Danfoss vacon nx apfiff20 Application guide
vacon
ac drives
®
nx
apfiff20
Crane control
Application manual
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VACON CRANE CONTROL APPLICATION MANUAL
INDEX
Document code: DPD01974B
Software code: APFIFF20V099
Date: 31.7.2020
1. Crane Control Application - introduction ....................................................................................................... 8
1.1 General .................................................................................................................................................. 8
1.2 Basic Features ........................................................................................................................................ 9
1.3 Crane Control Application Compatibility issues ....................................................................................... 9
2. Quick Commissioning for crane features ...................................................................................................... 10
2.1 Mechanical Brake Control and Monitoring ............................................................................................ 10
2.2 Catch Dropping load ............................................................................................................................. 13
2.3 Tandem Operation for Cranes............................................................................................................... 13
2.4 Speed limit switch for Horizontal Movement ........................................................................................ 14
2.5 Anti-Sway ............................................................................................................................................. 14
2.6 Speed Optimization (Power dependant speed control) ......................................................................... 15
2.7 Bumpless transfer from closed loop to sensorless control ..................................................................... 15
2.8 Shock Load Prevention ......................................................................................................................... 15
2.9 Slack Rope Prevention .......................................................................................................................... 16
2.10 Integrated functional safety.................................................................................................................. 16
2.11 Load Estimation.................................................................................................................................... 16
3. Control I/O ................................................................................................................................................... 17
4. “Terminal To Function” (TTF) programming principle .................................................................................. 18
4.1 Defining an input/output for a certain function on keypad .................................................................... 18
4.2 Defining a terminal for a certain function with NCDrive programming tool ............................................ 19
4.3 Defining unused inputs/outputs ........................................................................................................... 20
5. Crane Control Application – monitoring values ............................................................................................ 21
5.1 Monitoring values ................................................................................................................................ 22
5.1.1 Monitoring values 1 ......................................................................................................................... 22
5.1.2 Monitoring values 2 ......................................................................................................................... 23
5.1.3 Fieldbus Monitoring values .............................................................................................................. 24
5.1.4 Master/Follower Monitoring values ................................................................................................. 24
5.1.5 PI Control Monitoring values ............................................................................................................ 24
5.1.6 Frequency Chain .............................................................................................................................. 25
5.1.7 Torque Chain.................................................................................................................................... 25
5.1.8 Brake Control ................................................................................................................................... 25
5.1.9 Motion ............................................................................................................................................. 25
5.1.10 Shaft Synch .................................................................................................................................. 25
5.1.11 Functional Safety Monitoring ....................................................................................................... 26
5.2 Monitoring Values description .............................................................................................................. 27
5.2.1 Monitoring values ............................................................................................................................ 27
5.2.2 Monitoring values 2 ......................................................................................................................... 29
5.2.3 FieldBus Monitoring values .............................................................................................................. 33
5.2.4 Master / Follower............................................................................................................................. 39
5.2.5 PI Control monitoring ....................................................................................................................... 42
5.2.6 Frequency Chain .............................................................................................................................. 42
5.2.7 Torque Chain.................................................................................................................................... 43
5.2.8 Brake Control ................................................................................................................................... 43
5.2.9 Motion ............................................................................................................................................. 44
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5.2.10 Tandem Operation (Shaft Synch) .................................................................................................. 44
5.2.11 Functional Safety Monitoring ....................................................................................................... 45
5.2.12 Counters ...................................................................................................................................... 51
6. Crane Control Application – Parameter lists ................................................................................................. 53
6.1 Basic parameters .................................................................................................................................. 53
6.2 Reference Handling .............................................................................................................................. 54
6.2.1 Basic Settings ................................................................................................................................... 54
6.2.2 Constant Reference .......................................................................................................................... 54
6.2.3 Torque Reference............................................................................................................................. 55
6.2.4 Prohibit frequency parameters ......................................................................................................... 56
6.2.5 Motor Potentiometer ....................................................................................................................... 56
6.2.6 Adjust Reference .............................................................................................................................. 56
6.2.7 End limits reference handling ........................................................................................................... 57
6.3 Ramp Control ....................................................................................................................................... 58
6.3.1 Basic Settings ................................................................................................................................... 58
6.3.2 Quick Stop........................................................................................................................................ 58
6.3.3 Ramp Control Options ...................................................................................................................... 58
6.3.4 Slack Rope and Shock Load functions................................................................................................ 59
6.4 Input Signals ......................................................................................................................................... 60
6.4.1 Basic Settings ................................................................................................................................... 60
6.4.2 Digital inputs .................................................................................................................................... 61
6.4.3 Analogue input 1 .............................................................................................................................. 62
6.4.4 Analogue input 2 .............................................................................................................................. 62
6.4.5 Analogue input 3 .............................................................................................................................. 63
6.4.6 Analogue input 4 .............................................................................................................................. 63
6.4.7 Options ............................................................................................................................................ 63
6.5 Output Signals ...................................................................................................................................... 64
6.5.1 Digital output signals ........................................................................................................................ 64
6.5.2 Analogue output 1 ........................................................................................................................... 65
6.5.3 Analogue output 2 ........................................................................................................................... 65
6.5.4 Analogue output 3 ........................................................................................................................... 66
6.5.5 Analogue output 4 ........................................................................................................................... 66
6.5.6 Delayed digital output 1 ................................................................................................................... 67
6.5.7 Delayed digital output 2 ................................................................................................................... 67
6.5.8 Supervision Limits ............................................................................................................................ 68
6.6 Limit Settings........................................................................................................................................ 69
6.6.1 Current handling .............................................................................................................................. 69
6.6.2 Torque Handling............................................................................................................................... 69
6.6.3 Frequency Handling ......................................................................................................................... 70
6.6.4 DC-Link Handling .............................................................................................................................. 71
6.6.5 Limit Settings Options ...................................................................................................................... 71
6.7 Flux and DC Current handling ............................................................................................................... 72
6.7.1 Flux and DC Current handling OL Settings ......................................................................................... 72
6.7.2 Flux and DC Current handling CL Settings.......................................................................................... 72
6.8 Motor Control ...................................................................................................................................... 73
6.8.1 Motor Control Basic Settings ............................................................................................................ 73
6.8.2 Open Loop Settings .......................................................................................................................... 73
6.8.3 Closed Loop Control Settings ............................................................................................................ 74
6.8.4 PMSM Control settings ..................................................................................................................... 75
6.8.5 Stabilators ........................................................................................................................................ 76
6.8.6 Tuning parameters ........................................................................................................................... 76
6.8.7 Identification parameters ................................................................................................................. 77
6.8.8 Fine tuning parameters .................................................................................................................... 78
6.8.9 AOL Control Tuning parameters ....................................................................................................... 78
6.9 Speed Control ...................................................................................................................................... 79
6.9.1 Speed Control Basic settings ............................................................................................................. 79
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6.9.2 Speed Control OL Settings ................................................................................................................ 79
6.9.3 Speed Control CL Settings ................................................................................................................. 79
6.10 Drive Control ........................................................................................................................................ 79
6.11 Master Follower Control Parameters .................................................................................................... 80
6.12 Protections ........................................................................................................................................... 82
6.12.1 General settings ........................................................................................................................... 82
6.12.2 Temperature sensor protections .................................................................................................. 82
6.12.3 Stall Protection ............................................................................................................................ 83
6.12.4 Speed error monitoring ................................................................................................................ 83
6.12.5 Motor thermal protections........................................................................................................... 83
6.12.6 Living Zero monitoring ................................................................................................................. 84
6.12.7 Underload protection................................................................................................................... 84
6.12.8 Earth Fault protection .................................................................................................................. 84
6.12.9 Cooling protection ....................................................................................................................... 84
6.12.10 Fieldbus protection ...................................................................................................................... 85
6.12.11 External Fault ............................................................................................................................... 85
6.12.12 Encoder Fault ............................................................................................................................... 85
6.12.1 Options ........................................................................................................................................ 85
6.13 Fieldbus parameters ............................................................................................................................. 85
6.13.1 Value Control ............................................................................................................................... 88
6.13.2 DIN ID Control 1 ........................................................................................................................... 88
6.13.3 DIN ID Control 2 ........................................................................................................................... 88
6.13.4 DIN ID Control 3 ........................................................................................................................... 88
6.13.5 ID Controlled Digital Output 1 ..................................................................................................... 89
6.13.6 ID Controlled Digital Output 2 ...................................................................................................... 89
6.13.7 Free DIN Delay ............................................................................................................................. 89
6.14 Brake Control Parameters..................................................................................................................... 90
6.14.1 Brake Control Start up torque for CL............................................................................................. 90
6.14.2 Roll Back Control for CL ................................................................................................................ 90
6.14.3 Brake Fault handling .................................................................................................................... 91
6.14.4 Functions ..................................................................................................................................... 91
6.14.5 Brake Test Function ..................................................................................................................... 91
6.15 Auto Reset parameters ......................................................................................................................... 92
6.16 PI Control Parameters .......................................................................................................................... 92
6.17 Shaft Synchronization ........................................................................................................................... 93
6.18 Load Estimation.................................................................................................................................... 93
6.19 Functional Safety .................................................................................................................................. 93
6.20 Anti-Swing Function ............................................................................................................................. 94
6.21 Keypad control (Control keypad: Menu M3) ......................................................................................... 95
6.22 System menu (Control keypad: Menu M6) ............................................................................................ 95
6.23 Expander boards (Control keypad: Menu M7) ....................................................................................... 95
7. Description of parameters ........................................................................................................................... 96
7.1 Basic Parameters .................................................................................................................................. 96
7.2 Reference Handling – “Ref Handling” ...................................................................................................106
7.2.1 Basic Parameters .............................................................................................................................107
7.2.2 Constant Reference .........................................................................................................................110
7.2.3 Torque Reference............................................................................................................................112
7.2.4 Prohibited frequencies ....................................................................................................................118
7.2.5 Motor potentiometer ......................................................................................................................119
7.2.6 Adjust Reference .............................................................................................................................121
7.2.1 Speed limits reference handling for horizontal movement ...............................................................123
7.3 Ramp control ......................................................................................................................................125
7.3.1 Ramp Options .................................................................................................................................129
7.3.2 Slack Rope and Shock Load ..............................................................................................................131
7.4 Input signals ........................................................................................................................................132
7.4.1 Basic Settings ..................................................................................................................................132
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7.4.2 Digital inputs ...................................................................................................................................134
7.4.3 Analogue Input 1 & 2.......................................................................................................................140
7.4.4 Analogue input 3 & 4 .......................................................................................................................145
7.4.5 Inversion control .............................................................................................................................148
7.5 Output signals .....................................................................................................................................149
7.5.1 Digital output signals .......................................................................................................................149
7.5.2 Analogue outputs 1 & 2 & 3 & 4 ......................................................................................................154
7.5.3 Delayed Digital Output 1 & 2 ...........................................................................................................158
7.5.4 Supervision limits ............................................................................................................................161
7.6 Limit settings .......................................................................................................................................163
7.6.1 Current limit handling .....................................................................................................................163
7.6.2 Torque limit handling ......................................................................................................................164
7.6.3 Frequency limit handling .................................................................................................................167
7.6.4 DC Link handling..............................................................................................................................169
7.6.5 Limit options ...................................................................................................................................172
7.7 DC current and magnetization handling ...............................................................................................173
7.7.1 Open loop settings ..........................................................................................................................174
7.7.2 Closed loop settings ........................................................................................................................177
7.8 Motor Control .....................................................................................................................................179
7.8.1 Open Loop Settings .........................................................................................................................184
7.8.2 Close Loop Settings .........................................................................................................................188
7.8.3 Permanent magnet synchronous motor settings..............................................................................191
7.8.4 Stabilization settings .......................................................................................................................197
7.8.5 Tuning settings ................................................................................................................................200
7.8.6 Identification settings .....................................................................................................................202
7.8.7 AOL control for IM...........................................................................................................................204
7.9 Speed Control settings.........................................................................................................................205
7.10 Drive Control .......................................................................................................................................211
7.11 Master-Follower ..................................................................................................................................214
7.11.1 Master-Follower: Standard system ..............................................................................................214
7.11.2 Master Follower: DriveSynch system ...........................................................................................215
7.11.3 Master-Follower configuration ....................................................................................................218
7.12 Protections ..........................................................................................................................................223
7.12.1 General settings ..........................................................................................................................223
7.12.2 Temperature sensor protections .................................................................................................224
7.12.3 Stall protection ...........................................................................................................................226
7.12.4 Speed Error .................................................................................................................................228
7.12.5 Motor Protection ........................................................................................................................229
7.12.6 Over Load Protection ..................................................................................................................232
7.12.7 4mA Protection ...........................................................................................................................233
7.12.8 Underload protection..................................................................................................................234
7.12.9 Earth Fault ..................................................................................................................................236
7.12.10 Cooling protection ......................................................................................................................236
7.12.11 Fieldbus communication .............................................................................................................237
7.12.12 External Fault function ................................................................................................................237
7.12.13 Encoder Fault function ................................................................................................................238
7.13 Fieldbus settings..................................................................................................................................240
7.13.1 General settings ..........................................................................................................................240
7.14 ID Functions ........................................................................................................................................244
7.14.1 Value Control ..............................................................................................................................244
7.14.2 DIN ID Control .............................................................................................................................246
7.14.3 ID-controlled DO .........................................................................................................................247
7.14.4 Free DIN Delay ............................................................................................................................248
7.15 Brake Control ......................................................................................................................................249
7.15.1 Brake time control timing in closed loop......................................................................................250
7.15.2 Brake control timing in open loop ...............................................................................................251
7.15.3 Start Up torque ...........................................................................................................................254
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7.15.4 Roll Back Control for Closed Loop ................................................................................................255
7.15.5 Brake monitoring function ..........................................................................................................256
7.15.6 Functions ....................................................................................................................................258
7.15.7 Brake Test Function ....................................................................................................................258
7.16 Auto Fault Reset ..................................................................................................................................259
7.17 PI Control ............................................................................................................................................262
7.18 Tandem operation ...............................................................................................................................264
7.19 Load Estimation...................................................................................................................................265
7.20 Functional Safety .................................................................................................................................266
7.21 Anti-Swing Function ............................................................................................................................267
7.22 Keypad control parameters .................................................................................................................270
8. Identification function for permanent magnet synchronous motor ............................................................271
8.1 Identification with absolute encoder. ..................................................................................................271
8.2 Identification with incremental encoder without Z-pulse input ............................................................271
8.3 Identification with incremental encoder with Z-pulse input..................................................................272
9. Status and control word in detail ................................................................................................................273
9.1 Fieldbus ..............................................................................................................................................273
9.1.1 Combination 1, ProfiDrive – Standard with Profibus option board....................................................274
9.1.2 Combination 2, ByPass – ProfiDrive .................................................................................................275
9.1.3 Combination 3, ByPass – Standard ...................................................................................................282
9.2 Application Status Word ......................................................................................................................283
9.3 Regulator Status ..................................................................................................................................283
9.4 Data Logger Trigger Word ....................................................................................................................284
9.5 MC Status Word ..................................................................................................................................284
9.6 Brake Control Status ............................................................................................................................285
10. Problem solving ......................................................................................................................................287
11. Fault codes..............................................................................................................................................288
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1. CRANE CONTROL APPLICATION - INTRODUCTION
Software APFIFF20, Crane Control application
Crane Control application is designed for use in crane systems.
1.1 General
This application is not backwards compatible. Please read the application change note or
chapter 2: Brake Control versions compatibility issues in this manual to see what needs to be
noted when updating the application. See also the updated parameter description in NCDrive
when commissioning.
Help is available in NCDrive through selecting “Variable Text” and pressing “F1”.
See below an example from the Identification parameter help text from the NCDrive.
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1.2 Basic Features
The Crane Control application provides a wide range of parameters for controlling induction
motors and permanent magnet motors. It can be used for various kinds of different processes
where wide flexibility of I/O signals is needed and only simple PI control logic.
Flexible ID control possibilities takes the application suitability to different processes to a new
level, allowing any input or actual value to be connected to any parameter with a scaling factor.
Additional functions:
• Joystick input dead zone
• Master-Follower function
• Cooling monitor input from heat exchange unit with selectable response
• Brake monitoring input and actual current monitor for immediate brake close
• Separate speed control tuning for different speeds and loads
• Inching function with two different references
• Possibility to connect FB Process data to any parameter and some monitoring values
• Analogue input 3 and 4 can control any parameter by ID number
• Support for four analogue outputs
• Support for two PT100 boards
• Roll-Back control and Torque memory
• Brake slipping monitor (Start to falling load)
1.3 Crane Control Application Compatibility issues
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2. QUICK COMMISSIONING FOR CRANE FEATURES
2.1 Mechanical Brake Control and Monitoring
The Mechanical Brake Control function in drive supports to build-up torque smoothly against the
closed brake before releasing the mechanical brake for smooth startup , and drive will continue
to deliver torque until mechanical brake control takes over the command.
Mechanical brake control parameters are in the group G 2.15.x.
See chapter 8.15 Brake Control for more details on parameters and their behaviour.
Easy commissioning tips for Mechanical Brake Control:
The application software makes calculations for parameter setting during the identification run
based on motor nominal parameters, brake mechanical opening delay (P2.15.3) and brake
mechanical closing delay (P2.15.4).
1. Enter motor name plate value G2.1 Basic Parameters.
a. Enter motor magnetization current P2.1.8 if known (calculated from Cos Phi if not
given).
2. Make identification run in standstill with P2.1.9 Identification: selection 1 - ID No Run.
a. If magnetization current is not known, arrange so that Identification selection 6 -
U/f + magn ID run can be made.
3. After identification, upload the parameters from the drive.
4. Brake related parameters are gathered to G2.15.
a. Select output for controlling the brake P2.15.1 BrakeOpen, Direct.
b. Select feedback input if used: P2.15.2 Brake Feedback.
c. Enter brake mechanical time delay for opening the brake: P2.15.3.
d. Enter brake mechanical time delay for closing the brake: P2.15.4.
e. Depending on system, Brake Timing identification run can be made.
5. Make necessary parameter changes to control place and control signal.
6. Make Crane ID Run for hoisting P2.1.11 Crane Identification modes.
a. If mode accurate timings for brake are found during commissioning, it is
recommended to make Crane Identification again. See detailed list of modified
parameters from P2.1.11 explanation.
7. Make Open Loop run without load with monitoring signals below.
a. Use ~7 ms monitoring interval if possible (see chapter 10 Problem Solving).
- Value: BrakeStatusWord
- Value: Motor Torque
- Value: Motor Current
- Value: Freq.Ramp Out
- Value: Output Frequency
- Value: Shaft Frequency
- Value: Motor Voltage
- Value: DC Voltage
b. Monitor that Shaft Frequency from encoder is correct.
In some cases, filtering a few ms may be needed: P2.8.5.6.
c. See that current and torque do not show abnormal behaviour.
8. Change to Closed Loop Control P2.8.1 Motor Control Mode: 3 / CL Speed Control.
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Easy commissioning tips for Mechanical Brake Control:
The application software makes calculations for parameter setting during the identification run
based on motor nominal parameters, brake mechanical opening delay (P2.15.3) and brake
mechanical closing delay (P2.15.4).
Set Motor Parameters as per Motor name plate – Parameter
group G 2.1
Set Brake opening Delay time – P2.15.3
Set Brake closing Delay time – P2.15.4
Set control place & signals selection for DI/DO & AI through
parameter P2.4.1.x to P2.4.4.x
Set Ramp times through parameter P2.3.x
Set brake resistor parameters P2.6.x
External
Brake Chopper or
AFE ?
Set P2.6.4.3 Brake chopper to
Recomendation is [3] Used when stopped/running
Set P2.6.4.4 Brake Chopper Level:
For 400V Supply: 400*1.35*1.18 = 638V
For 500V Supply: 500*1.35*1.18 = 808V
For 690V Supply: 690*1.35*1.18 = 1100V
No
Yes
Set P2.6.4.3 Brake chopper to [2] External
Set Brake control relay output in P2.15.1 BrakeOpen, Direct
Set Brake feedback input (if used) in P 2.15.2 Brake Feedback
Continue….
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Run in CL?
No
Yes
Perform Motor ID Run in standstill ,P2.1.9 -select 1/ID No
Run. If magnetizing current is known ( calcuated from
cosphi)
Set Encoder parameters in G7.3.x
Set Motor control mode in P2.8.1 to 3/CL speed
control
Set Motor speed and current limits as per application
appropriate P-2.6.xx
VFD is Ready to perform test run on load
Perform Crane ID Run with hoistingoption select with
P2.1.11. for Crane ID run explanation -refer ID run in chapter
basic parameters
Once ID run completed, upload parameters from the drive
ID run Ok
No
Check Motor Name plate and verify with parameters set
Magnetizing
current known?
Perform identification mode 6 (U/F + magnetizing) – refer
chapeter basic parameters
Start Scope Monitor Windowto check if
Encoder 1 freq is equal to motor frequency,
Make Open Loop run without load with monitoring signals
like Brake StatusWord, Motor torque, Motor current,
Frequency Ramp out, Output frequency, Shaft frequency,
Motor Voltage, DC voltage
Check Motor current and torque do not show
abnormal behavior
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➢ Roll Back Control for CL
Roll Back function prevents downwards movement of the load when brake is opening and giving
smooth lifting at start. Parameters available in group G2.15.12.x
2.2 Catch Dropping load When Drive is in standby mode (No start command given) and if Mech. Brake failed,
VFD will detects and take over automatically detects, takes over(starts) and bring the
load down to the ground in controlled way. (Operator can only give down command,
forced
lowering, no hoist will be allowed.
This function required closed loop operation.
This function can activate in parameter P2.15.13.5
2.3 Tandem Operation for Cranes
➢ Master-Follower (Speed-Torque sharing)
Master-Follower (Speed-Torque sharing) function is mainly used when motor shafts are
coupled to each other for running a common load. In this case, the master will be in
speed control mode and the follower will be in torque control mode.
The external control signals are connected to the master NXP only. The master controls
the follower(s) via a system bus. The master station is typically speed-controlled, and the
other drives follow its torque reference.
Master
Slave
Master-Follower parameters are in group G 2.11.x in chapter 6.11
➢ Tandem Hoist (Shaft Sync)
Tandem Hoist function is used to lift higher capacity load with synchronizing of two axes
at the same time OR more than 01 lifting gear to be connected.
System bus
OPTD2
Torque Sharing
M M
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Tandem operation helps to monitor and control the position difference of the hooks and
synchronize the movement of each axes.
Shaft synchronization works between master-slave axes through system bus with crane
application software.
Maximum four axes can be synchronized.
Tandem operation communication is enabled with Master-Follower mode P2.11.1
(selection 3 and 4). See chapter 7.11 Master-Follower.
Tandem operation (Shaft Sync) parameters are in group G 2.11.x and G2.18.x in chapter
7.11 and chapter 8.18.
2.4 Speed limit switch for Horizontal Movement Speed limit switch function help to limit speed for horizontal movement when trolley or
travel motion moving towards end direction. External sensors for forward and reverse
direction will connect to Digital inputs of VFD. Forward and reverse speed can be set
independently. Parameters are in group G 2.2.12.x
2.5 Anti-Sway
Typically, overhead cranes are used in manufacturing or maintenance processes where
productivity and safety are considered the most important requirements. Swinging of the load
during the crane’s movement is a natural phenomenon as load is suspended from a gripping
device by cables and acts as a pendulum device.
NXP offers an integrated sensorless Anti-Sway control, where there is no need for encoders or
communication with a hoist drive. The Anti-Sway feature is to be used in trolley and travel
motion only.
The Anti-Sway function is license protected. Users need to buy a license key from a Danfoss
supplier to make the Anti-Sway function effective. License key status can be checked and
verified in monitoring parameter V1.31.2.
To eliminate sway, two different methods are available in Crane application software. User
needs to set either Average Swinging Period or Maximum Rope length.
How to calculate swinging period
• Lower the hook to the lowest practical position. There is no need to connect load on the
hook.
• Run the crane with full speed and give stop command.
• Measure the duration of 5–10 swings (back and forth) and calculate the swinging period.
• Enter the swinging period into parameters.
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Anti-Sway parameters are in group 2.21.x. Refer to group 2.21.x for different
modes for Anti-Sway with swinging period method.
Rope Length
Maximum rope length (in cm), to be entered in P 2.21.4. From drum to hook touch
down to the ground or just above.
NOTE: If swinging period method is to be used, then Rope Length parameter is to be kept
“ZERO”. If the value for Rope Length is other than zero, then the swinging period method will not
work. With Rope Length method, only “Mode 1” will work effectively.
Anti-Sway parameters are in group P2.21.x. See chapter 6.20 and chapter 7.21 for more details.
2.6 Speed Optimization (Power dependant speed control)
Speed optimizing function limits speed directly to requested power(kW) level. There are different
settings for forward limit speed and reverse limit speed. This function can activate in parameters
G2.6.3.7 and G2.6.3.8.
2.7 Bumpless transfer from closed loop to sensorless control
For closed loop operation, in case of encoder failure, VFD will switch to sensorless
mode with last speed recorded before encoder failure and display “Encoder loss warning”. It will
be Bump less transfer because customer will not see any jerk, speed variation during
changeover from closed loop to sensorless mode and allow them to run in sensorless mode
without any interruption in process. It is Customer responsibility to take safety of crane
movement in account while running in sensorless mode.
This function can activate in parameter P2.12.12.1.
2.8 Shock Load Prevention
Shock Load function enables smooth load pick-up until the load is lifted to air. This protects the
crane from extra stress caused by sudden load change detected by hoist drum and rope at
higher speed.
With Shock Load Prevention, the hoist drive monitors the load. If it is lifted too fast, the hoisting
speed will reduce with predefined “Shock load ref” until “Shock load time” has elapsed.
Shock Load and Slack Rope parameters are in group P2.13.14.x. See chapter 6.3.4 and chapter
7.3.2 for more details.
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2.9 Slack Rope Prevention
When the load or hook is approaching the ground, it will generate slack at the rope, which could
damage the rope. The rope could also jump out of the rope guides when the load or hook
touches the ground at high speed.
Slack Rope protection mode can be activated through parameter P2.3.14.1. While lowering the
hook load, drive will activate “Zero speed Reference” when actual torque drops below the “Load
off the hook”.
2.10 Integrated functional safety
To activate integrated functional safety features in compliance with SIL3/”Ple”, an advanced
safety option board is required to be installed in C or D slot. There are three types of safety
option boards available (OPTBL, OPTBM and OPTBN), and they can be selected according to
application requirements. See VACON® Advanced Functional Safety Operating Guide for more
details.
Crane application supports Stop Function (STO, SQS, SS1 and SS2 ) and Speed Limit Function
(SLS, SSR and SDI). Functional safety parameters can be activated in parameter group
P2.20.x. See chapter 6.19 and chapter 7.20 for more details.
2.11 Load Estimation
Hoist drive will estimate load on the hook to protect the crane against overload mode. This
means that when the drive detects overload it gives an alarm and stops the crane.
To calculate actual load, hoist mechanical parameters are required to be set in group P2.19.x.
It is important to know that actual load measurement is based on hoist mechanical parameters.
Therefore if the values have not been correctly entered, the drive will not show an accurate
value.
See chapter 6.18 and chapter 7.19 for more details.
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3. CONTROL I/O
NXOPTA1
Terminal
Signal
Description
1
+10V
ref
Reference voltage output
Voltage for potentiometer, etc.
2
AI1+
Analogue input 1.
Range 0-10V, Ri = 200
Range 0-20 mA Ri = 250
Analogue input 1 frequency reference.
Input range selected by jumpers.
Default range: Voltage 0 – 10 V
3
AI1-
I/O Ground
Ground for reference and controls
4
AI2+
Analogue input 2.
Range 0-10V, Ri = 200
Range 0-20 mA Ri = 250
Analogue input 2 frequency reference
Input range selected by jumpers.
Default range: Current 0 – 20 mA
5
AI2-
6
+24V
Control voltage output
Voltage for switches, etc. max 0.1 A
7
GND
I/O ground
Ground for reference and controls
8
DIN1
Programmable G2.2.7
No function defined at default
9
DIN2
Programmable G2.2.7
No function defined at default
10
DIN3
Programmable G2.2.7
No function defined at default
11
CMA
Common for DIN 1—DIN 3
Connect to GND or +24V
12
+24V
Control voltage output
Voltage for switches (see #6)
13
GND
I/O ground
Ground for reference and controls
14
DIN4
Programmable G2.2.7
No function defined at default
15
DIN5
Programmable G2.2.7
No function defined at default
16
DIN6
Programmable G2.2.7
No function defined at default
17
CMB
Common for DIN4—DIN6
Connect to GND or +24V
18
AOA1+
Analogue output 1
Programmable P2.3.1.2
Output range selected by jumpers.
Range 0—20 mA. RL, max. 500
Range 0—10 V. RL > 1k
19
AOA1-
20
DOA1
Digital output
Programmable
Open collector, I50mA, U48 VDC
NXOPTA2
21
RO1
Relay output 1
Programmable G2.3.3
Switching capacity
24 VCD / 8 A
250 VAC / 8 A
125 VDC / 0.4 A
22
RO1
23
RO1
24
RO2
Relay output 2
Programmable G2.3.3
Programmable
No function defined at default
25
RO2
26
RO2
Table 3-1. Brake Control application default I/O configuration and
connection example.
Note: See User Manual, chapter Control Connections, for hardware specification and
configuration.
Note: See jumper selections below.
More information in VACON® NX
User Manual.
220
VAC
Jumper block X3:
CMA and CMB grounding
CMB connected to GND
CMA connected to GND
CMB isolated from GND
CMA isolated from GND
CMB and CMA
internally connected together,
isolated from GND
= Factory default
Reference potentiometer,
1…10 k
mA
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4. “TERMINAL TO FUNCTION” (TTF) PROGRAMMING PRINCIPLE
The programming principle of the input and output signals in the Multipurpose Control
Application NXP as well as in the Pump and Fan Control Application (and partly in the other
applications) is different compared to the conventional method used in other VACON® NX
applications.
In the conventional programming method, Function to Terminal Programming Method (FTT), you
have a fixed input or output that you define a certain function for. The applications mentioned
above, however, use the Terminal to Function Programming method (TTF) in which the
programming process is carried out the other way round: Functions appear as parameters which
the operator defines a certain input/output for. See Warning on page 19.
4.1 Defining an input/output for a certain function on keypad
Connecting a certain input or output with a certain function (parameter) is done by giving the
parameter an appropriate value. The value is formed of the Board slot on the VACON® NX
control board (see VACON® NX User Manual) and the respective signal number, see below.
Function name
Slot Terminal number
Terminal type
Example: You want to connect the digital output function Reference fault/warning (parameter
2.3.3.7) to the digital output DO1 on the basic board NXOPTA1 (see VACON® NX User Manual).
First find the parameter 2.3.3.7 on the keypad. Press the Menu button right once to enter the edit
mode. On the value line, you will see the terminal type on the left (DigIN, DigOUT, An.IN,
An.OUT) and on the right, the present input/output the function is connected to (B.3, A.2 etc.), or
if not connected, a value (0.#).
When the value is blinking, hold down the Browser button up or down to find the desired board
slot and signal number. The program will scroll the board slots starting from 0 and proceeding
from A to E and the I/O selection from 1 to 10.
Once you have set the desired value, press the Enter button once to confirm the change.
READY
I/Oterm
DigOUT:B.1
AI Ref Faul/Warn
READY
I/Oterm
DigOUT:0.0
READY
I/Oterm
DigOUT:0.0
READY
I/Oterm
DigOUT:B.1
enter
AI Ref Faul/Warn AI Ref Faul/Warn AI Ref Faul/Warn
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4.2 Defining a terminal for a certain function with NCDrive programming tool
If you use the NCDrive Programming Tool for parametrizing you will have to establish the
connection between the function and input/output in the same way as with the control panel. Just
pick the address code from the drop-down menu in the Value column (see the Figure below).
Figure 4-1. Screenshot of NCDrive programming tool; Entering the address code
Be ABSOLUTELY sure not to connect two functions to one and
same output in order to avoid function overruns and to ensure
flawless operation.
!
WARNING
Note: The inputs, unlike the outputs, cannot be changed in RUN state.
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4.3 Defining unused inputs/outputs
All unused inputs and outputs must be given the board slot value 0 and the terminal number
value 1. The value 0.1 is also the default value for most of the functions. However, if you want to
use the values of a digital input signal for e.g. testing purposes only, you can set the board
slot value to 0 and the terminal number to any number between 2…10 to place the input to a
TRUE state. In other words, the value 1 corresponds to 'open contact' and values 2 to 10 to
'closed contact'.
In case of analogue inputs, giving the value 1 for the terminal number corresponds to 0% signal
level, value 2 corresponds to 20%, value 3 to 30% and so on. Giving value 10 for the terminal
number corresponds to 100% signal level.
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5. CRANE CONTROL APPLICATION – MONITORING VALUES
On the next pages you will find the lists of parameters within the respective parameter groups.
The parameter descriptions are given on pages 96 to 259. The parameter description includes
more than is available in this application, see parameter list for parameters that are available in
this application.
Column explanations:
Code = Location indication on the keypad; Shows the operator the present parameter
number
Parameter = Name of parameter
Min = Minimum value of parameter
Max = Maximum value of parameter
Unit = Unit of parameter value; given if available
Default = Value preset by factory
Cust = Customer’s own setting
ID = ID number of the parameter
_____ = On parameter code: Parameter value can only be changed after the FC has
been stopped.
_____ = Apply the Terminal to Function method (TTF) to these parameters (see chapter
4)
_____ = Monitoring value is possible to control from fieldbus by ID number
The manual presents signals that are not normally visible for monitoring. i.e. is not a parameter
or standard monitoring signal. These signals are presented with [Letter]. e.g.
[FW]MotorRegulatorStatus
[V] Normal monitoring signal
[P] Normal parameter in application
[FW] Firmware signal, Can be monitored with NCDrive when signal type is selected Firmware
[A] Application signal, can be monitored with NCDrive when signal type is selected
Application
[R] Reference type parameter on keypad
[F] Function. Signal is received as a output of function.
[DI] Digital input signal
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5.1 Monitoring values
The monitoring values are the actual values of parameters and signals as well as statuses and
measurements.
5.1.1 Monitoring values 1
Code
Parameter
Unit
Form.
ID
Description
V1.1
Output frequency
Hz
#,##
1
Output frequency to motor
V1.2
Frequency reference
Hz
#,##
25
Frequency reference to motor control
V1.3
Motor speed
rpm # 2
Motor speed in rpm
V1.4
Motor current
A
Varies
3
1 s linear filtering
V1.5
Motor torque
%
#,#
4
In % of Motor nominal torque
V1.6
Motor Power
%
#,#
5
V1.7
Motor voltage
V
#,#
6
Calculated motor voltage
V1.8
DC link voltage
V # 7
Measured DC voltage, filtered.
V1.9
Unit temperature
C
# 8 Heatsink temperature
V1.10
Motor temperature
%
#
9
Calculated motor temperature
V1.11
Analogue input 1
%
#,##
13
AI1, unfiltered.
V1.12
Analogue input 2
%
#,##
14
AI2, unfiltered.
V1.13
Analogue input 3
%
#,##
27
AI3, unfiltered.
V1.14
Analogue input 4
%
#,##
28
AI4, unfiltered.
V1.15
Analogue Out 1
%
#,##
26
AO1
V1.16
Analogue Out 2
%
#,##
50
AO2
V1.17
Analogue Out 3
%
#,##
51
AO3
V1.18
Analogue Out 4
%
#,##
1526 V1.19
DIN1, DIN2, DIN3
15
Digital input statuses
V1.20
DIN4, DIN5, DIN6
16
Digital input statuses
V1.21
Torque reference
%
#,#
18
Used Torque Reference
V1.22
PT-100 Temperature
Cº
#,#
42
Highest temperature of OPTB8 board. 4 s
filtering.
G1.23
Multimonitoring items
Displays three selectable monitoring
values
Table 5-1. Monitoring values
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5.1.2 Monitoring values 2
Code
Parameter
Unit
Form.
ID
Description
V1.24.1
Current
A
Varies
1113
Unfiltered motor current
V1.24.2
Torque
%
#,#
1125
Unfiltered motor torque
V1.24.3
DC Voltage
V # 44
Unfiltered DC link voltage
V1.24.4
Status Word 1
(Application)
43
V1.24.5
Encoder 1 Frequency
Hz
#,##
1124
Unfiltered
V1.24.6
Output Power
kw
Varies
1508
Unfiltered electrical power
V1.24.7
Measured temperature
1
Cº
#,#
50
4 s filtering.
V1.24.8
Measured temperature
2
Cº
#,#
51
4 s filtering.
V1.24.9
Measured temperature
3
Cº
#,#
52
4 s filtering.
V1.24.10
Measured temperature
4
Cº
#,#
69
4 s filtering.
V1.24.11
Measured temperature
5
Cº
#,#
70
4 s filtering.
V1.24.12
Measured temperature
6
Cº
#,#
71
4 s filtering.
V1.24.13
ABS Encoder
Revolutions
r
#
55
V1.24.14
ABS Encoder Position
#
54
V1.24.15
Step response
Hz
#,##
1132
V1.24.16
CosPhiiActual
#,###
68 V1.24.17
Flux Current
%
#,#
72 V1.24.18
Regulator Status
77 V1.24.19
Frequency Delta
1847
V1.24.20
Rotor Flux
%
#,#
1158
V1.24.21
DataLogger Trigger
Word
97
V1.24.22
Ident Failure Code
98 V1.24.23
Non Ready Causes
1608
V1.24.24
Prevent MC Ready
1609
Table 5-2. Monitoring values 2
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5.1.3 Fieldbus Monitoring values
Code
Parameter
Unit
Form.
ID
Description
V1.25.1
FB Control Word
1160
V1.25.2
FB Speed Reference
875 V1.25.3
FB Status Word
65 V1.25.4
FB Actual Speed
865 V1.25.5
FB Torque Reference
%
#,#
1140
Default Control of FB PD 1
V1.25.6
FB Limit Scaling
%
#,##
46
Default Control of FB PD 2
V1.25.7
FB Adjust Reference
%
#,##
47
Default Control of FB PD 3
V1.25.8
FB Analog Output
%
#,##
48
Default Control of FB PD 4
V1.25.9
FB Motor Current
A
#,#
45
Motor current (drive
independent) given with one
decimal point
V1.25.10
Fault Word 1
1172
V1.25.11
Fault Word 2
1173
V1.25.12
Warning Word 1
1174
V1.25.13
AuxStatusWord
1163
V1.25.14
Last Active Fault
37 V1.25.15
AuxControlWord
1161
V1.25.16
Din Status Word
56
V1.25.17
Din Status Word 2
57 V1.25.18
MC Status
64 V1.25.19
Last Active Warning
74 V1.25.20
Encoder Rounds
1170
V1.25.21
Encoder Angle
1169
V1.25.22
Fault Word 10
1202
V1.25.23
Warning Word 10
1269
Table 5-3. Fieldbus Monitoring values
5.1.4 Master/Follower Monitoring values
Code
Parameter
Unit
Form.
ID
Description
V1.26.1
SB System Status
1601
V1.26.2
Total Current
A
#,#
80
Sum current of all drives (DS)
V1.26.3
Master Control Word
93 Code
Parameter
Unit ID
Description
V1.26.4.1
Motor Current D1
A 1616
V1.26.4.2
Motor Current D2
A 1605
V1.26.4.3
Motor Current D3
A 1606
V1.26.4.4
Motor Current D4
A 1607 Code
Parameter
Unit ID
Description
V1.26.4.1
Status Word D1
1615
V1.26.4.2
Status Word D2
1602
V1.26.4.3
Status Word D3
1603
V1.26.4.4
Status Word D4
1604
Table 5-4. Master/Follower Monitoring values
5.1.5 PI Control Monitoring values
Code
Parameter
Unit
Form.
ID
Description
V1.27.1
PI Reference
20
Used PI Reference
V1.27.2
PI Actual Value
21
PI Actual value
V1.27.3
PI Output
23
PI Output before scaling
V1.27.4
PI Output Scaled
1807
Scaled PI Output
This is used for ID connection
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5.1.6 Frequency Chain
Code
Parameter
Unit
Form.
ID
Description
V1.28.1
Frequency Reference 1
Hz
1126
V1.28.2
Frequency Reference 2
Hz
1127
V1.28.3
Frequency reference
Hz
#,##
25
Frequency reference to motor
control
V1.28.4
Frequency Reference
Actual
Hz
1128
V1.28.5
Frequency Ramp Out
Hz
1129
V1.28.6
Frequency Reference
Final
Hz
1131
V1.28.7
Encoder Frequency
Hz
1164
5.1.7 Torque Chain
Code
Parameter
Unit
Form.
ID
Description
V1.29.1
Torque Reference
% 18 V1.29.2
Torque Reference 3
% 1144
V1.29.3
Torque Ref Final
% 1145
V1.29.4
Speed Control Out
% 1134
V1.29.5
Torque Reference
Actual
% 1180
Final torque reference from
speed control and/or torque
control
5.1.8 Brake Control
Code
Parameter
Unit
Form.
ID
Description
V1.30.1
Brake Status Word
89 V1.30.2
Load Estimation
kg
#
1914
V1.30.3
Load Estimation 100
kg
#,##
1913
V1.30.4
RopeLengthInUse
cm
#
1915
5.1.9 Motion
Code
Parameter
Unit
Form.
ID
Description
V1.31.1
Serial Number Key
V1.31.2
License Status
5.1.10 Shaft Synch
Code
Parameter
Unit
Form.
ID
Description
V1.32.1
Master Rotations
1820
V1.32.2
Own Rotations
1821
V1.32.3
Control Out
1822
V1.32.4
Rotation Error
1823
V1.32.5
Position Ref
1825
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5.1.11 Functional Safety Monitoring
Code
Signal
Unit
ID
Description
V1.33.1
Safety App Status
1653
V1.33.2
Integrity Level
1640
V1.33.3
Acknowledge Mode
1641
V1.33.4
Safety Encoder Speed
rpm
1642
V1.33.5
Ramp Selection
1643
V1.33.6
Function Reached
1644
V1.33.7
Request DIN
1645
V1.33.8
Request PLC
1646
V1.33.9
Function In Use
1647
V1.33.10
Safety Status Word
1648
V1.33.11
Safety General Status
Word
1649
V1.33.12
Safety Status
1650
V1.33.13
Safety Zero Speed
1651
V1.33.14
SBC Speed
rpm
1652
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5.2 Monitoring Values description
5.2.1 Monitoring values
V1.1 Output frequency [#,## Hz] ID1
Output frequency to motor, updated at 10 ms time level.
V1.2 Frequency reference [#,## Hz] ID 25
Frequency reference to motor control, after speed share function, updated at 1 ms
time level.
V1.3 Motor speed [ # rpm] ID 2
Motor speed in rpm
V1.4 Motor current [A] ID 3
Measured motor RMS current
Current scaling in different size of units
Note: ID45, usually in Process data OUT 3 is scaled to be with one decimal always.
Voltage
Size
Scale
208 – 240 Vac
NX0001 – NX0011
100 – 0.01A
208 – 240 Vac
NX0012 – NX0420
10 – 0.1A
208 – 240 Vac
NX0530
1 – 1A
380 – 500 Vac
NX0003 – NX0007
100 – 0.01A
380 – 500 Vac
NX0009 – NX0300
10 – 0.1A
380 – 500 Vac
NX0385 – NX2643
1 – 1A
525 – 690 Vac
NX0004 – NX0013
100 – 0.01A
525 – 690 Vac
NX0018 – NX0261
10 – 0.1A
525 – 690 Vac
NX0325 – NX1500
1 – 1A
V1.5 Motor torque % ID 4
In % of Motor nominal torque
V1.6 Motor Power % ID 5
Calculated motor power
V1.7 Motor voltage V ID 6
Calculated motor voltage
V1.8 DC link voltage V ID 7
Measured DC voltage, filtered.
V1.9 Unit temperature C ID 8
Heatsink temperature
V1.10 Motor temperature % ID 9
Calculated motor temperature
105 % is tripping limit if response is fault.
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V1.11 Analogue input 1 % ID 13
V1.12 Analogue input 2 % ID 14
Unfiltered analogue input level.
0% = 0 mA / 0 V, -100% = -10 V, 100% = 20 mA / 10 V.
Monitoring scaling is determined by the option board parameter.
V1.13 Analogue input 3 % ID 27
V1.14 Analogue input 4 % ID 28
It is possible to adjust this input value from fieldbus when the input terminal selection
is 0.1. This way it is possible to adjust the free analogue input from fieldbus and have
all analogue input functions available for fieldbus process data.
V1.15 Analogue Out 1 % ID 26
V1.16 Analogue Out 2 % ID 50
V1.17 Analogue Out 3 % ID 51
V1.18 Analogue Out 4 % ID 1526
Analogue Output value 0% = 0 mA / 0 V, 100% = 20 mA / 10 V
V1.19 DIN1, DIN2, DIN3 ID 15
V1.20 DIN4, DIN5, DIN6 ID 16
DIN1/DIN2/DIN3 status
DIN4/DIN5/DIN6 status
b0
DIN3
DIN6
b1
DIN2
DIN5
b2
DIN1
DIN4
V1.21 Torque reference % ID 18
Torque reference value before load share.
V1.22 PT-100 Temperature Cº ID 42
Highest temperature of OPTB8 board. 4 s filtering.
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5.2.2 Monitoring values 2
V1.24.1 Current A ID 1113
Unfiltered motor current, recommended signal for NCDrive monitoring.
V1.24.2 Torque % ID 1125
Unfiltered motor torque, recommended signal for NCDrive monitoring.
V1.24.3 DC Voltage V ID 44
Unfiltered DC link voltage, recommended signal for NCDrive monitoring.
V1.24.4 Application Status Word ID 43
Application Status Word combines different drive statuses to one data word.
Recommended signal for NCDrive monitoring.
Application Status Word ID43
FALSE
TRUE
b0
Flux not ready
Flux ready (>90 %)
b1
Not in Ready state
Ready
b2
Not Running
Running
b3
No Fault
Fault
b4
Direction Forward
Direction Reverse
b5
Emergency Stop Active
Emergency Stop NOT Active
b6
Run Disabled
Run Enable
b7
No Warning
Warning
b8
Power positive
Power negative or Gen torque or current
limit active
b9
b10
b11
No DC Brake
DC Brake is active
b12
No Run Request
Run Request
b13
No Limit Controls Active
Limit control Active
b14
External Brake Control OFF
External Brake Control ON
b15
V1.24.5 Shaft Frequency Hz ID 1124
Encoder frequency after filter. P2.8.4.6 Encoder1FiltTime.
V1.24.6 Output Power [kw] ID1508
Unfiltered electrical drive output power.
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V1.24.7 Measured temperature 1 Cº ID 50
V1.24.8 Measured temperature 2 Cº ID 51
V1.24.9 Measured temperature 3 Cº ID 52
V1.24.10 Measured temperature 4 Cº ID 69
V1.24.11 Measured temperature 5 Cº ID 70
V1.24.12 Measured temperature 6 Cº ID 71
Separate measurement from two PT100 boards. The signal has 4 s filtering time.
V1.24.13 ABS Encoder Revolutions ID55
Absolute encoder revolution information.
V1.24.14 ABS Encoder Position ID54
Absolute encoder position within one rotation. See encoder manual for scaling.
V1.24.15 Step response Hz ID 1132
Frequency error. Compares ramp output to actual encoder frequency with 0.001 Hz
accuracy. Can be used for speed control tuning in closed loop control.
V1.24.16 CosPhiiActual ID 68
Estimated Cos Phii.
V1.24.17 Flux Current % ID 72
Flux current part or the total current. 100% = Motor Nominal Current.
V1.24.18 Regulator Status ID 77
Regulator status ID77
b0
Motoring Current Regulator Status
b1
Generator Current Regulator Status
b2
Motoring Torque Regulator Status
For CL monitor B0
b3
Generator Torque Regulator Status
For CL monitor B1
b4
Over Voltage Regulator Status
DC Voltage
b5
Under Voltage Regulator Status
DC Voltage
b6
b7
b8
b9
b10
b11
b12
b13
b14
b15
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