

M1KpArmCur

M1TiArmCur

M1DiscontCurLim

MotCur

1.15

EMF -calculation

Firing unit

RevDly

M1NomVolt

M1NomCur

Mainsvoltagemeasurement

Convertercurrentmeasurement.

NomMainsVolt

MainsVoltActRel

MainsVoltAct

ConvCurActRel

ConvCurAct

1.111.12

1.151.16

EMF VoltActRel

1.17

internal scaling:M n == 10000M max = 3.25 * M n

97.09

FilterFilter

MainsCompTime

MaxCurLimSpeed

MotSpeed

ArmCurLimSpeed1

ArmCurLimSpeed2

ArmCurLimSpeed3

ArmCurLimSpeed4

ArmCurLimSpeed5

MainsVoltActRel

Language

Motor data

EMF ActFiltTime

Armaturecurrentmeasurement

ConvCurActRel

- +

+Current limitation Bridge

internal scaling:Imot nom == 10000

Imax= 3.25 * I mot nom

Armature current control

ARMATURE CURRENT CONTROL

Armature currentmeasurement andmotor data

ConvNomVolt4.04

ConvNomCur4.05

3.12

1.06

43.01

43.05

43.0643.0743.0843.24

1.11

43.13

43.1220.15

20.14

99.02

99.03

99.1199.12

99.04

99.10

99.01

43.09

43.10

97.25

43.04

43.01

Limiter

ArmAlphaMin

ArmAlphaMax

Uk

FiringLimMode

CurRef311CurRefExtAI1…AI6FexCurRefFluxRefEMF

CurSel

FluxRefFldWeak

Scale

n

3.2443.03

3.11

43.02

3.303.27

12-pulse master

Local

43.01

Panel³DW

DWL

0

CurCtrlStat2

6.04

6.0543.14

44.0944.1044.0744.08

is set to maximum flux ifFldCtrlMode (44.01) = Fix

ParChange

M1FldHeatRef

FldHeatSel

If M1SpeedFbSel (50.03) = External,then MotSpeed (1.04) can be written to.

M1FldRefMode

Fieldcurrentmeasurement

Mot1FldCurRel

Mot1FldCur

1.29

1.30

Motor 1 fieldcurrent controller

M1KpFex

M1TiFex

FldCurFlux40

FldCurFlux70

FldCurFlux90

Flux linearizationEMF controller

KpEMFTiEMF

Flux control

M1BaseSpeed

MotSpeed

FluxRefFldWeak

3.24

FluxRefSumCurCtrlStat1

FluxRefEMF

VoltCorr

VoltRefSlope

V refmodification

VoltRef2

FldWeakDyn

is set to zero ifFldCtrlMode (44.01) = Fix

EMF InternalVoltRefExtAI1, …, AI6

EMF RefSel

EMF CtrlPosLim

EMF CtrlNegLim

44.25

44.26

M1FldRefExt

FluxCorr

FldCurRefM1

++

internal scaling:Ifnom

== 10000

M1PosLimCtrl

MainsVoltActRel-

RevVoltMargin

Min

M1NomVolt

B9=1

B 9=0

VoltRef1

EMF and flux control Field current control Motor 1 Fieldcurrent measure-ment and motordata

44.21

1.11

99.0244.22

3.25

1.04

99.0444.15

3.263.27 3.28

44.1244.1344.14

44.0445.06

10.1021.1845.05

44.02

44.03

3.30

45.02

44.27

M1NomFldCur

M1 field data

99.12

99.11

M1UsedFexType

44.236.03 B9

Fieldreversal(group 45)

OptiTorque

Bridge

FIELD CURRENT CONTROL(two field exciters)

ParChange

M2FldHeatRef

FldHeatSel

M2FldRefMode Motor 2 fieldcurrent controller

M2KpFex

M2TiFex

M2FldRefExt

FldCurRefM2

M2PosLimCtrl

49.0645.14

10.1021.1845.13

49.10

49.11

3.31

45.16

-

-145.17

FldCurTrim

-Fieldcurrentmeasurement

Mot2FldCurRel

Mot2FldCur

1.31

1.32

internal scaling:Ifnom

== 10000

M2NomFldCur

M2 field data

49.07

49.05

M2UsedFexType

Bridge

Motor 2 Fieldcurrent measure-ment and motordata

DCS800_Fw_structure_diagram_rev_e.dsf

³

³

ArmVoltAct ArmVoltActRel

1.14 1.13

M

Motor 1

M

Motor 2