2 Contents Matti Turtiainen - ABB today ABB in Finland Technology leadershipABB DrivesJere Syvänne –Kenttäväylien kehitystyöJulle Ala-Lahti –RFID:n käyttö logistiikassaVAL - konsepti
3 ABB today ABB Group: Revenues 24 billion USD ABB is a global leader in power and automation technologies that enable utility and industry customers to improve their performance while lowering environmental impact.ABB Group:Revenues 24 billion USDin around 100 countriesR&D investments around 1.1 billion USDMarket leader in key businesses
5 ABB in Finland ABB Oy: revenues 1.7 billion EUR more than 6000 employees on over 40 locationsR&D investments 7 % of revenuesfactories in Helsinki and Vaasa
6 ABB Oy organization Automation Products Pekka Tiitinen Process AutomationLasse MäkelinPower SystemsJukka SoininenPower ProductsMikko NiinivaaraDistributionAutomationKalle HuittinenMedium VoltageApparatus andSwitchgearAnders ZittraTransformersJukka AuranenDrivesPekka TiitinenMachinesJuha SilvennoinenMotorsMikko HelinkoLow VoltageProductsHeikki UusitaloSystemsAntti HeikkiläProcess IndustryJuha MoisioMarine &TurbochargingLasse MäkelinSubstationsJukka SoininenPower GenerationMikael StrömbäckRoboticsTimo ToissaloProduct Support Pauli JärvinenService Ilkka TykkyläinenDomestic Product Sales Kalle MattilaLegal Affairs &ComplianceTapio MetsoCountry ManagerMikko NiinivaaraFinanceErkki LuhtaHuman ResourcesHarri MattilaCommunicationsCarita JernTechnologyKimmo Forsman
7 Automation Technology ProductsDrivesMotorsMachinesLow Voltage ProductsLow Voltage SystemsRobotsInstrumentsSystemsElectrification and Automation SystemsDrive SystemsPropulsion systems for shipsServicesService and maintenanceABB:llä on tuotantoa ja tuotekehitystä Suomessa automaatio- ja sähköteknologiankeskeisillä alueilla.Automaatioteknologian puolella maailmanlaajuinen tuotekehitysvastuu useista alueista on Suomessa, niiden joukosssa drives. Helsingin Pitäjänmäellä toimiva taajuusmuuttajatehdas onkin maailman suurin.Vastuu ABB:n metsäteollisuus- ja marine-liiketoiminnasta on myös Helsingissä.Improves energy efficiency and productivity
8 Improves reliability of power distribution Power TechnologyProductsTransformersDistribution AutomationSwitchgearMV-apparatusHV-apparatusCablesSystemsTransmission and distribution systemsPower generation systemsServicesService and maintenanceSähkövoimateknologiassa Suomen ABB:lla on maailmanlaajuinen tuotekehitysvastuu sähkönjakeluautomaatiosta.Vaasassa on sekä muuntaja- että keskijännitekoje- ja kojeistovalmistusta.Valmistus tähtää yhä enemmän erikoistuotteisiin ja räätälöintiin.Vaasassa toimivat myös energiayhtiöiden automaatioon ja järjestelmiin erikoistuneet yksiköt.AImproves reliability of power distribution
12 Permanent magnet technology applications Gearless drivesbased on new permanent magnet motor technology with a new patented rotor designfewer components; no gears and no encoderslower engineering, installation and maintenance costslower energy consumptionapplications delivered to paper mills, wind power and ships
13 MarineYear 2006 was a record year for the division: totally 19 Azipod®-units were ordered to 11 ships.Genesis – the largest cruise ship everOwner: Royal Caribbean InternationalBuilt by Aker Yards, FinlandDelivery: autumn 2009ABB scope of supply:3 x Azipod® Propulsion Units3 x ACS6000SD Frequency Converters6 x Main Generators11 kV Main Switchboards4 x Thruster MotorsDistribution and Propulsion TransformersSubstation Switchgears
14 Marine Admiralty – two Arctic shuttle tankers Customer: Sovcomflot Built at the Admiralty Shipyards in St. Petersburg, RussiaDelivery: year 2009ABB delivery:two 8.5 MW Azipod units (Russian ice class LU6)medium voltage generatorsmain switchboardstransformersfrequency convertersThe first Azipod system delivery to Russian Shipyards.In August, ABB Marine signed the contract to deliver a complete shaftline propulsion and power system for the first Superyacht to be built by Fincantieri in Italy. The 134 metre yacht will be completed in 2010 at the naval shipyard in Muggiano.
15 Wind Power GeneratorsNew, extended global frame agreements with the biggest wind turbine manufacturersABB is the world leader in Megawatt class wind power generatorsDemand of generators for wind power generation was very high in A new record of orders recieved and generators delivered was made. The order backlog is very highFirst multi-megawatt permanent magnet generator specificly designed for off-shore turbines was delivered
16 Power SystemsGas Engine Power Plants Continuous co-operation with Wärtsilä in control system deliveries.E.g. five gas engine power plant projects to Azerbaizan including 52 engines.Gas Turbine Power PlantsContract with Svenska Kraftnät for retrofit of Hallstavik and Lahall gas turbine power plants in Sweden, 6 x 60 MWHydro Power Plants Electrification and automation system to Kierikki Hydro Power Plant, ~ 2x20 MVAElectrification and automation system to Kaltimo Hydro Power Plant, ~ 2 x 20 MVAAstara, AzerbaizanKaltimo Hydro Power Plant
17 Introduction to ABB drives BU LV DrivesUpdated 10/2006
18 LV Drives worldwide About 2700 people in 50 countries ABB Inc., New Berlin, WI, USALV AC DrivesABB Oy , Helsinki, FinlandLV AC DrivesABB Beijing Drive Systems,Beijing, ChinaLV AC DrivesABB Automation, Ladenburg, GermanyDC DrivesABB Motors/Drives , Menden, GermanyCentral Stock EuropeABB Motors/Drives , SingaporeCentral Stock AsiaABB Ltd, Peenya, Bangalore, IndiaLV AC DrivesManufacturing and R&DEngineering & assemblyCentral stocks
19 Worldwide market shares The worldwide market for low voltage AC & DC drives was estimated to be worth $5.87 billion in 2005Source IMS Studies 2004, 2005, 2006
21 ABB drives save energyThe installed base of ABB drives saves 115 TWh per year, the equivalent of 14 nuclear reactorsThe installed base of ABB drives reduces CO2 emissions by 97 million ton per year, more than the yearly emission of Finland
28 Product specification HelpABB high performance machinery drivesACSM1Product specificationWelcome to ABB Machinery drives training. This training module will introduce you to the ASCM1, the new ABB machinery drive.If you need help navigating this module, please click the Help button in the top right corner. To view the presenter notes as text, please click the Notes button in the bottom right corner.
29 ACSM1, ABB high performance machinery drive For synchronous and induction motorsComplete range of feedback interfacesModular and compact designSolution programsMemory unit for easy drive managementSafety as standardThe new ABB machinery drive, ACSM1, will provide OEMs and system integrators competitive solutions to axis control tasks.The ACSM1 provides high performance speed and torque or motion control for demanding machinery applications.Almost any kind of motor type can be controlled in open or closed loop mode as a standard feature.The ACSM1 supports various feedback types and configurations.The compact hardware, including four frame sizes, is based on a modular design.Ready-made solution programs and different technology function libraries, with an easy and flexible programming environment, can meet complex requirements of machine control.The drive functionality can easily be defined, modified and updated with a standard memory unit. This also enables easy and fast after-sales service.The Safe Torque Off (STO) function is integrated as a standard feature.
30 Types & ratings (1/3) A B C D E 2,5…7,0A 5,3…14,7A Types and ratingsTypes & ratings (1/3)Frame sizeABCDECurrent & PowerNominal current Maximum current2,5…7,0A 5,3…14,7A9,5…16A 16,6…28A24…46A 42…80A60…90A 105…150A110…210A 165…326ATypical motor power0,75…3 kW4…7,5 kW11…22 kW*30…45 kW*55…110 kWBraking chopperBraking resistorMains chokeMains filter (EMC)StandardOption, external*With a mains chokeThe ACSM1 covers a power range from 0.75kW to 45kW with a supply voltage of 400 V. The nominal supply voltage can be between 380…480V. The ACSM1 product series includes four frame sizes: A, B, C and D.The braking chopper is standard in all types and can be used with an external braking resistor.The mains choke and filter are external options. Need for the mains filter depends on EMC requirements.
31 Types & ratings (2/3) Feature / Frame A B C D E Mounting and cooling Types and ratingsTypes & ratings (2/3)Feature / FrameABCDEMounting and coolingCold plate variant–■Air cooled variant- Back plate mounting●- DIN-rail mountingRemovable power connectorsRemovable control connectorsLegend:Standard■Product variant FrameHeight (mm)Width (mm)Depth (mm) *Weight (kg) *A364901463B3801002235C46716522510D22017E70031439864The ACSM1 has two main cooling variants:An air cooled version with normal heat sink and fan for the whole power range.A cold plate version without a heat sink for frames C and D, which can be used with an external cooling element (a water cooling element, own air cooling element, etc.).The main mounting methods with the air-cooled version are:Normal back plate mounting.DIN-rail mounting as standard for frames A and B.Frames A and B have removable power connectors.All frame types have removable control connectors.Dimensions and weights are for standard types without options.Height includes power connection terminals, but not clamping plates.Depth will increase by 25mm when options are installed. For motor feedback, cabling should be reserved additionally about 50mm in depth.* without options
32 Control connections 1 2 3 4 5 6 7 8 9 Control interface 1. Status display7-segment display Main status and fault messages2. Control voltage supplyInternal or external supply (24VDC) input for the control unit3. Digital I/O6xDI, 3xDI/O, 1xRO4. Analogue I/O2xAI, 2xAO5. Thermistor inputMotor thermistor (PTC, KTY)6. Drive to Drive link (D2D)Galvanic RS-485 link for communication between drives7. Safe Torque Off (STO)Designed for Safety Integrity Level 3 (SIL 3) acc. to IEC and Safety Category 4 acc. to EN 954-18. User interface (HMI)PC-tools and control panel connection (RJ45)9. Memory unit (MU)Complete drive configuration and settings are stored in the memory unit.123456Standard control connections are in the control unit (CU) of the ACSM1. This control unit is identical in all ACSM1 types.A seven-segment status display is located at the top right corner of the drive to show the main status, and warning and fault messages.The standard control I/O connections are on the right side of the control unit:In addition to internal supply it is also possible to connect an external power supply (24 VDC) to keep the control unit up and running regardless of the mains supply.The digital I/O includes six digital inputs, three digital I/O’s (which can be configured as input or output) and one relay output.The analogue I/O includes two analogue inputs with 12-bit resolution and two analogue outputs. The analogue inputs can be configured as voltage or current input. Also, +/- 10 V reference voltages are available.The thermistor input can be used for thermal protection of the motor with PTC or KTY types.The drive-to-drive link is a galvanic RS-485 link for communication between drives.Safe Torque Off (STO) is a safety function that corresponds to an uncontrolled stop in accordance with category 0 of IEC and can also be used to prevent an unexpected start-up.A human-machine interface (HMI) is located below the control connections and can be used as a connection to PC tools or a control panel.The memory unit, which stores the complete drive configuration and settings, is located below the user interface. The drive functionality can easily be defined, modified or updated with the memory unit, and it also enables easy and fast after-sales service.789
33 ACSM1 Safe Torque Off interface STO interfaceSafe Torque Off (STO)SIL 3 / IEC 61508,SILCL 3 / EN 62061Category 4 / EN 954-1PL e / ENSTOSafe Torque Off (X6)Both circuits must be closed forthe drive to start.OUT11OUT22IN13IN24
34 Control & communication options Three slots for control and communication optionsOptionsDataInstall inAnalogue & digital extensionSlot 1 or 2FIO-014xDI/O, 2xROFIO-113xAI, 1xAO, 2xDOFeedback interfaceFEN-012 inputs (TTL incremental encoder), 1 outputFEN-112 inputs (SinCos absolute, TTL incremental encoder), 1 outputFEN-212 inputs (Resolver, TTL incremental encoder), 1 outputCommunicationSlot 3FPBA-01PROFIBUSFCAN-01CANopenFDNA-01DeviceNetFENA-01Ethernet/IP, Modbus/TCP12The ACSM1 control unit has three slots for control and communication options.The analogue and digital I/O extension options can be installed in either slot 1 or slot 2.The digital I/O extension (FIO-01) has four digital I/O’s (which can be configured as input or output), and two relay outputs.The analogue I/O extension (FIO-11) has three analogue inputs, one analogue output and two digital outputs.The feedback interface options for different motor feedback types can be installed in either slot 1 or slot 2. Each of them has two inputs and one output. The other input is always used for TTL incremental encoders. Possible feedback types on the other input depend on the option type:a TTL incremental encoder with FEN-01;a SinCos incremental and absolute encoder, including Endat, Hiperface and SSI protocols with FEN-11;a Resolver with FEN-21.Additionally, all feedback interface options have two fast digital inputs with a 24 V user voltage.Options for communication with different masters are installed in slot 3:FPBA-01 for PROFIBUS communication;FCAN-01 for CANopen communication;FDNA-01 for DeviceNet communication;FENA-02 for Ethernet/IP communication, including Modbus/TCP.Different option combinations are possible, but similar types are not allowed simultaneously.3
35 External options Flexibility with different external options Mains chokeReduce harmonics and mains current RMSReduce mains disturbance and low-frequency interferenceIncrease the allowed DC bus continuous powerMains filter (EMC)Meet category C2 level with installation including motor (max. 50m cable).EMC standards in generalEN /A11 (2000), product standardEN (2004), product standardEN 55011, product family standard for industrial, scientific and medical (ISM) equipment1st environment, unrestricted distributionCategory C1Group 1, Class B1st environment, restricted distributionCategory C2Group 1, Class A2nd environment, unrestricted distributionCategory C3Group 2, Class A2nd environment, restricted distributionCategory C4Not applicableBraking resistorConvert generated kinetic energy into thermal energyAvailable for different kind of pulse duty performanceEquipped with a thermal sensor as standardThe following external options are available for the system engineering with the ACSM1: mains chokes, mains filters for EMC, and braking resistors.Mains chokes:The ACSM1 drive does not necessarily need mains chokes for operation. It should be checked case-by-case whether they are needed. Mains chokes are typically used to:reduce harmonics in the mains current,reduce the RMS mains current,reduce mains disturbance and low-frequency interference,increase the allowed DC bus continuous power.Mains filters for EMC:The measures required on the mains side for the drive systems in order to reduce the noise emission will vary depending on the area of application and system configuration. Noise emission limits for the drives are defined in product specific standard EN However, if this standard can not be applied, the machine or system should meet application specific or generic EMC standards. Mains filters are available to meet category C2 level with ACSM1 drive installation including a motor with a cable not longer than 50m. This level corresponds to the A limits of group 1 equipments according to ENBraking resistors:Depending on the application, an external braking resistor may be needed to convert generated kinetic energy into thermal energy. A selection of resistors are available for different kind of pulse duty performance. Moreover, all brake resistors are equipped with a thermal sensor.
36 PC Tools / Drive Studio, DriveSize Motor controlPC Tools / Drive Studio, DriveSizeMotion ControlTechnology functions, solution programsPosition sequenceCAMFlying cut…Position controlSpeed & Torque ControlTechnology functions, solution programsWinderLift…Speed controlTorque controlMEACSM1 motor control standard features are the following:Control modes are open and closed loop DTC, or scalar mode (U/f).As a standard feature, many kinds of motors can be controlled like asynchronous motors (including standard induction motors and asynchronous servo motors) and synchronous motors (including synchronous servo motors and high torque motors).Current and torque control is on a 100 μs cycle time level.Switching frequency is adjustable between 2 and 16kHz.Maximum output frequency is 500Hz in closed loop mode.Motor identification can be made in different modes like full, reduced and static mode.Auto phasing of the rotor is a standard feature.With the motor database feature, the right motor data (such as type, rated values, and identified values) can be set easily. The motor database is stored in the memory unit and can easily be updated with PC tools.Performance data with different ACSM1 and motor combinations is available on request.ACSM1 / Memory UnitACSM1 / Power Unit, Control Unit, Control and comm. optionsSynchronous Asynchronous
37 Speed and Torque control PC Tools / Drive Studio, DriveSizeMotion ControlTechnology functions, solution programsPosition sequenceCAMFlying cut…Position controlSpeed & Torque ControlTechnology functions, solution programsWinderLift…Speed controlTorque controlMEThe Speed and Torque Control variant is suitable for open and closed loop speed or torque control applications. With accurate motor control features, the speed control mode can meet the most demanding requirements.ACSM1 / Memory UnitACSM1 / Power Unit, Control Unit, Control and comm. optionsSynchronous Asynchronous
38 PC Tools / Drive Studio, DriveSize Motion controlPC Tools / Drive Studio, DriveSizeMotion ControlTechnology functions, solution programsPosition sequenceCAMFlying cut…Position controlSpeed & Torque ControlTechnology functions, solution programsWinderLift…Speed controlTorque controlMEThe Motion control variant includes all features of Speed and Torque control. In addition, the Motion control variant has the following main functionality and performance:Position control is on a 500 μs time level.Position reference can be updated via the feedback interface and fieldbus communication.Synchronization can be controlled at the same time level with position control.Register control is supported with fast touch probe inputs.ACSM1 / Memory UnitACSM1 / Power Unit, Control Unit, Control and comm. optionsSynchronous Asynchronous
39 Application solutions PC Tools / Drive Studio, DriveSizeMotion ControlTechnology functions, solution programsPosition sequenceCAMFlying cut…Position controlSpeed & Torque ControlTechnology functions, solution programsWinderLift…Speed controlTorque controlMEThe drive functionality can be easily modified or extended.A standard function block library is included in the Speed and Torque control, and Motion Control variants. This library provides reasonable additions and modifications to standard functionality.The technology function block library is an optional feature. With these optional libraries the drive functionality can be extended to meet specific machine or application requirements.Solution programs are ready-made application-specific programs based on certain technology functions. These programs can be also modified, if needed.The DriveStudio programming tool and environment is the same for all control variants and options.ACSM1 / Memory UnitACSM1 / Power Unit, Control Unit, Control and comm. optionsSynchronous Asynchronous
40 Sizing tool MCSize PC tool for sizing the motor and drive Motion profile and mechanicsDifferent kind of linear or rotary movement mechanismsIntegral part of DriveSize toolMCSize is a PC tool for helping the machine designer to select the optimum drive and motor combination with certain motion profile and mechanics. With predefined input sheets it is very easy to specify the dimensions of different kinds of linear or rotary movement mechanisms, such as:lead screw,rack and pinion combination,belt and pulley,conveyor,feed roll, androtating table.MCSize is an integral part of the well-known DriveSize tool, whose standard features are also available for ACSM1 sizing.
41 Other ABB products extending the portfolio Induction motorsServo motorsACSM1ACS350ACS150ACS55
42 *) Only For Internal Use ACSM1 Trainings (eLearning Modules)Step 1Step 2Step 3Introduction*)Motion control basicsProduct specificationControl&Performance: -Part A Speed&Torque*) -Part B MotionServomotor theoryServomotors product specification *)Feedback DevicesFieldbus communication *)Tools overview *)DriveStudio *)Solution Program Composer *)Motion SizingMCSizeDriveCAM (tbd)User Panel (tbd)Commissioning (tbd)Hands-On-Cases (tbd)System Engineering Guide HW (tbd)Control Engineering *)Sales Network Support (tbd)Customer Support *)Competitor analysis *)Expert Package (tbd)7. AC500 Introduction8. AC500 Configurations9. AC500 ….*) Only For Internal Use
43 ABB Machinery Drives Portfolio is Ready It is time to work for growth in themachinery business!
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