5.4.2 External Connections. ABB ACS800 CraneDrive Control, ACC800 7.1

ACS800 CraneDrive Control Firmware Manual

ACC800 Crane Application Program 7.1

for ACS 800 Frequency Converters

ACC800 Crane Application Program 7.1

for ACS 800 Frequency Converters

Firmware Manual

3BSE 011179 R1025

EN

EFFECTIVE: 2004-10-26

SUPERSEDES: 2004-10-01

2004 ABB Automation Technologies AB, Crane Systems. All Rights Reserved

Safety Instructions

Overview

These are safety instructions which must be followed when installing, operating and servicing the ACS 800. If neglected, physical injury and death may follow, or damage may occur to the frequency converter, the motor and driven equipment. The material in this chapter must be studied before attempting any work on, or with the unit.

Warnings and Notes

This manual distinguishes between two sorts of safety instructions.

Warnings are used to inform of conditions that can, if proper steps are not taken, lead to a serious fault condition, physical injury and death.

Notes are used when the reader is required to pay special attention or when there is additional information available on the subject. Notes are less crucial than Warnings, but should not be disregarded.

Warnings

Readers are informed of situations that can result in serious physical injury and/or serious damage to equipment with the following symbols:

Dangerous Voltage Warning: warns of situations in which a high voltage can cause physical injury and/or can damage equipment. The text next to this symbol describes ways to avoid the danger.

General Warning: warns of situations that can cause physical injury and/or can damage equipment by means other than electrical. The text next to this symbol describes ways to avoid the danger.

Electrostatic Discharge Warning: warns of situations in which an electrostatic discharge can damage equipment. The text next to this symbol describes ways to avoid the danger.

Notes

Readers are notified of the need for special attention or additional information available on the subject with the following symbols:

CAUTION! Caution aims to draw special attention to a issue.

Note: Note gives additional information or points out more information available on the subject.

ACC 800 Firmware Manual i

General Safety Instructions

These safety instructions are intended for all work on the ACS 800.

In addition to the instruction given below there are more safety instructions on the first pages of the Hardware Manual.

WARNING!

All electrical installation and maintenance work on the

ACS 800 should be carried out by qualified electricians.

The ACS 800 and adjoining equipment must be properly earthen

Do not attempt any work on a powered ACS 800. After switching off the mains, always allow the intermediate circuit capacitors 5 minutes to discharge before working on the frequency converter, the motor or the motor cable. It is good practice to check (with a voltage indicating instrument) that the frequency converter is in fact discharged before beginning work.

The ACS 800 motor cable terminals are at a dangerously high voltage when mains power is applied, regardless of motor operation.

There can be dangerous voltages inside the ACS 800 from external control circuits when the ACS 800 mains power is shut off. Exercise appropriate care when working with the unit. Neglecting these instructions can cause physical injury and death.

WARNING!

The ACS 800 introduces electric motors, drive train mechanisms and driven machines to an extended operating range. It should be determined from the outset that all equipment is up to these conditions.

Operation is not allowed if the motor nominal voltage is less than one half of the ACS 800 nominal input voltage, or the motor nominal current is less than 1/6 of the ACS 800 nominal output current. Proper attention should be given to the motor insulation properties. The ACS 800 output comprises short, high voltage pulses (approximately 1.35 ... 1.5 * mains voltage) regardless of output frequency. This voltage can be increased up to 100 % by unfavourable motor cable properties. Contact an ABB office for additional information if multi-motor operation is required. Neglecting these instructions can result in permanent damage to the motor.

All insulation tests must be carried out with the ACS 800 disconnected from the cabling. Operation outside the rated capacities should not be attempted. Neglecting these instructions can result in permanent damage to the ACS 800. ii ACC 800 Firmware Manual

Table of Contents

Overview ............................................................................................................................................i

Warnings and Notes...........................................................................................................................i

Warnings ............................................................................................................................................i

Notes ..................................................................................................................................................i

General Safety Instructions ............................................................................................................... ii

1 Chapter 1 - Introduction to this Manual ........................................................................................ 1-1

1.1 Overview ................................................................................................................................. 1-1

1.2 Before You Start...................................................................................................................... 1-1

1.3 What This Manual Contains .................................................................................................... 1-1

1.4 Related Publications................................................................................................................ 1-2

2 Chapter 2 - Overview of CraneDrive Programming and the CDP 312R Control Panel............. 2-1

2.1 Overview ................................................................................................................................. 2-1

2.2 CraneDrive Programming........................................................................................................ 2-1

2.2.1 Application Macros......................................................................................................... 2-1

2.2.2 Parameter Groups ......................................................................................................... 2-1

2.3 Control Panel........................................................................................................................... 2-1

2.3.2 Display ........................................................................................................................... 2-2

2.3.3 Keys ............................................................................................................................... 2-2

2.4 Panel Operation ...................................................................................................................... 2-4

2.4.1 Keypad Modes ............................................................................................................... 2-4

2.4.2 Operational Commands ............................................................................................... 2-14

3 Chapter 3 - Start-up ........................................................................................................................ 3-1

3.1 Overview ................................................................................................................................. 3-1

3.2 Start-up Procedure .................................................................................................................. 3-1

3.3 Start-up Data ........................................................................................................................... 3-7

3.3.1 Start-up Data Parameters .............................................................................................. 3-7

4 Chapter 4 - Control Operation ....................................................................................................... 4-1

4.1 Overview ................................................................................................................................. 4-1

4.2 Actual Signals.......................................................................................................................... 4-1

4.3 Signal Selection - Description of the Actual Signals, Groups 1 and 2..................................... 4-4

4.4 Fault History .......................................................................................................................... 4-10

4.5 Local Control vs. External Control......................................................................................... 4-10

4.5.1 Keypad Control ............................................................................................................ 4-10

4.5.2 External Control ........................................................................................................... 4-11

4.6 Control Signals Connection Stand Alone mode .................................................................... 4-12

4.7 Control Signals Connection in Fieldbus mode ...................................................................... 4-13

4.8 External 24V supply of RMIO board...................................................................................... 4-14

4.8.1 Power On Acknowledge input signal ........................................................................... 4-14

5 Chapter 5 - Crane Program Description ....................................................................................... 5-1

5.1 Overview ................................................................................................................................. 5-1

5.2 Application Macros .................................................................................................................. 5-1

5.3 Speed Reference chain........................................................................................................... 5-2

5.4 Stand alone mode operation ................................................................................................... 5-3

5.4.1 Input and Output I/O Signals.......................................................................................... 5-3

ACC 800 Firmware Manual iii

5.4.2 External Connections ..................................................................................................... 5-4

5.4.3 Control Signals Connection Stand Alone mode ............................................................. 5-6

5.4.4 Parameter Settings for the Stand alone mode ............................................................... 5-7

5.5 Fieldbus mode operation ......................................................................................................... 5-8

5.5.1 Input and Output I/O Signals .......................................................................................... 5-8

5.5.2 External Connections ..................................................................................................... 5-9

5.5.3 Control Signals Connection in Field Bus mode ............................................................ 5-10

5.5.4 Speed correction in Fieldbus mode.............................................................................. 5-11

5.5.5 External Chopper monitoring (available in both Fieldbus and Standalone mode) ....... 5-11

5.5.6 Parameter Settings for the Fieldbus mode................................................................... 5-12

5.6 Function Module Description ................................................................................................. 5-14

5.6.1 Local operation ( 60 ) ................................................................................................... 5-14

5.6.2 Speed monitor ( 61 )..................................................................................................... 5-15

5.6.3 Torque monitor ( 62 ).................................................................................................... 5-15

5.6.4 Fast stop ( 63 ) ............................................................................................................. 5-16

5.6.5 Crane ( 64 ) .................................................................................................................. 5-17

5.6.6 Logic handler ( 65 ) ...................................................................................................... 5-26

5.6.7 Torque proving (66)...................................................................................................... 5-29

5.6.8 Mechanical brake control ( 67) ..................................................................................... 5-30

5.6.9 Power optimisation ( 68 ).............................................................................................. 5-33

5.6.10 Reference handler ( 69 ) ............................................................................................ 5-37

5.6.11 Position measurement ( 70 ) ...................................................................................... 5-39

5.6.12 Field bus communication ( 71 ) .................................................................................. 5-40

5.6.13 Master/Follower ( 72 ) ................................................................................................ 5-48

5.6.14 Electric shaft (73) ....................................................................................................... 5-54

5.6.15 Crane lifetime monitor (74)......................................................................................... 5-56

5.7 User Macros .......................................................................................................................... 5-57

6 Chapter 6 - Parameters ................................................................................................................... 6-1

6.1 Overview.................................................................................................................................. 6-1

6.2 Parameter Groups ................................................................................................................... 6-1

6.2.1 Group 10 Digital Inputs................................................................................................... 6-2

6.2.2 Group 13 Analogue Inputs ............................................................................................. 6-6

6.2.3 Group 14 Relay Outputs................................................................................................. 6-8

6.2.4 Group 15 Analogue Outputs......................................................................................... 6-10

6.2.5 Group 16 System Ctr Inputs......................................................................................... 6-13

6.2.6 Group 20 Limits ............................................................................................................ 6-15

6.2.7 Group 21 Start/Stop ..................................................................................................... 6-18

6.2.8 Group 23 Speed Ctrl .................................................................................................... 6-19

6.2.9 Group 24 Torque Ctrl ................................................................................................... 6-24

6.2.10 Group 26 Motor Control (visible only in SCALAR mode) ........................................... 6-25

6.2.11 Group 27 Brake Chopper ........................................................................................... 6-26

6.2.12 Group 28 Motor Model ............................................................................................... 6-28

6.2.13 Group 30 Fault Functions........................................................................................... 6-29

6.2.14 Group 50 Pulse Encoder ............................................................................................ 6-35

6.2.15 Group 51 Comm module ............................................................................................ 6-36

6.2.16 Group 60 Local operation........................................................................................... 6-37

6.2.17 Group 61 Speed monitor ............................................................................................ 6-38

6.2.18 Group 62 Torque monitor ........................................................................................... 6-39

6.2.19 Group 63 Fast stop..................................................................................................... 6-40

6.2.20 Group 64 Crane.......................................................................................................... 6-41

6.2.21 Group 65 Logic handler.............................................................................................. 6-44

6.2.22 Group 66 Torque proving ........................................................................................... 6-45

6.2.23 Group 67 Mechanical brake contr. ............................................................................. 6-46

6.2.24 Group 68 Power optimisation ..................................................................................... 6-48

6.2.25 Group 69 Reference Handler ..................................................................................... 6-51

6.2.26 Group 70 Position measurement................................................................................ 6-52 iv ACC 800 Firmware Manual

6.2.27 Group 71 Fieldbus Comm.......................................................................................... 6-53

6.2.28 Group 72 Master/Follower ......................................................................................... 6-55

6.2.29 Group 73 Electric Shaft.............................................................................................. 6-61

6.2.30 Group 74 Crane Lifetime............................................................................................ 6-63

6.2.31 Group 90 Dataset REC Addr ..................................................................................... 6-64

6.2.32 Group 92 Dataset TR Addr ........................................................................................ 6-65

6.2.33 Group 98 Option modules.......................................................................................... 6-66

6.2.34 Group 99 Start-up Data.............................................................................................. 6-69

7 Chapter 7 - Fault Tracing and Maintenance ................................................................................. 7-1

7.1 Overview ................................................................................................................................. 7-1

7.2 Warnings ................................................................................................................................. 7-2

7.3 Faults....................................................................................................................................... 7-5

7.3.1 Fault History................................................................................................................... 7-5

7.4 Maintenance.......................................................................................................................... 7-12

7.4.1 Heatsink ....................................................................................................................... 7-12

7.4.2 Fan............................................................................................................................... 7-13

7.4.3 Capacitors.................................................................................................................... 7-13 manual. They can be found from the ACS800-01/U1 Hardware Manual, ACS800-

02/U2 Hardware Manual, ACS800-04/U4 Hardware Manual or ACS 600 Multidrive

Hardware Manual.

ACC 800 Firmware Manual v

This page is intentionally left blank vi ACC 800 Firmware Manual

1

Chapter 1 - Introduction to this Manual

1.1 Overview

This chapter describes the purpose, contents and the intended audience of this manual. It also explains the conventions used in this manual and lists related publications. This ACS 800 CraneDrive Control Fimware

Manual is compatible with ACC 800 Application Software version 7.1

(signal 5.2 = ACAR71xx)

1.2 Before You Start

The purpose of this manual is to provide you with the information necessary to control and program your ACS 800 CraneDrive Control, from now on mentioned as the CraneDrive.

The audience for this manual is expected to have:

• Knowledge of standard electrical wiring practices, electronic

components, and electrical schematic symbols.

• Minimal knowledge of ABB product names and terminology.

1.3 What This Manual Contains

Safety Instructions can be found on pages i and ii of this manual.

instructions which must be followed.

The

Safety Instructions describe the formats for various warnings and notations used in this manual. This chapter also states the general safety

Chapter 1 – Introduction, the chapter you are reading now, introduces you to the CraneDrive Firmware Manual and conventions used throughout

Chapter 2 – Overview of CraneDrive Programming and CDP 312R

Control Panel provides an overview of programming your CraneDrive.

This chapter describes the operation of the CDP 312R Control Panel used for controlling and programming.

Chapter 3 – Start-up gives a Start-up procedure and also lists and explains the Start-up Data parameters.

Chapter 4 – Control Operation describes actual signals, keypad and external controls and external 24V power supply.

Chapter 5 – Crane Program Description defines the Crane program by

describing the included crane specific functions and presenting them in a block diagram. This chapter also describes the User Macro function.

Chapter 6 – Parameters lists the CRANEDRIVE parameters and explains the functions of each parameter.

Chapter 7 - Fault Tracing describes the fault tracing procedure when warnings and faults are indicated. Warnings and faults are listed in tabular form with possible causes and remedies.

ACC 800 Firmware Manual

Appendix A - Complete Parameter and Default Settings lists, in tabular form, all parameter settings and the default values for the CraneDrive.

1-1

Chapter 1 - Introduction to this Manual

Appendix B - User I/O interface diagrams showing default I/O signal connections for Stand alone and Fieldbus modes.

1.4 Related

In addition to this manual the CraneDrive user documentation includes the following manuals:

• ACS800 Pulse encoder RTAC-01 User’s manual (optional)

• ACS800 I/O Extension modules (RDIO-01 & RAIO-01) User’s manuals

(optional)

• ACS800 Fieldbus adapter module, User’s manuals (optional)

• DriveWindow User’s Manual (optional)

New manuals will be prepared as more Option Modules and other optional extras become available. Please ask for them from the local ABB distributor.

1-2 ACC 800 Firmware Manual

2

Chapter 2 - Overview of CraneDrive Programming and the CDP 312R Control Panel

2.1 Overview

This chapter describes the programming principles of the CraneDrive; the operation of the CDP 312R Control Panel; and how to use the panel to modify parameters, measure actual values and control the drive(s).

The user can change the configuration of the CraneDrive to meet the needs of the requirements by programming. The CraneDrive is programmable through a set of parameters.

Parameters can be set one by one or a preprogrammed set of parameters can be selected. Preprogrammed parameter sets are called

Application Macros. Refer to Chapter 5 - Crane Program Description for further information on Application Macros.

In order to simplify programming, parameters of the CraneDrive are organised into logical Groups. Parameters of the Start-Up Data Group are described in Chapter 3 – Start-up Data and other parameters in

Chapter 6 - Parameters. Signals are described in the chapter 4.

Start-up Data Parameters

The Start-up Data parameters (Group 99) contains the basic settings needed to match the CraneDrive with your motor. This group also contains a list of preprogrammed Application Macros. The Start-up Data

Group includes parameters that are set at start-up and should not need to be changed later on. Refer to Chapter 3 – Start-up Data for description of each parameter.

The Start-up Data Group is displayed as the first parameter group in the

Parameter Mode. The correct procedure for selecting a parameter and changing its value is described in the paragraph Keypad Modes -

Parameter Mode. Parameters are described in Chapter 6 - Parameters.

The CDP 312R Control Panel is the device used for locally controlling and programming the ACS 800. It can monitor and control up to 31 drives. The Panel can be attached directly to the door of the cabinet or it can be mounted, for example, in a control desk.

ACC 800 Firmware Manual 2-1

Chapter 2 – Overview of ACC 800 Programming and the CDP 312 Control Panel

The CDP312R Drives Panel is connected to the drive through Modbus communication bus. Modbus, which is based on the RS485 standard, is a common bus protocol for ABB Drives products. The communication speed is 9600 bit/s. 31 drives and one panel can be connected on this bus. Each station must have a unique ID-number.

1 L -> 50.0% 1

SPEED 470 rpm

TORQUE 50 %

CURRENT 40 A

ACT PAR FUNC DRIVE

ENTER

LOC

REM

RESET REF

0

CDP 312R

Figure 2-1 CDP 312R Control Panel

2.3.2 Display

The LCD type display has 4 lines of 20 characters.

The Control Panel display is an LCD type display of drive functions, drive parameter selections, and other drive information. Letters or numbers appear on the display according to which Control Panel keys are pressed.

2.3.3 Keys

The 16 Control Panel keys are flat, labeled, push-button keys that allow you to monitor drive functions, select drive parameters, and change drive macros and settings.



1 L -> 50.0% 1

SPEED 470 rpm

TORQUE 50 %

CURRENT 40 A

1 L -> 50.0% 1

13 ANALOGUE INPUTS

1 SCALE AI1

1.000

1 L -> 50.0% 1

UPLOAD <=<=

DOWNLOAD =>=>

CONTRAST 4

ACS 800 0050_3SR

Main hoist

ACXR7100 040930

ID-NUMBER 1

Actual Signal Display Mode

ACT

Parameter Mode

PAR

Function Mode

FUNC

Drive Selection Mode

DRIVE

Figure 2-2 Control Panel Display indications and function of the Control Panel keys.

LOC

REM

Keypad /

External Control

RESET

Fault Reset

Forward

Reverse

Start

Stop

0

REF Reference Setting

Function

Figure 2-3 Operational commands of the Control Panel keys .



The following is a description of the operation of the CDP 312R Control

Panel. The Control Panel Keys and Displays are explained in Figures 2-

1, 2-2 and 2-3.

The CDP 312R Control Panel has four different keypad modes: Actual

Signal Display Mode, Parameter Mode, Function Mode, and Drive

Selection Mode. In addition to this there is a special Identification

Display, which is displayed after connecting the panel to the link. The

Identification Display and the keypad modes are described briefly below.

When the panel is connected for the first time, or the power is applied to the drive, the Identification Display appears showing the panel ID number and the number of drives connected to the link.

Note: The panel can be connected to the drive while power is applied to the drive.

ACS 800 0050_3SR

ID-NUMBER 1

After two seconds, the display will clear, and the Actual Signals of the selected drive will appear.

Actual Signal Display Mode

This mode includes two displays, the Actual Signal Display and

the Fault History Display. The Actual Signal Display is displayed first when the Actual Signal Display mode is entered. If the drive is in a fault condition, the Fault Display will be shown first.

The panel will automatically return to Actual Signal Display Mode from other modes if no keys are pressed within one minute (exceptions:

Status Display in Drive Selection Mode and Fault Display Mode).

In the Actual Signal Display Mode you can monitor three Actual Signals at a time. For more information of actual signals refer to Chapter 4

Control Operation. How to select the three Actual Signals to the display is explained in Table 2-3, page 2-6.

The Fault History (logger) includes information on the 64 most recent events, like faults, warnings and resets, that have occurred in your ACS

800. The 18 last events are backed up during RMIO power off. The name of the event and the total time since last RMIO power-on is displayed. If the AC800M (or AC80, AC4x0) overriding system has been connected to the drive (DDCS channel 0), this time can be seen in the date format instead of power-on time. The procedure for clearing the

Fault History is described in Table 2-4, page 2-7.



The following table shows the events that are stored in the Fault History.

For each event it is described what information is included.

Table 2-1 Events stored in the Fault History

Event

A fault is detected by

ACS 800

A fault is reset by user.

A warning is activated by

ACS 800

A warning is deactivated by ACS 800

Information

Sequential number of the event.

Name of the fault and a “+” sign in front of the name. Total power on time or date and time updated by overriding system.


-RESET FAULT text.

Total power on time or date and time updated by overriding system.


Name of the fault and a “+” sign in front of the name. Total power on time or date and time updated by overriding system.


Name of the warning and a “-” sign in front of the name. Total power on time or date and time updated by overriding system.

Display

1 L -> 0.0% 0

2 LAST FAULT

+OVERVOLTAGE

1121 H 1 MIN 23 S

1 L -> 0.0% 0

1 LAST FAULT

-RESET FAULT

1121 H 1 MIN 23 S

1 L -> 0.0% 0

1 LAST WARNING

+JOYSTICK

1121 H 1 MIN 23 S

1 L -> 0.0% 0

1 LAST WARNING

-JOYSTICK

1121 H 1 MIN 23 S

When a fault or warning occurs in the drive, the message will be displayed immediately, except in Drive Selection Mode. Table 2-5, page

2-7, shows how to reset a fault. Refer to chapter 7 for information on fault tracing. From the fault display, it is possible to change to other displays without resetting the fault. If no keys are pressed the fault or warning text is displayed as long as the fault exists.



Table 2-2 How to display the full name of the three Actual Signals.

Step Function

1.

2.

To display the full name of the three actual signals

To return to the Actual Signal

Display Mode

Press key

Hold

ACT

Release

ACT

Display after key is pressed

1 L -> 50.0% 1

MOTOR SPEED FILT

MOTOR TORQUE FILT

MOTOR CURRENT

1 L -> 50.0% 1

SPEED 470 rpm

TORQUE 50 %

CURRENT 40 A

6a. or

6b.

Table 2-3 How to select Actual Signals to the display.

Step Function

1. To enter the Actual Signal

Display Mode

2.

3.

4.

5.

To select the desired row.

To enter the Actual Signal

Selection Mode.

To select a different group.

To select a index.

To accept the selection and to return to the Actual Signal

Display Mode.

To cancel the selection and keep the original selection, press any of the Mode keys.

The selected Keypad Mode is entered.

Press key

ACT

ENTER


1 L -> 50.0% 1

SPEED 470 rpm

TORQUE 50 %

CURRENT 40 A

1 L -> 50.0% 1

SPEED 470 rpm

TORQUE 50 %

CURRENT 40 A

1 L -> 50.0% 1

1 ACTUAL SIGNALS

5 TORQUE

50 %

ENTER

ACT PAR

FUNC DRIVE

1 L -> 50.0% 1

2 INT SIGNALS

1 SP REF 2

470 rpm

1 L -> 50.0% 1

2 INT SIGNALS

3 SP REF 4

470 rpm

1 L -> 50.0% 1

SPEED 470 rpm

SP REF 4 470 rpm

CURRENT 40 A

1 L -> 50.0% 1

SPEED 470 rpm

TORQUE 50 %

CURRENT 40 A



Table 2-4 How to display a fault and reset the Fault History.

Step Function

1.

2.

3.

4.

To enter the Actual Signal

Display Mode

To enter the Fault History

Display.

Logging time can be seen either total power-on time or in the date format, if overriding system

(ex. AC80) has been connected to control the drive.

To select previous (UP) or next fault (DOWN).

To clear the Fault History.

After the fault text there is letter r or s indicating the status of the fault: s = set r = reset

The Fault History is empty.

Note! An active fault does not clear a fault in the logger

To return to the Actual Signal

Display Mode.

Press key

ACT


1 L -> 50.0% 1

SPEED 470 rpm

TORQUE 50 %

CURRENT 40 A

1 L -> 50.0% 1

1 LAST FAULT

+OVERCURRENT r

6451 H 21 MIN 23 S

RESET

1 L -> 50.0% 1

2 LAST FAULT

+OVERVOLTAGE r

1121 H 1 MIN 23 S

1 L -> 50.0% 1

2 LAST FAULT

H MIN S

1 L -> 50.0% 1

SPEED 470 rpm

TORQUE 50 %

CURRENT 40 A

Table 2-5 How to display and reset an active fault.

Step Function

1. To enter the Actual Signal

Display Mode.

Press key

ACT

2. To reset the fault. Reset button functions also in the REMOTE mode. RESET


1 L -> 50.0% 1

ACS 800 75 kW

** FAULT **

ACS 800 TEMP

1 L -> 0.0% 1

SPEED 0 rpm

TORQUE 0 %

CURRENT 0 A



Parameter Mode

The Parameter Mode is used to make changes to the CraneDrive parameters. When this mode is entered for the first time after power up, the display will show the first parameter of the first group. Next time the

Parameter Mode is entered, the previously selected parameter is shown.

NOTE: If you try to write to a write-protected parameter, the following warning will be displayed:

** WARNING **

WRITE ACCESS DENIED

PARAMETER SETTING

NOT POSSIBLE

Table 2-6 How to select a parameter and change the value.

2-8

Step Function

1.

2.

3.

4.

5.

6a. or

6b.

To enter the Parameter Mode

Selection

To select another parameter group.

While holding the arrow down, only the group name and number are displayed. When the key is released, name, number and value of the first parameter in the group are displayed.

To select a index.

While holding the arrow down, only the parameter name and number are displayed. When the key is released the value of the parameter is also displayed.

To enter the Parameter Setting

Mode.

To change the parameter value.

(slow change)

(fast change)

To send a new value to the drive.

To cancel the new setting and keep the original value.


Press key

PAR


1 L -> 50.0% 1


1 SCALE AI1

1.000

1 L -> 50.0% 1


1 SCALE AI1

1.000

1 L -> 50.0% 1

14 RELAY OUPUTS

1 RELAY RO1 OUTPUT

BRAKE LIFT

1 L -> 50.0% 1

14 RELAY OUPUTS


FAULT-N

ENTER

ENTER

ACT PAR

FUNC DRIVE

1 L -> 50.0% 1

14 RELAY OUPUTS


[FAULT-N]

1 L -> 50.0% 1

14 RELAY OUPUTS


[CONTROL LOC]

1 L -> 50.0% 1

14 RELAY OUPUTS


CONTROL LOC

1 L -> 50.0% 1


1 SCALE AI1

1.000



UPLOAD

DOWNLOAD

ACS 800

Drive

The Function Mode is used to select special functions. These functions include Parameter Upload, Parameter Download and setting the contrast of the CDP 312R Control Panel display.

Parameter Upload will copy all parameters and the results of motor identification from the drive to the panel. The upload function can be performed while the drive is running. Only the STOP command can be given during the uploading process.

By default, Parameter Download will copy existing parameter Groups

10 to 97 stored in the panel to the drive.

Note: Parameters in Groups 98 and 99 concerning options, macro and motor data, and also ID Run data are not copied.

Table 2-7, page 2-10, describes how to select and perform Parameter

Upload and Parameter Download functions.

Uploading has to be done before downloading. If downloading is attempted before uploading, the following warning will be displayed:

** WARNING **

NOT UPLOADED

DOWNLOADING

NOT POSSIBLE

The parameters can be uploaded and downloaded only if the software package version and application software version(see signal 5.01 SW

PACKAGE VERSION and 5.02 APPL SW VERSION) of the destination drive are the same as the software version of the source drive.

Otherwise the following warning will be displayed:

** WARNING **

DRIVE INCOMPATIBLE

DOWNLOADING

NOT POSSIBLE

The drive must be stopped during the downloading process. If the drive is running and downloading is selected, the following warning is displayed:

** WARNING **

DRIVE IS RUNNING

DOWNLOADING

NOT POSSIBLE



Table 2-7 How to select and perform a function.

Step Function

1. To enter the Function Mode.

Press key

FUNC

2.

3.

To select a function (a blinking cursor indicates the selected function).

To activate the selected function.

ENTER


1 L -> 0.0% 0

UPLOAD <=<=

DOWNLOAD =>=>

CONTRAST 4

1 L -> 0.0% 0

UPLOAD <=<=

DOWNLOAD =>=>

CONTRAST 4

1 L -> 0.0% 0

=>=>=>=>=>=>=>

DOWNLOAD

4. Loading completed.

1 L -> 0.0% 0

SPEED 470 rpm

TORQUE 50 %

CURRENT 40 A

Table 2-8 How to set the contrast of the panel display.

Step Function

1. To enter the Function Mode.

Press key

FUNC

2.

3.

To select a function.

To enter contrast setting function.

ENTER


1 L -> 0.0% 0

UPLOAD <=<=

DOWNLOAD =>=>

CONTRAST 4

1 L -> 0.0% 0

UPLOAD <=<=

DOWNLOAD =>=>

CONTRAST 4

1 L -> 0.0% 0

CONTRAST [4]

2-10

4. To set the contrast.

(0...7)

5a. or

5b.

To accept the selected value

To cancel the new setting and keep the original value, press any of the Mode keys.


1 L -> 0.0% 0

CONTRAST [6]

ENTER

ACT PAR

FUNC DRIVE

1 L -> 0.0% 0

UPLOAD <=<=

DOWNLOAD =>=>

CONTRAST 6

1 L -> 0.0% 0

UPLOAD <=<=

DOWNLOAD =>=>

CONTRAST 4



Copying parameters from one unit to other units

You can copy parameters 10...97 from one drive to another by using the

Parameter Upload and Parameter Download functions in the Function

Mode. Typically this kind of function can be used if the processes and the motor types are same. This procedure is permitted only if the swversions are same. Follow the procedure below:

1. Select the correct options (Group 98) and macro (Group 99) for each

drive.

2. Set the rating plate values for the motors (Group 99) and perform

the identification run for each motor if required (see page Error!

Reference source not found.Error! Bookmark not defined.).

3. Set the parameters in Groups 10 to 97 as preferred in one ACC 800

drive.

4. Upload the parameters from the CraneDrive to the panel

(see Table 2-7).

5. Disconnect the panel and reconnect it to the next CraneDrive unit.

6. Ensure the target CraneDrive is in Local control (L shown on the first row of the display). If necessary, change the control location by

pressing

LOC

REM .

7. Download the parameters from the panel to the CraneDrive unit

(see Table 2-7).

8. Repeat steps 5 and 6 for the rest of the units.

Note: Parameters in Groups 98 and 99 concerning options,

macro and motor data are not copied.

1)

Setting the contrast

If the Control Panel Display is not clear enough, set the contrast according to the procedure explained in Table 2-8.


71.

The restriction prevents downloading of incorrect motor data (Group 99).

In special cases it is also possible to upload and download Groups 98

2-11

Chapter 2 – Overview of ACC 800 Programming and the CDP 312 Control Panel and 99 and the results of motor identification.

For more information, please contact your local ABB representative.



Drive Selection Mode

In normal use the features available in the Drive Selection Mode are

not needed; these features are reserved for applications where several drives are connected to one Modbus Link.

Modbus Link is the communication link connecting the Control Panel and the CraneDrive. Each on-line station must have an individual

identification number (ID). By default, the ID number of the CraneDrive is

1.

CAUTION! The default ID number setting of the CraneDrive should not be changed unless it is to be connected to the Modbus Link with other drives on-line.

Table 2-9 How to select a drive and change ID number.

Step Function

1.

2.

3.

To enter the Drive Selection Mode

To select the next view.

The ID number of the station is changed by first pressing ENTER

(the brackets round the ID number appear) and then adjusting the value with arrow buttons

The new value is accepted with

ENTER. The power of the

.

CraneDrive must be switched off to validate its new ID number setting

(the new value is not displayed until the power is switched off and on.

The Status Display of all devices connected to the Panel Link is shown after the last individual station. If all stations do not fit on the display at once, press to view rest of them.

To connect to the last displayed drive and enter another mode, press one of the Mode keys.


ACT PAR

FUNC

Press key Display after key is pressed

DRIVE

ACS 800 0005_3

Trolley

ACXR7100 040930

ID-NUMBER 1

ACS 800 0005_3

Trolley

ACXR7100 040930

ID-NUMBER 1

1á 2 Ñ 3 Ü 4 Ö 5 Ö

6á 7F 8Ö 9Ö 10Ö

á

= Drive stopped, direction forward

Ñ

= Drive running, direction reverse

F

= Drive has tripped on a fault

1 L -> 50.0% 1

SPEED 470 rpm

TORQUE 50 %

CURRENT 40 A



Operational commands control the operation of the CraneDrive. They include starting and stopping the drive, changing the direction of rotation and adjusting the reference. The reference value is used for controlling the motor speed.

Changing control Location

Operational commands can be given from the CDP 312R Control Panel

always when the status row is displayed and the control location is the panel. This is indicated by L (Local Control) on the display. See the following figure.

1 L -> 50.0% 1

Remote Control (control from the overriding system or I/O is indicated by empty field. See the following figure.

1 -> 50.0% 1

Operational commands cannot be given from this panel when in Remote

Control. Only monitoring actual signals, setting parameters, uploading and changing ID numbers is possible.

The control is changed between Keypad and External control locations by pressing the LOC / REM key. Changing control location only possible while motor is stopped. Only one of the Local Control devices (CDP 312R or Drives Window) can be used as the local control location at a time.

Refer to Chapter 4 - Control Operation for the explanation of Keypad and

External control.

Direction of actual rotation is indicated by an arrow.

1 -> 50.0% 1 1 <- 50.0% 1

Forward Reverse

Start, Stop Direction and Reference

Start, Stop and Direction commands are given from the panel by pressing the keys

Forward 0 Reverse

Start Stop

Table 2-10 explains how to set the Reference from the panel.



Table 2-10 How to set the reference.

Step Function

1. To display enter a Keypad Mode displaying the status row.

2.

3.

4.

To enter the Reference Setting

Mode

To change the reference.

(slow change):

(fast change):

To escape the Reference

Setting Mode.


Press key

ACT PAR

FUNC


1 L -> 50.0% 1

SPEED 470 rpm

TORQUE 50 %

CURRENT 40 A

REF

ACT PAR

FUNC DRIVE

1 L -> [ 50.0%] 1

SPEED 470 rpm

TORQUE 50 %

CURRENT 40 A

1 L -> [ 56.0%] 1

SPEED 526 rpm

TORQUE 50 %

CURRENT 40 A

1 L -> 56.0% 1

SPEED 526 rpm

TORQUE 50 %

CURRENT 40 A


3

Chapter 3 - Start-up

3.1 Overview

This chapter lists and explains the Start-up Procedure and the Start-up

Data Parameters. The Start-up Data Parameters are a special set of parameters that allow you to set up the CraneDrive and motor information. Start-up Data Parameters should only need to be set during start-up and should not need to be changed afterwards.

The start-up procedure of CraneDrive frequency converters equipped with Standard or CraneDrive Application Program is described in this chapter.

WARNING! All electrical installation and maintenance work described in this chapter should only be undertaken by a qualified electrician. The

Safety Instructions on the first pages of this manual and appropriate hardware manual must be followed.

Refer to Chapter 7 – Fault Tracing in case of trouble.

START-UP FLOWCHART

SAFETY

❏

❏

❏

The start-up procedure should only be carried out by a qualified electrician.

Follow the safety instructions on the first pages of this manual during the start-up procedure.

Check the installation before the start-up procedure. Refer to Installation Checklist in hardware manual.

❏ Check that starting the motor does not cause any danger.

It is recommended having the driven equipment disengaged when first start is performed if there is the risk of damage to the driven equipment in case of incorrect rotation direction of the motor.

ACC 800 Firmware Manual 3-1

Chapter 3 – Start-Up


1 – POWER-UP

❏ Apply mains power. The ACS 800 should not be powered up more than five times in ten minutes to

avoid charging resistor overheating (no limitation for

ACS 600 MultiDrive units).

The Control Panel enters the Identification Display.

The Control Panel enters the Actual Signal Display Mode automatically in a few seconds.

❏

❏

CDP312 PANEL

ID NUMBER 31

TOTAL 12 DRIVES

1 L -> 0.0% 0

SPEED 0 rpm

TORQUE 0 %

CURRENT 0 A

2 – START-UP DATA ENTERING

Select the Application Macro.

Press PAR key.

Press ENTER. Square brackets appear around the parameter value. Scroll available options with and .

Accept the selection with ENTER.

A detailed description of the Application Macros is included in Chapter 5.

Select the motor control mode. DTC is suitable in most cases.

1 L -> 0.0% 0

99 START-UP DATA

2 APPLICATION MACRO

CRANE

1 L -> 0.0% 0


2 APPLICATION MACRO

[CRANE]

1 L -> 0.0% 0


4 MOTOR CTRL MODE

[DTC]

2 – START-UP DATA ENTERING


❏



Enter the motor data from the motor nameplate.

Note: Use the motor´s (continuous duty) data = true electrical data. If nameplate is showing only duty cycle data e.g. S3-60% data, please contact motor manufacturer for S1 data.

Nominal voltage

Press PAR key. Press to move to Parameter 99.5.

Press ENTER. Enter the value by and . Press

ENTER.

Allowed range: ½ · U

N

... 2 · U

N

of ACS 800. ( U

N

refers to the highest voltage in each of the nominal voltage ranges: 415 VAC for

400 VAC units, 500 VAC for 500 VAC units and 690 VAC for 600 VAC units.)

Note: Enter exactly the value given on the nameplate.

Repeat the procedure for the following parameters:

Nominal current 99.6

Allowed range: 1/6 · Ihd ... 2 · Ihd of ACS 800

Nominal frequency 99.7

Range: 8 ... 300 Hz

1 L -> 0.0% 0


5 MOTOR NOM VOLTAGE

[ ]

1 L -> 0.0% 0


6 MOTOR NOM CURRENT

[ ]

1 L -> 0.0% 0


7 MOTOR NOM FREQ

[ ]



❏

❏


Nominal speed 99.8

Range: 1 ... 18000 rpm

Set the motor data exactly the same as on the motor nameplate (should be the rated full-load speed). For example, if the motor nominal speed is 1440 rpm on the nameplate, setting the value of Parameter 99.8

MOTOR NOM SPEED to 1500 rpm (e.g. no-load speed) results in wrong operation of the drive.

Nominal power 99.9

Range: 0 ... 9000 kW

1 L -> 0.0% 0


8 MOTOR NOM SPEED

[ ]

1 L -> 0.0% 0


9 MOTOR NOM POWER

[ ]

When the motor data has been entered a warning appears. It indicates that the motor parameters have been set, and the CraneDrive is ready to start the motor indentification (ID magnetisation or ID Run). Press PAR to go to the next parameter 99.10 Motor ID Run.

1 L -> 0.0% 0

STANDARD DRIVE

** WARNING **

ID MAGN REQ

❏ Motor ID Run 99.10

Selection ID MAGN is sufficient for less demanding travel drives. The next step of this flowchart is performed with

Motor ID Run selection ID MAGN. Motor identification magnetisation is performed instead of Motor ID Run.

Motor ID Run is recommended for hoist drives.

Motor Identification Run (ID Run) can be performed to enhance the mathematical model of the motor. This is required e.g. in demanding motor control applications when no pulse encoder feedback is used, as 100 % motor control accuracy is usually only achieved with the ID Run.

Refer to Section 3 – Start-up Data for performance procedure of the ID Run.

1 L -> 0.0% 0


10 MOTOR ID RUN

[ID MAGN]




71.

– IDENTIFICATION MAGNETISATION with Motor ID Run selection ID MAGN

❏ Press the key. The motor is magnetised at zero speed.

Duration approximately 10 to 60 s.

1 L -> 0.0% 1

STANDARD DRIVE

** WARNING **

ID MAGN

1 L -> 0.0% 0

STANDARD DRIVE

** WARNING **

ID DONE

❏

4 – ROTATION DIRECTION OF THE MOTOR

Increase the speed reference from zero to a small value:

Press ACT, PAR or FUNC key to enter Keypad Mode with the status row visible. Change the Speed Reference value by pressing REF and then or . Press (Start) to start the motor. Check that the motor is running in the desired direction. Stop the motor by pressing .

To change the rotation direction of the motor:

71. Disconnect mains power from the CraneDrive, and wait 5 minutes for the intermediate circuit capacitors to discharge. Measure the voltage between each input terminal (U1, V1 and W1) and earth with a multimeter to ensure that the frequency converter is discharged.

2. Exchange the position of two motor cable phase conductors at the motor terminals or at the motor connection box.

3. Verify your work by applying mains power and repeating the check as described above.

1 L -> [ xx.x]% 1

SPEED xxxx rpm

TORQUE xx %

CURRENT xx A



71.

– SPEED LIMITS AND ACCELERATION/DECELERATION TIMES


5 – SPEED LIMITS AND ACCELERATION/DECELERATION TIMES

❏ Press PAR. Use and to scroll parameters.

Minimum speed

Enter the value by ENTER and or . Press ENTER.

Repeat the procedure for the following parameters:

Maximum speed

Acceleration times

Deceleration times

For other parameters see Chapter 5 – Parameter setting tables 5-1 and 5-2.

1 L -> 0.0% 0

20 LIMITS

1 MINIMUM SPEED

[ ]

1 L -> 0.0% 0

20 LIMITS

2 MAXIMUM SPEED

[ ]

1 L -> 0.0% 0

69 REFERENCE HANDLER

2 ACC TIME FORW

[ ]

1 L -> 0.0% 0


3 ACC TIME REV

[ ]

1 L -> 0.0% 0


4 DEC TIME FORW

[ ]

1 L -> 0.0% 0


5 DEC TIME REV

[ ]



3.3.1 Start-up Data Parameters

To access the Start-up Data Parameters you must enter the Parameter

Mode. The Start-up Data Parameters appear on the display (Parameter

Group 99). After the Start-up parameters for the motor are set, the display shows the last edited Parameter Group when entering Parameter Mode and no longer returns to the Parameter Group 99.

In the Start-up Data group there are parameters for selecting the

Application Macro and the Motor Information Parameters containing the basic settings required to match the CraneDrive with your motor.

When changing the value of the Start-up Data Parameters, follow the procedure described in Chapter 2 - Overview of CraneDrive

Programming, Table 2-6, page 2-8. Table 3-1, page 3-8, lists the Start-up

Data Parameters. The Range/Unit column in Table 3-1 shows the parameter values, which are explained in detail below the table.

NOTE: The drive will not start, if the Start-up Data Parameters have not been changed from the factory settings or the nominal current of the motor is too small compared to the nominal current of the inverter. The following warning will be displayed:

** WARNING **

NO MOT DATA

If the Motor Control Mode (Parameter 99.4) is set to SCALAR, the comparison between the nominal current of the motor and the nominal current of the inverter is not made.

WARNING! Running the motor and the driven equipment with incorrect start-up data can result in improper operation, reduction in control accuracy and damage to equipment.



Table 3-1 Group 99, Start-up Data Parameters.

Parameter

1 LANGUAGE

Range/Unit

Languages

Description

Display language selection.

Application macro selection.

MACRO

RESTORE

4 MOTOR CTRL

MODE

5 MOTOR NOM

VOLTAGE

6 MOTOR NOM

CURRENT

7 MOTOR NOM

FREQ

8 MOTOR NOM

SPEED

9 MOTOR NOM

POWER

1/6 * I

2 * I hd hd

of ACS 800 ...

of ACS 800

8 ... 300 Hz

1 ... 18 000 rpm

0 ... 9000 kW

10 ID MAGN;

RUN? STANDARD;

REDUCED

11 DEVICE NAME

DTC; SCALAR

½ * U

N

2 * U

N

of ACS 800 ...

of

ACS 800

“free text”

Restores parameters to factory setting values.

Motor control mode selection.

Nominal voltage from the motor rating plate.

Matches the ACS 800 to the rated (S1) motor current.

Nominal frequency from the motor rating plate.

Nominal speed from the motor rating plate.

Nominal (S1) power from the motor rating plate.

Selects the motor ID selftune run.

NOTE: This will cause the motor to operate after

start command.

Drive section name, e.g.

“Main Hoist”.

3-8

The following is a list of the Start-up Data Parameters with a description of each parameter. The motor data parameters 99.5 ... 99.9 are always to be set at start-up.

1 LANGUAGE The ACS 800 displays all information in the language you select. The 13 alternatives are: English, American English, German, Italian, Spanish,

Portugese, Dutch, French, Danish, Finnish, Swedish, Czech and Polish.

Please note that for ACC 800 sw version 7.1 only following languages are available: English, German, French, Spanish and

Finnish.

2 APPLICATION This parameter is used to select between the CRANE macro, for crane

MACRO

drive functions but not including Master/Follower bus communication, and the M/F CTRL macro with the crane drive functions plus Master/Follower bus communication.. Refer to Chapter 5 – Crane Program Description, for a description of the two available Macros. There is also a selection for saving the current parameter settings as a User Macro (USER 1 SAVE or

USER 2 SAVE), and recalling these settings (USER 1 LOAD or USER 2

LOAD).

Parameter group 99 is not included in CRANE and M/F CTRL macros.

The parameter settings will remain the same even though the macro is changed.



NOTE: User Macro load restores also the motor settings of the Start-up

Data group and the results of the Motor ID Run. Check that the settings correspond to the motor used.

3 APPLIC RESTORE Selection Yes restores the original settings of an application macro as follows:

- If application macro CRANE or M/F CTRL is selected, the parameter values are restored to the settings loaded at the factory. Exceptions:

Parameter setting in groups 50, 51, 98 and 99 remain unchanged.

- If User Macro 1 or 2 is selected, the parameter values are restored to the last saved values. In addition, the results of the motor identification run are restored (see Chapter 5). Exceptions: Parameter setting in groups

50, 51 and 98 remain unchanged.

CTRL MODE

DTC

The DTC (Direct Torque Control) mode is suitable for most applications.

The CraneDrive performs precise speed and torque control of standard squirrel cage motors. Pulse encoder feedback is required on all Crane

Hoist Drives.

In multi-motor applications the nominal voltage of each motor has to be equal to the nominal voltage of the inverter and the nominal frequency of each motor must be the same. The sum of the motor nominal currents has to fall within the limits specified at Parameter 99.6 (MOTOR

NOMINAL CURRENT).

SCALAR

The SCALAR control mode is recommended for multi-motor drives when number of motors connected to the CraneDrive is variable. The SCALAR control is also recommended when the nominal current of the motor is less than 1/6 of the nominal current of the inverter or the inverter is used for test purposes with no motor connected.

With SCALAR control the drive is not as effective as with DTC control.

The differences between the SCALAR and DTC control modes are discussed further in this manual in relevant parameter lists.

The motor identification run, torque control, and motor phase loss check

(Parameter 30.10) are disabled in the SCALAR control mode.

5 MOTOR This parameter matches the CraneDrive with the nominal voltage of

NOM VOLTAGE the motor as indicated on the motor rating plate. It is not possible to start the CraneDrive without setting this parameter.

Note: It is not allowed to connect a motor with nominal voltage less than

½ * U

N or more than 2 * U

N where U

N is either 415 V, 500 V or 690 V depending on the voltage rating of the ACS 800 used.



6 MOTOR NOM This parameter matches the ACS 800 to the rated motor current. The

CURRENT allowed range 1/6 * I hd of ACS 800 ... 2 * I hd of ACS 800 is valid for DTC motor control mode. In SCALAR mode the allowed range is 0 * I hd of

ACS 800 ... 3 * I hd of ACS 800.

Correct motor run requires that the magnetising current of the motor does not exceed 90 per cent of the nominal current of the inverter.

7 MOTOR NOM This parameter matches the ACS 800 to the rated motor frequency,

FREQUENCY adjustable from 8 Hz to 300 Hz.

8 MOTOR NOM This parameter matches the ACS 800 to the nominal speed as indicated

SPEED on the motor rating plate

NOTE: It is very important to set this parameter in order to achieve the best possible accuracy in speed control.

9 MOTOR NOM This parameter matches the ACS 800 to the rated power of the motor,

POWER adjustable between 0.5 kW and 9000 kW.

10 MOTOR ID RUN This parameter is used to initiate the Motor Identification Run. During the run, the ACS 800 will identify the characteristics of the motor for optimum motor control. The ID Run takes about one minute.

NOTE: Torque monitor and Torque proving is automatically disabled during ID Magn (first start) and ID Run. Other optional crane functions like: Power optimisation and Torque memory should also be disabled during ID Run!

Any change of limitations (Parameter Group 20) should be done after performing the Motor ID Run (Use default values). These limits may affect the result of the ID Run.

The Motor ID Run is not performed. This can be selected in most applications. The motor model is calculated at first start by magnetising the motor for 10 to 60 s at zero speed.

Note: The ID Run (Standard or Reduced) should be selected if:

• operation point is near zero speed

• operation at torque range above the motor nominal torque within wide speed range and without any pulse encoder (i.e. without any measured speed feedback) is required

STANDARD

Performing the Standard Motor ID Run guarantees that the best possible control accuracy is achieved. The motor must be decoupled from the driven equipment before performing the Standard Motor ID Run.



REDUCED

The Reduced Motor ID Run should be selected instead of the Standard

ID Run:

• if mechanical losses are higher than 20 % (i.e. the motor cannot be de-coupled from the driven equipment)

• if flux reduction is not allowed while the motor is running (i.e. there are auxiliary devices connected in parallel with the motor)

Check the rotation direction of the motor before starting the Motor

ID Run. During the run the motor will rotate in the forward direction.

WARNING! The motor will run at up to approximately 50 % ... 80 % of the nominal speed during the Motor ID Run. BE SURE THAT IT IS SAFE

TO RUN THE MOTOR BEFORE PERFORMING THE MOTOR ID RUN!


To perform the Motor ID Run (Drive must be in LOCAL mode):

Note: If parameter values (Group 10 to 98) are changed before the ID

Run, check that the new settings meet the following conditions:

• 20.1 MINIMUM SPEED < 0

• 20.2 MAXIMUM SPEED > 80 % of motor rated speed

• 20.3 MAXIMUM CURRENT A > 100 % I hd

(Amp)

• 20.4 MAXIMUM TORQUE > 50 %

71.

Change the selection to STANDARD or REDUCED:

1 L -> 0.0% 0


10 MOTOR ID RUN

[STANDARD]

71.

Press ENTER to verify selection.

The following message will be displayed:

1 L -> 0.0% 0

ACS 800 75 kW

** WARNING **

ID-RUN SEL

3) To start the ID Run, press the key. The Power On Ackn input (e.g.

DI2, see parameter 10.5) must be active if used.

Warning during the ID Run:

1 L -> 11.3% 1

ACS 800 75 kW

** WARNING **

MOTOR STARTS

Warning after a succesfully completed ID Run:

1 L -> 11.3% 1

ACS 800 75 kW

** WARNING **

ID DONE

3-11


After completing the ID Run, the Actual Signal Display mode is entered by pressing the RESET key.

The Motor ID Run can be stopped at any time by pressing the key.

Pressing any other key than ACT, FUNC or DRIVE while the previous warning messages are displayed will clear the display and return the panel to Parameter Mode, Parameter 99.10. Either STANDARD,

REDUCED or ID MAGN will be displayed according to whether the ID

Run is in progress or not. If no keys are pressed within 60 seconds and the ID Run is still in progress, the warning message is restored.

Actual signal no. 1.16 IDENTIF RUN DONE will be set True when the

ID Run has been completed OK.

NOTE: Any change of the motor data parameters 99.5 ... 99.9 after a completed ID Run will delete the ID Run performed. A new ID Run (or

First start) has to be performed without load before being able to

operate the drive again.

The parameter can only be set using DriveWindow PC tool (it is not possible to enter text from the CDP312R panel). The name will appear on the DriveWindow configuration picture, and also on the CDP312R panel if pressing DRIVE key.


4

Chapter 4 - Control Operation

4.1 Overview

This chapter describes the Actual Signals, the Fault History and explains

Keypad and External control.

Note: The ACS800 is a speed controlled device. If you need to change frequency to speed use the following formula:

FREQUENCY (Hz)

SPEED (rpm) = * 120

NUMBER OF POLES

Pole pairs = 1, 2, 3,..

Number of poles = 2, 4, 6,...

Actual Signals monitor CraneDrive functions. They do not affect the performance of the CraneDrive. Actual Signal values are measured or calculated by the drive and they cannot be set by the user

The Actual Signal Display Mode of the Control Panel continuously displays three actual signals. When the ACT key is pressed, the full name of the three Actual Signals will be displayed. When the key is released, the short name (8 characters) and the value are displayed.

1 L -> 50.0% 1

SPEED 470 rpm

TORQUE 50 %

CURRENT 40 A

Figure 4-1 Actual Signal Display Mode.

Table 4-1 on the next page lists the Actual Signals: selected or monitored values, and functions.

To select the actual values to be displayed follow the procedure described in Chapter 2 - Overview of CraneDrive Programming, Table

2-3, page 2-6.


Chapter 4 – Control Operation

Table 4-1 Group 1, Actual Signal

Actual Signal (Group 1) Short name Range/Unit Description

1 SPEED ESTIMATED SP ESTIM

2 MOTOR SPEED FILT SPEED rpm rpm

3 FREQUENCY FREQ Hz

4 MOTOR CURRENT

The estimated motor speed value, in rpm.

Filtered motor speed value, in rpm.

Frequency to motor

CURRENT A Motor

5 MOTOR TORQUE FILT TORQUE

6 POWER

7 DC BUS VOLTAGE V

8 MAINS VOLTAGE

9 OUTPUT VOLTAGE

10 ACS 800 TEMP

POWER

DC BUS V

MAINS V

OUT VOLT

%

%

V

V

V

ACS TEMP C (deg Celcius)

Calculated motor torque. 100 is the motor nominal torque rating.

Motor power. 100 is the nominal power rating.

Intermediate circuit voltage displayed in V

DC

.

Calculated supply voltage at power on.

Calculated motor voltage.

Temperature of the heatsink.

11 APPLICATION

MACRO

12 SPEED REF

MACRO CRANE; M/F CTRL;

USER 1 LOAD;

USER 2 LOAD

SPEED REF Rpm

13 CTRL LOCATION CTRL LOC LOCAL; I/O CTRL;

FIELDBUS; M/F

CTRL

14 OP HOUR COUNTER OP HOURS h (Hours)

Speed reference before ramp.

Active control location.

Elapsed power-on time meter.

15 KILOWATT HOURS kW HOURS kWh kWh

16 IDENTIF RUN DONE ID RUN

17 DI7-1 STATUS DI7-1

True; False Motor ID Run is done.

Status of RMIO digital inputs.

V Value of RMIO analogue input 1. 18 AI1 (V)

19 AI2 (mA)

20 EXT AI1 (V)

21 RO3-1 STATUS

AI1 (V)

AI2 (mA)

EXT AI1

RO3-1 mA

V

Value of RMIO analogue input 2.

Value of RAIO-01 input 1.

Status of RMIO relay outputs.

22 AO1 (mA)

23 AO2 (mA)

24 INERTIA

25 EXT DI6-1 STATUS

AO1 (mA) mA

AO2 (mA) mA

INERTIA kgm

2

EX DI6-1

Value of RMIO analogue output 1.

Value of RMIO analogue output 2.

Calculated inertia from power optimisation autotune

Status of RDIO digital inputs.

26 EXT RO4-1 STATUS EX RO4-1

27 MOTOR RUN-TIME RUN-TIME H (hours)

Status of RDIO digital outputs.

Elapsed motor run-time meter.

28 MOTOR TEMP EST MOT TEMP C (deg Celcius)

29 CTRL BOARD TEMP CTRL B T C (deg Celcius)

Estimated motor temperature.

Temperature of RMIO board.


Actual Signal (Group 1) Short name Range/Unit

30 FAN ON TIME

31 AI3 (mA)

FAN TIME H (Hours)

AI3 (mA) mA

32 TOTAL OPER TIME

35 LIFETIME LEFT %

TOTAL OP hrs (hours)

33 LOAD TORQUE ton LOAD ton

34 LOAD SPEC FACT Km FACT Km ton

LIFETIME %


Description

Accumulated fan operating hours.

Value of RMIO analogue input 3.

Elapsed run-time with brake open

The calculated hoist load in tons.

Load spectrum factor Km.

Crane lifetime left %



4.3 Signal Selection - Description of the Actual Signals, Groups 1 and 2

1 SPEED ESTIMATED Displays the estimated speed of the motor, as calculated by the

CraneDrive (shows estimated speed also if encoder is enabled). The speed is displayed in rpm.

2 MOTSPEED FILT Displays a filtered value of the actual speed of the motor, as calculated or measured by the CraneDrive.The speed is displayed in rpm.

3 FREQUENCY Displays the CraneDrive frequency (Hz) applied to the motor, as calculated by the CraneDrive.

4 CURRENT Displays the motor current, as measured by the CraneDrive.

5 MOTOR TORQUE Displays the motor torque in per cent of the rated motor torque, as calculated by the CraneDrive.

6 POWER Displays the motor power in per cent of the rated motor power.

7 DC BUS VOLTAGE V Displays the DC bus voltage, as measured in the CraneDrive. The voltage is displayed in Volts DC.

8 MAINS VOLTAGE Displays the mains voltage, as calculated by the CraneDrive. The voltage is displayed in Volts. NOTE: Calculation only done at power on.

9 OUTPUT VOLTAGE Displays the motor voltage, as calculated by the CraneDrive.

10 ACS 800 TEMP Displays the temperature of the heatsink in degrees centigrade.

11 APPLICATION MACRO Indicates application or user macro selected (=parameter 99.2).

12 SPEED REF Displays the value of the total speed reference before ramp in %. 100 % corresponds to SPEED SCALING RPM, parameter 69.1.

13 CTRL LOCATION Displays the active control location. Alternatives are: LOCAL, I/O CTRL,

FIELDBUS and M/F CTRL. Refer to Keypad vs. External Control in this chapter.

14 OP HOUR COUNTER This Actual Signal is an elapsed-time indicator. It counts the time that the

RMIO board has been powered. The counted time cannot be reset.

15 KILOWATT HOURS This Actual Signal counts the kilowatt hours of CraneDrive in operation.

16 IDENTIFICATION This signal indicates if the motor ID Run is completed OK.

RUN DONE

17 DI7-1 STATUS Status of the RMIO digital inputs DI1-6 + DI_IL (DI_IL here called “DI7”).

If the input is connected to +24 VDC, the display will indicate 1. If the input is not connected, the display will be 0. Example: 1000010 = DI_IL is on, DI6 to DI3 is off, DI2 is on and DI1 is off.

18 AI1 (V) Value of RMIO analogue input 1 displayed in volts.

19 AI2 (mA) Value of RMIO analogue input 2 displayed in milliamperes.



20 EXT AI1 (V) Value of RAIO-01 analogue input 1 displayed in volts.

21 RO3-1 STATUS Status of the RMIO three relay outputs. 1 indicates that the relay is energised and 0 indicates that the relay is de-energised.

22 AO1 (mA) Value of RMIO analogue output 1 signal in milliamperes.

23 AO2 (mA) Value of RMIO analogue output 2 signal in milliamperes.

24 INERTIA This actual signal is giving the calculated inertia value from running the

Power Optimisation Autotune and has to be set in parameter 68.4

INERTIA TOTAL UP and 68.5 INERTIA TOTAL DWN.

25 EXT DI6-1 STATUS Status of the six (3+3) RDIO digital inputs. If the input is connected to voltage, the display will indicate 1. If the input is not connected, the display will be 0.

26 EXT RO4-1 STATUS Status of the four (2+2) RDIO relay outputs. 1 indicates that the relay is energised and 0 indicates that the relay is de-energised. hours, that the motor has been running with current. The counted time can be reset with parameter 97.10 RESET MOTOR RUNTIME.

28 MOTOR TEMP EST This signal is displaying the estimated motor temperature in degrees

Centigrade.

Note: The estimated motor temperature calculation starts at 30 deg C after a RMIO power on (init).

29 CTRL BOARD TEMP This signal is displaying the measured temperature on the RMIO board in degrees Centigrade.

30 FAN ON TIME This signal is displaying the accumulated operating hours for the cooling fan.

NOTE: Using DriveWindow tool, this signals value can be reset to zero if replacing fan unit.

31 AI3 (mA)

If replacing the RMIO board, please restore (copy) the value for this signal from old to new board (read value before replacing board).

Value of RMIO analogue input 3 displayed in milliamperes. See description of parameter 20.10 for details.

32 TOTAL OPER TIME Total operating time of drive, in hours, with brake open. Backed up in non-volatile memory.

33 LOAD TORQUE ton Load torque signal scaled in ton using parameters 68.12-13 & 74.1

34 LOAD SPEC FACT Km Load spectrum factor Km (value between 0.0 and 1.0) is the degree of utilization over the lifetime for the hoist mechanics. Calculated by the

Crane lifetime monitor function (par. group 74).

35 LIFETIME LEFT % The calculated mechanical lifetime left of hoist. In percent of lifetime set in parameter 74.2



Table 4-2 Group 2, Internal Signals

INT SIGNALS (Group 2) Range/Unit Description

1 SPEED REF 2

2 SPEED REF 3

3 SPEED REF 4 rpm rpm rpm

4 SPEED ERROR NEG

5 TORQUE PROP REF rpm

%

6 TORQUE INTEG REF %

7 TORQUE DER REF

8 TORQ ACC COMP REF %

9 TORQUE REF 1

10 TORQUE REF 2

11 TORQUE REF 3

12 TORQUE REF 4

13 TORQUE REF 5

14 TORQ USED REF

%

%

%

%

%

%

%

Ramp input reference limited by speed limits

(parameters 20.1 & 20.2)

Ramp output reference

Total speed reference = ramp output reference + speed correction reference

Actual speed - total speed reference

Speed controller proportional part output

Speed controller integration part output

Speed controller derivative part output

Acceleration compensation reference

Torque reference input to drive (torque ramp output)

Speed controller total output + acceleration compensation reference.

Limited with parameters 20.4 & 20.5

Output of “Torque Selector”, see parameter 72.2

Torque ref 3 + Load compensation

Torque ref 4 + Torque step

Final torque reference used by torque controller

(Torque ref 5 with limits)

Actual motor torque 15 MOTOR TORQUE %

16 FLUX ACT %

17 SPEED MEASURED rpm

18 POS ACT PPU

19 START

+/- 32767

True; False

20 RUNNING

21 BRAKE LIFT

22 FAULT

True; False

True; False

True; False

Actual motor flux

Measured (RTAC) motor speed

Position measurement value (scaled with par. 70.1)

Start-order given

Drive running (producing torque) acknowledgment

Brake lift order

Drive fault indication (tripped)

24 SPEED CORR rpm

25 POWOP SPEEDREF %

Speed correction reference

Power optimisation calculated speed reference

26 ELSHAFT POS ERROR Electric shaft control position error in Slave drive

27 LIMIT WORD 1

28 FAULTED INT INFO

29 TORQUE SELECTOR

30 dV/dt

31 LOAD TORQUE %

32 LIMIT WORD INV

33 INT SC INFO

0 – FFFF Packed boolean (Hex)

0 – FFFF Packed boolean (Hex)

0 – 5

Limit word indicating if drive is running in any limitation, For bit details see table 4-3 below

INT board fault info, For bit details see table 4-4 below

Torque reference (2.11) mode active:

0 = Zero control (=speed control in CraneDrive)

1 = Speed control (Torq ref 2)

2 = Torque control (Torq ref 1)

3 = Minimum control (min of Torq ref 1 and 2)

4 = Maximum control (max of Torq ref 1 and 2)

5 = Add control (sum of Torq ref 1 and 2) rpm/s

%

Derivative of speed reference ramp output, Speed ref3. That is, rate of change (with sign) in rpm per sec

Calculated load torque in % of motor nominal torque.

Signal is filtered with parameter 68.10 .

0 – FFFF (Hex) Indicating details if 2.27 bit 4 Torq_inv_cur_lim is set.

See table 4-5 below for details.

0 – FFFF (Hex) Info on short circuit location. See table 4-6 below.



Table 4-3 Signal 2.27 LIMIT WORD 1

3

4

5

6

Bit

0

1

2

Name

TORQ MOTOR LIM

SPD_TOR_MIN_LIM

SPD_TOR_MAX_LIM

TORQ_USER_CUR_LIM

TORQ_INV_CUR_LIM

TORQ_MIN_LIM

TORQ_MAX_LIM

Active Limit

Motor pull-out torque limit reached.

Speed control torque min. limit

Speed control torque max. limit.

User-defined current limit

Internal current limit.

Any torque min. limit.

Any torque max. limit

7

8

9

10

TREF_TORQ_MIN_LIM

TREF_TORQ_MAX_LIM

FLUX_MIN_LIM

FREQ_MIN_LIMIT

Torque reference min. limit.

Torque reference max. limit.

Flux reference min. limit

Speed/Frequency min. limit.

11 FREQ_MAX_LIMIT

12

13

14

15

DC_UNDERVOLT

DC_OVERVOLT

TORQUE LIMIT

FREQ_LIMIT

Speed/Frequency

DC undervoltage limit.

DC overvoltage limit.

Any torque limit. limit

Any speed/frequency limit.

Note: Bit 4 TORQ_INV_CUR_LIM is activated if thermal overload from inverter or braking chopper is detected. See details in 2.32 LIMIT WORD INV

Table 4-4

Signal 2.28 FAULTED INT INFO.

This word includes information on the location of faults: PPCC LINK, OVERCURRENT, EARTH

FAULT, SHORT CIRCUIT, ACS800 TEMP, TEMP DIF and POWERF INT.

2

3

4

5

Bit

0

1

Name

INT 1 FLT

INT 2 FLT

INT 3 FLT

INT 4 FLT

INT 5 FLT

INT 6 FLT

Description

INT 1 board fault (R8i module #1)

INT 2 board fault * (R8i module #2)

INT 3 board fault * (R8i module #3)

INT 4 board fault * (R8i module #4) a.s.o.

INT 5 board fault *

INT 6 board fault *

6

7

8

9

INT 7 FLT

INT 8 FLT

INT 9 FLT

INT 10 FLT

INT 7 board fault *

INT 8 board fault *

INT 9 board fault *

INT 10 board fault *

10

11

INT 11 FLT

INT 12 FLT

12…14 Not in use

15 PBU FLT



PBU board fault

* In use only with parallel inverters. INT 1 is connected to PBU CH1, INT 2 to CH2 a.s.o.



Table 4-5

Signal 2.32 LIMIT WORD INV.

This word gives more detailed information when the TORQ INV CUR LIM (bit 4 in 2.27 LIMIT

WORD 1) is active, indicating that output current limit of the drive is exceeded. The current limitation protects the drive in various cases, e.g. integrator overload, high IGBT temperature etc.

Bit

2

3

4

Name Description

Current limit at 200% integrator overload. *

Temperature model is not active.

150


INT LOW FREQ Current limit at high IGBT temperature with low output frequency (<10 Hz). *


INTG PP TEMP Current limit at high IGBT temperature. *


PP OVER TEMP Current limit at high IGBT temperature.

Temperature model is active.

6

7

INV POW LIM

INV TRIP CUR

Temperature model is active.

If the IGBT junction to case temperature continues to rise in spite of the current limitation, PP OVERLOAD alarm or fault occurs.

Current limit at inverter output power limit (at chopper power limit if during braking with chopper).

Current limit at inverter overcurrent trip limit

At maximum inverter current limit I max

. See par. 20.03 .

10 CONT OUT CUR Continuous output current limit (I cont.max

).

11…15 Not in use

* Only active with ACS600 type inverters (with NINT board)



Table 4-6 Signal 2.33 INT SC INFO

This word includes info on the location of the SHORT CIRCUIT fault

Bit

0

1

2

3

4

5

Name

U-PH SC U

U-PH SC L

V-PH SC U

V-PH SC L

W-PH SC U

W-PH SC L

6…15 Not in use

Description

Phase U upper-leg IGBT(s) short circuit

Phase U lower-leg IGBT(s) short circuit

Phase V upper-leg IGBT(s) short circuit

Phase V lower-leg IGBT(s) short circuit

Phase W upper-leg IGBT(s) short circuit

Phase W lower-leg IGBT(s) short circuit

Note: For information on Group 3 (FB REC WORDS) and Group 4 (FB TRA WORDS) signals, see

Appendix A.



4.4

Fault History

The Fault History includes information on the fifteen most recent faults and warnings that occurred in the CraneDrive. The description of the fault and the total power-on time are available. The power-on time is calculated always when the RMIO board of the CraneDrive is powered.

Chapter 2 - Overview of CraneDrive Programming, Table 2-4, page 2-7, describes how to display and clear the Fault History from the Control

Panel.

4.5 Local Control vs. External Control

The CraneDrive can be controlled (i.e. reference, ON/OFF and Start

commands can be given) from an external control location or from Local control (Control Panel Keypad or a DrivesWindow PC tool). Figure 4-2 below shows the CraneDrive control locations.

The selection between Keypad control and External control can be done with the LOC REM key on the Control Panel keypad. keypad reference (%)

Stand alone

I/O

Fieldbus communication

4-10

ON/START, Speed ref (%) ON/START Speed ref (%)

Figure 4-2 Control Locations

If the device controlling the CraneDrive stops communicating, the operation defined by Parameter 30.12 MASTER FAULT FUNC, or

30.2 PANEL LOSS is executed.

The control commands are given from the Control Panel keypad when

CraneDrive is in Keypad Control. This is indicated by L (Local) on the

Control Panel display.

0 L 52.3 %

If operational commands and reference cannot be given from this Control

Panel, it displays a blank character as shown below.

71.

52.3 %

Note: All references are always given in % of SPEED SCALING RPM

(Parameter 69.1)



4.5.2

External Control

When the CraneDrive is in External Control, the commands are given either from Fieldbus or I/O (Stand Alone mode). Selection is done with parameter 64.1 Stand Alone Sel. alone

If par. Stand Alone Sel (parameter 64.1) is set True (default value) the

Stand Alone mode is selected.

In external control the digital inputs DI 1 - DI 6 and Ext DI1 – DI4 as well as analog inputs AI1 & AI2 wired directly from joystick and limit switches, are connected to a CRANE function module (except in FB JOYSTICK control mode where joystick signals are sent via fieldbus to CRANE function module, see end of section 5.6.5 for details).

.

The CRANE function module is producing the references and commands like ON/OFF, START and so on.

Fieldbus

When the CraneDrive is in Fieldbus mode (64.1 Stand Alone Sel=False) the commands are given from the supervisory system and received over the fieldbus communication link (see section 5.6..



4.6 Control Signals Connection Stand Alone mode

STAND

ALONE

DI1-DI6

EXT DI1-4

AI.1

SPEED

REF

CRANE

MODULE

SPEED REF

Power

Otimization

MAX

SELECTOR

EXTERNAL

KEYPAD

SPEED

CONTROLER

MINIMUM SPEED 20.1

MAXIMUM SPEED 20.2

SPEED CTRL

Group 23

AI.2

TORQUE REF.

EXT AI1

SPEED CORR

TORQUE REF.

TORQUE

CONTROLLER

MAXIMUM

TORQUE 20.4, 20.5

TORQUE CTRL

Group 24

CDP 312R

PANEL

REF

LOC

REM

REF. WITH SIGN.

KEYPAD

EXTERNAL

ON/START

1

0

Figure 4-3 Selecting control location and control source



4.7 Control Signals Connection in Fieldbus mode

FIELD BUS

DataSet1, Word1

Bit 2 and 4

ON, START

DataSet1,

Word2

SPEED REF.

DS1.1 Bit 7

SELECT

TORQ. CTRL

DataSet1,

Word3

TORQUE REF.

SPEED CORR.

DS3,2

CDP 312R

PANEL

REF

LOC

REM

Power

Optimization

MAX

SELECTOR

EXTERNAL

KEYPAD

REF. WITH SIGN.

KEYPAD

EXTERNAL

ON/START

SPEED CONTROLLER

MINIMUM SPEED 20.1

MAXIMUM SPEED 20.2

SPEED CTRL

Group 23

TORQUE CONTROLLER

MAXIMUM

TORQUE 20.4, 20.5

TORQUE CTRL

Group 24

1

0

Figure 4-4 Selecting control location and control source.



4.8 External 24V supply of RMIO board

To keep the control panel and the RMIO board active when the mains supply is switched off, a separate 24 Vdc supply can be connected. See

ACS 800 Hardware manual for details.

4.8.1 Power On Acknowledge input signal

If the CraneDrive is equipped with an external 24 V supply to RMIO board, it is recommended to connect a NO (Normally Open) auxiliary contact of AC power contactor to digital input for signal “Power On Ackn”, e.g. DI2. Input is selected with parameter 10.5. Drive is automatically reset at power on using the Power On Ackn input signal. Also a proper masking of Chopper fault and PPCC Link fault during power off, is achieved using the Power On Ackn signal.

A “0” on Power On Ackn input will generate an “Off” command of the

CraneDrive, that is: coast stop plus closing of mechanical brake.

No operation of CraneDrive is possible if Power On Ackn input is “0”!

NOTE: If using ACS 800 Multidrive, parameter 10.5 POWER ON ACKN

SEL should be set = DI2 !.


5

Chapter 5 - Crane Program Description

5.1 Overview

This chapter describes the functionality of the Crane program with its two

Application Macros: CRANE and M/F CTRL, and the two external control modes: Field bus mode and Stand Alone mode.

The chapter also describes how to use the two User Macros.

The chapter contains the following information:

• Operation, Fieldbus and Stand alone mode

• Functional Block diagram of program

• Function module descriptions

The Parameter Settings tables in this chapter indicate parameters you may have to modify. These parameters are indicated in the tables with an arrow (-->) symbol.

Refer to Appendix A – Complete Parameter Settings for the alternative settings for each parameter.

5.2

Application Macros

There are two application macros: CRANE and M/F CTRL.

Selection is done with parameter 99.2 Application macro.

Default setting is CRANE macro.

CRANE macro includes all the crane software functions except the

Master/Follower bus functionality.

M/F CTRL macro includes all functions of the CRANE macro plus

Master/Follower bus functionality (see description of function module

“Master/Follower (72)”).

NOTE: A change of application macro will reset all parameter settings to default, except for parameter group 99 and motor ID Run data stored.

Therefore macro selection should be done before making the application parameter settings.


Chapter 5 – Crane Program Description

Material to be issued later.



5.4 Stand alone mode operation

All drive commands and reference settings can be given from the Control

Panel keypad or selectively from an external control location.

The active control location is selected with the LOC REM key on the

Control Panel keypad. The drive is speed controlled.

In External Control the control location is the basic I/O. The reference signal is connected to analogue input AI1 and On/Start and Direction signals are generated from digital inputs DI2 ... DI4 on terminal block

X21.

DI5 is used for connecting slowdown limit switches in series, and DI6 for

Fast Stop order from mechanical overload and slack rope indications.

The mechanical brake is controlled from DO1 and the acknowledgement is connected to DI1.

Two analogue and three relay output signals are available on terminal blocks. Default signals for the Actual Signal Display Mode of the Control

Panel are SPEED, TORQUE and CURRENT.

The feedback data through Fieldbus communication: drive -> PLC is available also in stand alone mode (by enabling Comm module; parameter 98.2).

Operation Diagram

Input

Power

Ext. Controls

Motor

~

M

3~

~

Brake

rpm

Nm

Speed

Torque

Relay

Outputs

1 L -> 50.0% 1

SPEED 470 rpm

TORQUE 50 %

CURRENT 40 A

Reference and Start/Stop and Direction commands are given from the

Control Panel. To change to External ctrl, press LOC REM key at standstill.

1 50.0% 1

SPEED 470 rpm

TORQUE 50 %

CURRENT 40 A

Speed reference is read from analogue input AI1 (Terminal Block

X21). On/Start and Direction commands are generated from digital inputs DI2, DI3 and DI4.

Figure 5-1 Operation Diagram for Stand Alone Mode.

5.4.1 Input and Output I/O Signals

Input and Output I/O Signals as default (“Joystick” control type) assigned by the Crane program. (For more details see Crane module (64) description in section 5.6.5)

Input Signals

Brake Ackn: (DI1)

Zero Pos: (DI2)

Start Dir A: (DI3)

Start Dir B: (DI4)

Slow Down-N: (DI5)

Fast Stop-N: (DI6)

Speed Ref: (AI1)

Torque Ref: (AI2)

Speed Corr: (Ext AI1)

Output Signals

Analogue Output AO1: Speed

Analogue Output AO2: Torque

Relay Output RO1: Brake lift

Relay Output RO2: Watch dog-N

Relay Output RO3: Fault-N



5.4.2

External Connections

The following connection example is applicable when the Crane program with Stand Alone control mode and Joystick control is used. rpm

Nm

TE

Terminal Block X20

1

VREF -

2 GND

Terminal Block X21

4

5

6

1

2

3

VREF +

GND

AI1+

AI1-

AI2+

AI2-

7

8

9

AI3+

AI3-

AO1+

10

11

AO1-

AO2+

12 AO2-

Terminal Block X22

Function

Reference voltage -10 V max 10 mA

Function

Reference voltage 10 V max 10 mA

Speed reference

0 ... 10V

Torque reference

0 ... 20 mA

Not used

0 ... 20 mA

Speed actual

0 ... 20mA <-> 0 100 %

Torque actual

0 ... 20mA <-> 0 ... T

N

TE

1

2

3

DI1

DI2

DI3

6

7

4

5

8

9

DI4

DI5

DI6

+24DVDC

+24DVDC

DGND1

10

11

DGND2

DI_IL

Terminal Block X23

BRAKE ACKN

ZERO

START DIR A

START DIR B

SLOWDOWN-N

FAST STOP-

+24 VDC max 100 mA

Not connected

Digital ground 1

Digital ground 2

Digital input DI_IL (programmable)

1 +24 VDC

2

GND

Terminal Block X25

Auxiliary voltage output 24 VDC

0 V

Brake lift

1

RO11

RO12

2

3

RO13

Terminal Block X26

Relay output 1

Brake lift

1

RO21

Relay output 2

Watch dog

2

RO22

Watch dog -N

3

RO23

Terminal Block X27

E-stop

1 RO31

Relay output 3

Fault

2 RO32

Fault -N

3 RO33

Figure 5-2 External connections to RMIO board in Stand Alone mode,

Joystick control.


230 Vac N

+24Vdc 0 V

Electric shaft control

+/- 10V


RDIO-01, DI/O Ext module no. 1

Terminal block

(24 – 250 V)

X11:

1 DI1A

Stop Lim A -N

2 DI1B

X12:

1 DI2A

Stop Lim B –N

2 DI2B

3 DI3A

Fast stop –N

4 DI3B

RDIO-01, DI/O Ext module no. 2

Terminal block

(24 – 250 V)

X11:

1 DI1A

Step Ref 2

2 DI1B

X12:

1 DI2A

Step Ref 3

2 DI2B

3 DI3A

Step ref 4

4 DI3B

RAIO-01, AI/O Ext module

Terminal block X1 Function

1 AI1-

Speed Correction

2 AI1+

3 AI2-

"not used"

4 AI2+

5 SHLD

6 SHLD

Figure 5-3 External connections to extended I/O modules RDIO-01 and

RAIO-01, in Stand Alone mode, Step joystick control.



5.4.3 Control Signals Connection Stand Alone mode

STAND

ALONE

DI1-DI6

EXT DI1-4

AI.1

SPEED

REF

CRANE

MODULE

SPEED REF

Power

Otimization

MAX

SELECTOR

EXTERNAL

KEYPAD

SPEED

CONTROLER

MINIMUM SPEED 20.1

MAXIMUM SPEED 20.2

SPEED CTRL

Group 23

AI.2

TORQUE REF.

EXT AI1

SPEED CORR.

CDP 312R

PANEL

REF

LOC

REM

REF. WITH SIGN.

TORQUE REF.

KEYPAD

EXTERNAL

ON/START

TORQUE

CONTROLLER

MAXIMUM

TORQUE 20.4, 20.5

TORQUE CTRL

Group 24

1

0

Figure 5-4 Control Signals Connection Stand Alone mode



5.4.4 Parameter Settings for the Stand alone mode

Table 5-1 Listing of parameters typically requiring changes during start-up.

Stand alone mode.

99 START-UP DATA

99.2 APPLICATION MACRO

99.3 APPLIC RESTORE

99.4 MOTOR CTRL MODE

99.5 MOT NOM VOLTAGE

99.6 MOTOR NOM CURRENT

99.7 MOTOR NOM FREQ

99.8 MOTOR NOM SPEED

99.9 MOTOR NOM POWER

99.10 MOTOR ID RUN

99.11 DEVICE NAME

10 DIGITAL INPUTS

10.1 BRAKE ACKN SEL

10.2 ZERO POS SEL

10.3 SLOWDOWN-N SEL

10.4 FAST STOP-N SEL

10.5 POWER ON ACKN SEL

10.6 SYNC SEL

10.7 CHOPPER FLT-N SEL

10.8 STEP REF2 SEL

10.9 STEP REF3 SEL

10.10 STEP REF4 SEL

10.11 HIGH SPEED SEL

10.12 SNAG LOAD-N SEL

10.13 ACCELERATE SEL

10.14 FB STOPLIM SEL

10.15 ELSHAFT ON SEL

20 LIMITS

20.1 MINIMUM SPEED

20.2 MAXIMUM SPEED

20.3 MAXIMUM CURRENT A

20.4 MAXIMUM TORQUE

20.5 MINIMUM TORQUE

20.6 OVERVOLTAGE CTRL

20.7 UNDERVOLTAGE CTRL

20.10 SPEED LIMIT AI3

21 START/STOP

21.1 START FUNCTION

21.2 CONST MAGN TIME

23 SPEED CTRL

23.1 GAIN

23.2 INTEGRATION TIME

23.3 DERIVATION TIME

23.4 ACC COMPENSATION

23.5 SLIP GAIN

23.6 AUTOTUNE RUN ?

NO

→ DTC

→ 0 V

→ 0.0 A

→ 50.0 Hz

→ 1 rpm

→ 0.0 kW

→ ID MAGN

→

DI1

→ DI2

→ DI5

→ DI6

→ NOT USED

NOT USED

→ NOT USED

NOT USED

NOT USED

NOT USED

NOT USED

NOT USED

NOT USED

NOT USED

NOT USED

62.1 TORQ MON SEL

62.2 SP DEV LEV

62.3 TORQ FLT TD

62.4 SP DER BLK LEV

63 FAST STOP

63.1 FAST STOP TYPE 11


64.1 STAND ALONE SEL

64.2 CONTIN GEAR

64.3 HIGH SPEED LEVEL 1

64.4 DEADZONE A

64.5 DEADZONE B

64.6 REF SHAPE

64.7 SLOWDOWN SPEEDREF

64.8 ZERO POS OK TD

64.9 TORQUE REF SCALE

→ (calculated)

→ (calculated)

→ 200 % I hd

(A)

→ 200 %

→ -200 %

OFF

ON

100%

CONST DC-MAGN

→ 500 ms

66.1 TORQ PROV SEL

66.2 TORQ PROV FLT TD

66.3 TORQ PROV REF

68 POWER OPTIMIZATION

68.1 POWOP SELECT

68.2 BASE SPEED

68.3 POWOP AUTOTUNE SEL

68.4 INERTIA TOTAL UP

68.5 INERTIA TOTAL DWN

68.6 TQLIM UP

68.7 TQLIM DWN

68.8 POWOP RESET LEV

68.9 T MAX

→ 10.0

→ 2.50 s 69 REFERENCE HANDLER

0.0 ms 69.1 SPEED SCALING RPM

0.00 s

100.0 %

NO

69.2 ACC TIME FORW

69.3 ACC TIME REV

69.4 DEC TIME FORW

69.5 DEC TIME REV

69.6 S-RAMP TC

69.7 RAMP SCALE LOCAL

23.7 FEEDB FILTER TIME

23.8 SPEED STEP

27 BRAKE CHOPPER

27.1 BRAKE CHOPPER CTL

27.2 BR OVERLOAD FUNC

27.3 BR RESISTANCE

27.4 BR THERM TCONST

27.5 MAX CONT BR POWER

27.6 BC CTRL MODE

4 ms

0.0 rpm

→ OFF (R2&R3=ON)

→ NO

→ 100.00 ohm

→ 0.000 s

→ 0.00 kW

AS GENERATOR

50 PULSE-ENCODER (visible when 98.1 is activated)

50.1 ENCODER PULSE NR → 1024

50.2 SPEED MEAS MODE A_-_B_-_

64.10 CONTROL TYPE

64.11 MINIMUM REF

64.12 JOYSTICK WARN TD

64.13 STEP REF LEVEL 1




69.10 RAMP RATE=1

98 OPTION MODULES

98.1 ENCODER MODULE

98.2 COMM. MODULE

98.3 CH3 NODE ADDR

98.4 CH0 NODE ADDR

98.5 DI/O EXT MODULE 1


98.7 AI/O EXT MODULE 1

→

→

→

→

→ FALSE

→ 100 %

FALSE

→ 3 KGM 2

→ 30 KGM 2

→ 100 %

→ 75 %

12 %

→ 500 %

→ 1500 rpm

→ 5.0 s

→ 5.0 s

→ 5.0 s

→ 5.0 s

0.0 s

2.0

TRUE

NO

NO

1

1

NO

NO

NO

TRUE

10 %

600 ms

→ 13 % /s *)

NOT USED

→ NOT USED

TRUE

FALSE

98 %

→ 0 %

→ 0 %

20

→ 25 %

0.3 s

1.00

→ JOYSTICK

0.0 %

400 ms

10 %

25 %

50 %

100 %

→ FALSE

0.5 s

20 %

50.3 ENCODER ALM/FLT FAULT

50.4 ENCODER DELAY 1000 ms *) Calculate as: 100 / (RT x 1.5) %/s where RT = longest ramp time in seconds

→

Typical parameter values to check during start-up. If required, alter the values to meet the needs of your application. A complete parameter list is provided in Appendix A.



5.5 Fieldbus mode operation

All drive commands and reference settings can be given from the Control

Panel keypad or selectively from an external control location.

The active control location is selected with the LOC REM key on the

Control Panel keypad. The drive is normally speed controlled.

In External Control the control location is from the Fieldbus communication. The reference signal, On/Start a.s.o. are connected to corresponding datasets, see Fieldbus Receive description for details.

The mechanical brake is controlled from DO1 and the acknowledgement is connected to DI1 as a default.

Example of digital input connections:

DI2 Power On Ackn, is connected to an auxiliary contact of the incoming power breaker. DI3 Sync, is position measurement synchronisation. DI4

Chopper Fault-N, is connected to the braking chopper fault contact.

Two analogue and three relay output signals are available on terminal blocks. Default signals for the Actual Signal Display Mode of the Control

Panel are SPEED, TORQUE and CURRENT.

Operation Diagram

1 L -> 50.0% 1

SPEED 470 rpm

TORQUE 50 %

CURRENT 40 A

Fieldbus comm. module

Nm Torque

Relay

Outputs

Reference and Start/Stop and Direction commands are given from the Control Panel. To change to External ctrl, press LOC REM key

~

~

rpm Speed at standstill.

1 50.0% 1

SPEED 470 rpm

TORQUE 50 %

CURRENT 40 A

Motor

M

3~

Brake Start/Stop commands and References are received through the

Fieldbus communication

Figure 5-5 Operation Diagram for Fieldbus Mode.

5.5.1 Input and Output I/O Signals

Example of Input and Output I/O Signals selected when Fieldbus mode is selected i.e. supervisory controller (PLC) is used:

Input Signals

Brake Ackn: (DI1)

Power On Ackn: (DI2)

Sync: (DI3)

Chopper Flt-N: (DI4)

Output Signals

Analogue Output AO1: Speed

Analogue Output AO2: Torque

Relay Output RO1: Brake lift

Relay Output RO2: Watchdog-N

Relay Output RO3: Fault-N



The following connection example is applicable when the Crane program is used in Fieldbus mode. rpm

Nm

Terminal Block X20

1

VREF -

2 GND

Terminal Block X21

4

5

6

1

2

3

VREF +

GND

AI1+

AI1-

AI2+

AI2-

7

8

9

AI3+

AI3-

AO1+

10

11

AO1-

AO2+

12 AO2-

Terminal Block X22

Function

Reference voltage -10 V max 10 mA

Function

Reference voltage 10 V max 10 mA

Not used in this mode

Not used in this mode

Not used

0 ... 20 mA

Speed actual

0 ... 20mA <-> 0 100 %

Torque actual

0 ... 20mA <-> 0 ... T

N

TE

1

2

3

DI1

DI2

DI3

6

7

4

5

8

9

DI4

DI5

DI6

+24DVDC

+24DVDC

DGND1

10

11

DGND2

DI_IL

Terminal Block X23

BRAKE ACKN

POWER ON ACKN (example)

SYNC (example)

+24 VDC max 100 mA

Not connected

Digital ground 1

Digital ground 2

Digital input DI_IL, programmable

1 +24 VDC

2 GND

Terminal Block X25

Auxiliary voltage output 24 VDC

0 V

Brake lift

1

RO11

RO12

2

3

RO13

Terminal Block X26

Relay output 1

Brake lift

Watch dog

1

RO21

2

RO22

3

RO23

Terminal Block X27

Relay output 2

Watch dog -N

E-stop

1 RO31

Relay output 3

Fault

2 RO32

Fault -N

3 RO33

Figure 5-6 External connections in Fieldbus mode



5.5.3 Control Signals Connection in Field Bus mode

FIELD BUS

DataSet1, Word1

Bit 2 and 4

ON, START

DataSet1,

Word2

SPEED REF.

DS1.1 Bit 7

SELECT

TORQ. CTRL

TORQUE REF.

DataSet1,

Word3

DS3,2

SPEED CORR.

CDP 312R

PANEL

REF

LOC

REM

Power

Optimization

MAX

SELECTOR

EXTERNAL

KEYPAD

REF. WITH SIGN.

KEYPAD

EXTERNAL

ON/START

SPEED CONTROLLER

MINIMUM SPEED 20.1

MAXIMUM SPEED 20.2

SPEED CTRL

Group 23

TORQUE CONTROLLER

MAXIMUM

TORQUE 20.4, 20.5

TORQUE CTRL

Group 24

1

0

Figure 5–7 Control Signals Connection in Fieldbus mode


5.5.4

5.5.5


Speed correction in Fieldbus mode

In Fieldbus mode there is a possibility to send a speed correction

reference (“non-ramped” reference added to ramp unit output), to the drive:

In the Fieldbus communication interface: DataSet 3, Word 2 is connected as a Speed Correction input signal (8 ms updating time in ACC 800 application software).

The speed correction reference is limited so that the sum of the normal

“ramped” speed reference and the speed correction reference cannot exceed Maximum/Minimum Speed setting (parameters 20.1 & 20.2).

External Chopper monitoring (available in both Fieldbus and Standalone mode)

If using an external braking chopper, the braking chopper fault contact

(use the “normally open” contact; closed contact when DC voltage is on and no fault), can be monitored by the drive if connected to a digital input

(Parameter 10.7 Chopper Flt-N Sel). If open contact (“0”) to the digital input, the drive will trip and indicate CHOPPER FAULT to panel, faultlogger and Fieldbus faultword. Also the Watchdog signal (DO2) will indicate.

WARNING! If a braking chopper fault occurs, the incoming AC voltage to the drive must be disconnected! (This is the only way to stop the current in the braking resistor if the fault is a short circuit in the braking chopper)

This is done by connecting the Watchdog-N output DO2 to the drive emergency stop circuit.

During power on of drive (Power On Ackn ,e.g. DI2, changing from “0” to

“1”) the Chopper fault monitoring is blocked during the time Chopper

Monit Td, parameter 71.3, to avoid false indications.

Parameter value must be kept as low as possible (approx. 1000 ms).

This is to avoid burning out the charging resistor in the drive, if switching on power to the drive when there is a short circuit in the braking chopper.



5.5.6 Parameter Settings for the Fieldbus mode

Table 5-2 Listing of parameters typically requiring changes during start-up. Fieldbus mode.

99 START-UP DATA 62 TORQUE MONITOR

99.2 APPLICATION MACRO

99.3 APPLIC RESTORE

99.4 MOTOR CTRL MODE

99.5 MOT NOM VOLTAGE

99.6 MOTOR NOM CURRENT

99.7 MOTOR NOM FREQ

99.8 MOTOR NOM SPEED

99.9 MOTOR NOM POWER

99.10 MOTOR ID RUN

99.11 DEVICE NAME

10 DIGITAL INPUTS

10.1 BRAKE ACKN SEL

10.2 ZERO POS SEL

10.3 SLOWDOWN-N SEL

10.4 FAST STOP-N SEL

10.5 POWER ON ACKN SEL

10.6 SYNC SEL

10.7 CHOPPER FLT-N SEL

10.8 STEP REF2 SEL

10.9 STEP REF3 SEL

10.10 STEP REF4 SEL

10.11 HIGH SPEED SEL

10.12 SNAG LOAD-N SEL

10.13 ACCELERATE SEL

10.14 FB STOPLIM SEL

10.15 ELSHAFT ON SEL

20 LIMITS

20.1 MINIMUM SPEED

20.2 MAXIMUM SPEED

20.3 MAXIMUM CURRENT A

20.4 MAXIMUM TORQUE

20.5 MINIMUM TORQUE

20.6 OVERVOLTAGE CTRL

20.7 UNDERVOLTAGE CTRL

20.10 SPEED LIMIT AI3

21 START/STOP

21.1 START FUNCTION

21.2 CONST MAGN TIME

23 SPEED CTRL

23.1 GAIN

23.2 INTEGRATION TIME

23.3 DERIVATION TIME

23.4 ACC COMPENSATION

23.5 SLIP GAIN

23.6 AUTOTUNE RUN ?

23.7 FEEDB FILTER TIME

23.8 SPEED STEP

50 PULSE-ENCODER (visible when 98.1 = yes)

50.1 ENCODER PULSE NR

50.2 SPEED MEAS MODE

50.3 ENCODER ALM/FLT

50.4 ENCODER DELAY

50.5 SPEED FEEDB USED

51 COMM MODULE (visible when 98.2 = yes)

CRANE

NO

→ DTC

→ 0 V

→ 0.0 A

→ 50.0 Hz

→ 1 rpm

→ 0.0 kW

→ ID MAGN

DI1

! NOT USED

! NOT USED

! NOT USED

→ NOT USED

NOT USED

NOT USED

NOT USED

NOT USED

NOT USED

NOT USED

NOT USED

NOT USED

→ NOT USED

NOT USED

→ (calculated)

→ (calculated)

→ 2 * I hd

(A)

→ 200 %

→ -200 %

OFF

ON

100%

CONST DC-MAGN

→ 500 ms

→ 15.0

→ 0.50 s

0.0 ms

0.00 s

100.0 %

NO

4 ms

0.0 rpm

→ 1024

A_-_B_-_

FAULT

1000 ms

TRUE

62.1 TORQ MON SEL

62.2 SP DEV LEV

62.3 TORQ FLT TD

62.4 SP DER BLK LEV

63 FAST STOP



64.1 STAND ALONE SEL

64.2 CONTIN GEAR

64.3 HIGH SPEED LEVEL 1

64.4 DEADZONE A

64.5 DEADZONE B

64.6 REF SHAPE

64.7 SLOWDOWN SPEEDREF

64.8 ZERO POS OK TD

64.9 TORQUE REF SCALE

64.10 CONTROL TYPE

64.11 MINIMUM REF

64.12 JOYSTICK WARN TD





66 TORQUE PROVING

66.1 TORQ PROV SEL

66.2 TORQ PROV FLT TD

66.3 TORQ PROV REF

68 POWER OPTIMIZATION

68.1 POWOP SELECT

68.2 BASE SPEED

68.3 POWOP AUTOTUNE SEL

68.4 INERTIA TOTAL UP

68.5 INERTIA TOTAL DWN

68.6 TQLIM UP

68.7 TQLIM DWN

68.8 POWOP RESET LEV

68.9 T MAX

69 REFERENCE HANDLER

69.1 SPEED SCALING RPM

69.2 ACC TIME FORW

69.3 ACC TIME REV

69.4 DEC TIME FORW

69.5 DEC TIME REV

69.6 S-RAMP TC

69.7 RAMP SCALE LOCAL

69.10 RAMP RATE=1

98 OPTION MODULES

98.1 ENCODER MODULE

98.2 COMM. MODULE

98.3 CH3 NODE ADDR

98.4 CH0 NODE ADDR



→

→

→

→

→

→

→

→

→

→

→

→

→

→

→

→

TRUE

10 %

600 ms

→ 13 % /s *)

→ NOT USED

NOT USED

! FALSE

FALSE

98 %

0 %

0 %

20

25 %

0.3 s

1.00

JOYSTICK

0.0 %

400 ms

10 %

25 %

50 %

100 %

FALSE

0.5 s

FALSE

100 %

FALSE

3 KGM

2

30 KGM 2

100 %

75 %

12 %

500 %

1500 rpm

5.0 s

5.0 s

5.0 s

5.0 s

0.0 s

2.0

TRUE

NO

NO

1

1

20 %

NO

NO

51.1 MODULE TYPE

51.2…51.15 (See manual for fieldbus module used)

98.7 AI/O EXT MODULE NO

*) Calculate as: 100 / (RT x 1.5) %/s where RT = longest ramptime in sec.

→ Typical parameter values to check during start-up. If required, alter the values to meet the needs of your application. A complete parameter list is provided in Appendix A.

! Parameter value different from default setting


D

FUNCTION BLOCK DIAGRAM

C B


A

1

2

3

Figure 5-8 Function Block Diagram


RU

N

4

5

5-13


5.6.1 Local operation ( 60 )

This function module contains the necessary logic for Local mode operation by the operator’s panel on the front of the frequency converter.

Normally used only for commissioning and maintenance. The unit isreceives commands: Start/stop, Speed ref local, Local/remote and Reset from the panel. All crane drive functions (such as mechanical brake control) are active also in Local control mode (except power optimisation).

Please note that inputs for Slowdown limits, Stop limits and Fast

stop are NOT active when running in Local control mode.

Speed correction references are active when running in Local mode.

Parameter (60.1) LOC OPER INH = ” true ” will force the drive to external control mode (LOCAL = ” 0 ”). The drive is then only controlled from the

Field Bus communication or in Stand alone mode from I/O signals.

To be able to change the mode from External control to Local control or reverse the motor has to be stopped with brakes set, that is: ZERO

SPEED = ”1” and RUNNING = “0”.

Local running is performed from the operators panel which contains push-buttons for START PANEL, STOP PANEL of the converter, and for controlling the speed of the motor up and down with the REF plus Up and Down Arrow push-buttons for Fast and Slow reference change respectively. Ramp times (par. 69.2 - 5) are in Local multiplied with a scaling factor: RAMP SCALE LOCAL (parameter 69.7, default = 2.0).

The direction of the drive is changed with the push buttons Forward and

Reverse.

Pressing Start push-button will give both ON = Magnetising and Startorder, ramping up per given speed reference.

If pressing Start on panel but no reference higher than ZERO SPEED

LEV (67.6) given within the time LOC ZERO SPEED TD (60.3), than the drive will switch off again.

Pressing Stop push-button while running will ramp motor to zero speed, and switch motor magnetising off after the time OFF TD (65.2) if

CONTIN ON (65.1) = False.

If pressing Stop push-button (a second time) when at zero speed the magnetising will be switched off = converter switched off. cannot be started in Local (or External) mode unless input selected for

POWER ON ACKN = “1”.


5.6.2


Speed monitor ( 61 )

The function module is used to supervise overspeed of the motor, to give tripping signal at motor overspeed.

If the motor speed exceeds the level determined by MOT OVERSPEED

LEV (61.3) then the drive is tripped instantanuously (converter Off + brakes set) via the signal MOT OVER SPEED, indicating fault on panel, to Fieldbus and faultlogger.

5.6.3 Torque monitor ( 62 )

T he function module is used to supervise the torque of the motor by checking that the motor is following the speed reference in terms of direction of change during accel-/deceleration and without excessive speed error during accel-/deceleration and normal running.

For the supervision to be active TORQ MON SEL (62.1) has to be set

”True”.

If the absolute value of the speed error (SPEED REF4 - SPEED ACT) is higher than SP DEV LEV (Parameter 62.2) for a time longer than TORQ

FLT TD (Parameter 62.3), the drive trips for torque fault; TORQ FLT, indicating fault to panel, Fieldbus and faultlogger.

Parameter SP DER BLK LEV (62.4), rate of actual speed change in % per second, can be set so that it blocks the protection during acceleration and deceleration. As long as the actual rate of change (derivative) of the motor speed during acceleration or deceleration is higher than the setting of parameter SP DER BLK LEV, the torque fault protection is blocked.

Example: Acceleration ramp times set to e.g. 5 seconds. With SP DER

BLK LEV set to 8 %/s, the drive will not trip for torque fault if reaching torque limit during acceleration, as long as the actual acceleration time

(0-100%) is below 12.5 seconds (100% / 8%/s = 12.5 s).



5.6.4 Fast stop ( 63 )

The module contains logic for fast stopping the drive.

Three different types of fast stop can be obtained with this module.

They are:

- With torque limit only = fast stop 1

- With torque limit and mechanical braking = fast stop 2

- With mechanical braking only = fast stop 3

Note that fast stop is not to be mixed up with emergency stop.

NOTE: Fast stop functions are not active when in Local control!

The module has three output signals to achieve the different fast stops.

FAST ZERO SET is set to ” 1 ” when fast stop 1 is ordered, i. e. fast stop with torque limit only (brake is applied at zero speed).

All three signals FAST ZERO SET, SPEED OFF and FAST STOP are set to ” 1 ” when fast stop 2 is ordered, i. e. stop with both current limit and mechanical breaking.

FAST STOP is set to “1” when fast stop 3 is ordered, i.e. fast stop with mechanical braking only.

To run the drive again after reaching zero speed, the START-signal must be reset before accepting a new start-order.

There are two input signals from the Fieldbus Command Word (DS1.1),

FAST STOP 1 and FAST STOP 11 to order fast stop (active in both

Fieldbus and Stand alone mode):

-FAST STOP 1 = ” 1 ” gives fast stop 1

-FAST STOP 11 = ” 1 ” gives a fast stop per selection parameter 63.1

FAST STOP TYPE 11

Please note that drive cannot be started from External control place, if any of FAST STOP 1 or FAST STOP 11 (if activated in 63.1) control bits are active =“1”. Local start (from e.g. CDP panel) is possible.

To use FAST STOP 11 for:

Fast stop 1: set FAST STOP TYPE 11 (63.1) = FAST STOP 1



When using Stand alone modes there is also a signal FAST STOP 12, activated by digital input e.g. DI6 (FAST STOP-N) = “0” (see function module CRANE (64) for more details), which can be programmed to give anyone of the three types of fast stop. This is done with parameter 63.2

FAST STOP TYPE 12.

For settings of FAST STOP TYPE 12 see FAST STOP TYPE 11 above.

Note: If in Stand alone mode selecting the Control type (parameter

64.10) = FB JOYSTICK, than both FAST STOP 12 through digital input as well as FAST STOP 1 and FAST STOP 11 through the Fieldbus

Command Word are available to use.

Any active Fast stop is indicated in signal 4.5 FB AUX STATUSWORD bit 11.


5.6.5


Crane ( 64 )

NOTE: Stand Alone mode is active if parameter 64.1 STAND ALONE

SEL is set = “True”.

Table 5-3 Stand Alone default I/O signal interface and functions.

Signal

BRAKE ACKN

ZERO POS

START DIR A

START DIR B

SLOWDOWN-N

FAST STOP-N

SPEED REF

TORQ REF

SPEED CORR

BRAKE LIFT

WATCHDOG-N

FAULT-N

MEAS VALUE 1

MEAS VALUE 2

Input

(DI set in

Group10)

DI1

Function

DI2

DI3

(fixed)

DI4

(fixed)

DI5

DI6

AI1

(fixed)

AI2

(fixed)

Ext AI1

(fixed)

DO1

DO2

DO3

AO1

AO2

Brake acknowledge from aux. contact on brake contactor (and from brake)

Zero position contact from joystick

Direction A (pos.=up) from joystick, to be connected in series with Stop Lim

A and contact from mechanical overload protection equipment

Direction B (neg.=down) from joystick, to be connected in series with Stop

Lim B and contact from slack rope protection equipment

Slow down lim A and B. Direction from

START DIR inputs. After a power down (main contactor off) only slow speed is possible until this input is ”1”.

Fast stop signal to the converter

Speed reference signal from joystick.

0-10 V (or “par. 13.7”-10V) for 0-100

%

Torque reference signal from joystick.

0-20 mA for 0 to maximum torque reference (maximum set with

Parameter 64.9 TORQ REF SCALE).

Speed Correction signal from e.g. electric shaft control unit.

0 – (+/-)10V for 0 - (+/-)100% speed correction signal.

Output to brake contactor

Closed contact indicates ”healthy” drive.

Open contact makes hardwired emergency stop; main contactor(s) off and brakes on.

Fault (trip) signal indication

Default selection: Motor speed

Default selection: Motor torque



Joystick control mode ( 64.10=JOYSTICK)

When connecting a joystick directly to the drive I/O, then parameter 64.10

CONTROL TYPE should be selected to “JOYSTICK” (= default).

ANALOGUE REF INPUTS: The analogue reference signal (0 - max. reference) is connected to Analogue input 1 for speed reference, and to

Analogue input 2 for torque reference. The sign for the reference, speed as well as torque reference is given by inputs DI3 (Start Dir A) for positive reference (=up for hoist) and DI4 (Start Dir B) for negative reference (=down for hoist). With parameter 13.7 “AI1 0% REF LEV” the minimum AI1 voltage level corresponding to 0% speed reference is set (used e.g. with 4-20mA signal).

REFERENCE CURVE: The joystick for giving reference has parameters for setting of the deadzone in direction A and B (64.4 and 64.5).

REF SHAPE (64.6) is for giving the reference a parabolic shape.

Parameter set to ”0” = straight line, “20” = X 2 and ”100” = X 3 curve.

JOYSTICK CHECKS: The drive is stopped (normal deceleration ramp if speed control) and prevented from a new start until the joystick is moved back to the neutral position, i.e. Zero Position (ZERO POS: e.g. DI2 = “1”, DIR A: DI3 = “0”

& DIR B: DI4 = “0”) indicated longer than time ZERO POS OK TD (64.8), if any of following conditions (joystick or wiring problems) occur for a duration longer than JOYSTICK WARN TD (64.12):

- START DIR A= ”1” and START DIR B=”1” at the same time.

- SPEED REF is > 1V or TORQUE REF is > 2mA when joystick is in the neutral position (ZERO POS = “1”, DIR A = “0” and DIR B = “0”). Indicates a possible loose ground connection.

Panel also indicates this with an alarm text: “WARNING

JOYSTICK”.

START: The drive is started when one of the signals START DIR A or START

DIR B is ”1” and ZERO POS is “0”, unless any of the above listed fault conditions occur. The sequence starts with a magnetising phase = ON (unless already magnetised) which is immediately followed by the reference ramp-up.

At a normal stop the switching off of the magnetising current is off-delayed by an adjustable time (parameter 65.2 OFF TD).

Power-up: Start order is not accepted after READY signal is active, until joystick is first in zero position.

SLOWDOWN: The speed is limited by a preset level (parameter SLOWDOWN

SPEEDREF 64.7) if the SLOWDOWN-N input e.g. DI5 is zero-set. The converter remembers the direction of movement and allows full speed in the opposite direction as long as the supply voltage (AMC board supply) is not switched off. If the voltage has been switched off and the input SLOWDOWN-

N = ”0” than only slow speed is allowed in both directions.

By setting parameter 10.3 SLOWDOWN-N SEL = DI5 + DI6, separate inputs are available for wiring of slowdown limit switches to the drive. Slowdown direction A is wired to digital input 5 and slowdown direction B is wired to digital input 6. If input 5 is open, speed is limited to slowdown reference level in positive (A) speed direction (e.g. upwards), but no limitation for negative speed

(e.g. downwards) operation. And vice versa if input 6 is open. If both inputs 5 and 6 are closed (“1”), there is no slowdown speed limitation active - full speed allowed.



Slowdown selection “DI5 + DI6” is also possible to use when operating in

Fieldbus mode.



FAST STOP: When the FAST STOP-N input e.g. DI6 changes to “0” (activates on a negative edge) while running, the drive is fast stopped (active in both speed and torque control). Three alternatives Fast Stop 1 = Torque limit braking, Fast Stop 2 = Torque limit and mechanical braking or Fast stop 3 =

Mechanical braking can be selected from by parameter FAST STOP TYPE 12

(63.2).

After reaching zero speed and the “ZEROPOS” input has been set to ”1”, with a positive edge required for reset of fast stop condition, for a time longer than parameter ZERO POS OK TD, start of the drive is allowed. That is: the joystick must be returned to the neutral position for a minimum of 0.3 seconds (default value) before starting in other direction is possible.

To avoid running in the same direction (hoisting after overload indication or lowering after slack rope indication) the appropriate direction input must be wired in series with an additional contact from the protection equipment. These contacts must be of “NO” type and are closed when the protection equipment is energised and opens when a fault occurs.

TORQUE CONTROL is activated when the current level of input AI2 TORQ

REF the first time (after each power on) passes the level 2 mA, and if the speed reference to AI1 is below 1V.

Speed reference is activated the first time AI1 passes the level 1V (and after each power on = default).

If both inputs are above limit, than speed control is active.

Updating time for speed and torque references are 32 ms.

If a slowdown limit switch is activated, drive will change to speed control and limit speed to slowdown speed reference level set.

SPEED CORRECTION: The additional speed reference input Speed

Correction (Ext AI1 = RAIO input AI1) is a reference without any ramp that is added to the output of the normal speed reference ramp generator. Can be used as a correction input from a “electric shaft” control unit. Updating time is 8 ms for the speed correction input.

0 V signal is 0 % reference level and the 0 – (+)10 V range corresponds to 0 –

(+)100 % speed. 0 – (-) 10 V range corresponds to 0 - (-)100 % speed.

Additionally the fieldbus Speed correction signal (DS3.2) can also be used

(added to Ext AI1 signal) in Stand alone mode.

The speed correction reference is limited so that the sum of the normal

“ramped” speed reference and the speed correction reference cannot exceed

Maximum/Minimum Speed setting (parameters 20.1 & 20.2).

WATCHDOG: The signal WATCHDOG-N (digital output 2 as default) is used to indicate a healthy drive. This output is zero-set if the software detects any of the following faults:

Fieldbus communications fault (MAS OSC FLT)

- Master/Follower bus (Ch2) communication fault

- Brake long falling time

- Chopper fault (e.g. short circuit or overload)

- External fault

- CPU stalls out

If this relay output contact opens, the supply contactor to the converter must immediately be opened and mechanical the brakes applied by removing power from the brake contactor = emergency stop of the crane drive.



Fast stop-N (DI 6)

Trigg

"Speedref < 5%"

Zero speed

Running

&

<Zero Pos OK TD> t 0

&

Zero pos (DI 2)

Dir A (DI 3)

Dir B (DI 4)

& &

&

S

R

S

R

Fast stop 12

Fault or Fast Stop

> 1

<Joystick Warn TD> t 0

> 1

=1

& &

Start

&

1V

Speed ref (AI1)

<Deadzone>

<Ref. shape>

MAX

Slowdown-N (DI 5)

<Minimum ref.>

< Speed ref.

reduced>

INV

"0"

Drive speed ref.

<Abcd> = Parameter

CRANE stand alone logic using Joystick Control type

Figure 5-9 Crane Stand Alone logic in Joystick mode



Radio control mode (64.10=RADIO CTRL)

If the joystick is connected to and monitored by an external unit such as a Radio controller or PLC, then Control type “Radio Control” (parameter

64.10) can be used. The differences from “Joystick” control are:

- The “Zero Pos” input signal (e.g. DI2) is not used/required.

- If receiving both direction orders “Start Dir A” and “Start Dir B” at the same time, the start order and reference are interlocked while the error occurs, but no indication is given to the panel nor any requirement for both signals to be zero before releasing the interlock

- No check of reference level is made before responding to the start order.

Reference inputs for speed, torque and speed correction reference (AI1-

Ext AI1) have the same scaling and functions as in “Joystick” control mode.

Fast stop-N (DI 6)

"Speedref < 5%"

Zero speed

Trigg

&

S

R

Fast stop 12

Dir A (DI 3)

Dir B (DI 4)

&

=1

&

Start

Speed ref. (AI 1)

MAX

Drive speed ref

Slowdown-N (DI 5)

<Minimum ref>

< Speed ref.

reduced>

INV

"0"

Figure 5-10 Crane Stand Alone logic in Radio Control mode



Motorised Potentiometer control mode (64.10=MOTOR POT)

If using (for example) a pendant controller with push-buttons for start

and increase speed, then Control Type (parameter 64.10) should be set to “Motor Pot”.

“Start Dir A” and “Start Dir B” contacts connects to DI3 & DI4. “Increase” contacts should be connected in parallel to DI2 (activated by setting parameter 10.13 ACCELERATE SEL = DI2).

The Drive will start and accelerate on ramp towards (+ or -) 100 % speed if both direction and increase inputs are activated (= closed). If increase order is removed before reaching 100 % speed, drive will stop accelerating and run with the speed level reached. With a new increase order the drive will continue to accelerate towards 100 %.

If direction order is removed, the drive will decelerate on ramp towards 0

% speed. Reclosing the direction contact before reaching 0 % speed will stop deceleration and hold speed at the level reached.

Inputs AI1 and AI2 are inactive in this control mode. Other inputs have normal functions.

Fast stop-N (DI 6)

Trigg

Zero speed

Dir A (DI 3)

Dir B (DI 4)

&

&

=1

Increase (DI 2)

100%

Ramp output

MAX

<Minimum ref>

< Speed ref.

reduced>

Slowdown-N (DI 5)

INV

&

"0"

S

R

Fast stop 12

Start

Drive speed ref

Figure 5-11 Crane Stand Alone logic in Motorised Potentiometer



NOTE: “Motor pot” mode does not work if drive is using Scalar control mode.

Step joystick reference mode (64.10=STEP JOYST)

When using a step type joystick having reference contacts instead of an analogue potentiometer, the control mode STEP JOYST (parameter

64.10) should be used. Up to 4 different speed levels are supported, direction order giving first speed level + 3 more contacts for different speed levels. Contacts can be connected to selectable digital inputs

(including extended I/O modules), see parameters 10.8 STEP REF2 SEL,

10.9 STEP REF3 SEL and 10.10 STEP REF4 SEL. The corresponding speed reference levels are set with parameters 64.13 SPEED REF

LEVEL 1 up to 64.16 SPEED REF LEVEL 4.

All lower step reference contacts must remain closed for next level to be active.

Example: when closing contact corresponding to Step reference level 4, contacts for level 2 and level 3 must still be closed.

Note that Zero Pos signal from joystick is required in this mode, similar to control mode JOYSTICK. Joystick monitoring function is active.

Step radio reference mode (64.10=STEP RADIO)

When using a radio controller or PLC having step reference output contacts, the control mode STEP RADIO (parameter 64.10) can be used.

Maximum 4 different speed levels available.

Digital inputs and speed reference levels are selected as described above with Step Joystick mode.

Zero Pos input signal is not required in this control mode. Joystick monitoring is not active.



FB JOYSTICK control mode (64.10 = FB JOYSTICK & 64.1 = True)

This mode is used if the joystick I/O is wired to a PLC which has fieldbus communication to the CraneDrive drive, and we still want to use the

Stand alone mode (CRANE module).

When FB Joystick mode is selected the drive is reading signals START

DIR A, START DIR B, ZERO POS and the Reference from fieldbus datasets instead of the digital inputs DI2, DI3, DI4, and analog input AI1.

Dataset 5 word 1 from PLC is used with the following bit mapping:

Dataset 5 Word 1: Aux Command word

Bit number Signal Range Description

0 = Bit 0, LSB FB ZERO POS ”1”, ”0” Joystick Zero Position signal

1

2

FB START DIR A ”1”, ”0” Joystick direction A signal (pos.=up)

FB START DIR B ”1”, ”0” Joystick direction B signal (neg.=down)

JOYST Joystick torque control

CTRL enable

ON

ELSHAFT Electric shaft control on

Bits 0 – 2 are used for sending the joystick signals from PLC. Dataset 1 word 2 DRIVE SPEED REF (see section 5.5.12 for scaling information) is used for sending the joystick analog reference (without sign) in FB

JOYSTICK mode.

If using torque control, bit 3 in dataset 5 word 1 should be set to “1”. The torque reference (without sign) is then sent with dataset 1 word 3 TORQ

REF (see section 5.5.12 for scaling information).

Bit 4 FB ELSHAFT ON is only used with Electric shaft control, see section

5.5.14 for details.

Slowdown limit switches can still be wired to the drive digital input(s), selections per parameter 10.3 SLOWDOWN-N SEL.

End limit switches can be wired to drive digital inputs DI3 + DI4, see parameter 10.14 FB STOPLIM SEL, when FB JOYSTICK mode is used

(also available in Fieldbus mode).

When using FB JOYSTICK mode the fieldbus Command word, dataset 1 word 1 (see section 5.5.12) can be used except for the following bits that are not active: START OVR and TORQ CTRL.

Please note that the fieldbus communication supervision is active:

Comtest toggle bit in Command word + Status word must be connected in the PLC program (see section 5.5.12) to avoid communication fault in drive!



5.6.6 Logic handler ( 65 )

Contains logic for on-, off and start-order.

On is the motor magnetising command and start command releases speed and torque controllers. To get an On-order to the converter the signal ON must become ” 1”. This can only be obtained if no off order is issued which means if:

- Power On Ackn (e.g. DI2) = “1”.

- Converter is not tripped (FAULT = ” 0 ”)

- The button ” 0 ” at the panel is not pushed (LOCAL STOP = ” 0 ”)

When an “On signal” is given either in local mode with the panel LOCAL

START or in remote mode with the signal DRIVE ON (field bus mode) or

START DIR A/ START DIR B (stand-alone mode) to get the signal ON, then a signal Ready For Run is awaited, acknowledging that the motor is magnetised. If this acknowledgement is not received within 5 seconds the ON-order signal is reset to zero.

Off order is given by the panel LOCAL STOP at zero speed (stop pushbutton on panel) or in external control when signal DRIVE ON is set to

”0” (field bus mode ).

If parameter CONTIN ON (65.1) = ” false ” and running becomes ” 0 ” the

ON signal will be reset to ” 0 ” after expired time OFF TD ( 65.2 ). This is a ” magnetising shut-off” function if the drive is not operated within the last OFF TD seconds.

“Start order” is issued when START 2 = ” 1 ”. In remote mode the signal

START OVR (Fieldbus mode) or START DIR A / START DIR B (standalone mode) is giving this (the start order). In local mode the start order is given with signal LOCAL START (start push-button on panel).

No start order can be given unless the converter is “On” = magnetised, acknowledged by the signal Ready For Run.

Signal REF ZERO SET will hold the speed reference to ” 0 ” when Fast

Stop is ordered.

See also timing and logic diagrams on the next 2 pages.



Figure 5-12 Start and stop sequence time diagram



Running

<Contin on>

Ready for run

<OFF TD> t 0

0

5 sec t

&

> 1

Power on ackn

Stop panel

Zero speed

&

Fault

> 1

On "FieldBus"

Start "Panel"

Start "I/O"

> 1 TRIG

R

S

On

&

Start 2

Start "Fieldbus"

> 1

Logic handler (65)

Figure 5-13 Logic Handler logic


5.6.7


Torque proving (66)

Torque proving is a function module included in the drive control to ensure, before releasing the brake and starting the crane operation, that the drive is able to produce torque, and that brakes are not slipping

(signal “Zero speed”=1). The function module is mainly intended for hoist drives, but can also be used with other motions using encoder feedback.

Torque proving is performed by giving a positive torque reference with the brake applied. If torque proving is successful, that means torque reaches the correct level, the brake is lifted and the next step in the starting sequence is initiated.

The time to execute the torque proving sequence is so short

(approximately 100 ms) that the operator does not experience any time delay in the starting sequence.

The torque proving is activated by setting:

- TORQ PROV SEL (66.1) = ” True ”

The torque proving reference, TORQ PROV REF (66.4) sets output signal TORQ PROV REF. The actual torque is read from signal MOT

TORQ.

When the torque proving is activated but not yet performed, the output signal TORQ PROV OK is ” 0 ”

The torque proving sequence starts when the input signal RUNNING is ”

1 ”, i. e. when the converter is started. When the torque proving sequence is completed the output signal TORQ PROV OK is set to ” 1 ”.

If any fault is detected during the proving sequence, signal TORQ PROV

OK does not go to ” 1 ” but output signal TORQ PROV FLT is set to ” 1 ” and the drive trips. A message is displayed on the drive panel and an indication given to the supervisory control.

NOTE: Torque proving is not active (even if selected with parameter

66.1) if the drive is in torque control mode.

<TORQ PROV SEL>

Motor torque

S

R

> 1 Torq prov OK

Zero Speed

Running

<TORQ PROV REF>

<TORQ PROV FLT TD> t 0

> 1 & Torq prov flt

Torq prov ref

Torque proving (66)

Figure 5-14 Torque Proving logic



5.6.8 Mechanical brake control ( 67)

The program supports electrical and mechanical braking to stop the motor. Electrical braking gives a controlled and smooth braking which is the most common way to bring a motor to stop. Mechanical braking should only be used in critical situations and if so there are two possibilities:

- Emergency stop (category 0 stop)

- Fast stop

The function module contains logic for controlling the mechanical brake.

Output signal BRAKE LIFT (2.21) is the brake lift order. Brake lift acknowledgement is received as input (e.g. DI1) BRAKE ACKN.

In the starting sequence it is possible to set a rampstart time delay related to the brake actual lifting time with parameter 67.8 SPEED REF

TD.

After the motor has come to zero speed during a stop (by electrical braking) the mechanical brake should be applied without unnecessary delay.

Detection of the motors zero speed rotation at stop:

While running the motor the output signal ZERO SPEED (signal 4.1:4) is

”0”. When the speed is below the level ZERO SPEED LEV (67.6) and the time ZERO SPEED TIME ( 67.7) has elapsed the signal ZERO

SPEED becomes ”1”, indicating zero speed on the motor and the mechanical brake will be set if no start order exist.

A brake lift is initiated by a start order i. e. brake control input signal

START 2 = ”1”. This will set output signal RUN = ”1” releasing speed & torque controllers. After receiving TORQ PROV OK = ”1” and no stop orders are active the BRAKE LIFT is set ”1”. With a slow brake, start of the speed ref. ramp can be delayed with par. 67.8 SPEED REF TD.

Normal stop sequence:

Removing the start order will set the reference to zero and the drive will, if speed controlled, ramp to zero speed (Reference handler). When the input signal ZERO SPEED = ”1” then BRAKE LIFT is set to zero. When receiving acknowledgement BRAKE ACKN = ”0” the RUN order is reset to ”0” after delay time BRAKE FALL TIME (67.1). Except at emergency stop (EMERG STOP = ”1” when Power On Ackn = 0 in Fieldbus mode) and fast stop (FAST STOP = ”1”) the brake module maintains the

BRAKE LIFT and RUN order as long as ZERO SPEED is not detected.

With parameter 67.4 BRAKE REOPEN TD, a minimum time delay between a stop and next start, i.e. a “close brake order” (BRAKE LIFT=0) and next “brake lifting order” (BRAKE LIFT=1), can be set.

A brake fault, i.e. Brake Ackn (DI1) = 0 (during start or normal running) with a duration longer than setting of BRAKE FLT TD (67.2), activates an output signal BRAKE FLT that will trip the drive and indicate.



A long falling time at stop (Brake Ackn =1) with a duration longer than setting of BRAKE LONG FT TD (67.5), keeps torque on the motor and provides indication with an output signal BRAKE LONG FTIME to: panel,

Fieldbus statusword and activates the Watchdog output contact (DO2) to make an emergency stop of the drive (brake and drive power off).

See also logic diagram on this page and timing diagram in chap. 5.6.6

Torque prov OK

Power On Ackn

Running

Fast stop

&

&

> 1

> 1

&

<BRAKE REOPEN TD>

t 0

Brake lift

Speed off

Zero Speed

&

On

Start 2

Brake ackn

<BRAKE FALL TIME>

0 t

&

&

> 1

> 1

&

&

<BRAKE FLT TD> t 0

RUN

Brake fault

&

<BRAKE LONG FT TD> t 0

Brake long fall time

Mechanical Brake Control (67)

Figure 5-15 Mechanical Brake Control logic



Conical motor function

This section describes how to handle the use of a conical motor (rotor displacement motor) with built-in brake instead of standard motor plus external mechanical brake. In a conical motor the rotor will move along it’s length, thereby separating the brake disc mounted on the shaft from the counterpart mounted on the stator, as soon as magnetizing current is applied to the motor winding. When current is switched off at stop, rotor is pushed back closing the brake by spring force.

By setting parameter 67.11 MOTOR TYPE = CONICAL the conical motor function is activated. Following parameters will than automatically get the new default values below, suitable for use with conical motors

(parameters are reset to normal defaults if par. 67.11 is set to

STANDARD).

10.1 BRAKE ACKN SEL = INTERNAL ACK

21.2 CONST MAGN TIME = 30 ms

65.2 OFF TD = 0.0 s

67.1 BRAKE FALL TIME = 0.0 s

67.6 ZERO SPEED LEV = 3.0 %

67.7 ZERO SPEED TIME = 1000 ms

To minimize the “roll-back” (load dip) of a hoist conical motor when stopping, the flux is reduced during stop to a level set in parameter 67.12

RED FLUX LEVEL. Default value 75 % is sufficient for most conical motors, but for larger motors (30-40 kW) there can be a need to lower this value further to minimize the “roll-back”. Note that during stopping when reducing the flux the motor current will increase proportional. Due to this there can be a need to check converter sizing to have enough current margin. Normally one size bigger converter is selected.

This flux reduction is only active if conical motor function is activated with parameter 67.11 (=CONICAL).

To minimize the “roll-back” (load dip) of a hoist conical motor at start, the flux level at start can be increased to a level set in parameter 67.13

START FLUX LEVEL (100 - 140 %) during a time set with parameter

67.14 START FLUX TIME.

With parameter 67.7 ZERO SPEED TIME it’s possible to delay the closing of conical motor brake at stop. For example to get faster response to a new start order within this time.

NOTE: When making ID Run with a conical motor, the REDUCED type of ID Run must be selected in parameter 99.10 . The STANDARD type of

ID Run cannot be used as it is making measurements with low flux levels, making conical motor stop.

Conical motors used on hoist applications must have an encoder speed feedback.


5.6.9


Power optimisation ( 68 )

The power optimisation function module can only be used in drives with an active (pulling) load, i. e. in general only on hoist drives. Speed reference in hoisting direction must be positive value (Dir A).

When increasing the motor speed above motor nominal speed (base speed), field weakening is used. Field weakening, however reduces the maximum available torque of the motor. To ensure that the motor will always be able to produce sufficient torque for controlling the load in the field weakening range, a maximum allowed speed is calculated. This function is called power optimisation. This means that for a heavy load the maximum allowed speed is less than that of a light load.

Fieldbus mode: Speed reference from PLC (DS1.2) when accelerating hoist drive must be limited to Base speed level (set in parameter 68.2, e.g. 50%). If the power optimisation receives a logical 1 on the signal

HIGH SPEED, from fieldbus Command word (DS1.1) bit 2 , telling that maximum speed is requested by the driver, the maximum speed reference in field weakening area (above base speed) calculated by power optimisation is than used as input to the ramp unit and the motor will accelerate up to the corresponding speed. When driver is reducing reference from maximum, the HIGH SPEED signal should be set = 0.

The speed will now be below base speed unless PLC reference has been rescaled to be proportional to maximum reference (SPEED REF3 in DS4.1) reached during acceleration.

Stand alone mode: Speed reference is received through I/O (e.g. AI1 if

JOYSTICK control mode) or from PLC (DS1.2) if FB JOYSTICK control mode selected (parameter 64.10 CONTROL TYPE used for Stand alone control mode selection). Speed reference is given as 0 – 100 % (% of parameter 69.1 SPEED SCALING RPM). The minimum of this requested reference and the reference calculated by power optimisation is than used as input to ramp unit. Note that parameter 64.3 HIGH

SPEED LEVEL 1 should be set equal to the Base speed level (set in parameter 68.2) to get the HIGH SPEED signal correctly (this signal is created internally in Stand alone mode).

To be active the parameter POWOP SELECT(68.1) must be set ” True ”.

Parameters TQLIM UP (68.6) and TQLIM DWN (68.7) are maximum load torque (power limits) in positive/negative running directions.

When the speed, during acceleration towards base speed, has reached

90% of base speed the module makes a calculation (using speed and torque measurements during 250 ms before reaching 90% of base speed) of the maximum allowed speed by the formula: maximum speed =

BASE SPEED * TQLIM

TORQ HOLD



TORQ HOLD is the torque needed to hold the load (this level is equal to the motor torque value you can see when reaching steady state = constant speed), and is calculated by the module during acceleration. If the module receives the order HIGH SPEED = ”1”, commonly given when the master switch is in its outermost position, output SPEED REF POWOP is set to the calculated maximum speed reference. The quality of the calculation depends on the measurements done before reaching 90% of base speed. The speed must have a linear acceleration and without excessive ripple.

The power optimisation output speed reference SPEED REF POWOP is set to zero if the input signal HIGH SPEED is set to “0”. The calculated maximum reference is reset to zero when the actual speed SPEED ACT has decreased to a speed corresponding to the parameter POWOP RESET LEV (parameter

68.8).

The calculated reference value (before the “HIGH SPEED switch”) can be seen in signal 2.25 POWOP SPEEDREF.

The TORQUE HOLD value mentioned above is continuously calculated by the power optimisation module. It’s available as signal LOAD TORQUE % (2.31), in % of the motor nominal torque. This signal is filtered with a filter time constant set in parameter 68.10 LOAD TORQ FILT TC.

This LOAD TORQUE signal is used to detect a “Slack rope” situation, that is load torque dropping below the level set in par. 68.11 SLACK ROPE TQ LEV.

SLACK ROPE is indicated in signal 4.05 FB AUX STATUSWORD (DS12.1) bit

10. A detected slack rope will make a Fast stop1 of the drive. This Fast stop can be disabled via signal DISABLE SLACKROPE in fieldbus Dataset 5 Word

1: FB AUX COMMAND WORD (signal 3.07) Bit 7. Also setting of parameter

68.11 = -400% (default) will disable the Fast stop.

NOTE: When dimensioning the hoist motor it must be ensured that the available motor breakdown torque (T max

) in the frequency converter duty, is sufficient for the total torque required during acceleration (hoisting) and deceleration (lowering) in the field weakening area. The breakdown torque decreases proportionally to 1/n 2 in the field weakening area!

Power optimising will during acceleration, using total torque measured (load + accel), calculate the maximum speed possible in field weakening without exceeding the motors stated breakdown torque TMAX (parameter 68.9).

This value is used to limit the SPEED REF POWOP reference.



Commissioning instructions for the power optimisation.

This is an instruction how to adjust the parameters INERTIA TOTAL UP (68.4) ,

INERTIA TOTAL DWN (68.5) , TQLIM UP (68.6), TQLIM DWN (68.7) and

TMAX (68.9).

1. Set the parameter POWOP SELECT (68.1) to ”True”. Also temporarily set 68.9 to maximum = 500%.

2. Set the parameter TQLIM UP (68.6) to the rated torque of the motor (100%).

3. Temporarily set the parameter TQLIM DWN (68.7) to 75% of rated torque of the motor. The reason to set TQLIM DWN lower than TQLIM FLD WEAK UP is to get about same speed in positive and negative directions, with a certain load on the hoist.

4. The parameters INERTIA TOTAL UP and INERTIA TOTAL DWN are acceleration constants in positive and negative direction. Use a load that is 75 -

100% of full load.

5. Set parameter POWOP AUTOTUNE SEL (68.3) to ” true ”. The tuning part is now activated for one autotune cycle.

6. Start the drive with base speed reference (from Local or External control) in positive (respectively negative) direction, and the motor will accelerate up to base speed. The motor will keep at base speed for about 4 seconds for calculation to be completed. If giving start and reference from External control place it’s required to disconnect HIGH SPEED OK signal during Autotune (in

Standalone set par. 64.3=100%). Calculation is completed when actual signal no. 24 TOTAL INERTIA is showing a non-zero value. Stop the drive.

7. Read the actual signal no.24 TOTAL INERTIA on the panel.

Repeat this procedure 2-3 times in each direction and calculate the average value for parameter INERTIA TOTAL UP and INERTIA TOTAL DWN respectively.

8. Set this value to parameter INERTIA TOTAL UP (68.4) or INERTIA TOTAL

DWN (68.5) depending upon the direction. Reconnect HIGH SPEED OK signal

(i.e. in Standalone, set par. 64.3 back to 98%).

9. Adjusting TQLIM UP and TQLIM DWN:

Connect a load equal to the highest load specified to operate to max field weakening = 100% speed. Lower parameters TQLIM UP and TQLIM DWN to a low value, e.g. 40%. Testrun from joystick giving full reference up (resp. down).

Check max speed reached. If not equal to 100%, than increase TQLIM UP

(resp. TQLIM DWN) in steps of 5% until reaching 100% speed each time.

10. Now with this same load decrease TMAX 68.9 step-by-step and testrun up respectively down until you find the first value where speed starts to be limited below 100% in either up or down direction. Than slightly increase TMAX 68.9 to still reach 100 % speed both in hoisting and lowering direction.



An alternative to points 4 – 8 above for finding the Inertia values is:

Monitor signal 2.31 LOAD TORQUE % with DrivesWindow while making start and stop test runs (acceleration, constant speed for a couple of seconds and deceleration) with different settings on Inertia parameter. Any load 20 - 100% is possible to use. Do not run faster than base speed. First run in hoisting direction.

When you have found the correct value for parameter 68.4 INERTIA TOTAL UP, than signal 2.31 LOAD TORQUE % will show the same level during acceleration and deceleration as during constant speed. If the Load torque signal is showing a higher value during acceleration than during constant speed, the INERTIA TOTAL UP parameter should be increased. If lower value during accel. than during constant speed, than Inertia should be lowered.

Next make similar test runs in lowering direction to find correct value for parameter 68.5

INERTIA TOTAL DWN. If Load torque signal is now showing a higher value during acceleration than during constant speed, the INERTIA TOTAL DWN parameter should instead be decreased (and increased if showing lower value during accel).


5.6.10


Reference handler ( 69 )

The function module includes:

- Setting of ramp times

- Handling of speed references

- Torque memory function

Setting of ramp times can be made for both acceleration and deceleration and can be set differently for forward and backward (or upwards and downwards) with parameters: 69.2 ACC TIME FORW, 69.3

ACC TIME REV, 69.4 DEC TIME FORW and 69.5 DEC TIME REV.

The possibility to use a scaling factor for the set ramp times is available in external (only in Fieldbus mode) and local control mode. In external control mode the scaling is done with signal RAMP RATE (DS3.1) from supervisory control, if parameter 69.10 “RAMP RATE=1” is set False.

Parameter RAMP SCALE LOCAL (69.7) is used when running in local.

Default setting is 2.0 (except for the Master drive in Master/Follower macro operation, then the setting is fixed at: 1.0), meaning that the actual ramp times when running in local control mode are double the settings of the ramp time parameters 69.2 - 69.5.

Speed reference when running in external Fieldbus control mode

(64.1=False):

The drive is using the higher value from DRIVE SPEED REF or SPEED

REF POWOP. The DRIVE SPEED REF is a reference up to base speed at start. Then if the power optimisation has calculated, for the actual load, that it is possible to run above base speed, it will use SPEED REF

POWOP which brings the speed into the field weakening range. DRIVE

SPEED REF should then normally be rescaled to ”follow” the maximum speed reached to have a smooth behaviour when decreasing the reference from the joystick (continuous gear).

When running in Stand alone mode (64.1=True), the drive is instead using the lower value of driver reference given (via AI1 or the DRIVE

SPEED REF from PLC, if FB Joystick mode) and the SPEED REF

POWOP.

Speed reference when running in local control mode is SPEED REF

LOCAL and the direction is chosen with the direction push-buttons on the panel.

Speed reference output to speed controller can be delayed if having a slow acting brake (long lifting time) using the time SPEED REF TD

(67.8).

The ramp unit is equipped with an S-curve function, for “smoothing” both the beginning and the end of the ramp. S-curve time constant is set with parameter 69.6 S-RAMP TC.

Parameter START TORQ SEL (67.9) is used for selecting type of torque memory function , to avoid “roll-back” at start on a hoist drive:

NOT USED = No extra starting torque

AUTO TQ MEM = Automatic torque memory will store the load torque needed when stopping and apply the same torque reference when


Chapter 5 – Crane Program Description starting again. The value of parameter 67.10 START TORQ REF is used as a minimum value for the torque memory.

LOAD MEAS = Starting torque reference is received from a PLC (DS5.2

LOAD MEAS REF) or from the extended RAIO analog input 2

(connected e.g. from a load cell). The “Ext AI2” input is filtered with parameter 13.6 (also used for Ext AI1) and scaling is done with par. 64.9

TORQUE REF SCALE. Parameter 64.9 = 2.0 gives following scaling: Ext

AI2= 10V corresponds to 200% starting torque reference.

NOTE: signal LOAD MEAS SEL from Fieldbus command word must be set “true” to enable the fieldbus reference from DS5.2.

The fieldbus DS5.2 reference and Ext AI2 reference are added together.

PAR 67.10 = Starting torque reference is set fixed equal to value given in parameter 67.10 START TORQ REF.

Brake lift

Start 2

Local

Speed ref local

Drive speed ref

Speed ref powop

<SPEED REF TD>

t 0

MAX/

MIN

"0" "0"

Ref zero set

Ramp hold

Fast zero set

"0"

<ACC TIME FORW>

<DEC TIME FORW>

1 2

<S-RAMP TC>

Speed ref 3

3 4

<DEC TIME REV>

<ACC TIME REV>

Figure 5-16 Reference Handler logic

Reference handler (69)



5.6.11 Position measurement ( 70 )

The function module is used to give a position measurement from a pulse encoder input RTAC or NTAC. Position measurement can be used in both Fieldbus and Stand alone modes.

The measurement can be synchronised to the value POS PRECOUNT

PPU sent from the supervisory controller, either by signal PGMSYNC from the fieldbus Command word or from digital input hw-sync

(parameter 10.6 SYNC SEL).

NOTE: Hw-sync from digital input is blocked when drive is not running

(2.20 RUNNING = 0).

Acknowledgement of synchronisation is done with the signal SYNC RDY to the supervisory controller. Reset of the acknowledgement is done with signal RESET SYNC RDY from the supervisory controller.

Hardware synchronisation through e.g. DI.3 can be blocked if HW SYNC

INHIBIT from supervisory controller = ” 1 ”. Synchronising edge of DI.3 is selected with parameter SYNC COND (70.2).

Measurement value POS ACT PPU sent to the supervisory controller is the number of pulses counted divided with the value of parameter POS

SCALE (70.1).

The number of pulses counted depends upon the settings of parameters

50.1 Pulse Nr and 50.2 Speed Meas Mode. Default setting of Speed

Meas Mode parameter is that both positive and negative edges from both A and B signals are counted.

Example: If 50.1 is set to 1024 ppr and 50.2 is set to default: “A_-_B_-_”, then a total of 4*1024=4096 pulses are added per revolution of the pulse encoder.

Position measurement can be used also if the pulse encoder is not mounted directly on the motor shaft (e.g. pulse encoder mounted on a separate measurement wheel). Parameter 50.5 SPEED FEEDB USED should than be set to ”False”, thereby not using speed measurement signal from pulse encoder (drive will then use the calculated speed signal instead). Pulse encoder signals are now used only for position measurement.



5.6.12 Field bus communication ( 71 )

Receive

This part is used to receive signals from a superior controller via a high speed serial bus in the form of a Field Bus (e.g. Advant link, CS31 (max

8 words), Profibus (10 words), Modbus, Interbus-S, Devicenet. Please check the respective fieldbus adapter manual for limitations on the number of words possible for sending and receiving. The ACC receive signal interface is standardised as a block of 12 words where each signal has its specific position. The module also includes one element for unpacking the Command word signal to 16 Boolean signals. Updating interval for datasets 1, 3 & 5 is 32 ms, except FB SPEED REF, FB

TORQ REF and FB SPEED CORR that are updated every 8 ms. For transmission of signals from drive to superior controller, see Fieldbus communication Transmit.

NOTE: If parameter 71.5 DSET BASE ADDRESS is set to 10 instead of the default value 1, than add 9 to all dataset numbers below (e.g.

DS1 -> DS10, DS3 -> DS12 aso).

Table 5-4 Receive Dataset 1 (alt. 10) Word 1

FB COMMAND WORD = DataSet 1 Word 1 (signal 3.1)


0 = Bit 0, LSB COMTEST REC ”1” ”0” Comtest receive bit.

(1=active) PLC in Fieldbus mode

3

4

START OVR

RAMP HOLD

(1=active)

”1” ”0”

(1=active)

”1” ”0”

(1=active)

(Power optimisation)

Startorder from PLC in

Fieldbus mode

Speedramp hold signal

SEL

(1=active) signal (only in M/F ctrl)

CTRL Torque control selected.

(1=active) (Torque ref = DS1.3)

9

10

SEL

MEAS Load measurement select

(1=active) (enable LOAD MEAS REF)

”0 → 1”

(edge)

Reset fault from overriding control (PLC)

FAST STOP 1 ”1” ”0”

(1=active)

FAST STOP 11 ”1” ”0”

(1=active)

11 PGM → 1”

(edge)

Fast stop type 1 (torque limit stop)

Fast stop 11 type select

(see par. 63.1)

Program synchronisation of position measurement

INHIBIT

READY

(1=active)

Hardware (DI) sync. of pos. measurement blocked

SYNC Reset synchronisation

(1=active) ready

15 = Bit 15,

MSB

CHANGE

ENABLE FB

CTRL

(0=User1)

”1” ”0”

(1=active) change request

Enable fieldbus control in

Stand alone Joystick mode

(used by SwayControl)



Table 55 Receive DataSets 1, 3, 5 and 7 (alt. 10, 12, 14 and 16)

Example: DS1.2 = DataSet 1, Word 2

DataSet.Word Signal Range corresp. to

+/- 32767

Description

DS1.2 (DS10.2) FB SPEED REF -163.84-

DS1.3 (DS10.3) FB TORQ REF

DS3.1 (DS12.1) FB RAMP RATE 0.00-32.767

(Integer

1000 equals a rate=1.0)

DS3.2 (DS12.2) FB SPEED

CORR

+163.84

-327.67-

+327.67

-163.84-

+163.84

Drive speed reference, %

(20000=100%)

Torque reference, %

(10000=100%)

Ramp rate multiplying factor for the speed ramp times set in drive, normally=1.0

(1000=1.0)

Speed correction signal, %

(20000=100%)

DS3.3 (DS12.3) FB POS

PRECOUNT

-32767-

+32767

DS5.1 (DS14.1) FB AUX COMM

WORD

DS5.2 (DS14.2) FB LOAD MEAS

REF

DS5.3 (DS14.3) “not used”

-327.67-

+327.67

DS7.1 (DS16.1) PAR VALUE 1 -32767-

+32767

Preset value to position counter = sync value

(1=1)

Auxiliary Command Word

(see Table 5-6 below for details)

Load measure reference,

% (10000=100%)

DW signal 3.9

DS7.2 (DS16.2) PAR VALUE 2

DS7.3 (DS16.3) PAR VALUE 3

-32767-

+32767

-32767-

+32767

Parameter value for parameter selected with parameter 90.1



“SPEED” signals have scaling: 20 000 corresponds to 100 %

”TORQUE” signals have scaling: 10 000 corresponds to 100 %.

The communication is supervised continuously using a “toggle bit” received in FB STATUS WORD (DS1.1) bit 0 COMTEST REC:


If ”next edge” is not received within a certain time COMTEST FLT TD

(71.1), the MAS OSC FLT fault occurs and the drive trips.

The drive is inverting the bit received from the superior controller (PLC):

COMTEST REC and sending it back in FB COMMAND WORD (DS2.1)

Bit 14 COMTEST TRA.

NOTE: In the superior controller the received bit should be sent to the drive again without inverting!

5-41


Table 5-6 - Receive Dataset 5 (alt. DS14) Word 1

FB AUX COMM WORD = DS5.1 (signal 3.7)

Bit number

Signal Range Description

0 = Bit 0,

LSB

1

FB ZERO POS ”1” ”0”

(1=active)

FB START DIR A ”1” ”0”

(1=active)

FieldBus transmitted Zero Position signal from joystick (if par. 64.10 =

FB JOYSTICK)

FieldBus transmitted Start Dir A signal from joystick (if par. 64.10 =

FB JOYSTICK)

2 FB START DIR B ”1” ”0”

(1=active)

4

TQREF SEL (1=active)

FB ELSHAFT ON ”1” ”0”

(1=active)

5 RESTART ”0 → 1”

(edge)

FieldBus transmitted Start Dir B signal from joystick (if par. 64.10 =

FB JOYSTICK)

FieldBus Joystick mode Torque control enabling (if par. 64.10 = FB

JOYSTICK)

FieldBus Electric Shaft control On

(enabled) for Master or Slave drive

Restart the drive DataLoggers

7 DISABLE

SLACKROPE

(edge)

”1” ”0”

(1=active)

Forced trigg (stop) of the drive

DataLoggers

Disable that Slack rope makes a

Fast stop (stop on torque limit)



Transmit

This part is used to transmit signals from the drive to a supervisory controller via high-speed serial bus in the form of a Field Bus (e.g.

Advant link, CS31 (max 8 words), Profibus (10 words), Modbus,

Interbus-S, Devicenet. Please check the respective fieldbus adapter manual for limitations on the number of words possible for sending and receiving. The ACC transmit signal interface is standardised as a block of 14 words where each signal has its specific position. The module also includes elements for packing 16 Boolean signals to word signals.

Updating interval for datasets 2, 4 & 12 is 32 ms, except for signals

SPEED ACT and POS ACT PPU that are updated every 8 ms. Updating interval for datasets 6 & 8 is 56 ms.

Note: If parameter 71.5 DSET BASE ADDRESS is set to 10 instead of the default value 1, than add 9 to all dataset numbers below (e.g.

DS2 -> DS11, DS4 -> DS13 aso).

Table 5-7 Transmit DataSet 2 (alt. DS11) Word 1

FB STATUS WORD = DataSet 2 Word 1 (signal 4.1)


0 = Bit 0, LSB

2

3

4

5

6

7

8

9

10

11

RDY FOR ON ”1” ”0”

ACKN

RDY FOR RUN

RUNNING

ZERO SPEED

REM LOC

TORQ PROV OK ”1” ”0”

USER 1 OR 2

FAULT

WARNING

LIMIT

SYNC

”1” ”0”

”1” ”0”

”1” ”0”

”1” ”0”

”1” ”0”

”1” ”0”

”1” ”0”

”1” ”0”

”1” ”0”

Ready for on

Power on acknowledgement, e.g. DI_IL

Ready for run

(magnetized)

Running (producing torque)

At zero speed

Remote /Local

(1= Remote)

Torque proving OK

User macro 1 or 2 active

Fault active

Warning active

Drive in torque limit

Sync input (e.g. DI3) status

14

FTIME

COMTEST TRA

15 = Bit 15, MSB SNAG LOAD

”1” ”0”

”1” ”0” ready

Brake long falling time indication

Communication test transmit bit

Snag load indication



Table 5-8 Transmit DataSets 2, 4, 6, 8 & 12 (alt. 11, 13, 15, 17 & 21)

Example: DS2.2 = DataSet 2, Word 2

DataSet.Word Signal Description

DS2.2 (DS11.2) SPEED ACT

(fixed)

DS2.3 (DS11.3) MOTOR

TORQUE FILT

(fixed)

DS4.1 (DS13.1) SPEED REF 3

(p92.1 to select)

Range corresp. to

+/- 32767

-163.84-

+163.84

-327.67-

+327.67

-163.84-

+163.84

Speed actual (%)

(20000=100%)

Torque actual (%)

(10000=100%)

-32767-

+32767

-3276.7-

+3276.7

Speed reference 3 = ramp output (%)

(20000=100%)

Position actual value

(1=1)

Motor current (A)

(10=1A)

DS4.2 (DS13.2) POS ACT PPU

(92.2)

DS4.3 (DS13.3) MOTOR CURR

(92.3)

DS6.1 (DS15.1) FB FAULT

WORD 1

(92.4)

DS6.2 (DS15.2) FB FAULT

WORD 2

(92.5)

DS6.3 (DS15.3) FB ALARM

WORD

(92.6)

DS8.1 (DS17.1) MOTOR VOLT

(92.7)

DS8.2 (DS17.2) DC VOLT

(92.8)

DS8.3 (DS17.3) POWER

(92.9)

DS12.1 (DS21.1) FB AUX

STATUSWORD

(fixed)

DS12.2 (DS21.2) AI1 REF

(fixed)

Warnings

-32767-

+32767

-32767-

+32767

-3276.7-

+3276.7

-163.84-

+163.84

Motor control faults

Motor voltage (V)

(1=1V)

DC voltage (V)

(1=1V)

Motor shaft power

(%) (10=1%)

Aux status word

Standard analog input 1 speed reference value (%)

(20000=100%)



Table 5-9 Transmit Dataset 12 (alt. DS21) Word 1

FB AUX STATUSWORD = DS12.1 (signal 4.5)

Bit number Signal

0 = Bit 0, LSB DIR A

Range

“1” “0”

Description

Stand alone direction A order

1 DIR B “1” “0”

2 ZERO POS

DIR A

DIR B

“1” “0”

Stand alone direction B order

Stand alone zero position order

Stand alone slowdown dir

A

Stand alone slowdown dir

B

6

7

ACKN

BRAKE LIFT “1” “0”

FOLL SEP ACKN “1” “0”

READY

Electric shaft control on acknowledge

Brake lift order

Follower Separate acknowledge

Drive datalogger data ready (triggered)

10

11

12

ACTIVE

“1” “0”

SLACK ROPE

COMTEST MF

FAST STOP

“1” “0”

“1” “0”

“1” “0”

Analog input 3 speed limit is active (AI3<10mA)

Slack rope is detected

Master/Follower comtest

Fast stop is active

4

5

6

7

Table 5-10 FB Fault Word 1 Dataset 6 (alt. DS15) Word 1

FB FAULT WORD 1 = Dataset 6, Word 1 (signal 4.2)

Bit number Signal (panel

Fault text)

Description

0 = Bit 0, LSB

1

2

3

MOT OVERSP

TORQ FLT

BRAKE FLT

ELECTR SHAFT

Motor overspeed fault

Torque fault

Mechanical brake fault

Electrical shaft control fault

TORQ PR FLT

MAS OSC FLT

Torque proving fault

Fieldbus “oscillator” (toggle) bit fault

CHOPPER FLT Braking chopper faults

INV OVERLO Inverter overload

9

10

11

12

13

14

MF COMM ERR

PANEL LOSS

I/O COMM

Master/Follower bus communication fault

Panel communication fault

I/O board communication fault

AMBIENT TEMP ACS800 ambient over temperature

THERMISTOR

MF RUN FLT

Thermistor fault (DI6)

Master/Follower running fault

15 = Bit 15, MSB COMM MODULE Comm module communication fault



Table 5-11 FB Fault Word 2 DataSet 6 (alt. DS15) Word 2

FB FAULT WORD 2 = Dataset 6, Word 2 (signal 4.3)


Fault text)

Description

0 = Bit 0, LSB

1

DC OVERVOLT DC-link over voltage

DC UNDERVOLT DC-link under voltage

7

8

9

3

4

5

6

10

11

12

13

EARTH FAULT

MOTOR PHASE

USER MACRO

ACS 800 TEMP

MOTOR TEMP

OVERFREQ

START INHIBIT

ENCODER ERR

Earth fault

Motor phase loss fault

User macro requested is not saved

Over temperature in IGBT Power plate

Motor over temperature (calculated)

Over frequency fault

Start inhibit fault (“Prevention of unexpected start” active)

SHORT CIRCUIT Short circuit at output

PPCC LINK Power Plate communication link fault

(INT board)

SUPPLY PHASE Supply phase missing (DC ripple)

Encoder module / speed deviation fault

14 LINE CONV Line converter fault (4Q drive)

15 = Bit 15, MSB THERMAL MODE Thermal protection mode fault (30.5)



Table 5-12 FB Alarm Word DataSet 6 (alt. DS15) Word 3

3

4

5

6

FB ALARM WORD = Dataset 6, Word 3 (signal 4.4)


Warning text)

Description

0 = Bit 0, LSB

1

2

MOTOR TEMP Motor high (95%) temperature

(calculated)

COMM MODULE Comm module communication alarm

ID RUN FAIL ID Run failed

ACS 800 TEMP

ENCODER ERR

JOYSTICK

High temperature in IGBT Power plate

Encoder module speed deviation alarm

Joystick supervision alarm (Stand alone)

START INHIBIT Start inhibit alarm (“Prevention of unexpected start” active)

8

9

10

THERMISTOR Thermistor alarm (DI6)

NO MOT DATA No motor data or too low nominal current entered

LIFETIME>90% Crane hoist machinery lifetime exceeded

90% of total lifetime set in par. 74.2

15 = Bit 15, MSB “Not used”



5.6.13 Master/Follower ( 72 )

General

The Master/Follower is a load sharing Application and is designed for applications in which the system is run by two CraneDrives and the motor shafts are coupled to each other via gearing, rail, shaft, etc.

The Master/Follower application is then controlling the load distribution between the drives. The Master drive is sending order signals and references (speed and torque) through the Master/Follower bus to the

Follower drive. The Master is also reading back status information from the Follower drive to ensure a safe operation.

The Master/Follower application can be used for both hoist and travel motions, in both Fieldbus mode and Standalone mode.

The Master station shall always be speed controlled and the Follower station normally be Torque controlled.

NOTE: Both drives must be in DTC control mode (i.e. M/F ctrl does not work in Scalar mode).

To ensure correct Follower load sharing the Follower speed limits 20.1 &

20.2 must be set 5 % higher than the setting of Master parameter 69.1

SPEED SCALING.

Checklist for a Quick Start-up

The installation and start-up procedure of the CraneDrive is explained in

ACS 800 Hardware manual.

An additional checklist for the

Master/Follower application is given below:

1 Switch off the power supplies to the CraneDrive units. Wait for five minutes to ensure that the intermediate circuits are discharged.

2 Build the M/F link, Master Ch2 to Follower Ch2.

See Figure 5-17 Master/Follower configuration in Stand Alone mode.

NOTE: Optical fibers for Master/Follower bus to be ordered

separately!

3 Connect the external control signals to the Master.

4 Switch on the power supplies.

5 Activate M/F control Macro in both CraneDrives (Parameter

99.2 Application Macro = M/F CTRL)

6A Stand Alone Mode

In the Master set parameter:

- Stand Alone Sel (Parameter 64.1) to True

- Master/Follower Mode (Parameter 72.1) to Master.

In the Follower set parameter:

- Stand Alone Sel (Parameter 64.1) to True

- Master/Follower Mode (Parameter 72.1) to Follower.

- Torque Selector (Parameter 72.2) to Torque

- Brake Int Ackn (Parameter 67.3) to True



6B Fieldbus mode

In the Master set parameter:

- Enable Comm module (Parameter 98.2)

- Stand Alone Sel (Parameter 64.1) to False

- Master/Follower Mode (Parameter 72.1) to Master.

In the Follower set parameter:

- Enable Comm module if required (Parameter 98.2)

- Stand Alone Sel (Parameter 64.1) to False

- Master/Follower Mode (Parameter 72.1) to Follower.

- Torque Selector (Parameter 72.2) to Torque

- Brake Int Ackn (Parameter 67.3) to True

7 Set all application parameters in both drives

8 Switch the CraneDrive units to external control with the

LOC

REM

- key on the Control Panel (there should be no L on the first row of the display). Reset both drives.

9 Perform the test run with the motors still de-coupled from the driven machinery. For this test temporary set the Follower in speed control mode (Parameter 72.2 Torque Selector = Speed). Give the control signals both through the Master analogue/digital or through fieldbus inputs and from the master Control Panel.

Check the correct operation of the Master and Follower drives visually (motor & Control Panel display):

• Start and Stop signals to the Master are received by the drives.

• The Master follows the speed reference given

• The Follower follows the master speed reference.

10 The Control Panel on the Follower is not active and can not control

11 Change Follower back to Torque mode (set Parameter 72.2 =

Torque)

71.

Switch off the power supplies.

13 Couple the motor shafts to the driven machinery and switch on the



Speed ref.

Brake ack.

Zero Pos.

Dir A

Dir B

Slowdown-N

Fast Stop-N

The external control signals are connected to the drive concerned. The

Master controls the Follower via a fiber optic serial communication link.

NOTE: For hoist applications pulse encoder and RTAC-01 (or NTAC-02) is compulsory on both drives.

ACC 800

Master Drive

AI 1

DI 1

DI 2

DI 3

DI 4

DI 5

DI 6

CH2

*

RO1

RO2 Watch dog-N

RO3 Fault-N

RTAC-01

Pulse encoder module

Brake lift

ACC 800

Follower Drive

CH2

*

RO1

RTAC-01

Pulse encoder module

RO2 Watch dog-N

RO3 Fault-N

Tx Rx Tx Rx

*

Used with hoist drive

Figure 5-17 Master/Follower wiring information for Stand Alone application



The Master, which is controlled from the Fieldbus, controls the Follower via a fiber optic serial communication link. The external control signals are connected to the drive concerned. (DI1 - DI4)

ACC 800

Master Drive

Brake ack.

DI1

Power on ack.

DI2

Sync DI3

Chopper fault DI4

RO1

RO2

RO3

RxxA

Fieldbus adapter modul

Brake lift

Watch dog-N

Fault-N

Power on ack.

Sync

Chopper fault

ACC 800

Follower Drive

DI2

DI3

DI4

RxxA modul

Fieldbus adapter

RO1

RO2 Watch dog-N

RO3 Fault-N

CH2

Tx Rx

CH2

Tx Rx

Operation

Figure 5-18 Master/Follower wiring information for Fieldbus application

Master and Follower Stations

The default settings of the Master/Follower Control macro parameters

does not define the station as Master or Follower. The selection is done with parameter 72.1 MAST/FOLL MODE.

If Follower operation is selected the convertor can not be operated from the panel.



Redundancy operation

If one motion is driven by two mechanically coupled motors with separate drives in Master/Follower mode, than separate operation of Master or

Follower drive can be used for redundancy operation (if one drive fails).

The drives can be run separately by User Macro 1 for normal

Master/Follower operation. (Parameter 99.2 = M/F CTRL) and

User Macro 2 for redundancy operation (Parameter 99.2 = CRANE).

For changeover from User Macro 1 to User Macro 2 a digital input or bit

14 in fieldbus Command word can be used (see parameter 16.5).

Brakes needs to be controlled by both drives if motors mechanically connected.

Separate operation

The signal SEPARATE in the fieldbus Command word (DS1.1 bit 5) can also be used for changing M/F drives from Master/Follower operation to normal, non-Master/Follower operation. This is available in both Stand alone and Fieldbus modes. For Follower drive there is a “separate change acknowledge” signal available in fieldbus Aux status word

(DS12.1 Bit 7), see also section 5.5.12 .

NOTE: Changing of signal SEPARATE (0 to 1 or 1 to 0) can only be done if status signal RUNNING=0.

Panel separate operation

The Master and Follower drives can be operated separately from the

Control Panel or DriveWindow, e.g. during maintenance, by setting parameter 72.1 MAST/FOLL MODE = OFF.

Multiple Followers

It is possible to connect more than one Follower drive in a

Master/Follower configuration by activating the “Broadcast mode”

(parameter 72.11=YES) in all drives. See also section 6.2.27 .

Master drive is on the Ch2 M/F bus sending the Torque and Speed references to any Follower connected. But in this mode there is no start order sent from Master to Followers. Neither is there any check of

Followers status done by the Master drive. Start order and status check

(e.g. any faulty Follower) must be done externally via I/O or fieldbus to all

Master/Follower drives.



Master/Follower link Specification

Size of the Link: One Master and one Follower station can be connected.

Transmission medium: Fiber Optic Cable.

• Construction: Plastic core, diameter 1 mm, shielded with plastic jacket

• Attenuation: 0.31 dB/m

• Maximum length between Stations: 10 m

• Other:

Parameter

Storage Temperature

Short Term Tensile Force

Short Term Bend Radius

Minimum

-55

Installation Temperature -20

25

Long Term Bend Radius 35

Long Term tensile Load

+85

+70

50

1

Unit o C o C

N mm mm

N

Various lengths of fiber optic cables are available as optional add-on kit

for the CraneDrive.

Connectors on the RDCO-0x board: Blue - receiver (hp 9534, T-1521); grey – transmitter

(hp 9534, R-2521)

Serial Communication Type:

Transmission Rate:

Transmission Interval:

Synchronous, full duplex

4 Mbit/s

4 ms



5.6.14 Electric shaft (73)

The electric shaft control is used for synchronized operation of two drives.

For example, two independent hoist machineries connected to the same load.

To use Electric shaft control both drives are required to have pulse encoder feedback. They are also required to have fiber optic connection between channel 2 in Master and Slave drive (RDCO-0x board needed).

Basic function is that position counter values from the Master and Slave drive are compared and the difference is controlled to zero by adding a speed correction reference (positive or negative) in Slave drive. This correction is limited to +/- 5 %. When stopping (startorder=0) the correction is disabled below a speed set in parameter 73.6 ELSH CTRL

MIN SPD (but position difference is still measured and used for correction when new start order is given).

Correction P-controller is adjusted with parameter 73.2 ELSHAFT GAIN.

Electric shaft control can be used in both Stand alone and Fieldbus mode.

Electric shaft control can be switched on or off with an external signal

ELSHAFT ON using a digital input, parameter 10.15 ELSHAFT ON SEL, or fieldbus Aux. command word (DS5.1:4) signal FB ELSHAFT ON. This external signal should be connected to both Master and Slave drive.

When Electric shaft control is switched on, start orders and reference are only required for Master drive. Master sends orders and reference to

Slave drive via channel 2 Master/Follower bus. Ramp times in Slave must be set equal to or shorter than Master.

When Electric shaft control is switched off, both drives work as two individual “normal” drives (similar to activating “Separate” with M/F drives).

If switching Electric shaft control on or off while motors are running, drives will make a ramp stop. New start is possible after returning joystick to zero position.

When any of the Master or Slave drive receives a Slowdown limit switch indication, both drives will be limited to this slowdown speed (if Electric shaft control is active).

Power optimisation can be utilised on Electric shaft hoist drives. Both drives should have power optimisation enabled. The lower reference value calculated by Master or Slave will be used by both drives.

When using different gear box ratios for Master and Slave drive, a speed ratio between Master and Slave can be set using parameters 73.3 GEAR

NUMERATOR and 73.4 GEAR DENOMINATOR (see section 6.2,28 for details).

If Master and Slave drive are set to have different 100 % speed (i.e. different setting of parameter 69.1 SPEED SCALING RPM), than parameter 70.1 POS SCALE must be adjusted accordingly in one of the drives e.g. Slave.




Example: If Slave speed scaling is 2 times Master speed scaling, than

Slave Pos scale should be set 2 times Master drive Pos scale.

If electric shaft position error (signal 2.26 ELSHAFT POS ERROR) exceeds the level set in parameter 73.5 POS ERROR LIMIT, both drives will trip and the Slave indicates “ELECTR SHAFT” fault. Master will then also indicate “FOLL FAULT” (Follower fault).

Configuring the Electric shaft control:

Both drives, designated “Master” and “Slave”, are to be set up with Ch2

Master/Follower communication. This is done by selecting parameter

99.2 APPLICATION MACRO = M/F CTRL. Also fiber optic connection is required between Ch 2 in both drives.

To define communication master and slave: Set parameter 72.1

MAST/FOLL MODE = MASTER in the “Master” drive.

Set parameter 72.1 MAST/FOLL MODE = FOLLOWER and set 72.2

TORQUE SELECTOR = SPEED in the “Slave” drive.

Set parameter 73.1 ELSHAFT MODE SEL = MASTER in “Master” drive and to SLAVE in “Slave” drive.

If using drives in Stand alone mode (i.e. parameter 64.1 STANDALONE

SEL = True), select what digital input is used for enabling the Electric shaft control. Set with parameter 10.15 ELSHAFT ON SEL.

Example: Selecting parameter 10.15 = EXT DI3 refers to extended NDIO module #2, digital input #1.

To be set in both “Master” and “Slave” drive.

If using Fieldbus mode (i.e. parameter 64.1 = False) or Stand alone FB

Joystick mode, the enabling of Electric shaft control can also be done with bit number 4 (bit numbering 0…15) in dataset no. 5, word 1.

Other related parameters to be checked:

98.1 Encoder module = e.g. RTAC SLOT1

50.1 Encoder pulse nr

69.1 Speed scaling rpm = max. operating Speed

69.2 – 5 Acc/Dec ramp times forward and reverse

70.1 Pos scale (e.g. no. of pulses/mm)

20.1 – 2 Minimum/Maximum speed limits (to be 5% higher than

98.5 – 6 DI/O Ext modules 1 – 2 selection

5-55


5.6.15 Crane lifetime monitor (74)

The main function of the Crane lifetime monitor is to indicate how much is left of the crane hoist mechanical lifetime, signal 1.35 LIFETIME LEFT %.

This is done with the help of the following signals:

- Total operating time (= brake open time) of the drive, signal 1.32 TOTAL

OPER TIME. Signal is backed up in non-volatile memory.

- Continuously calculated actual hoist load, signal 1.33 LOAD TORQUE ton.

- Load spectrum factor Km (function of load and time), signal 1.34 LOAD

SPEC FACT Km. Signal is backed up in non-volatile memory.

To get a correct load signal the Inertia parameters 68.4 and 68.5 must be tuned, see tuning instruction on page 5-34 (part of commissioning power optimisation instruction).

NOTE: There is no requirement to set parameter 68.1 POWOP SELECT or 68.2 BASE SPEED in order to get the load torque signal to work.

For compensating the mechanical efficiency of hoist machinery to get equal load torque value in both hoisting and lowering direction, parameters 68.12 LOADCORR FACT UP and 68.13 LOADCORR FACT

DWN should be adjusted.

These parameters are also used for scaling the motor utilization, i.e. the motor torque level (in per unit; % torque/100) when hoisting rated load.

The signal 1.33 “LOAD TORQUE ton” must to be scaled using parameter

74.1 NOMINAL LOAD.

The mechanical lifetime is set with parameter 74.3 CRANE LIFETIME.

When all settings are done the Crane lifetime calculation is started by setting parameter 74.3 START LIFETIMEMON = ON.

Note: This parameter cannot be reset with user parameters.

When the signal LIFETIME LEFT % has reached a level below 10%, the drive will give a warning: “LIFETIME>90%”.

NOTE:

To transfer the latest TOTAL OPER TIME and LOAD SPEC FACT Km signals values from an existing RMIO control board to a spare board in case of service repair, please contact ABB Service.



User Macros allow the current parameter settings to be stored in memory. Two User Macros can be created. This can be used for Shared motion operation, i.e. two different motors using same converter via contactors.

To store your customised parameters:

1. Access the Start-up Data group as described in Table 2-6 in Chapter 2

- Overview of CraneDrive Programming .

2. Change Parameter 99.2 APPLICATION MACRO to USER1 SAVE or

USER2 SAVE.

Note: It’s recommended to keep parameter 10.17 “User macro ch srce” =

NOT SEL until User macro saving is completed (10.17 is not saved in

User macros).

3. Press ENTER to save.

The current settings are now stored in the User Macro. The storing will take a few minutes, please wait. The Parameter settings can be changed thereafter without loosing the settings saved to the User Macro. After power switch off, when you turn on the power again the original User

Macro settings are valid. (With other Application Macros the parameter setting will be permanently saved when you press ENTER after changing the parameter value and during power up default values of the parameters are not restored.)

To recall the last saved parameters (User Macro):

1. Access the Start-up Data group as described in Table 2-6 in Chapter 2

- Overview of CraneDrive Programming .

2. Change Parameter 99.2 APPLICATION MACRO to USER1 LOAD or

USER2 LOAD.

3. Press ENTER to load.

If there exists no User Macro is saved and you try to load one a fault indication is displayed

** FAULT **

USER MACRO


The User Macros can also be switched via digital inputs or Fieldbus; selectable with Parameter 10.17 as described in chapter 6.

The User Macro used can be changed via a digital input or Fieldbus communication (edge triggered) only after the drive is off (magnetising is off) i.e. Rdy For Run = 0. During the change the drive will not start. The acknowledgement signal USER 1 OR 2 (digital output or Fieldbus) indicates when the change is completed and the drive can be started again.

5-57


NOTE: User Macro load restores also the motor settings of Start-up

Data group and the results of the Motor ID Run. Check that the settings correspond to the motor used.


This page is intentionally left blank.



5.4.2 External Connections. ABB ACS800 CraneDrive Control, ACC800 7.1

ACS800 CraneDrive Control Firmware Manual

ACC800 Crane Application Program 7.1

ACC800 Crane Application Program 7.1

Firmware Manual

Safety Instructions

Overview

Warnings and Notes

Warnings

Notes

General Safety Instructions

WARNING!

WARNING!

Table of Contents

Chapter 1 - Introduction to this Manual

1.1 Overview

1.2 Before You Start

1.3 What This Manual Contains

1.4 Related

Chapter 2 - Overview of CraneDrive Programming and the CDP 312R Control Panel

2.1 Overview

0

Chapter 3 - Start-up

3.1 Overview

MACRO

To perform the Motor ID Run (Drive must be in LOCAL mode):

Chapter 4 - Control Operation

4.1 Overview

4.3 Signal Selection - Description of the Actual Signals, Groups 1 and 2

Table 4-4

Table 4-5

4.4

Fault History

4.5 Local Control vs. External Control

4.6 Control Signals Connection Stand Alone mode

4.7 Control Signals Connection in Fieldbus mode

4.8 External 24V supply of RMIO board

Chapter 5 - Crane Program Description

5.1 Overview

5.2

Application Macros

5.4 Stand alone mode operation

5.5 Fieldbus mode operation

FUNCTION BLOCK DIAGRAM

Fast stop-N (DI 6)

"Speedref < 5%"

Zero speed

Running

Zero pos (DI 2)

Dir A (DI 3)

Dir B (DI 4)

Fast stop 12

Fault or Fast Stop

Start

Speed ref (AI1)

Slowdown-N (DI 5)

Drive speed ref.

CRANE stand alone logic using Joystick Control type

Fast stop-N (DI 6)

"Speedref < 5%"

Zero speed

Fast stop 12

Dir A (DI 3)

Dir B (DI 4)

Start

Speed ref. (AI 1)

Drive speed ref

Slowdown-N (DI 5)

Fast stop-N (DI 6)

Zero speed

Dir A (DI 3)

Dir B (DI 4)

Increase (DI 2)

100%

Ramp output

Slowdown-N (DI 5)

Fast stop 12

Start

Drive speed ref

Running