ABB ACS580 & ACS880 VFD Manual + Drive Composer Practical Training

All 26 ABB VFD Labs — Jump to Any Step Sequence

Every lab below opens with its objective, the exact panel and Drive Composer click paths, a numbered step table showing the action, the setting to enter and the expected result, the parameter groups involved, and a pass criterion. Use this index to jump straight to the lab you need.

LAB 01Safety, Hardware & Drive Identification LAB 02Go Online with ABB Drive Composer LAB 03Basic Commissioning & First Local Run LAB 04Motor Data, Control Mode & ID Run LAB 05Digital, Analog & Relay I/O Practical LAB 06Macro Selection Engineering LAB 07Macro: ABB Standard & ABB Standard (Vector)LAB 08Macro: 3-Wire & Alternate LAB 09Macro: Motor Potentiometer LAB 10Macro: Hand / Auto LAB 11Macro: Hand/PID, PID & Panel PID LAB 12Macro: PFC / Multi-Pump Staging LAB 13Macro: Compressor / Application Control LAB 14Macro: Torque Control LAB 15Control Word, Status Word & Cyclic Data LAB 16Protocol & Adapter Selection LAB 17Modbus RTU over RS-485 LAB 18PROFINET Setup: GSDML, Device Name & Cyclic Data LAB 19PROFINET Run, Reference & Loss-of-Comms Test LAB 20EtherNet/IP Setup: EDS, Module & Assemblies LAB 21EtherNet/IP Run, Reference & Recovery LAB 22Modbus TCP over Ethernet LAB 23Diagnostics, Fault Finding & Recovery LAB 24Backup, Restore & Parameter Change Control LAB 25Final Integrated Project LAB 26Practical Assessment & Handover Record

26 labs · 10 training days · 230+ numbered practical steps · ACS580 and ACS880 · last reviewed 20 September 2026.

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DAY
01

Drive Composer Online, Safety & Baseline Backup

Start the training the way a real commissioning job starts. Identify the drive, prove the safety circuit, connect ABB Drive Composer and take a baseline backup before a single parameter is changed.

ACS580ACS880Drive ComposerSTO & SafetyBaseline .dcbak

Lab 01 Safety, Hardware & Drive Identification

90 minFoundationNo power appliedDay 01

Objective: Verify drive identity, supply, motor, earthing, STO and control wiring so the first energization is safe, correct and traceable.

CLICK PATH

PanelHome → Menu → System info → drive type and firmware

ParameterMenu → Parameters → Complete list → Group 07 → 07.05 Firmware version

Lab 01 step sequence

Lab 01 — Safety, Hardware & Drive Identification: numbered practical steps with the setting to enter and the expected result.
#	Action	Setting / what to enter	Expected result	Rec
1	Read the drive nameplate and record the type code, frame and rating	ACS580-01 / ACS880-01 type code, rated voltage and current	Drive rating recorded on the lab sheet	☐
2	Check the incoming supply, disconnect and protective device against the drive rating	Site single-line drawing plus the drive hardware manual	Supply and protection are within the drive rating	☐
3	Verify PE/earth continuity and the motor U/V/W connections	Power terminals, torque values from the hardware manual	Earthing and phase connections correct	☐
4	Record the motor nameplate data before touching any parameter	Voltage, current, frequency, speed, power, cos φ	Motor data sheet complete	☐
5	Validate the STO wiring and E-stop chain before the first run	STO terminals and safety relay chain	Safe torque off proven to inhibit the drive	☐
6	Check DI/AI commons, screening and control-cable segregation	Shield earthed as specified; control cable away from motor cable	No noise coupling path into the control wiring	☐
7	Confirm the motor and driven load can rotate safely	Coupling, guards and permitted direction agreed	Low-speed rotation authorised by the trainer	☐
8	Record the firmware version and any installed option or fieldbus module	07.05 Firmware version plus a physical slot inspection	Configuration baseline recorded	☐

Parameters & menus used: 07.05 Firmware version · hardware manual torque and clearance data

PASS RESULT: Safe commissioning baseline recorded and the drive cleared for first energization.

SAFETY: Do not continue to Lab 02 if the drive or motor rating is uncertain, PE is missing, STO/E-stop is unproven, or the load cannot be rotated safely.

Lab 02 Go Online with ABB Drive Composer

90 minFoundationSoftwareDay 01

Objective: Connect the PC to the drive, browse live parameters, monitor real signals and create the baseline .dcbak backup that every later lab is compared against.

CLICK PATH

ConnectionPC USB → assistant control panel / supported interface → drive powered → drive appears in the Drives list

ParametersDrives list → drive → vertical ellipsis (…) → Parameters

BackupDrives list → drive → … → Backup → select folder → file name → Save

Lab 02 step sequence

Lab 02 — Go Online with ABB Drive Composer: numbered practical steps with the setting to enter and the expected result.
#	Action	Setting / what to enter	Expected result	Rec
1	Start Drive Composer and confirm the drive appears in the Drives list	USB or panel interface connected, drive powered	Drive listed with no broken-connection icon	☐
2	Open the Parameters browser from the drive menu	Use the group browser or the search field	Live parameter values visible	☐
3	Record 07.05 Firmware version	Group 07 → 07.05	Firmware version written on the lab sheet	☐
4	Open the monitor view and add status, reference, actual speed and current	Add or drag the signals into the monitor	Live values updating at the selected interval	☐
5	Write one safe training parameter, for example an acceleration time	Trainer-approved non-critical value	Write accepted by the drive	☐
6	Read the parameter back and then restore the original value	Compare before and after	Write/read cycle proven and baseline restored	☐
7	Create the baseline backup	File name DriveTag_Date_Firmware_Baseline.dcbak	Backup file saved and entered in the log	☐

Parameters & menus used: 07.05 Firmware version · ramp parameters (Group 23 / 28 as applicable)

PASS RESULT: Drive online, firmware recorded and a baseline .dcbak backup saved.

ENGINEERING NOTE: The Parameters browser is available only while the drive is connected. Drive Composer stores backups in .dcbak format — keep them in the same folder as the PLC project for the life of the machine.

DAY
02

Basic Commissioning, Motor ID & I/O Proving

Enter motor nameplate data, choose scalar or vector control, complete the identification run, then prove every digital input, analog input, analog output and relay output before any macro is trusted with a Start command.

Motor DataScalar vs VectorID RunDI / AI / AO / ROLocal first run

Lab 03 Basic Commissioning & First Local Run

120 minFoundationMotor runsDay 02

Objective: Enter motor data, select a starting macro, set conservative ramps and limits, and prove a safe low-speed rotation in LOCAL control.

CLICK PATH

MotorHome → Menu → Primary settings → Motor → Nominal values

MacroPrimary settings → Macro → choose macro → Select

Ramps / LimitsPrimary settings → Ramps | Primary settings → Limits

Lab 03 step sequence

Lab 03 — Basic Commissioning & First Local Run: numbered practical steps with the setting to enter and the expected result.
#	Action	Setting / what to enter	Expected result	Rec
1	Enter motor nominal voltage, current, frequency, speed and power	Exact nameplate values, Group 99 Motor data	Motor data accepted with no warning	☐
2	Select the basic macro for the first test	96.04 Macro select → ABB Standard or the drive-family equivalent	Macro loaded and its defaults written	☐
3	Set conservative acceleration and deceleration times	Suited to the training motor and its inertia	No aggressive ramp on the first start	☐
4	Set minimum and maximum speed or frequency plus current limits	Primary settings → Limits (Group 30)	Output constrained to a safe training range	☐
5	Press LOC/REM to take LOCAL control	Panel shows LOC	Command authority is the panel, not the field wiring	☐
6	Set a low reference and press Start	Low safe speed or frequency	Motor rotates smoothly in the expected direction	☐
7	Observe direction, current, actual speed and mechanical noise	Panel display or Drive Composer monitor	All values reasonable for the motor and load	☐
8	Press Stop and leave the drive in LOCAL	Do not select REMOTE yet	Remote sources stay inactive until deliberately configured	☐

Parameters & menus used: Group 99 motor data · 96.04 Macro select · ramp and limit groups (23 / 28 / 30)

PASS RESULT: Motor direction and current verified at low reference under LOCAL control.

ENGINEERING NOTE: Keep the drive in LOCAL until remote command and reference sources have been deliberately configured in a later lab. Most uncommanded starts during training happen at this transition.

Lab 04 Motor Data, Control Mode & ID Run

90 minFoundationMotor runsDay 02

Objective: Understand scalar against vector/DTC control and complete the identification workflow that all vector performance depends on.

CLICK PATH

PanelPrimary settings → Motor → Control mode / Nominal values / ID run

ParameterMenu → Parameters → Complete list → Group 99 → 99.13 ID run requested

Lab 04 step sequence

Lab 04 — Motor Data, Control Mode & ID Run: numbered practical steps with the setting to enter and the expected result.
#	Action	Setting / what to enter	Expected result	Rec
1	Confirm every motor nominal value is entered before changing the control mode	Group 99 Motor data	Motor record complete	☐
2	Select scalar or vector/DTC control for the application	99.04 Motor control mode	Control mode documented together with the reason	☐
3	Verify run enable, STO, mechanical clearance and load condition	Safety precondition for the ID run	Rig confirmed safe for the requested ID-run type	☐
4	Open 99.13 ID run requested and review the choices offered by this firmware	Standstill, reduced or normal as offered	Available ID-run types understood, not guessed	☐
5	Select the trainer-approved ID-run type and start it from the panel	Stay ready to press Stop throughout	ID run completes without a fault	☐
6	Monitor current and speed during the run	Drive Composer monitor or panel	No abnormal behaviour or trip	☐
7	Repeat the Lab 03 low-speed run and compare torque behaviour	Same low reference as before identification	Improvement in low-speed behaviour recorded	☐
8	Create the post-ID-run backup	DriveTag_Date_PostID.dcbak	Motor setup archived	☐

Parameters & menus used: 99.04 Motor control mode · 99.13 ID run requested · Group 99 nominal values

PASS RESULT: Control mode, ID-run result and post-ID backup recorded.

SAFETY: A rotating ID run can accelerate the motor to significant speed. Select the ID-run type only when the coupling, guards and driven load allow it, and stay at the Stop key.

Lab 05 Digital, Analog & Relay I/O Practical

90 minFoundationSignal provingDay 02

Objective: Prove every physical control signal before any macro or fieldbus is trusted with Start/Stop or reference.

CLICK PATH

PanelHome → Menu → I/O → DI / AI / AO / RO views

ParameterGroups 10 (relay outputs), 12 (analog inputs), 13 (analog outputs) and the start/reference groups

Lab 05 step sequence

Lab 05 — Digital, Analog & Relay I/O Practical: numbered practical steps with the setting to enter and the expected result.
#	Action	Setting / what to enter	Expected result	Rec
1	Open the I/O menu and record the digital input states	Toggle one field switch at a time	Each DI changes state exactly as wired	☐
2	Apply a known signal to AI1	Check the voltage/current selection and the scaling	AI1 scaled value matches the injected signal	☐
3	Apply a known signal to AI2	Verify range and engineering scaling	AI2 reads correctly in engineering units	☐
4	Select and monitor an analog output source	Measure the output with a meter	AO follows the selected source across the range	☐
5	Verify RO1/RO2/RO3 assignment and actual contact switching	Typically Ready / Running / Fault	Contacts agree with the drive status	☐
6	Remove one signal deliberately and diagnose it from the I/O menu	Use diagnostics before editing any logic	Fault isolated without changing the configuration	☐

Lab 05 record sheet

Lab 05 terminal-to-function record — complete this for the actual training panel
Signal	Configured function	Range / type	Pass
DI1	Start / Stop	24 V digital	☐
DI2	Direction	24 V digital	☐
DI3 / DI4	Constant speed select	24 V digital	☐
AI1	Speed / process reference	0–10 V or configured	☐
AI2	Process feedback	4–20 mA or configured	☐
AO1	Actual speed / current	Configured analog out	☐
RO1 / RO2 / RO3	Ready / Running / Fault	Relay contact	☐

Swipe the table sideways to see every column →

Parameters & menus used: Groups 10, 12 and 13 · DI start and reference groups (19 / 20 / 22 / 28)

PASS RESULT: A complete terminal-to-function I/O map with fault isolation demonstrated.

ENGINEERING NOTE: This map is the document field technicians will actually use. Fill it in on the real panel — a macro default list is not an I/O map.

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DAY
03

Macro Selection + Standard Control Labs

Macro engineering: match the written control philosophy to the correct macro, then commission 2-wire speed control, vector control, momentary 3-wire push-button control and separate Forward/Reverse commands on real I/O.

96.04 Macro selectABB StandardVector3-WireAlternate FWD/REV

Lab 06 Macro Selection Engineering

60 minCore skillConfigurationDay 03

Objective: Choose the correct macro from the application requirement and know exactly which default I/O assignments the macro writes into the drive.

CLICK PATH

PanelPrimary settings → Macro → choose macro → Select

ParameterMenu → Parameters → Complete list → Group 96 → 96.04 Macro select → value → Save

Lab 06 step sequence

Lab 06 — Macro Selection Engineering: numbered practical steps with the setting to enter and the expected result.
#	Action	Setting / what to enter	Expected result	Rec
1	List the application command sources, reference source and direction requirement	Written control philosophy, one page	Requirement defined before touching the drive	☐
2	Open the macro list actually available on the installed firmware	Primary settings → Macro	Only macros supported by this drive and firmware are offered	☐
3	Select the candidate macro and save	96.04 Macro select	Macro loaded and defaults written	☐
4	Re-verify every DI, AI, AO and RO assignment the macro changed	Menu → I/O	Actual assignments documented rather than assumed	☐
5	Confirm the active command and reference location	Groups 19 / 20 / 22 — EXT1 / EXT2	Control location matches the philosophy	☐
6	Record every parameter you still had to change after the macro	Parameter change log	Deviation from macro default captured for handover	☐

Lab 06 record sheet

ACS580 standard control program macro quick reference — verify the value list on the installed firmware
96.04	Macro	Use when	Key default signals / concept
1	ABB Standard	General-purpose 2-wire control	AI1 reference; DI1 Start/Stop; DI2 direction; DI3/DI4 constant speeds
2	Hand/Auto	Two external control locations	Separate Hand and Auto commands and references
3	Hand/PID	Manual speed plus automatic PID	Hand reference, PID feedback and a mode selector
7	Compressor control	Cooling / refrigeration compressor	Application-specific PID and permissive control
11	3-Wire	Momentary Start/Stop station	Start pulse, Stop pulse, direction
12	Alternate	Separate FWD / REV start	Independent Start Forward and Start Reverse commands
13	Motor potentiometer	Digital Up/Down reference	No analog speed reference needed
14	PID	Process control loop	External setpoint plus process feedback
15	Panel PID	PID with operator panel setpoint	Panel setpoint plus process feedback
16	PFC	Pump / fan staging	PID plus auxiliary motor relay logic
17	ABB Standard (vector)	General vector control	Standard I/O concept with vector motor control
28	Torque control	Torque / tension applications	Speed and torque reference plus mode selection

Swipe the table sideways to see every column →

Parameters & menus used: 96.04 Macro select · Groups 19 / 20 / 22 / 28 command and reference sources

PASS RESULT: Macro choice documented together with the wiring and control philosophy it implements.

COMMON MISTAKE: The values above are the ACS580 standard control program set. ACS880 and other ABB families present a different macro list and different defaults. Always read the value list on the installed firmware before writing 96.04.

Lab 07 Macro: ABB Standard & ABB Standard (Vector)

120 minCore skillMotor runsDay 03

Objective: Commission general-purpose 2-wire speed control, then repeat it in vector mode and compare low-speed and load behaviour on the same rig.

CLICK PATH

PanelPrimary settings → Macro → ABB Standard (or ABB Standard Vector) → Select

ParameterGroup 96 → 96.04 Macro select → 1 (standard) or 17 (vector) on ACS580 → Save

Drive ComposerConnected drive → … → Parameters → 96.04 → write value

Lab 07 step sequence

Lab 07 — Macro: ABB Standard & ABB Standard (Vector): numbered practical steps with the setting to enter and the expected result.
#	Action	Setting / what to enter	Expected result	Rec
1	Select the macro and confirm the resulting motor control mode	96.04 = 1 or 17; Motor → Control mode	Macro and control mode both active as intended	☐
2	Verify motor nameplate data is complete before any vector operation	Primary settings → Motor → Nominal values	Data complete and matching the machine	☐
3	Perform or review the ID run when vector control is used	Motor → ID run, or 99.13	Identification suitable for the control mode	☐
4	Check DI1 Start/Stop and DI2 direction states in the I/O menu	Menu → I/O	States visible and matching the field switches	☐
5	Apply a low AI1 reference	Scaled analog reference	Drive reference follows the analog input	☐
6	Command Start through DI1	DI1 = ON	Motor runs at the analog reference	☐
7	Toggle DI2 only under safe conditions	Direction input	Direction changes as intended, with correct ramping	☐
8	Test the constant-speed selections if DI3/DI4 are wired	Preset speed selection combinations	Correct preset reference selected in each combination	☐
9	Verify RO1/RO2/RO3 Ready, Running and Fault indications	Menu → I/O → relay outputs	Panel lamps agree with the drive status	☐
10	Compare scalar against vector low-speed and load response, then back up	Record current and speed for both modes	Difference documented; lab backup saved	☐

Parameters & menus used: 96.04 · Group 12 analog inputs · Group 10 relay outputs · Group 22 / 28 reference · Group 99

PASS RESULT: Remote 2-wire I/O control proven and scalar against vector response documented.

ENGINEERING NOTE: Application exercise: conveyor or fan rig — selector switch Start/Stop, AI1 potentiometer reference, DI2 permitted direction, relay outputs driving panel lamps.

Lab 08 Macro: 3-Wire & Alternate

120 minCore skillMotor runsDay 03

Objective: Commission momentary push-button control with drive-side latching, then separate Forward and Reverse start commands with a proven interlock response.

CLICK PATH

PanelPrimary settings → Macro → 3-Wire | Alternate → Select

ParameterGroup 96 → 96.04 → 11 (3-Wire) or 12 (Alternate) on ACS580 → Save

Lab 08 step sequence

Lab 08 — Macro: 3-Wire & Alternate: numbered practical steps with the setting to enter and the expected result.
#	Action	Setting / what to enter	Expected result	Rec
1	Select the 3-Wire macro and read the DI assignments it wrote	96.04 = 11; Menu → I/O	Start pulse, Stop pulse and direction inputs mapped	☐
2	Wire or simulate momentary Start and Stop contacts	DI1 momentary, DI2 momentary	Input states change only while the button is pressed	☐
3	Apply a low analog reference and pulse Start	AI1 low value	Drive latches into Run after the button releases	☐
4	Pulse Stop and confirm the latch drops	DI2 momentary	Drive stops and stays stopped	☐
5	Test the permitted direction input	DI3	Direction logic behaves as designed	☐
6	Change to the Alternate macro	96.04 = 12	Separate Forward and Reverse start inputs now active	☐
7	Command Forward, stop safely, then command Reverse	Independent start inputs	Each direction runs only from its own command	☐
8	Apply the trainer-defined simultaneous-command test	Both start commands together	Safe interlock or stop behaviour observed and recorded	☐
9	Verify ramps and reversing precautions	Primary settings → Ramps / Limits	No abrupt or unsafe reversal of the load	☐
10	Record restart behaviour after a stop or power condition, then back up	Stop/start and power-cycle test	Behaviour documented; backup saved	☐

Parameters & menus used: 96.04 · digital input groups · Group 23 / 28 ramps · Group 30 limits

PASS RESULT: Momentary latching and dual-direction start logic proven, with interlock behaviour recorded.

COMMON MISTAKE: An external machine interlock, not the drive macro alone, must prevent unsafe instantaneous reversal on a loaded conveyor or hoist.

DAY
04

Motor Potentiometer, Hand/Auto + PID Macro Labs

Reference-source labs: digital Up/Down control with no analog signal, two external control locations with a safe transfer, and the built-in process PID with hand, external analog and panel setpoints.

Motor PotentiometerEXT1 / EXT2Hand/AutoProcess PIDPanel PID

Lab 09 Macro: Motor Potentiometer

75 minCore skillMotor runsDay 04

Objective: Operate the drive with digital Up/Down reference only, with no analog speed signal anywhere in the loop.

CLICK PATH

PanelPrimary settings → Macro → Motor potentiometer → Select

Parameter96.04 = 13 on ACS580 · motor-potentiometer group for ramp rate and reference retention

Lab 09 step sequence

Lab 09 — Macro: Motor Potentiometer: numbered practical steps with the setting to enter and the expected result.
#	Action	Setting / what to enter	Expected result	Rec
1	Select the motor potentiometer macro	96.04 = 13	Macro active and defaults written	☐
2	Identify the Start, direction and Reference Up/Down inputs	Menu → I/O	Inputs verified against the actual terminal strip	☐
3	Start at the minimum safe reference	Remote control, minimum limit	Motor starts at the lower limit	☐
4	Hold or pulse Reference Up	Digital Up input	Reference ramps upward at the configured rate	☐
5	Hold or pulse Reference Down	Digital Down input	Reference ramps downward at the configured rate	☐
6	Verify the minimum and maximum reference limits	Primary settings → Limits	Reference clamps at both ends of the range	☐
7	Stop, restart and observe reference retention or reset	Stop/start cycle	Retention behaviour recorded	☐
8	Power-cycle the drive and repeat the retention check, then back up	Full power cycle	Stored-reference behaviour documented; backup saved	☐

Parameters & menus used: 96.04 · motor potentiometer group · Group 30 limits

PASS RESULT: Push-button-only speed control proven, including reference retention across stop and power cycles.

ENGINEERING NOTE: Reference retention is the detail operators notice first. Decide deliberately whether the drive should restart at the last reference or at minimum, and write it into the handover.

Lab 10 Macro: Hand / Auto

90 minCore skillMotor runsDay 04

Objective: Commission two external control locations and prove a controlled, predictable transfer between them.

CLICK PATH

PanelPrimary settings → Macro → Hand/Auto → Select

Parameter96.04 = 2 on ACS580 · Group 19 EXT1/EXT2 selection · Group 20 commands · Group 22 / 28 references

Lab 10 step sequence

Lab 10 — Macro: Hand / Auto: numbered practical steps with the setting to enter and the expected result.
#	Action	Setting / what to enter	Expected result	Rec
1	Select the Hand/Auto macro	96.04 = 2	Macro active	☐
2	Identify the Hand/Auto selector input and both control paths	Menu → I/O and Group 19	EXT1 and EXT2 sources identified and written down	☐
3	Verify the Hand command and reference	Typically AI1 plus the assigned digital inputs	Hand operation works at low reference	☐
4	Verify the Auto command and reference while the drive is stopped	Typically AI2 plus the assigned digital inputs	Auto signals valid and readable	☐
5	Run in Hand at a low reference	Selector in Hand	Manual operation stable	☐
6	Prepare a safe Auto command and reference before transferring	Auto inputs set to a safe state	No unexpected start command waiting at the transfer	☐
7	Transfer to Auto and verify authority	Mode select input	Auto location now controls the drive	☐
8	Stop from both locations and record behaviour, then back up	Hand stop and Auto stop tests	Both paths stop the drive safely; backup saved	☐

Parameters & menus used: 96.04 · Group 19 EXT1/EXT2 · Group 20 · Group 22 / 28

PASS RESULT: Two control locations proven with a documented, safe transfer between them.

COMMON MISTAKE: The most common Hand/Auto incident is an Auto start command already present at the moment of transfer. Always read the Auto command state before switching the selector.

Lab 11 Macro: Hand/PID, PID & Panel PID

150 minAdvancedProcess loopDay 04

Objective: Commission the built-in process PID with all three setpoint sources: hand/manual, external analog and panel entry.

CLICK PATH

PanelPrimary settings → Macro → Hand/PID | PID | Panel PID → Select

Parameter96.04 = 3, 14 or 15 on ACS580 · Group 40 Process PID

PID menuPrimary settings → PID → setpoint, feedback, scaling and tuning

Lab 11 step sequence

Lab 11 — Macro: Hand/PID, PID & Panel PID: numbered practical steps with the setting to enter and the expected result.
#	Action	Setting / what to enter	Expected result	Rec
1	Select the required PID macro variant	96.04 = 3, 14 or 15	Macro active	☐
2	Scale the process feedback in engineering units	AI2 / PID feedback, Groups 12 and 40	Feedback reads the correct engineering value	☐
3	Set the setpoint source for the selected variant	Hand reference, external AI1 or panel entry	Setpoint source matches the chosen macro	☐
4	Set safe PID output and reference limits	PID output limits and Group 30	Output cannot drive the process outside the safe range	☐
5	Start in manual or hand mode and stabilise the process	Hand mode	Stable manual operation established	☐
6	Transfer to PID automatic control	Mode selector or panel	Closed loop active with the output tracking the error	☐
7	Apply a small setpoint step	Setpoint change within the safe range	Rise, overshoot and settling time recorded	☐
8	Introduce a small process disturbance	Training simulator	PID recovers the process variable to setpoint	☐
9	Adjust gain and integration time one term at a time, only as approved	Group 40 tuning	Stable response with no hunting	☐
10	Record the final tuning values and create the backup	Change log plus Drive Composer backup	Tuning archived and reproducible	☐

Parameters & menus used: 96.04 · Group 40 Process PID · Group 12 analog scaling · Group 30 limits

PASS RESULT: A PID loop commissioned, tuned and documented for hand, external and panel setpoints.

ENGINEERING NOTE: Start with proportional action only, add integral action to remove offset, and change one term at a time. Record the loop response after every change or the tuning cannot be defended later.

DAY
05

PFC, Compressor, Torque Control + CW/SW

Application-level control: pump and fan staging, compressor permissives, torque and tension mode, and the Control Word / Status Word model that every fieldbus lab in Days 06 to 09 depends on.

PFC / MultipumpCompressorTorque / TensionControl WordStatus Word

Lab 12 Macro: PFC / Multi-Pump Staging

120 minAdvancedSimulated auxiliariesDay 05

Objective: Run a variable-speed lead pump under PID control and stage and de-stage a simulated auxiliary motor from a relay output.

CLICK PATH

PanelPrimary settings → Macro → PFC → Select

Parameter96.04 = 16 on ACS580 · Group 76 pump and fan control

PFC menuPrimary settings → Pump and fan control → multipump settings

Lab 12 step sequence

Lab 12 — Macro: PFC / Multi-Pump Staging: numbered practical steps with the setting to enter and the expected result.
#	Action	Setting / what to enter	Expected result	Rec
1	Select the PFC macro	96.04 = 16	Macro active	☐
2	Verify the PID setpoint and feedback carried over from Lab 11	Primary settings → PID / Group 40	Loop signals valid in engineering units	☐
3	Open the pump and fan control settings	Group 76	PFC options visible on this firmware	☐
4	Set the motor count to match the training simulator	PFC configuration	No unused relay output is energized	☐
5	Identify the relay output used for the auxiliary motor	Group 10 and the I/O menu	Output documented on the I/O map	☐
6	Run the lead motor under low demand	PID operation	Drive regulates alone with no staging	☐
7	Increase simulated demand past the staging point	Process simulator	Auxiliary stage command appears after the start delay	☐
8	Reduce demand below the de-staging point	Process simulator	Auxiliary stage releases after the stop delay	☐
9	Record the staging and de-staging thresholds and delays	Group 76 values	Anti-hunting behaviour understood and written down	☐
10	Back up the configuration	Drive Composer backup	Settings archived	☐

Parameters & menus used: 96.04 · Group 76 PFC / multipump · Group 40 PID · Group 10 relay outputs

PASS RESULT: Staging and de-staging demonstrated with documented thresholds and delays.

SAFETY: Never switch real motors or contactors from a classroom worksheet. Live PFC needs electrical interlocks, individual motor protection and a site-approved design.

Lab 13 Macro: Compressor / Application Control

90 minAdvancedSimulator onlyDay 05

Objective: Practise application-specific macro commissioning where firmware support and permissive logic decide what is actually possible.

CLICK PATH

PanelPrimary settings → Macro → Compressor control → Select (where supported)

Parameter96.04 = 7 on ACS580 firmware that offers it · 07.05 to confirm the firmware first

Lab 13 step sequence

Lab 13 — Macro: Compressor / Application Control: numbered practical steps with the setting to enter and the expected result.
#	Action	Setting / what to enter	Expected result	Rec
1	Confirm the installed firmware actually supports the compressor macro	07.05 plus the ABB manual for that revision	Availability confirmed before the lab is planned	☐
2	Select the macro only on a compatible drive	96.04 = 7	Macro active	☐
3	Verify motor data and the compressor permissive inputs	Group 99 and the input logic	Permissives correct and wired	☐
4	Verify the process setpoint and feedback signals	PID / application settings	Signals valid in engineering units	☐
5	Review the application-specific protections in this firmware	Minimum on/off time, pressure protection, lubrication interlocks	Functions documented	☐
6	Run a simulated command test before any real compressor	Training simulator	Logic behaves exactly as designed	☐
7	Remove a permissive while the drive is running	Permissive input	Controlled stop observed and timed	☐
8	Record firmware, settings and create a backup	System info plus backup	Configuration fully traceable	☐

Parameters & menus used: 96.04 · application and PID groups · Group 20 permissives · 07.05

PASS RESULT: Application macro logic proven on a simulator with permissive behaviour recorded.

SAFETY: Real refrigeration compressors add lubrication, minimum run-time and pressure constraints. Follow the ABB application guide and the equipment OEM requirements before any live run.

Lab 14 Macro: Torque Control

120 minAdvancedLoaded rigDay 05

Objective: Operate in torque and tension mode with correct vector identification and conservative limits acting as the safety boundary.

CLICK PATH

PanelPrimary settings → Macro → Torque control → Select

Parameter96.04 = 28 on ACS580 · Motor → Control mode (vector / DTC) · Group 26 torque reference · Group 30 limits

Lab 14 step sequence

Lab 14 — Macro: Torque Control: numbered practical steps with the setting to enter and the expected result.
#	Action	Setting / what to enter	Expected result	Rec
1	Select the torque control macro	96.04 = 28	Macro active	☐
2	Confirm vector/DTC control and complete motor data	Motor → Control mode and Nominal values	Vector setup valid	☐
3	Perform or review the ID run	Motor → ID run, or 99.13	Identification good enough for torque accuracy	☐
4	Verify the speed-reference and torque-reference sources	I/O and reference settings	Both sources documented	☐
5	Set conservative speed, torque and current limits	Group 30 Limits	Overspeed and overload constrained before the first run	☐
6	Run in speed mode first	Mode selection input	Stable low-speed operation	☐
7	Transfer to torque mode on a suitably loaded rig	Torque reference applied	Torque response observed against the load	☐
8	Increase the load and watch the speed limiter take over	Monitor speed, torque and current	Speed limiter behaves as the designed boundary	☐
9	Stop, record actual torque and current, then back up	Monitor plus backup	Lab record complete	☐

Parameters & menus used: 96.04 · 99.04 and 99.13 · Group 26 torque reference chain · Group 30 limits

PASS RESULT: Torque mode demonstrated with the speed limiter proven as the protective boundary.

SAFETY: Torque mode will accelerate an unloaded motor toward the speed limit. Use a mechanically suitable load and conservative speed, torque and current limits every time.

Lab 15 Control Word, Status Word & Cyclic Data

90 minCore skillPrerequisite for Days 06–09Day 05

Objective: Read and decode the command and state model before any fieldbus is allowed to issue a Run command.

CLICK PATH

ProfileGroup 51 (adapter) or Group 58 (embedded) → select the communication profile

MonitoringDrive Composer monitor for CW/SW, plus the PLC watch table on the controller side

Lab 15 step sequence

Lab 15 — Control Word, Status Word & Cyclic Data: numbered practical steps with the setting to enter and the expected result.
#	Action	Setting / what to enter	Expected result	Rec
1	Identify the active communication profile	ABB Drives profile, transparent or protocol-specific	Profile named and its manual open on the bench	☐
2	Read the Status Word with the drive stopped	Drive Composer monitor or PLC input data	Stable stopped-state bit pattern recorded	☐
3	Record the Status Word again once the drive reports ready	Same monitor view	Ready bits identified by observation	☐
4	Write a low reference with no Run bit set	Reference word only	Reference accepted and the motor stays stopped	☐
5	Check the reference scaling against the actual speed	Profile scaling rules	Engineering value confirmed on both sides	☐
6	Issue the valid Run sequence for this profile	Exact Control Word bit order from the profile manual	Drive runs at the low reference	☐
7	Record the running Status Word and actual value	Monitor	Running bits and actual-value scaling documented	☐
8	Command Stop and record the state transition	Control Word stop bit	Status Word returns to the stopped pattern	☐
9	Create a controlled fault or interlock and record the status	Trainer-defined fault condition	Fault bit identified in the Status Word	☐
10	Reset using only the method the profile permits	Reset bit or panel reset	Drive returns to ready	☐

Lab 15 record sheet

Lab 15 cyclic data model — record the actual values from your own profile
Direction	Data	Purpose	Training rule
Controller → Drive	Control Word	Enable, start, stop, reset and state commands	Use the exact profile manual, never another drive family
Controller → Drive	Reference 1	Speed, frequency or torque reference	Verify scaling before any Run command
Drive → Controller	Status Word	Ready, running, fault and state feedback	Read it first with the motor stopped
Drive → Controller	Actual value 1	Actual speed, frequency or other value	Check the engineering scaling against the panel

Swipe the table sideways to see every column →

Parameters & menus used: Groups 50–53 (adapter) or Group 58 (embedded) · Groups 19 / 20 / 22 source selection

PASS RESULT: Control Word and Status Word bit meanings plus reference scaling proven with the motor under control.

COMMON MISTAKE: Never copy Control Word bit patterns from a different communication profile or a different drive family. Bit meanings and reference scaling are profile-specific and a wrong pattern can produce an unexpected start.

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DAY
06

Protocol Selection + Modbus RTU Commissioning

Choose the interface before anything is wired, then commission the serial link end to end — registers read first, remote Run enabled last, and the communication-loss action tested rather than assumed.

EFB vs FBAAdapter selectionGroup 58Holding registersLoss of comms

Lab 16 Protocol & Adapter Selection

60 minEngineeringDesign decisionDay 06

Objective: Choose the correct drive interface and ABB adapter from the controller platform, the physical network and the application requirement.

CLICK PATH

EmbeddedMenu → Parameters → Complete list → Group 58 Embedded fieldbus

AdapterMenu → Parameters → Complete list → Group 50 → 50.01 FBA A enable · Group 51 adapter settings

Lab 16 step sequence

Lab 16 — Protocol & Adapter Selection: numbered practical steps with the setting to enter and the expected result.
#	Action	Setting / what to enter	Expected result	Rec
1	Map the controller platform to a protocol	Siemens S7 → PROFINET; Rockwell Logix → EtherNet/IP; generic client → Modbus	Protocol chosen for the controller, not from habit	☐
2	Check the physical network, topology and distance	RS-485 multidrop against switched industrial Ethernet	Physical layer decided and drawn	☐
3	Confirm which drive interface carries that protocol	Embedded fieldbus on the drive against a plug-in adapter module	Interface confirmed against the actual drive family	☐
4	Select the adapter and check firmware compatibility	FPNO-21, FEIP-21, FMBT-21, FENA-21 or FSCA-01 as applicable	Adapter revision and drive firmware confirmed compatible	☐
5	Plan node addressing or IP addressing and device names	Address list, IP plan, PROFINET device names	Network identity documented before installation	☐
6	Define the communication-loss action and time	Loss action and timeout parameters	Fail-safe behaviour agreed with the process owner in writing	☐

Lab 16 record sheet

Lab 16 protocol selection matrix — confirm adapter support for your drive and firmware
Protocol	Physical layer	Drive interface	Typical ABB hardware	Controller side	Lab
Modbus RTU	RS-485 serial	Embedded fieldbus or serial adapter	Embedded EIA-485 or FSCA-01	Generic Modbus master, Siemens MB_MASTER	Lab 17
PROFINET	Industrial Ethernet	Fieldbus adapter	FPNO-21 / FENA-21	Siemens S7 and TIA Portal	Labs 18–19
EtherNet/IP	Industrial Ethernet	Fieldbus adapter	FEIP-21 / FENA-21	Rockwell Logix and Studio 5000	Labs 20–21
Modbus TCP	Industrial Ethernet	Fieldbus adapter	FMBT-21 / FENA-21	PLC, SCADA or PC Modbus TCP client	Lab 22

Swipe the table sideways to see every column →

Parameters & menus used: 50.01 FBA A enable · Group 51 adapter settings · Group 58 embedded fieldbus

PASS RESULT: Architecture documented: protocol, adapter, addressing scheme and loss-of-communication action.

COMMON MISTAKE: ABB offers Modbus RTU as an embedded interface on several drive families and also supplies the FSCA-01 RS-485 adapter. Confirm which one your actual unit uses, because the parameter path differs completely — Group 58 for the embedded interface, Groups 50–53 for an adapter.

Lab 17 Modbus RTU over RS-485

180 minIntegrationRemote controlDay 06

Objective: Commission the serial interface, prove read-only data first, then enable remote command and reference and test the failure case.

CLICK PATH

DriveMenu → Parameters → Complete list → Group 58 Embedded fieldbus

Command sourcePrimary settings → Start, stop, reference — or Groups 20 / 22 / 28 directly

MasterModbus master tool → COM port → baud and parity → slave ID → holding register read request

TIA PortalInstructions → Communication → MODBUS (RTU) → MB_COMM_LOAD for port setup, MB_MASTER for requests

Lab 17 step sequence

Lab 17 — Modbus RTU over RS-485: numbered practical steps with the setting to enter and the expected result.
#	Action	Setting / what to enter	Expected result	Rec
1	Wire A/B and the shield with correct polarity and termination	Termination and biasing per the hardware manual	Physical network correct from end to end	☐
2	Set protocol, node address, baud rate and parity	58.01, 58.03, 58.04, 58.05	No mismatch remains between drive and master	☐
3	Apply or refresh the communication settings	58.06 Communication control	New settings active on the interface	☐
4	Set the communication-loss action and time	58.14 and 58.16	Fail-safe action defined before remote control is enabled	☐
5	Read the Status Word register with the drive stopped	Holding register 400004	Stable, repeatable Status Word response	☐
6	Read the actual-value registers	400005 and 400006	Live data that changes with drive state	☐
7	Write a safe reference with no Run bit	400002	Reference accepted and the motor stays stopped	☐
8	Select the embedded fieldbus as command and reference source	Groups 20, 22 or 28 as applicable	Remote authority established deliberately	☐
9	Send the valid profile Control Word sequence	400001	Drive runs at the low reference	☐
10	Stop from the master and watch the Status Word transition	400001 and 400004	Stop confirmed in the status data, not just by ear	☐
11	Disconnect the cable and verify the configured loss action	Loss-of-communication test	The configured safe action occurs within the set time	☐
12	Restore the link, reset if required and back up	Drive Composer backup	System restored and documented	☐

Lab 17 record sheet

Lab 17 default cyclic register map — verify against the installed firmware
Register	Direction	Data
400001	To drive	Control Word
400002	To drive	Reference 1
400003	To drive	Reference 2
400004	From drive	Status Word
400005	From drive	Actual value 1
400006	From drive	Actual value 2

Swipe the table sideways to see every column →

Parameters & menus used: 58.01, 58.03, 58.04, 58.05, 58.06, 58.14, 58.16 · Groups 20 / 22 / 28

PASS RESULT: Serial remote control proven, with a tested communication-loss response and a saved backup.

ENGINEERING NOTE: Master libraries display Modbus addresses differently — 400001 in one tool, a zero-based offset in another. Confirm the convention in the master library before you spend an afternoon chasing an off-by-one that does not exist.

DAY
07

PROFINET with Siemens TIA Portal

Siemens architecture end to end: GSDML installation, device naming, cyclic PZD layout and a PROFINET IO connection you can prove is healthy before the PLC is ever allowed to start the motor.

FPNO-21 / FENAGSDMLDevice namePZD mappingS7-1200 / 1500

Lab 18 PROFINET Setup: GSDML, Device Name & Cyclic Data

150 minIntegrationNetworkDay 07

Objective: Install the GSDML, configure the IO device, assign the PROFINET device name and reach a healthy cyclic connection before any control is attempted.

CLICK PATH

DriveParameters → Group 50 → 50.01 FBA A enable

AdapterGroup 51 FBA A settings → PROFINET profile and network identity → 51.27 FBA parameter refresh

MappingGroups 52 and 53 → controller-to-drive and drive-to-controller cyclic data

TIA: GSDMLOptions → Manage general station description files (GSD) → browse ABB GSDML → Install

TIA: deviceDevices & networks → Hardware catalog → add the ABB PROFINET device → connect to the PLC PN interface

TIA: nameOnline access → PG/PC interface → Update accessible devices → select by MAC → Assign device name

Lab 18 step sequence

Lab 18 — PROFINET Setup: GSDML, Device Name & Cyclic Data: numbered practical steps with the setting to enter and the expected result.
#	Action	Setting / what to enter	Expected result	Rec
1	Verify adapter LEDs, link status and module identity	Drive, adapter and switch	Adapter detected and powered	☐
2	Enable the fieldbus adapter on the drive	50.01 FBA A enable	Adapter communication enabled	☐
3	Configure the adapter profile and network identity	Group 51 per the adapter manual	Settings match the planned architecture	☐
4	Refresh the adapter parameters	51.27 FBA parameter refresh	Changed adapter settings taken into use	☐
5	Install the GSDML that matches the adapter firmware revision	TIA → Manage GSD files → Install	Device appears in the hardware catalog	☐
6	Add the device and connect it to the PLC PROFINET interface	Devices & networks	Device in the same PROFINET subnet as the CPU	☐
7	Configure the cyclic module and PZD layout	Device view → telegram / module selection	Layout matches the Groups 52 / 53 mapping exactly	☐
8	Assign the PROFINET device name online by MAC address	Accessible devices → Assign device name	Assigned name matches the project character for character	☐
9	Compile and download the hardware configuration	Compile → Download → Go online	IO connection healthy with no red diagnostics	☐
10	Confirm the drive end also reports the adapter as connected	50.02 or the adapter status parameter	Both ends agree the connection is established	☐

Parameters & menus used: 50.01, 50.02 · Group 51 · 51.27 FBA parameter refresh · Groups 52 / 53 mapping

PASS RESULT: A healthy PROFINET IO connection with a matching device name and verified cyclic layout.

COMMON MISTAKE: A correct IP address alone is not enough. A PROFINET device-name mismatch is the single most common reason an IO device stays offline — check the assigned name before you check anything else.

Lab 19 PROFINET Run, Reference & Loss-of-Comms Test

120 minIntegrationRemote controlDay 07

Objective: Prove input data first, then hand Start/Stop and reference to the PLC, then deliberately break the network and verify the drive behaves as designed.

CLICK PATH

TIAWatch table → monitor input and output PZD tags

DriveGroups 19 / 20 / 22 / 28 → select Fieldbus A as command and reference source

Lab 19 step sequence

Lab 19 — PROFINET Run, Reference & Loss-of-Comms Test: numbered practical steps with the setting to enter and the expected result.
#	Action	Setting / what to enter	Expected result	Rec
1	Monitor the input PZD with the drive stopped	PLC watch table: Status Word and actual value	Input data updating live	☐
2	Verify Control Word and Reference output tags while remote Run stays disabled	Watch table	Output PZD correct but not yet authoritative	☐
3	Check reference scaling against a known speed	Profile scaling rules	Engineering value agreed on both sides	☐
4	Select Fieldbus A as the command source	Group 20	Remote command authority established	☐
5	Select Fieldbus A as the reference source	Group 22 or 28	Remote reference active	☐
6	Send a low reference and the valid Run sequence	PLC Control Word	Motor runs at low speed under PLC control	☐
7	Stop from the PLC and verify the status transition	Watch table	Stop confirmed in the Status Word	☐
8	Unplug the network cable while the drive is running	Communication-loss test	Configured safe action occurs within the set time	☐
9	Restore the link, reset and confirm normal control	Reset per the profile	Control recovered cleanly	☐
10	Save the TIA project and the drive backup together	Project files plus .dcbak	Recovery package complete	☐

Parameters & menus used: Groups 19 / 20 / 22 / 28 · Groups 50–53 · adapter loss-of-communication parameters

PASS RESULT: PLC Start/Stop and reference proven with a tested communication-loss response.

ENGINEERING NOTE: Do the loss-of-communication test with the motor running, not stopped. A test done at standstill proves nothing about how the machine behaves on the day the switch fails.

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DAY
08

EtherNet/IP with Rockwell Studio 5000

Rockwell architecture end to end: EDS or AOP installation, assembly instances and sizes, RPI selection, and full Logix control of the drive with a tested failure response.

FEIP-21 / FENAEDS / AOPAssembly instancesRPICompactLogix / ControlLogix

Lab 20 EtherNet/IP Setup: EDS, Module & Assemblies

150 minIntegrationNetworkDay 08

Objective: Add the drive to the Logix I/O tree with the correct assembly instances and sizes, and reach a healthy connection before control is attempted.

CLICK PATH

DriveParameters → Group 50 → 50.01 FBA A enable

AdapterGroup 51 FBA A settings → EtherNet/IP profile and IP method → 51.27 FBA parameter refresh

MappingGroups 52 and 53 → map cyclic data consistent with the selected assembly

Studio 5000: EDSRockwell EDS Hardware Installation Tool → install the ABB EDS / AOP for the adapter revision

Studio 5000: moduleController Organizer → I/O Configuration → right-click the Ethernet network → New Module

Lab 20 step sequence

Lab 20 — EtherNet/IP Setup: EDS, Module & Assemblies: numbered practical steps with the setting to enter and the expected result.
#	Action	Setting / what to enter	Expected result	Rec
1	Plan and set the adapter IP address, subnet and gateway	Group 51 and the network plan	Adapter reachable on the network	☐
2	Enable the adapter and refresh its parameters	50.01 and 51.27	Adapter active with the new settings	☐
3	Install the EDS or AOP matching the adapter revision	EDS Hardware Installation Tool	Device available in the module catalog	☐
4	Add the module under the correct Ethernet path	I/O Configuration → New Module	Module created in the I/O tree	☐
5	Enter the Input and Output assembly instances and data sizes	Exactly as the selected ABB profile requires	Connection definition matches the drive side	☐
6	Enter the Configuration assembly if required and set the RPI	Module properties	RPI suitable for the application, not the default guess	☐
7	Download to the controller and go online	Who Active → Download → Go Online	Module shows healthy with no connection fault	☐
8	Verify controller tags appear for the input and output assemblies	Controller Tags	Tag structure matches the Groups 52 / 53 mapping	☐

Parameters & menus used: 50.01 · Group 51 · 51.27 · Groups 52 / 53 · Logix module properties and RPI

PASS RESULT: A healthy EtherNet/IP connection with verified assembly instances, sizes and RPI.

COMMON MISTAKE: A wrong assembly instance or data size is the usual cause of a Logix I/O connection fault. The IP address is rarely the real problem — check the instance numbers against the ABB profile first.

Lab 21 EtherNet/IP Run, Reference & Recovery

120 minIntegrationRemote controlDay 08

Objective: Move from read-only assembly data to full Logix control of the drive, including the loss-of-communication test and recovery.

CLICK PATH

Studio 5000Controller Tags → monitor input assembly, write output assembly

DriveGroups 19 / 20 / 22 / 28 → select Fieldbus A as command and reference source

Lab 21 step sequence

Lab 21 — EtherNet/IP Run, Reference & Recovery: numbered practical steps with the setting to enter and the expected result.
#	Action	Setting / what to enter	Expected result	Rec
1	Monitor the Input assembly and Status Word with the drive stopped	Controller tags	Drive data updating at the configured RPI	☐
2	Write a low reference into the Output assembly with no Run bit	Controller tags	Reference accepted and the motor stays stopped	☐
3	Confirm reference and actual-value scaling	Profile documentation	Engineering values agreed on both sides	☐
4	Select Fieldbus A as command and reference source	Groups 19 / 20 / 22 / 28	Remote authority established	☐
5	Send the valid profile control sequence	Output assembly	Motor runs at low speed under Logix control	☐
6	Stop from the controller and verify the status	Input and output assemblies	Stop confirmed in the input data	☐
7	Break the Ethernet connection while running	Fault test	Configured loss action occurs as designed	☐
8	Restore, reset and re-verify control	Controller and drive	Normal control recovered	☐
9	Save the Logix project and the drive backup together	Studio 5000 project plus .dcbak	Recovery package complete	☐

Parameters & menus used: Groups 19 / 20 / 22 / 28 · Groups 50–53 · adapter loss-of-communication parameters

PASS RESULT: Full Logix control of the drive with a documented, tested failure response.

ENGINEERING NOTE: Record the RPI you finally used and why. It is the first question the next engineer asks when the network is loaded with more devices.

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DAY
09

Modbus TCP + Diagnostics & Fault Tracing

Modbus TCP through the Ethernet adapter, then a fixed troubleshooting method that separates drive, motor, I/O, adapter, network and PLC causes instead of guessing at them one parameter at a time.

FMBT-21 / FENATCP port 502Register offsetsEvent loggerRoot cause method

Lab 22 Modbus TCP over Ethernet

150 minIntegrationRemote controlDay 09

Objective: Commission the Ethernet adapter as a Modbus/TCP server and prove reads before writes, then enable remote control and test the failure case.

CLICK PATH

DriveParameters → Group 50 → 50.01 FBA A enable

AdapterGroup 51 FBA A settings → Modbus/TCP profile → IP, subnet and gateway → 51.27 refresh

ClientModbus TCP client → target IP = adapter → TCP port 502 → holding register read request

TIA PortalInstructions → Communication → Others → MODBUS TCP → MB_CLIENT with the CONNECT structure

Lab 22 step sequence

Lab 22 — Modbus TCP over Ethernet: numbered practical steps with the setting to enter and the expected result.
#	Action	Setting / what to enter	Expected result	Rec
1	Verify the Ethernet link, IP address, subnet and gateway	Adapter settings against the network plan	Adapter reachable, link LED healthy	☐
2	Select the Modbus/TCP profile and refresh the adapter	Group 51 and 51.27	Profile active on the adapter	☐
3	Open a TCP client session to the adapter	Target IP, TCP port 502	Session established	☐
4	Read the Status Word and actual data with the drive stopped	Selected register map	Stable and sensible data returned	☐
5	Verify the register offset convention and scaling	Client library documentation	Mapping confirmed with no off-by-one	☐
6	Write a safe reference with no Run bit	Reference register	Reference accepted and the motor stays stopped	☐
7	Select Fieldbus A as command and reference source	Groups 20 / 22 / 28	Remote authority established	☐
8	Send the valid profile command sequence	Client write	Motor runs at the low reference	☐
9	Stop from the client and verify the state	Control and status registers	Stop confirmed in the register data	☐
10	Interrupt the TCP session or unplug the cable while running	Loss-of-communication test	Configured safe action occurs	☐
11	Reconnect, reset and confirm control	Client and drive	Communication and control restored	☐
12	Save the client configuration and the drive backup	Project files plus .dcbak	Backup package complete	☐

Parameters & menus used: 50.01 · Group 51 · 51.27 · Groups 52 / 53 · Groups 20 / 22 / 28

PASS RESULT: Modbus TCP remote control proven with verified scaling and a tested loss-of-communication response.

ENGINEERING NOTE: In TIA Portal use MB_CLIENT with the CONNECT structure, the server IP and port 502. The exact block interface depends on the CPU generation and TIA version — check the instruction help for your CPU.

Lab 23 Diagnostics, Fault Finding & Recovery

120 minCore skillMethodDay 09

Objective: Apply one fixed sequence that separates drive, motor, I/O, adapter, network and PLC causes instead of changing parameters hopefully.

CLICK PATH

PanelHome → Menu → Diagnostics → active faults and warnings

Drive ComposerDrives list → drive → … → Event logger

Lab 23 step sequence

Lab 23 — Diagnostics, Fault Finding & Recovery: numbered practical steps with the setting to enter and the expected result.
#	Action	Setting / what to enter	Expected result	Rec
1	Read the active fault or warning and its context before any reset	Diagnostics and Event logger	Code, timestamp and auxiliary data recorded	☐
2	Check the actual I/O states	Menu → I/O	Field-signal problem separated from a logic problem	☐
3	Check Local/Remote and the active command and reference source	Groups 19 / 20 / 22 / 28	Control authority confirmed, not assumed	☐
4	Check motor data, limits and run enables	Groups 20, 30 and 99	Drive permissives verified	☐
5	For serial: check node, baud, parity, polarity and termination	Group 58 plus the physical layer	Serial root cause isolated	☐
6	For Ethernet: check link LEDs, IP, device name and PLC module diagnostics	Adapter and PLC software	Network root cause isolated	☐
7	Compare the communication profile and data map on both sides	Groups 50–53 against the PLC module configuration	Control and Status Words interpreted consistently	☐
8	Perform a controlled communication-loss test	Disconnect the network deliberately	Safe action verified rather than assumed	☐
9	Restore communications and perform the permitted reset	Panel or PLC reset	Drive returns to ready	☐
10	Write the root cause, corrective action and preventive action	Fault report	Learning captured for the next shift	☐

Lab 23 record sheet

Lab 23 fault record template — one row per injected or real fault
Symptom	Where detected	Probable cause	Test performed	Actual cause	Corrective action

Swipe the table sideways to see every column →

Parameters & menus used: Diagnostics menu · Event logger · Groups 19 / 20 / 22 / 28 / 30 / 50–53 / 58 / 99

PASS RESULT: A documented root-cause method that survives handover to another engineer.

ENGINEERING NOTE: Read the event logger before resetting. A reset clears the one piece of evidence that would have told you what actually happened.

DAY
10

Backup, Restore, Final Project & Assessment

Close the project the way an engineer should: traceable backups and change control, one end-to-end integrated commissioning run using only the documented labs, and a practical assessment against a fixed marking scheme.

.dcbakChange controlRestore rehearsalIntegrated projectAssessment record

Lab 24 Backup, Restore & Parameter Change Control

90 minEngineeringDocumentationDay 10

Objective: Produce traceable baseline and final backups, compare them, and rehearse a controlled restore before it is ever needed on site.

CLICK PATH

BackupDrive Composer → Drives list → drive → … → Backup → location → file name → Save

RestoreDrive Composer → Drives list → drive → … → Restore → select .dcbak → Open

Lab 24 step sequence

Lab 24 — Backup, Restore & Parameter Change Control: numbered practical steps with the setting to enter and the expected result.
#	Action	Setting / what to enter	Expected result	Rec
1	Create the baseline backup before any change	DriveTag_Date_Firmware_Baseline.dcbak	Baseline exists and is stored with the project	☐
2	Apply the file naming standard consistently	DriveTag_Date_Firmware_Stage	File is traceable without being opened	☐
3	Record every changed parameter with old and new values	Parameter change log	Every deviation from default documented	☐
4	Create the final commissioned backup	DriveTag_Date_Firmware_Final.dcbak	Final file exists	☐
5	Compare the baseline and final parameter sets	Drive Composer compare workflow	Differences reviewed and each one explained	☐
6	Rehearse the restore onto an approved training drive only	Restore the .dcbak	Restore procedure demonstrated safely	☐
7	After restore, re-verify motor data, macro, fieldbus identity and command sources	Full commissioning checks	Restored configuration validated, not assumed	☐
8	Archive the PLC project, GSDML/EDS files and network notes with the backups	Single project folder	Complete recovery package assembled	☐

Lab 24 record sheet

Lab 24 parameter change log — the record that makes a drive supportable
Date	Parameter	Old value	New value	Reason	Changed by	Verified by

Swipe the table sideways to see every column →

Parameters & menus used: Drive Composer Backup / Restore · 07.05 firmware version for the file name

PASS RESULT: A recovery package that lets a different engineer rebuild the drive from scratch.

COMMON MISTAKE: A restore overwrites existing settings and may require the drive to be connected with the appropriate user-lock permissions. Never rehearse a restore on production equipment.

Lab 25 Final Integrated Project

300 minAssessmentEnd to endDay 10

Objective: Run one complete project from safety checks to handover using only the methods documented in Labs 01 to 24.

CLICK PATH

ScopeApplication brief → macro → protocol → interlock strategy → documentation set

Lab 25 step sequence

Lab 25 — Final Integrated Project: numbered practical steps with the setting to enter and the expected result.
#	Action	Setting / what to enter	Expected result	Rec
1	Choose the application: conveyor or fan, PID pump, Hand/Auto, PFC simulator or torque rig	Written application brief	Scope defined before any configuration	☐
2	Complete the safety and motor-data records	Labs 01 and 04	Pre-commissioning checks passed	☐
3	Go online and create the baseline backup	Lab 02	Baseline saved and named correctly	☐
4	Commission the motor locally and prove the I/O	Labs 03 and 05	Local run and full I/O map passed	☐
5	Select and commission the required macro	Labs 06 to 14	Macro passed with every assignment verified	☐
6	Choose one protocol and adapter	Lab 16	Architecture documented with reasons	☐
7	Map Control Word, Status Word, reference and actual values, and prove read-only data first	Lab 15	Read diagnostics healthy before any Run	☐
8	Enable remote Start/Stop and reference at low speed	Labs 17 to 22	Remote control passed	☐
9	Implement one permissive or interlock plus a fault-reset strategy	PLC and drive together	Logic tested against the brief	☐
10	Perform the communication-loss test and safe recovery	Fault test with the motor running	Safe behaviour confirmed	☐
11	Create final drive and PLC backups plus the change and network record	Lab 24	Recovery package complete	☐
12	Demonstrate to the trainer and complete the handover	Final demonstration	Project accepted	☐

Lab 25 record sheet

Lab 25 deliverables checklist — all items required for sign-off
Deliverable	Required	Trainer check
Drive baseline backup (.dcbak)	Yes	☐
Drive final backup (.dcbak)	Yes	☐
PLC project with GSDML / EDS files	Yes	☐
I/O and network map	Yes	☐
Parameter change log	Yes	☐
Communication-loss test record	Yes	☐

Swipe the table sideways to see every column →

Parameters & menus used: Every parameter group used in Labs 01–24, as required by the chosen application

PASS RESULT: An end-to-end commissioned system delivered with a complete document set.

ENGINEERING NOTE: The project is assessed on documentation as much as on the running motor. A drive that runs but cannot be rebuilt from its files has not been commissioned.

Lab 26 Practical Assessment & Handover Record

120 minAssessmentSign-offDay 10

Objective: Record practical competence against a fixed marking scheme and complete a documented handover.

CLICK PATH

RecordAssessment sheet → practical score per area → trainer comments → signatures

Lab 26 step sequence

Lab 26 — Practical Assessment & Handover Record: numbered practical steps with the setting to enter and the expected result.
#	Action	Setting / what to enter	Expected result	Rec
1	Submit the drive baseline and final backups	Correctly named files	Both files present and readable	☐
2	Submit the PLC project and the network map	Complete project folder	Configuration reproducible by someone else	☐
3	Present the parameter change log	Change log from Lab 24	Every deviation explained	☐
4	Demonstrate one macro commissioning unaided	Trainer-selected macro	Competence observed, not described	☐
5	Demonstrate one protocol commissioning unaided	Trainer-selected protocol	Competence observed end to end	☐
6	Diagnose one injected fault within the time limit	Trainer-injected fault	Root cause found by method, not guesswork	☐
7	Explain the communication-loss strategy for the application	Verbal or written	Safe behaviour justified against the process risk	☐
8	Complete the handover record and signatures	Assessment sheet	Training record closed	☐

Lab 26 record sheet

Lab 26 assessment record — 10 marks per area, 100 total
Assessment area	Max marks	Score	Trainer comments
Safety and hardware pre-check	10
Drive Composer online and backup	10
Basic commissioning and motor data	10
I/O proving and terminal map	10
Macro selection and standard macro	10
PID / PFC / torque macro understanding	10
Control Word and Status Word	10
One protocol commissioned independently	10
Diagnostics and communication-loss recovery	10
Final documentation, backup and handover	10

Swipe the table sideways to see every column →

Parameters & menus used: Assessment record · all deliverables from Labs 01–25

PASS RESULT: A completed practical assessment and signed handover record.

COMMON MISTAKE: This is a training record. It does not by itself authorise energized electrical work, override site competency requirements, or sign off machine-safety functions.

Ready for a complete 10-day ABB VFD practical batch or corporate program?

Share your PLC, drive model, fieldbus adapter and participant count. Softwell Automation can align the labs with your classroom, online, corporate or in-plant requirement.

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LAB
MAP

Protocol Selection Quick Reference

Use this before purchasing an option adapter or building the PLC project.

Protocol	Physical Network	Typical Drive Interface	Controller Software	Core Practice
Modbus RTU	RS-485 serial	Embedded fieldbus on supported ACS580 configurations / applicable adapter architecture	PLC Modbus master or test client	Node, baud, parity, registers, CW/SW, comm-loss
PROFINET	Industrial Ethernet	ABB PROFINET-capable fieldbus adapter such as FPNO/FENA family as supported	Siemens TIA Portal	GSDML, device name, IP, PZD, online diagnostics
EtherNet/IP	Industrial Ethernet	ABB EtherNet/IP-capable fieldbus adapter such as FEIP/FENA family as supported	Rockwell Studio 5000	EDS/module, assemblies, RPI, implicit I/O
Modbus TCP	Industrial Ethernet	ABB Modbus/TCP-capable Ethernet adapter such as FMBT/FENA family as supported	PLC / SCADA / Modbus TCP client	IP, TCP 502, register map, reconnect and loss response

ABB
REF

Official ABB Documentation Used for Lab Verification

Use the document revision that matches the installed ACS580/ACS880 firmware and fieldbus adapter.

ACS580 / ACS880 Application Macros

ABB documents application macros as coordinated parameter sets and uses parameter 96.04 Macro select in applicable standard control programs. Macro availability and defaults differ by drive/application program.

Open ABB Library

FENA Ethernet Adapter

ABB FENA Ethernet adapters support Modbus/TCP, EtherNet/IP and PROFINET IO for supported ABB drive families including ACS580 and ACS880. Verify adapter software and drive compatibility before commissioning.

FENA User Manual

ABB ACS580 / ACS880 VFD Training FAQ

Is this ABB VFD manual for both ACS580 and ACS880?

Yes. The 10-day practical structure targets both ACS580 and ACS880. Exact macros, parameters, firmware functions and fieldbus options must be verified on the installed drive and ABB manual.

Does the training include Drive Composer software?

Yes. The sequence includes going online, reading parameters, monitoring, backup/restore, parameter comparison and commissioning workflow with ABB Drive Composer.

Which communication protocols are included?

The practical sequence includes Modbus RTU, PROFINET, EtherNet/IP and Modbus TCP, including controller-side configuration, cyclic data, diagnostics and communication-loss tests.

Is this suitable for corporate and in-plant training?

Yes. The labs can be delivered as classroom, online, corporate or in-plant training and can be adapted to the customer PLC, motor, fieldbus adapter and application.

What is the duration of the ABB ACS580 and ACS880 course?

This page is organized as a 10-day practical training sequence covering 26 labs. Actual delivery hours can be adjusted for trainee experience, plant hardware and project scope.

Does every lab include step-by-step instructions?

Yes. Each of the 26 labs lists a numbered step sequence with the action to perform, the setting or value to enter, and the expected result, plus the click path, the parameter groups involved and a pass criterion you can sign off.

Which ABB parameter groups do the labs cover?

The labs work through groups 07, 10, 12, 13, 19, 20, 22, 26, 28, 30, 40, 50-53, 58, 76, 96 and 99 - including 96.04 macro select, 99.04 motor control mode, 99.13 ID run requested, 50.01 FBA A enable and 51.27 FBA parameter refresh.

What software do I need to follow these labs?

ABB Drive Composer for the drive side, plus the controller software for your chosen protocol: Siemens TIA Portal for PROFINET and Modbus RTU/TCP blocks, Rockwell Studio 5000 for EtherNet/IP, or any Modbus master or TCP client for the serial and Modbus TCP labs.

Can these lab steps be used on a live plant drive?

The steps are written for a supervised training rig. On production equipment, follow site LOTO rules, the machine risk assessment and STO validation first, and verify every parameter number and value against the firmware manual for the drive actually installed.

ABB ACS580 & ACS880 — 10-Day Practical Training Sequence

All 26 ABB VFD Labs — Jump to Any Step Sequence

Planning ABB ACS580 / ACS880 Training?

Drive Composer Online, Safety & Baseline Backup

Lab 01 Safety, Hardware & Drive Identification

Lab 01 step sequence

Lab 02 Go Online with ABB Drive Composer

Lab 02 step sequence

Basic Commissioning, Motor ID & I/O Proving

Lab 03 Basic Commissioning & First Local Run

Lab 03 step sequence

Lab 04 Motor Data, Control Mode & ID Run

Lab 04 step sequence

Lab 05 Digital, Analog & Relay I/O Practical

Lab 05 step sequence

Lab 05 record sheet

Need help selecting ACS580 vs ACS880 or commissioning your training hardware?

Macro Selection + Standard Control Labs

Lab 06 Macro Selection Engineering

Lab 06 step sequence

Lab 06 record sheet

Lab 07 Macro: ABB Standard & ABB Standard (Vector)

Lab 07 step sequence

Lab 08 Macro: 3-Wire & Alternate

Lab 08 step sequence

Motor Potentiometer, Hand/Auto + PID Macro Labs

Lab 09 Macro: Motor Potentiometer

Lab 09 step sequence

Lab 10 Macro: Hand / Auto

Lab 10 step sequence

Lab 11 Macro: Hand/PID, PID & Panel PID

Lab 11 step sequence

PFC, Compressor, Torque Control + CW/SW

Lab 12 Macro: PFC / Multi-Pump Staging

Lab 12 step sequence

Lab 13 Macro: Compressor / Application Control

Lab 13 step sequence

Lab 14 Macro: Torque Control

Lab 14 step sequence

Lab 15 Control Word, Status Word & Cyclic Data

Lab 15 step sequence

Lab 15 record sheet

Want trainer-led macro, PID, PFC and torque-control practicals?

Protocol Selection + Modbus RTU Commissioning

Lab 16 Protocol & Adapter Selection

Lab 16 step sequence

Lab 16 record sheet

Lab 17 Modbus RTU over RS-485

Lab 17 step sequence

Lab 17 record sheet

PROFINET with Siemens TIA Portal

Lab 18 PROFINET Setup: GSDML, Device Name & Cyclic Data

Lab 18 step sequence

Lab 19 PROFINET Run, Reference & Loss-of-Comms Test

Lab 19 step sequence

Need a Siemens PROFINET + ABB drive practical batch for your team?

EtherNet/IP with Rockwell Studio 5000

Lab 20 EtherNet/IP Setup: EDS, Module & Assemblies

Lab 20 step sequence

Lab 21 EtherNet/IP Run, Reference & Recovery

Lab 21 step sequence

Need Rockwell EtherNet/IP + ABB ACS580/ACS880 integration training?

Modbus TCP + Diagnostics & Fault Tracing

Lab 22 Modbus TCP over Ethernet

Lab 22 step sequence

Lab 23 Diagnostics, Fault Finding & Recovery

Lab 23 step sequence

Lab 23 record sheet

Backup, Restore, Final Project & Assessment

Lab 24 Backup, Restore & Parameter Change Control

Lab 24 step sequence

Lab 24 record sheet

Lab 25 Final Integrated Project

Lab 25 step sequence

Lab 25 record sheet

Lab 26 Practical Assessment & Handover Record

Lab 26 step sequence

Lab 26 record sheet

Ready for a complete 10-day ABB VFD practical batch or corporate program?

Protocol Selection Quick Reference