ABB ACS800 Drive Firmware & Control Board Programming Guide

Rectifier Programs for ACS800

Rectifier units in the ACS800 family require specific firmware to manage the conversion of AC to DC power. These programs ensure stable DC bus voltage and regenerative capabilities. Common rectifier firmware codes include:

• IXXR7210 – Standard rectifier control
• IXXR7240 – Enhanced rectifier with advanced grid monitoring
• IXXR7250 – High-power rectifier for parallel configurations
• IXXR7270 – Latest rectifier firmware with improved harmonics
• IWXR725I – Water-cooled rectifier control
• IWXR7330 – High-performance water-cooled unit
• IWXR7430 – Next-gen water-cooled rectifier

Motion Control Firmware

For applications requiring precise speed and torque control, such as winding, positioning, or synchronized movements, the motion control firmware is indispensable. The primary code is:

APXR7000 (+N685)

The N685 option enables advanced motion control features like camming and electronic gearing. This firmware transforms the ACS800 into a high-performance servo-like drive.

PFC (Pump and Fan Control) Programs

Pump and fan applications benefit from dedicated firmware that optimizes energy consumption and process control. The ACS800 offers:

• AQPB7220 (+N687) – Basic PFC with multi-pump control
• AQPM7070 – Advanced PFC with flow calculation and sleep boost

The N687 option adds pump cleaning and anti-jam functions, critical for water treatment plants.

System Control Firmware

For drives acting as system masters or handling complex communication tasks, the system control firmware is used:

AMXR7220

This firmware supports master-follower configurations and advanced fieldbus control, making it suitable for large-scale automation systems.

Hoist and Crane Programs

Hoisting applications demand precise torque control, brake logic, and safety features. The ACS800 provides several hoist firmware variants:

• ACXR7400 (+N652) – Standard hoist control
• ACXR7411 (+N652) – Enhanced hoist with extended speed range
• ACXR7431 (+N652) – High-performance hoist with adaptive programming
• AQCR7140 (+N697) – Crane control with anti-sway
• AQCR7160 (+N697) – Advanced crane with load measurement
• AQCR7210 (+N697) – Latest crane firmware with condition monitoring

The N652 option provides mechanical brake control, while N697 adds safety functions compliant with EN 81-20 for elevators.

Standard Control Programs

The standard firmware covers general-purpose applications like conveyors, mixers, and extruders. It offers a balance of simplicity and functionality. Available codes include:

Power Modification and Firmware Flashing

In some cases, the drive’s power rating can be modified via firmware to match a different motor or application requirement. This process involves reflashing the control board with a specific firmware package that includes the desired power parameters. It is crucial to ensure that the hardware (such as IGBT modules and cooling) supports the new power level to avoid damage.

Firmware flashing typically requires the ABB DriveWindow software and a compatible connection cable. The procedure must be performed by qualified personnel, as incorrect flashing can render the drive inoperable. Always back up the existing parameters before starting.

Choosing the Right Firmware

Selecting the correct firmware depends on the application, motor type, and required control features. For example:

• Use rectifier firmware for active front-end units.
• Motion control is ideal for high-precision positioning.
• PFC programs save energy in centrifugal pumps and fans.
• Hoist firmware ensures safety and smooth lifting.
• Standard programs cover most general machinery.

Always consult the ACS800 firmware manual or contact technical support for compatibility with your drive’s hardware revision.