Using Inverters for Elevating Machines. YASKAWA Varispeed f7

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Using Inverters for Elevating Machines

This section describes precautions to be observed when using the Varispeed F7 for elevating machines such as elevators and cranes.

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Brake ON/OFF Sequence

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Brake ON/OFF Sequence

For the holding brake’s ON/OFF sequence, use the following Inverter output signals according to the set control method.

Control Method

V/f (A1-02 = 0, factory setting)

V/f with PG (A1-02 = 1)

Open-loop vector (A1-02 = 2)

Brake ON/OFF Signal

Signal Name Constant

*1

Frequency detection 2

H2-01 = 05

Brake ON/OFF Level Adjustment

Signal Name Constant

Speed agree detection level

L4-01 = 1.0 to

3.0 Hz

*2

Speed agree detection width

L4-02 = 0.1 to

0.5 Hz

*3

Flux vector (A1-02 = 3) During run 2 H2-01 = 37

Zero-speed level

(OFF timing only) b2-01 = 0.1 to

0.5 Hz

* 1. This example shows multi-function output terminals M1-M2 used for the holding brake ON/OFF signal.

Do not set H2-01 to 0 (During run).

* 2. This is the standard setting range for open-loop vector control. For V/f control, set to approximately the motor rated slip frequency +0.5 Hz.

If the set value is too low, the motor torque is insufficient and the load may slip when the brake is applied. Be sure to set L4-01 to a value larger than that of E1-09 (Min. output frequency) and larger than that of L4-02 shown in Figure 6.80. If the set value is too large, the motor may not run smoothly when it starts running.

* 3. The hysteresis in frequency detection 2 can be adjusted (from 0.1 to 0.5 Hz) by L4-02 (speed agree detection width). Change the setting to approximately 0.1 Hz if there are drops while stopping.

Output frequency

L4-01

Frequency detection 2

ON

Fig 6.80

OFF

L4-02

Time

Using Inverters for Elevating Machines

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Sequence Circuit Configuration

The brake ON/OFF sequence circuit configuration is shown below.

Inverter (Varispeed F7)

Fault contacts

MA

UP

S1

(Forward run)

MB

DOWN

HIGH/LOW

S2

(Reverse run)

MC

S6

(Multi-step speed reference 2)

M1

SC

M2

Frequency detection 2 or

During run

Holding brake auxiliary relay coil

Sequence circuit

BR

Energizes the brake when ON

(250 VAC 1 A or less, 30 VDC

1 A or less)

Note Design the sequence so that the holding brake contact is open when the sequence operation conditions are satisfied and the contact between M1 and M2 is closed (ON).

Make sure that the holding brake contact is closed when the emergency stop signal or Inverter fault contact output signal is ON.

Fig 6.81 Brake ON/OFF Sequence Circuit Configuration

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Time Chart

The brake ON/OFF sequence time charts are shown in Figs. 6.82 and 6.83.

S1-SC UP

OFF

ON

S6-SC

High speed/

Low speed

OFF ON

Output frequency

0

L4-01 d1-03 d1-01 (Enabled when b1-01 = 0) b4-01

DC injection braking

Time

OFF

M1-M2

Frequency detection 2

(H2-01 = 05)

Holding brake operation

CLOSE

ON

OPEN CLOSE

Note For variable speed operation by an analog signal, set to b1-01 = 1.

Fig 6.82 Brake ON/OFF Sequence Time Chart (V/f, V/f with PG, open-loop vector)

S1-SC

UP

OFF

ON

S6-SC

High speed/

Low speed

OFF ON

Output frequency

0 d1-03 d1-01 (Enabled when b1-01 = 0) b2-01

Time

DC injection braking (Zero-speed control)

OFF

M1-M2

During run 2

(H2-01 = 37)

Holding brake operation

CLOSE

ON

OPEN CLOSE

Note For variable speed operation by an analog signal, set to b1-01 = 1.

Fig 6.83 Brake ON/OFF Sequence Time Chart (Flux Vector)

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Stall Prevention during Deceleration

If connecting a braking resistor to discharge regenerative energy, be sure to set Stall prevention selection during decel (L3-04) to 0 (Disabled).

IMPORTANT

If Stall prevention selection during decel (L3-04) is set to 1, 2, or 3 , the motor may not stop within the specified decelerating time.

Stall prevention selection during accel (L3-01) and Stall prevention selection during running (L3-05) should be set to their initial values 1 (Enabled) to enable these functions.

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Autotuning

Always perform autotuning with the motor before operating using vector control. Be sure to disconnect the motor from the load before conducting autotuning. Conducting autotuning while the motor is connected to an elevating machine system is dangerous because it automatically runs the motor for approximately one minute.

IMPORTANT

1. When the motor cannot be disconnected from the load, perform stationary autotuning 1 (T1-01 = 1) or stationary autotuning 2 (T1-01 = 4) . Stationary autotuning will apply current to the motor in its stopped condition and automatically measure the motor data. In the initial running period after stationary autotuning

1 (T1-01 = 1) (20% speed min., fixed speed for 1 s min.), the motor data measured by autotuning will automatically be corrected.

2. To improve low-speed torque characteristics using V/f control, conduct stationary autotuning for line to line resistance only (T1-01 = 2).

3. When conducting autotuning on wound motor or other special types of motors, obtain a test report for the motor in advance and confirm that the E2 motor constants after autotuning do not vary greatly from those of the test report.

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Braking Resistor Overheating Protection

When using a braking resistor other than the Braking Resistor Unit, provide a sequence with a thermal overload relay or similar means to turn off the power input to the Inverter when it detects resistor overheating. See the Connection Diagram on page 2-3 for this sequence circuit.

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Momentary Power Loss Restart

Do not use the momentary power loss restart and fault restart functions in applications for elevating machines.

Make sure that L2-01=0 and L5-01=0. If these functions are used, the motor coasts to a stop with the brake contact open when a momentary power loss or fault occurs during operation, possibly resulting in serious accidents.

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Torque Limit

The torque limit values (L7-01 to L7-04) are the motor's rated torque. When there is a possibility of insufficient torque at start-up or other time, increase the Inverter capacity and set the torque limit value to between

200% and 300% (factory setting is 200%).

Using Inverters for Elevating Machines

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I/O Open-phase Protection and Overtorque Detection

To prevent the machine from falling when the motor is open-phase or a similar situation, enable L8-05 and L8-

07 (Input and output open-phase protection selection) and L6-01 to L6-06 (Overtorque detection) (factory setting is Disabled).

Falling detection or a similar safety measure should also be provided on the machine side.

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External Baseblock Signal

If the external baseblock command (settings 8 and 9 of H1-01 to H1-06) is input while the motor is running, the motor will immediately coast to a stop. Do not input the external baseblock command while the motor is running unless necessary.

Make sure that the holding brake operates when using the external base block command for an emergency stop or interlock to start the Inverter.

If the external baseblock command is input and immediately reset, the Inverter does not output voltage during the value of L2-03 (Min. baseblock time), which factory setting is 0.5 to 2.0 seconds depending on the Inverter capacity. Do not use the external baseblock command in an application where the motor is frequently started and stopped.

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Acceleration/Deceleration Time

If the delay time for the holding brake’s mechanical operation is not taken into consideration and the acceleration/deceleration time on the Inverter side is set to a time that is too short, and overcurrent or wear on the brakes may occur at staring or the load will slip at stopping because the holding brake does not operate on time. If so, use the dwell function at start described on page 6-174 or the dwell function at stop described on page 6-175 to tune the timing for the holding brake.

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Magnetic Contactor on the Inverter’s Output-side

Do not install a magnetic contactor between the Inverter and the motor. If a magnetic contactor must be installed because of local electrical codes or regulations or to operate motors with an Inverter, excluding emergencies, open or close the magnetic contactor only when the holding brake is fully closed and the Inverter is in baseblock status with the baseblock signal ON.

If the magnetic contactor is opened or closed while the Inverter is controlling the motor or DC injection braking (Zero-speed control), surge voltage or a current from the motor by full-voltage starting may cause an

Inverter fault.

When a magnetic contactor is installed between the Inverter and the motor, set L8-07 (Output open-phase protection selection) to 1 or 2 (Enabled).

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Control-related Adjustments

The Varispeed F7 is designed to provide sufficient performance for elevating machines. However, if problems related to controllability should occur, such as vibration or slipping, adjust the following constants in accordance with the control method. Only constants that frequently require adjustment are listed in this table.

Control

Method

Open-loop vector control

(A1-02 = 2)

Constant

Number

N2-01

C4-02

C3-02

C3-01

C6-02

E1-08

E1-10

Name

Speed feedback detection control

(AFR) gain

Torque compensation primary delay time constant

Slip compensation primary delay time

Slip compensation gain

Table 6.4 Control-related Adjustments

Performance

Factory

Setting

Recommended

Setting

• Increasing torque and speed response

• Controlling hunting and vibration in middle-range speeds (10 to 40 Hz)

1.00

• Increasing torque and speed response

• Controlling hunting and vibration

• Increasing speed response

• Improving speed stability

• Improving speed accuracy

20 ms

200 ms

1.0

0.50 to 2.00

20 to 100 ms

100 to

500 ms

0.5 to 1.5

Adjustment Method

• Torque or speed response is insufficient: Reduce the setting

• Hunting or vibration occurs: Increase the setting

• Torque or speed response is insufficient: Reduce the setting

• Hunting or vibration occurs: Increase the setting

• Speed response is slow:

Reduce the setting

• Speed is not stable:

Increase the setting

• Speed is slow: Increase the setting

• Speed is too fast: Reduce the setting

Carrier frequency selection

• Reducing motor magnetic noise

• Controlling hunting and vibration at low speeds (10 Hz or lower)

*1

Mid. output frequency voltage (VC)

Min. output frequency voltage

(VMIN)

• Improving torque and speed response at low speeds

• Controlling shock at startup

11.0 V

*2

1 to F

12.0 to

13.0 V

*2

• Motor magnetic noise is high: Increase the setting

• Hunting or vibration occurs at low speeds:

Reduce the setting

• Torque or speed response is insufficient: Increase the setting

• Shock at startup is large:

Reduce the setting

Using Inverters for Elevating Machines

Control

Method

Flux vector control

(A1-02 = 3)

Constant

Number

C5-01

C5-03

C5-02

C5-04

Table 6.4 Control-related Adjustments (Continued)

Name Performance

Factory

Setting

Recommended

Setting

ASR proportional (P) gain 1

• Increasing torque and speed response

• Controlling hunting and vibration

20.00

10.00 to

50.00

ASR proportional (P) gain 2

ASR integral (I) time

1

ASR integral (I) time

2

• Increasing torque and speed response

• Controlling hunting and vibration

0.500 s

0.300 to

1.000 s

Adjustment Method

• Torque or speed response is insufficient: Increase the setting

• Hunting or vibration occurs: Reduce the setting

• Torque or speed response is insufficient: Reduce the setting

• Hunting or vibration occurs: Increase the setting

V/f control

(A1-02 = 0 or 1)

C5-07

C5-06

N1-02

C6-02

C4-01

E1-08

E1-10

ASR switching frequency

ASR primary delay time

Hunting-prevention gain

Carrier frequency selection

Switching the ASR proportional gain and integral time according to the output frequency.

• Controlling hunting and vibration

• Controlling hunting and vibration in middle-range speeds (10 to 40 Hz)

• Reducing motor magnetic noise

• Controlling hunting and vibration at low and medium speeds

0.0 Hz (no switching)

0.004 s

1.00

*1

Torque compensation gain

• Improving torque at low speeds (10 Hz or lower)

• Controlling hunting and vibration for light loads

1.00

Mid. output frequency voltage (VC) • Improving torque at low speeds

Min. output

• Controlling shock at frequency startup voltage

(VMIN)

2.0 V

*2

0.0 to max. output frequency

0.004 to

0.020

0.50 to 2.00

1 to F

0.50 to 1.50

5.0 to

7.0 V

*2

Set the output frequency at which to change the ASR proportional gain and integral time when the same values cannot be used for both high-speed and low-speed operation.

Machine rigidity is low and the system vibrates easily:

Increase the setting

• Torque is insufficient for heavy loads: Reduce the setting

• Hunting or vibration occurs for light loads:

Increase the setting

• Motor magnetic noise is high: Increase the setting

• Hunting or vibration occurs at low to middlerange speeds: Reduce the setting

• Torque is insufficient at low speeds: Increase the setting

• Hunting or vibration occurs for light loads:

Reduce the setting

• Torque is insufficient at low speeds: Increase the setting

• Shock at startup is large:

Reduce the setting

* 1. Varies depending on capacity.

* 2. The setting is given for 200 V Class Inverters. Double the voltage for 400 V Class Inverters.

Note 1. Do not change C4-01 (Torque compensation gain) from its factory setting of 1.00 when using open-loop vector control.

2. If speeds are inaccurate during regeneration in open-loop vector control, enable Slip compensation selection during regeneration (C3-04 = 1). If speeds are inaccurate in the high-speed range, enable Output voltage limit operation selection (C3-05 = 1).

3. Do not use Slip compensation gain (C3-01) during V/f control (A1-02 = 0). (It is not used with the factory setting.)

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4. Use the ASR constants (C5-01 to C5-05) in their factory settings when using V/f control with PG (A1-02 = 1). Vibration may occur if these constants are changed greatly from their factory settings.

5. The torque and speed response of high-resistance (high-slip) motors are insufficient. Use appropriate adjustments to improve them. On the contrary, low-resistance (low-slip) motors are easily subject to hunting and vibration. Here too, use appropriate adjustments to improve them.

6. The current during startup may increase when C4-02 (Torque compensation primary delay time constant) is increased. Check the current during startup while adjusting this constant.

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Reducing Shock during Elevating Machine Start, Stop, Acceleration, and

Deceleration

When the riding comfort during start, stop, acceleration, and deceleration is of high importance, as it is for elevators in which people ride, adjust the following constants.

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S-curve Characteristics, Acceleration/Deceleration Times

Output frequency

C2-01

C2-02

(High speed)

C2-03

(Low speed)

C2-04

C2-03

C2-04

Acceleration time Deceleration time DC injection braking when stopping

(Zero-speed control for flux vector control)

IMPORTANT

1. The factory setting for C2-04 (S-curve characteristic time at deceleration end) is 0.00 second, while the factory setting for all other S-curve characteristic times is 0.20 second. Make appropriate settings for the accel/decel times and S-curve characteristic times at each point. (S-curve characteristic time = Approximately 0.2 to 1.0 second)

2. The accel/decel rate can be automatically switched during acceleration and deceleration by using C1-11

(Accel/decel time switching frequency). (Factory setting: Disabled)

Output frequency ≥ set frequency: C1-01, C1-02 accel/decel times

Output frequency < set frequency: C1-07, C1-08 accel/decel times

3. If the output frequency during the S-curve characteristic time for deceleration falls below the value set for

E1-09 (Min. output frequency), the S-curve characteristic will be cancelled, and the DC injection braking

(Zero-speed control) will be applied.

4. Do not use the S-curve characteristic for applications where a short run time is desired, such as in cranes and hoists. (S-curve characteristic time = Approximately 0.0 to 0.2 second)

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Dwell Function at Start

b6-02

(Dwell time at start)

Output frequency

0.1 to 0.3 sec

Frequency detection

2 or During run 2

OFF

Holding brake operation

CLOSE

(High speed) b6-01 (Dwell frequency at start) 0.1 to 3.0 Hz

ON

OPEN t

Using Inverters for Elevating Machines

If the mechanical operation of the holding brake is slow, use the dwell function at start to prevent brake wear, and accelerate after the brake is completely open.

IMPORTANT

1. When using open-loop vector control and V/f control, set b6-01 (Dwell frequency at start) higher than frequency detection 2 (frequency when brakes open).

2. If the motor tends to have insufficient torque when started, use the DC injection braking function to allow sufficient motor current (torque) before starting.

• b2-03 (DC injection braking time at start): 0.2 to 0.5 s

• b2-02 (DC injection braking current): 50% to 80% (open-loop vector control, V/f control only)

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Stopping with DC Injection Braking and Zero-speed Control

Output frequency

Frequency detection 2 or

During run 2

Holding brake operation

(HIGH) b2-04 (DC injection braking time at stop

(zero-speed control time at stop): 0.3 to 0.5 s

(LOW)

ON OFF

OPEN

CLOSE t b2-01 [Zero speed level (DC injection braking starting frequency)]: 0.1 to 3.0 Hz b2-02 (DC injection braking current): 50% to 80%

(open-loop vector control, V/f control only)

When the holding brake’s mechanical operation is slow, use DC injection braking (zero-speed control for flux vector control) until the brakes are fully closed to prevent the brakes from slipping when stopping.

IMPORTANT

1. When the load cannot be maintained sufficiently using DC injection braking with open-loop vector control and V/f control, use the dwell functions at stop.

• b6-03 (Dwell frequency at stop): Min. output frequency to 3.0 Hz.

The value must be less than the frequency when frequency detection 2 is OFF (L4-01 − L4-02).

• b6-04 (Dwell time at stop): 0.3 to 0.5 s

[b2-04 (DC injection braking at stop): 0.0 s]

2. If the Inverter and motor must be isolated while stopping using a magnetic contactor, for example in an elevator, fully close the holding brakes and isolate the Inverter during baseblock (during baseblock signal: ON) as stipulated by law in the EU.

During motor control or DC injection braking (zero-speed control), an Inverter error may occur due to surge voltage. When a magnetic contactor is used between the Inverter and motor, set L8-07 (Output openphase protection) to 1 (enabled).

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Torque Compensation (Flux Vector Control Only) (SPEC: E or Later Only)

When flux vector control is used, the torque compensation signals corresponding to the load can be input from the multi-function analog input terminals in advance to reduce shock, such as that caused by opening and closing holding brakes. The load size and motoring/regenerating status must be detected at the machine side in advance. Check that polarity is correct. Incorrect polarity will increase the shock.

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Sequence Circuit Configuration

The following diagram shows the sequence circuit configuration for torque compensation.

UP

DOWN

S1 (Forward run)

HIGH/LOW

S6 (Multi-step speed reference 2)

SC

(Using elevator control circuit)

Torque compensation signal

−

10 to +10 V

A3

AC

H3-04 (multi-function analog input terminal A3 signal level)

= 1 (

−

10 to +10 V)

H3-05 (multi-function analog input terminal A3 function selection) = 14 (torque compensation)

Use H3-06 and H3-07 for fine tuning.

Fig 6.84 Torque Compensation Sequence Circuit Configuration

Time Chart

• Lifting

The analog signals corresponding to the load size are input as torque compensation signals from before the

Inverter starts until operation stops. (Factory setting: 10 V/100% torque)

Positive polarity is input for motor loads and negative polarity is input for regenerative loads.

The following diagram shows the time chart for lifting.

UP (Forward)

HIGH/LOW

Torque compensation signal: 0

ON

ON

OFF

OFF

Analog signals corresponding to load size

Same as above

(Motor load: Inputs positive polarity.)

(Regenerative load: Inputs negative polarity.)

Output frequency

Zero-speed control t

0

Motor torque

0

(Motor load)

(Regenerative load)

OFF During run 2

Holding brake operation

ON

OPEN

CLOSE

Fig 6.85 Torque Compensation Time Chart (Lifting)

• Lowering

In the same way as for lifting, when the torque decreases, the analog signals corresponding to the load size are input as torque compensation signals from before the Inverter starts until operation stops. (Factory setting: 10

V/100% torque)

Negative polarity is input for motor loads and positive polarity is input for regenerative loads.

The following diagram shows the time chart for lowering.

Using Inverters for Elevating Machines

DOWN (Forward)

HIGH/LOW

Torque compensation signal: 0

ON

ON

OFF

OFF

Analog signals corresponding to load size

Same as above

(Regenerative load: Inputs positive polarity.)

(Motor load: Inputs negative polarity.)

Output frequency

0 t

Motor torque

0

During run 2

Holding brake operation

ON

OPEN

(Regenerative load)

(Motor load)

OFF

CLOSE

Fig 6.86 Torque Compensation Time Chart (Lowering)

IMPORTANT

1. For either increasing or decreasing torque, externally maintain the torque compensation signals during operation to prevent them from fluctuating. Fluctuation in compensation signals during operation may result in vibration.

2. If reverse run is used for lifting and forward run is used for lowering, the torque compensation signal polarity must be reversed.

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Analog Input Filter Time Constant

If noise enters the analog frequency reference during operation using analog frequency reference (b1-01 = 1), and operation becomes rough, implement noise countermeasures and also set H3-12 (Analog input filter time constant) to between 0.01 and 0.10 s.

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Confirming Startup Current and Reducing Carrier Frequency

When performing trial operation, check the motor current using the Digital Operator or a clamp ammeter with and without a mechanical load. An extremely high current will flow if the motor torque at start is insufficient, or if timing is not correct and the motor locks with the holding brake.

If the current at start is more than the Inverter overload level, the IGBT in the Inverter will be subject to heat stress, resulting in a shortened life span. Refer to the previous precautions and take measures, such as retuning and reducing the load until the current drops to less than the Inverter overload level. If particularly low noise is not required, do not increase the Inverter’s carrier frequency to reduce the influence of heat stress.

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Overvoltage Inhibit Function (SPEC: E or Later Only)

Leave L3-11 (Overvoltage inhibit function selection) set to 0 (disabled: factory setting). This function is used to prevent overvoltage tripping when the braking resistor is not used with a regenerative load. When this function is enabled, the torque reference on the regenerative side is automatically inhibited in the Inverter during regeneration. Using this function in elevating machines is dangerous because the elevator may slip and fall.

Contact your Yaskawa representative for details on applications such as high-speed elevators (speed: 2 m/s or higher), direct-drive elevators, or Inverters designed for cranes.

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Troubleshooting

This chapter describes the fault displays and countermeasure for the Inverter and motor problems and countermeasures.

Protective and Diagnostic Functions ...........................7-2

Troubleshooting .........................................................7-18