Delta AFE2000, C2000 User Manual

Product Application

Industrial Automation BU, Delta Electronics, Inc.

Case

Issued by Solution Center Date November, 2010 Pages 5

Applicable to C2000 series AC motor drive, AFE2000 series active front-end unit

Key words

Introduction

A bridge crane (also known as an overhead travelling crane) finds wide application in warehouses, factories,

docks, open storage yards, and more. A three-phase induction motor offers many benefits including simple structure,

durability, low cost, and easy maintenance. If we employ a Delta AC motor drive to drive the induction motor rather

than using a traditional drive, the crane’s malfunction rate decreases substantially. Moreover, if Delta’s AFE2000

series active front-end unit is employed, it saves the cost of purchasing a brake resistor and excessive energy is

transformed into reusable energy through IGBT switch, which is fed back to the mains for other electronic devices.

Delta’s AC motor drive and AFE2000 is an outstanding combination for bridge cranes.

Application: Delta C2000 Series AC Motor Drive and AFE2000 Active Front-End Unit for Bridge
Crane (Overhead Travelling Crane)

crane, hoist, Delta AC motor drive, high-level field oriented control, built-in PLC, torque control,
reliability, AFE2000 active front-end, power quality, power improvement, power factor, harmonics,
fast braking, brake resistor, current control PWM converter, switch rectifier, energy-saving

Application

The bridge crane moves back and forth with four driving and passive wheels, but when the starting load is large,

it is common to install more wheels to share the wheel load. An articulated device is needed for bridge cranes with

more than four wheels. The device’s function is to balance out the load and distribute it evenly to each wheel. The

motion is done by three independent pulling systems, as shown in [Figure 1]:

1. Trolley: To execute leftward and rightward movement along the cross-axis bridge (left/right).

2. Endtruck: To execute forward and backward movement along the long-axis runway (FWD, REV).

3. Hoist: To lift and lower the item (up/down).

[Figure 1]

The bridge crane hoist, unlike the trolley and the runway girder, has lower requirements for precision control, and

it benefits a lot from the AC motor drive. Different from traditional drives, an AC motor drive offers more thorough

With solid experience and advanced technology, Delta’s IABU offers efficient and reliable solutions and service — we are your most
trustworthy partner.

COPYRIGHT © 2008 DELTA ELECTRONICS, INC. ALL RIGHTS RESERVED.

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Product Application

Industrial Automation BU, Delta Electronics, Inc.

safety protection and additional features such as large load inertia and 4-quadrant operation. The suggested AC

motor drive and the active front-end unit model for the bridge crane are:

 VFD  VFD110C23A

 AFE  AFE075A23A + CHOKE: 2.1mH

Application Case

System Solution

For bridge cranes, the Delta C2000 series AC motor drive has taken overload problems and long-term system

stability issues as target factors and offers excellent features such as:

1. Full vector control. Supports starting torque up to 150% rated torque at a low frequency of 1Hz in steady motion.

2. Optional braking unit is available to perform 4-quadrant operation

3. Constant torque at full speed range

4. With AFE2000, regenerative energy is converted by AFE2000 into reusable energy (clean power) and fed back to

the mains.

System Features

 SVC control

The Delta C2000 provides sensorless vector control (SVC) to perform a nearly close-loop control function which

saves from purchasing an encoder and lowers maintenance cost. In addition, it overcomes activation difficulties, and

is capable of initiating a start-up under full load and short-term over-load conditions.

 Braking process control

Prevention of sudden drops and jerky movements is an important factor in overall bridge crane system design.

The coordination between the AC motor drive and the mechanical control should be rigid to prevent sudden drops and

jerking, especially when lifting or lowering a heavy load and when stopping a heavy load in mid-air. The Delta C2000

series offers a special set of parameters and multiple output commands to promptly solve the problem.

.

 Overload capacity

Normal load: rated output current 120%/min; Heavy load: rated output current 150%/min. This offers sufficient

start-up torque and maintains the DC Bus voltage at 730VDC when torque decreases and it will not trigger OU alarm.

The test report reveals the system allows the bridge crane to operate long-term

 Soft-start, soft-stop, wide speed range and precise positioning.

With solid experience and advanced technology, Delta’s IABU offers efficient and reliable solutions and service — we are your most
trustworthy partner.

COPYRIGHT © 2008 DELTA ELECTRONICS, INC. ALL RIGHTS RESERVED.

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