Technical presentation

Crane control program

+N697

Dedicated for cranes

© ABB Group - 1 -
5-Jun-07
 Product offering for CRANES

„ Industrial drive ACS800 product family

Full power size portfolio
Braking choppers or regenerative drives

„ Premium crane performance

Improve operational safety and performance

„ Flexible crane control program +N697

Designed for hoist, trolley, long travel and slew motions
© ABB Group - 2 -

in industrial , harbour and tower cranes

5-Jun-07

Ready made solution dedicated for cranes ,easy to use

© ABB Group - 3 -
5-Jun-07

Industrial cranes
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5-Jun-07

Harbour cranes
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Tower cranes
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Crane motions
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Crane motions and drives

 Marketing material for CRANE business
„ Product note
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5-Jun-07
 Marketing material for CRANE business
„ Roll up screen available for presentations
© ABB Group - 9 -
5-Jun-07
 Marketing material for CRANE business
„ Demo unit available for technical presentations
© ABB Group - 10 -
5-Jun-07
 Support documents for crane control program
© ABB Group - 11 -
5-Jun-07
 Support documents for crane control program
Supplement Supplement Supplement
Crane control Crane control Crane control
Crane optimize Dimensioning Electrical drawings

(m0 + mL ) ⋅ g ⋅ v
Thss =
ω ⋅ ηmech

(m0 + mL ) ⋅ g ⋅ v ⋅ ηmech
Tlss =
ω
© ABB Group - 12 -
5-Jun-07
 Training for crane control program
„ ABB University Helsinki –Training center 2days course
„ For ABB and end customers
© ABB Group - 13 -
5-Jun-07
 Product offering = Flexible control platform

„ Flexibility with help of open software hierarcy ,easy to add or modify.

„ I/O control or Fieldbus control

„ Integrated mechanical brake control logic

„ Master-Follower + Synchro control

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„ Safety features and protections

5-Jun-07
 Crane control program features
„ Flexible control platform
„ Control places and user macros
„ Crane ramp time logic
„ Adaptive programming AP
„ Mechanical brake control and torque memory
„ Protection of zero speed without encoder
„ Crane system check
„ Master / Follower and shaft synchro control
„ Crane optimize
„ Safety control
„ Speed monitor
„ Speed matching
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„ Service counters
„ Field-bus system overview
5-Jun-07

„ Actual position measurement logic

 Start up procedure
„ Control panel in (L) Local mode control
„ Power ON acknowledge signal to DI_IL (ready for start)
„ Check of brake control logic status for mechanical brake on site.
-Brake lift from ACS800 relay output R01 (default )
-Brake acknowledge to ACS800 digital input DI3 (default)
„ Enter in motor nominal data in group99
„ Notice that group 99 is locked after ready made id run and power
off.Via pass code 584 it’s possible to open par99 again.
„ Notice ! Standard id_run selection open the brake
before start command is given !
(with open brake) Motor running
„ Notice ! Magnetising id_run selection don’t open the brake , even if
start command is given
(with closed brake) Motor standstill
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„ After motor model ready , other application parameters…

5-Jun-07
 Flexible control platform

„ Flexibility with help of open software parameters for

configuration of start-stop and reference logic.
„ Support for different joysticks(V,mA) and controller(DIx)
„ I/O control or Fieldbus control
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5-Jun-07
 Flexible control platform
„ Flexibility with help of open software parameters for
configuration of start-stop(par10)and reference logic(par11)

DI1F,DI2R
par10.01

AI1
par11.03
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 Flexible control platform

„ Step reference (par12) with DI joystick

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5-Jun-07
 Control places and user macros
„ Two programmable control places , EXT1 and EXT2
„ Two programmable user application macros USER 1 , 2
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5-Jun-07
 Crane control program connectivity
Loading package Aqcr7xxx(+N697)
Control Panel Internal power supply 24VDC
modbus
CDP312R 19,2 kbit/s

Slot 1
• Digital I/O Extension (RDIO)
AI reference voltage (±10V max 10mA) • Analogue I/O Extension (RAIO)
Unipolar or Bipolar joystick ,DI step reference • Pulse Encoder Interface (RTAC)
3 Analog inputs • Fieldbus Interface (RPBA profibus...
2 Analog outputs
Slot 2
•DI reference voltage 24VDC • Digital I/O Extension (RDIO)
6 Programmable digital inputs • Analogue I/O Extension (RAIO)
• Pulse Encoder Interface (RTAC)
1 Fixed digital input (power ON acknowledge)
External power supply 24VDC
Slot 3
• DDCS Link (RDCO-0x)
3 Relay outputs with default for
Brake lift , Running , Watchdog
PPCS Connection to interface board ,
8 Mbit/s
(drive internal hardware)
DDCS
1 Mbit/s
PC-Tool DDCS Connection to Application
-DriveWindow for parameters/trends 4 Mbit/s
Controller
-DriveAP for small PLC block program eg. AC80 or AC800M
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DDCS
4 Mbit/s DDCS
4 Mbit/s
I/O-Module Extension (AIMA)
RDIO , RAIO , RTAC
Master / Follower and synchro
5-Jun-07

control connection with

opto fibers
 Flexible control platform , digital inputs
„ Programmable digital inputs , with pointers or with ready made DI selections
DIx Start/stop UP/DOWN for EXT1 and EXT2
DIx Control place EXT1/EXT2
DIx Step referencing
DIx Brake acknowledge
DIx Endlimit high
DIx Endlimit low
DIx Slowdown zon
DIx Fast stop
DIx Zero position check,joystick
DIx Actual position reset
DIx Synch active
DIx Run enable
DIx External reset
DIx User macro change
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DIx Ramp pair block 1 or 2

DIx External fault
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„ Fixed digital input = power on acknowledge = DI_IL

 Flexible control platform , relay output
„ Programmable relay outputs only with pointers group.index.bit
R01 = +003.013.06 (direct software address to the output)
Easy to modify with AP or invert .
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5-Jun-07
 Incremental encoder for measured speed (rpm)
© ABB Group - 24 -
5-Jun-07
 Crane ramp time logic
„ special crane ramp time pair ACC/DEC DIR feature
„ ACC/DEC 1 pair (s) for DIRA , ACC/DEC 2 pair for DIRB (s)
„ time required for the speed to change from zero to max limit
speed or from max limit speed to zero.

+ rpm DIRA forward using ACC/DEC1

- rpm DIRB reverse using ACC/DEC2

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5-Jun-07
 Flexible control platform

„ ACC and DEC ramp times for cranes depend on direction

forward or reverse = ACC/DEC DIR
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5-Jun-07
 Adaptive programming AP

„ Small PLC inside the drive with help of 15 AP blocks

„ External logic/interlocks can be integrated in the drive or
new functions can be created
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5-Jun-07
 Mechanical brake control & torque memory
„ Application software inside drive control (RMIO) board is
controlling the mechanical brake via relay output to brake
contactor
„ Brake feedback (acknowledge) enable additional logic’s
for control and safety supervisions.

brake lift
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brake acknowledge
 Flexible control platform

„ Mechanical brake control parameters in par42.x

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5-Jun-07
 Mechanical brake control & torque memory
„ Torque memory , motor torque stored in memory when
stopping the motor and closing the brake.In next new start
same torque level is feeded out to the motor to avoid load
drop.Can be drive memory or external AI signals(load cell)
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5-Jun-07
 Mechanical brake control operation diagram

BRK Long FLT DLY

Indication out for alarm
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5-Jun-07
 Protection for zero speed without encoder
„ Available safety feature’s to avoid running in zero speed
without encoder feedback or internal speed used.

„ Low reference hold (stop and continue)

-when speed ref below ABS brake close level ,then low reference
brake hold time keep brake closed during this time , independent of
the reference signal level.

„ Safety close command (stop and fault)

-when speed is below 1% of nominal speed longer than 2s , then the
brake is closed and fault is generated. (fixed levels 1% and 2s)
If ABS brake close speed is set too low , this protect to run in to the
© ABB Group - 32 -

zero speed area.

Default = enable
5-Jun-07

(Disable in trolley and long travel motions)

 Crane system check
„ Crane control sw include crane system check features.
The crane system conditions are tested in every new start.
Electrical check = torque proving , motor winding+motor cable is tested
with 30% torq reference against closed brake , accepted torque feedback
is the test.

Mechanical check = brake slip , motor shaft speed is monitored against

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closed brake , accepted brake slip is the detected brake slip speed level.
5-Jun-07
 Master / Follower & shaft synchro
„ Crane control M/F software support up to 5 motors
„ M/F Load sharing control with common drum
© ABB Group - 34 -
5-Jun-07
 Master / Follower & shaft synchro
„ Crane control M/F software support up to 5 motors
„ M/F Synchro shaft control with separate drums .
„ Common brake lift , synchronized via CH2 fiber link to
followers after approved crane system check .
© ABB Group - 35 -
5-Jun-07
 Flexible control platform
„ Master-follower par60
„ Synchro control par78
© ABB Group - 36 -
5-Jun-07
 Crane optimization (Q4/2007)
„ Designed for optimizing operating time and crane capacity.
„ Maximize the hoist speed in relation to the load torque.
¨torque

With load

Without load

speed
n n
© ABB Group - 37 -

nom max
5-Jun-07
 Safety control
„ Slowdown speed level = reduced speed in special area
„ End-limit logic = special stop ramp time in case of end limit sensor
„ Fast stop = ensure that drive stop with fast deceleration time
„ Antisway = integrated antisway sw for the trolley motion ***
(*** separate software package in the first version of crane control , case by case)
© ABB Group - 38 -
5-Jun-07
 Speed monitor
„ Speed monitor = over speed protection
Ensure that crane motor is working in allowed speed area

Over speed level limit (% of max speed )

© ABB Group - 39 -
5-Jun-07
 Speed matching
„ Speed matching = compare actual speed and reference
Ensure that crane motor is following the actual speed reference
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5-Jun-07
 Service counters
„ Counter logic for crane actual signals
Crane operating time
Number of brake open
Number of power on
„ Possible to reset the counters by the user

„ Possible to create new logics with adaptive programming

Example of max crane operating time logic
Example of max brake opening number (lifelength of brake control)
© ABB Group - 41 -
5-Jun-07
 Flexible control platform
„ Overspeed(74) , speed match(75), crane system check(76)
„ Service counters(79)
© ABB Group - 42 -
5-Jun-07
© ABB Group - 43 -
5-Jun-07

Fieldbus system overview

 Position measurement logic
„ Actual position is calculated from motor encoder shaft
With help of scaling parameters, crane position in mm
Possibility of reset or pre-defined mm position.
Actual ACT POS signal stay in memory in case of power off

mm
© ABB Group - 44 -
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 Example of running crane control
„ Metso Tampere in Finland ,
3pcs industrial indoor cranes 80/50TON
© ABB Group - 45 -
5-Jun-07
 Example of running crane control
„ Drives ACS800-04 (main hoist and auxilary hoist)
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5-Jun-07
 Example of running crane control
„ Drives ACS800-04 (long travel and trolleys)
© ABB Group - 47 -
5-Jun-07