DAY 01
Softwell ABB Drive — Handwritten M-Step Manual
Drive Composer Pro Connection, Upload & Motor ID
Practical Outcome: Install Drive Composer Pro V2.9, connect ACS580/ACS880 through USB or Ethernet, upload parameter backup, run setup assistant and complete motor identification.
Trainer Note: Before any wiring or commissioning, isolate supply and wait until the drive DC bus / charging LED is fully discharged. Upload backup before factory reset.
01
Step 1. Install Drive Composer Pro V2.9 and FTDI / ACS-CP-C USB driver. Verify COM port in Windows Device Manager.
02
Step 2. Connect PC USB to ABB panel port / control panel port or use Ethernet direct connection for faster refresh.
03
Step 3. Open Drive Composer Pro, create new workspace and use Find Drives to scan serial or Ethernet connection.
04
Step 4. Go online and check live Group 01 actual values: motor speed, output current, DC bus voltage and drive status.
05
Step 5. Read all parameters from drive and save .acp backup file before changing factory or field parameters.
06
Step 6. Restore factory defaults only on lab drive and start Setup Assistant wizard for clean commissioning.
07
Step 7. Enter motor nameplate values in Group 99: voltage, current, power, frequency, speed and power factor.
08
Step 8. Select DTC control mode, standard macro, speed limits and ramp-up/ramp-down values.
09
Step 9. Run Static ID first, then Rotating ID only when shaft is free and area is safe.
10
Step 10. Save parameters to memory, create final backup and perform first supervised run from panel / Composer.
Parameter Reference
99.04 = DTC control mode 99.06 = Motor nominal voltage 99.07 = Motor nominal current 99.08 = Motor nominal power 99.09 = Motor nominal frequency 99.10 = Motor nominal speed 99.13 = Motor ID run selection 96.06 = Restore factory defaults
Daily Practice / Viva
Show online connection, uploaded backup file, motor data entry screen, ID run result and saved parameter backup.
DAY 02
Softwell ABB Drive — Handwritten M-Step Manual
Parameter Groups, Application Macros & Speed Reference
Practical Outcome: Understand ABB parameter groups, apply standard macros, configure start/stop source, speed reference and basic limits.
Trainer Note: Teach parameter grouping as a maintenance skill: actual values, command source, speed reference, limits, ramps, faults and motor data.
01
Step 1. Identify important ABB parameter groups: 01 actual values, 10 I/O, 19 mode, 20 start/stop, 22 speed reference, 30 limits, 31 faults and 99 motor data.
02
Step 2. Compare ACS580 and ACS880 usage: general purpose drive vs high-performance industrial drive.
03
Step 3. Apply ABB Standard macro and note default DI1 start, DI2 direction and AI1 speed reference behaviour.
04
Step 4. Configure start/stop/direction command source from terminal, keypad, fieldbus or external control location.
05
Step 5. Configure AI1 as 0–10 V or 4–20 mA speed reference and scale it to required min/max speed.
06
Step 6. Set acceleration and deceleration ramps for safe motor start/stop and avoid mechanical shock.
07
Step 7. Set current, torque and speed limits in Group 30 as per motor and machine requirement.
08
Step 8. Test local/remote control selection and verify reference source change from panel to terminals.
09
Step 9. Use parameter search, favourites and modified parameter list to document changed values.
10
Step 10. Export parameter report and prepare macro comparison note for maintenance engineers.
Typical Parameter Checklist
Group 10 = Digital input / output settings Group 20 = Start / stop / direction commands Group 22 = Speed reference selection Group 23 = Speed control / ramps Group 30 = Limits and protections Group 31 = Fault functions Group 99 = Motor data and control mode
Daily Practice / Viva
Create a parameter change sheet showing macro name, command source, reference source, ramps and speed limits.
DAY 03
Softwell ABB Drive — Handwritten M-Step Manual
I/O Configuration, Monitoring & Fault Diagnostics
Practical Outcome: Wire and test digital/analog I/O, monitor live status, diagnose alarms/faults and prepare a troubleshooting checklist.
Trainer Note: Maintenance engineers must know how to check terminal status before changing logic or parameters.
01
Step 1. Study ABB drive control terminal layout and identify DI, DO/relay, AI, AO and common terminals.
02
Step 2. Wire DI1 start command, DI2 direction / reset and verify terminal status in Drive Composer monitor.
03
Step 3. Configure digital output / relay output for Running, Fault, Ready or At Speed indication.
04
Step 4. Wire AI1 speed reference and check raw value, scaled value and actual motor speed response.
05
Step 5. Configure analog output for output frequency, motor current or actual speed indication.
06
Step 6. Use monitor panel to view live speed, current, torque, DC voltage, run status and reference.
07
Step 7. Create intentional safe fault / warning simulation and read fault code, text and time stamp.
08
Step 8. Use fault history and event logger to understand trip sequence before reset.
09
Step 9. Reset fault from panel, DI or Composer only after root cause is understood and safe.
10
Step 10. Prepare I/O commissioning sheet with terminal number, signal name, parameter number and test result.
Diagnostics Checklist
Check 01 actual values before reset. Check terminal status before changing DI assignment. Check Group 31 fault functions and history. Check motor current during acceleration. Check DC bus voltage before opening panel.
Daily Practice / Viva
Submit I/O test sheet, monitor screenshots and one fault diagnostic note with probable cause and corrective action.
DAY 04
Softwell ABB Drive — Handwritten M-Step Manual
Fieldbus Communication with PLC / SCADA
Practical Outcome: Configure ABB drive fieldbus for EtherNet/IP, PROFIBUS or Modbus communication and test control word, status word and speed reference.
Trainer Note: Explain drive communication as command word + speed reference + status word + feedback values.
01
Step 1. Identify installed fieldbus option: FENA-21 EtherNet/IP / Modbus TCP, FDNA-01 PROFIBUS or embedded Modbus RTU.
02
Step 2. Set drive IP address, subnet, gateway or PROFIBUS node / Modbus slave address as per network plan.
03
Step 3. Configure external control source from fieldbus and select speed reference from fieldbus word.
04
Step 4. Map control word bits for run enable, start, stop, direction, fault reset and quick stop.
05
Step 5. Map status word bits for ready, running, fault, warning, at speed and remote/local state.
06
Step 6. Configure speed reference scaling from PLC integer/word value to actual rpm or Hz value.
07
Step 7. Test start/stop from PLC with safe low-speed command and verify actual speed feedback.
08
Step 8. Disconnect network safely and verify communication fault / timeout response.
09
Step 9. Prepare PLC tag list for command word, reference, status word, actual speed and fault code.
10
Step 10. Save fieldbus parameter backup and network commissioning sheet.
PLC Mapping Example
Drive_CmdWord : WORD // PLC to Drive Drive_SpeedRef : INT // PLC to Drive Drive_StatusWord : WORD // Drive to PLC Drive_ActualSpeed : INT // Drive to PLC Drive_FaultCode : WORD // Drive to PLC
Daily Practice / Viva
Demonstrate fieldbus start/stop, speed command, status word monitoring and communication fault reaction.
DAY 05
Softwell ABB Drive — Handwritten M-Step Manual
Advanced Drive Features, Backup & Final Capstone
Practical Outcome: Use advanced monitoring, trends, safety awareness, PID/application features and complete final ABB drive commissioning demonstration.
Trainer Note: Final day should connect all skills: parameter backup, safe change, test run, diagnosis, report and handover.
01
Step 1. Use Drive Composer monitor / trend to record speed, current, torque and DC bus during ramp-up and ramp-down.
02
Step 2. Configure PID / process control concept for pump, fan or pressure/flow application as per available lab setup.
03
Step 3. Understand ACS580 vs ACS880 advanced differences: DTC performance, encoder feedback, safety and application functions.
04
Step 4. Review STO safety terminals and safety function parameter view without bypassing any safety circuit.
05
Step 5. Create final parameter backup before capstone and compare with Day 01 backup to identify changes.
06
Step 6. Complete final capstone: connect drive, upload backup, set motor data, run ID, configure I/O and run motor safely.
07
Step 7. Add PLC/fieldbus control or terminal control depending on trainer-selected final project mode.
08
Step 8. Simulate one fault, diagnose using fault history and reset only after cause is removed.
09
Step 9. Prepare handover report: wiring, parameter list, backup file, test results and safety note.
10
Step 10. Trainer review and viva: explain motor data, DTC, macro, reference source, fault code and backup process.
Final Handover Folder
01_Pre_Backup.acp 02_Final_Backup.acp 03_Parameter_Change_Report.pdf 04_IO_Test_Checklist.xlsx 05_Fieldbus_Tag_List.xlsx 06_Final_Commissioning_Report.pdf
Daily Practice / Viva
Participant must demonstrate full commissioning flow and submit final backup, parameter report and troubleshooting note.