Drivecon变频器XS Service Manual D2SV2051 3-7-08说明书（英文）

�������� �� �������� �� �������� �� �������� �� rev 6.0 with software D2S2V051 1/36 Drivecon Inc. reserves the right to alter or amend the above information without notice. ���� ���� �������������������������������������������� Traverse Inverter � �������� �� �������� �� �������� �� �������� �� ���� ���� 820 Lakeside Drive Gurnee, IL 60031-9165 Tel: 1-800-374-8266 Fax: 847-855-9650 www.drivecon.com�� � � ������� �� ��� ������� �������� � � ��� �������� ����������� � ���������������������� � ��� �� � ��������� ����� � �� ��� �� � ���� ������ ���������������������� ������������� ������������ ���� ��� ������������������������������������������������������� �� ���� ������������������� ������ �������������� � � �� ���������� � ��� ������������� �!""#������ � ��� ���$����������������������� �������� �� �������� �� �������� �� �������� �� rev 6.0 with software D2S2V051 2/36 Drivecon Inc. reserves the right to alter or amend the above information without notice. Read the instructions supplied with the product before installation and commissioning. Keep the instructions in a safe place for future reference. Table of contents 1 CAUTION………………………………………………………………………………………………………………….4 2 GENERAL………………………………………………………………………………………………………………...5 2.1 Technical data……………………………………………………………………………………………………….5 2.2 Type mark coding…………………………………………………………………………………………………...6 2.3 Main components…………………………………………………………………………………………………...6 2.4 Functional description………………………………………………………………………………………………7 2.5 Control methods…………………………………………….………………………………………………………7 2.6 Description of the control mode………………………………………………………………………………….. 8 2.6.1 MS2-control…………………………………………………………………………………………………... 8 2.6.2 EP2-control……………………………………………………………………………………………….… .. 8 2.6.3 EP3-control……………………………………………………………………………………… …….…….. 8 2.6.4 MS4-control…………………………………………………………………………………………..… …….9 2.6.5 MS5-control………………………………………………………………………………………..………… 9 2.6.6 AU/PO-control…………………………………………………………………………………..… ……….. 9 2.7 Slowdown-limit operation……...…………………………………………………………….…………………....10 2.8 Stop-limit operation……………………………………………………………………………………………......10 2.9 Mechanical brake control…………………………………………………………………………………………11 2.10 EMC…………………………………………………………………………………………………………………11 2.10.1 EMC levels……………………………………………………………………...………………………….…11 2.10.2 Fulfilled EMC-standards……………………………………………………………………………………..11 3 INSTALLATION……………………………………………………………………………………………...…………12 3.1 Power cabling………………………………………………………………………………………………………12 3.1.1 Shielded motor cable………………………………………………………………………………………...12 3.1.2 Double collectors………………………………………………………………………………………..…...12 3.1.3 4th Ground conductor…………………………………………………………………………………………12 3.1.4 Cable selection……………………………………………………………………………………………….12 3.1.5 Cable protection………………………………………………………………………………………………12 3.1.6 Cable length…………………………………………………………………………………………………..13 3.1.7 du/dt filters……..……………………………………………………………………………………………...13 3.1.7.1 XS 4050 - 4010………………………..…………………………………………………………….……...13 3.1.7.2 XS 4013 - 4048…………………………………………………..…………………………………….......13 3.2 EMC compatible grounding……………………………………………………………………..………………..13 3.2.1 Construction connections……………………………………………………………..…………………… 13 3.2.2 Cable connections…………………………………………………………………………………..……….13 4 COMPONENTS……………………………………………………………………………………………..………….14 4.1 Inverter…………………………………………………………………………………………….………………..14 4.1.1 Power supply unit (PSS)…………………………………………………………………………………….15 4.1.2 Control unit (CSS)……………………………………………………………………………………….. 16 4.1.3 I/O Extension board………………………………………………………………………………………….17 4.2 Control voltage transformer………………………………………………………………………………………17 5 PARAMETER ADJUSTMENTS………………………………………………………………………………………18 5.1 The display panel………………………………………………………………………………………………….18 5.2 Navigation on the control keypad……………………………………………………………………………….19 5.2.1 Editing numerical settings………………………………………………………………………………..…19 5.3 Monitor Parameter………………………………………………………………………………………………...19 5.4 Storing and restoring parameters………………………………………………………………………………..19 5.4.1 User parameters…………………………………………………………………………………………..…19 5.4.2 Factory parameters………………………………………………………………………………………….20 5.5 Motor parameterization…………………………………………………………………………………………...20 5.5.1 Voltage at low frequencies (U/f- curve)………………………………………………………………..….20 5.5.2 Mid Point Voltage adjustment…...………………………………………………………..………………..21 5.5.3 Zero Frequency voltage adjustment………………………………………………………………….…….21 �������� �� �������� �� �������� �� �������� �� rev 6.0 with software D2S2V051 3/36 Drivecon Inc. reserves the right to alter or amend the above information without notice. 5.5.4 Test Run………………………………………………………………………………………………………21 5.5.5 Autotuning…………………………………………………………………………………………………….22 6 PARAMETER DESCRIPTIONS……………………………………………………………………………………...23 6.1 General Description………………………………………………………………………………………………23 6.2 Parameter descriptions…………………………………………………………………………………………..23 6.2.1 Reverse Plugging……………………………………………………………………………………………28 6.2.2 Relay output………………………………………………………………………………………………….29 6.2.3 Ramp stretching……………………………………………………………………………………………..29 7 START-UP PROCEDURE……………………………………………………………………………………………30 7.1 Visual checks……………………………………………………………………………………………………...30 7.2 Checks before the first test run………………………………………………………………………………….30 7.3 Check motor parameters…………………………………………………………………………………………30 7.4 Test run without load……………………………………………………………………………………………..31 7.5 Test run with load…………………………………………………………………………………………………31 7.6 Test run with overload……………………………………………………………………………………………31 7.7 After the test run…………………………………………………………………………………………………..31 8 TROUBLESHOOTING………………………………………………………………………………………………...32 8.1 Field repair actions………………………………………………………………………………………………..32 8.2 Typical functional problems………………………………………………………………………………………32 8.3 Inverter fault codes………………………………………………………………………………………………..33 9 TROUBLESHOOTING TABLE…………………………………………………………………………………….35 10 SERVICE……………………………………………………………………………………………………………..36 �������� �� �������� �� �������� �� �������� �� rev 6.0 with software D2S2V051 4/36 Drivecon Inc. reserves the right to alter or amend the above information without notice. 1 CAUTION -This manual rev6.0 is for XS rev 1.0 with software D2S2V051. -Before starting, read the instructions carefully. -Verify all of the connections are in accordance to the drawings. -Verify the motor supply is connected correctly, faulty connection will destroy the inverter. -Check the device cover is properly installed. -High voltages are present in this device. Switch the power off and after the display turns off, wait 5 minutes before opening the cover. -Insulation resistance test with a megger multimeter requires special precautions. -Do not make any measurements inside the device when it is connected to the main supply. -Do not touch the components on the circuit boards. Electrostatic discharge may cause damage or destroy the IC-circuits. -Check all ventilation holes are clear and unobstructed. -Check that hot air coming from the brake resistors does not cause any danger. -Do not make any inspections unless the supply has been disconnected by the main switch. It is forbidden to use radiophones or portable phones near this device with the doors open. -All the doors and covers must be closed during crane operation. -Drive is not intended to be used in a low-voltage public network, which supplies domestic premises. Radio frequency interference is expected if used in such a network. �������� �� �������� �� �������� �� �������� �� rev 6.0 with software D2S2V051 5/36 Drivecon Inc. reserves the right to alter or amend the above information without notice. 2 GENERAL 2.1 Technical data Power class 4005 4010 4013 4018 4024 4032 4042 4048 Horsepower (Hp) at 460V 3 5 7.5 10 15 20 25 30 Output current In (A) 5.0 10 13 18 24 32 42 48 Max. current 1min (A) 7.6 15 20 27 36 48 63 72 Overloadability 1.5 x In, 1min/10min Max. output voltage Equals to supply voltage Supply Supply voltage 380-500VAC Allowable voltage fluctuation +/- 10% Nominal supply frequency 50/60Hz +/- 5% Signal input levels Digital controls S1, S2, DID3, DID4, DID5: 42 … 240Vac; 15mA Control features Control method Open loop vector control Frequency control range 0 ... 250Hz Frequency command Electronic potentiometer, 2-5-step controller or 0 … 10V analog signal Limit switch functions Slowdown and stop limit inputs for both directions Speed control range sN ... 100% (sN= motor nominal slip) Speed accuracy 1% of nominal speed at speed range 10 ... 100% 1/3 of motor nominal slip at speed below 10% Braking torque 150% Protections Motor overload protection Thermistor or Klixon thermostat based temperature measurement Overload protection Fault is detected if the current momentarily exceeds 280% of RMS rated current Undervoltage / blown fuse Fault is detected if DC voltage drops below 333V Overvoltage protection Fault is detected if DC voltage exceeds 911V Momentary power loss Immediate fault stop Inverter overtemperature Temperature sensor on the heat sink Mechanical brake Circuit breaker (from 4018 upward) Ground fault Provided by electronic circuitry Ambient conditions Ambient temperature -10C ... +50C (14F ... 122F) for 40% Duty Cycle Storage temperature -40C ... +70C (-31F ... 158F) dry Humidity <95%RH (no condensation) Altitude Maximum 1000m at In. Above 1000m: In reduces 1% per each 100m. Above 3000m: consult factory. Vibration Operation: maximum displacement amplitude 3mm at 2-9Hz. Maximum acceleration amplitude 0.5g (5m/s²) at 9-200Hz Conforms to LV and EMC directives. Power class dimensions 4005 4010 4013 4018 4024 4032 4042 4048 H x W x D (Inches) 7.2x3.3x6.8 11.5x5x7.48 15.4x5.6x8.4 20.4x7.6x9.3 �������� �� �������� �� �������� �� �������� �� rev 6.0 with software D2S2V051 6/36 Drivecon Inc. reserves the right to alter or amend the above information without notice. 2.2 Type mark coding Type marking is shown below. Device name 000- Base Drive (430) or Pre-engineered Panel (490,491,492,493) XS Series x- d (Base drive vector), s (open loop vector panel) Supply voltage 4 380 - 500VAC, 50/60Hz Rated Amps 005=5A, 010=10A, 013=13A, 018=18A, 024=24A, 032=32A, 042=42A, 048=48A Panel Motion and Duty Class 00=Base Drive only TC=Traverse class C TD=Traverse class D 000 XSx 4 010 TC 0 Option Control PCB’s 0 Standard 000 XSx 4 010 TC 0 55 0 Software Revision code The latest revision may differ 55 Special 0 None L Varnished boards 0 2.3 Main components The main components are: A1 Inverter F7 Brake supply circuit breaker K7 Brake contactor R1 Braking resistor unit Z1,Z2, Z3 Ferrite rings (Depending on EMC level,options CM1 Filtering capacitors (Depending on EMC level,options X1 Terminals 2.4 Functional description Operation when power is switched on - Stop limit switches S12 & S22 and slow down limit switches S11 & S21 are assumed to be normally closed, as well as the emergency stop button. - The control voltage is supplied to OL10 and ON. The main voltage is connected to inverter power supply and then inverter powers up. - If either of the direction signals S1 or S2 is on and the display shows F6 (see Chapter “Inverter fault codes”), driving can begin only after the fault has been reset and the direction signals have been off more than 0.3s. Normal operation �������� �� �������� �� �������� �� �������� �� rev 6.0 with software D2S2V051 7/36 Drivecon Inc. reserves the right to alter or amend the above information without notice. - For the description of the speed reference setting see Chapter “Control methods”. Travelling starts when switch S1 or S2 closes. Closing the contact ROD1 on A1 energizes K7, which opens the brake. Motor accelerates according to the acceleration ramp settings to the selected speed. - When the switch S1 or S2 opens motor stops according to the deceleration ramp settings and the brake closes. - R1 dissipates the regenerated energy during deceleration periods. The regenerated power from the motor is disapated by the resistor and controlled by the inverter. Other features - Thermistor relay function, which can be supplied as needed. - When the stop limit switch S12 or S22 opens, K7 de-energizes and the mechanical brake stops the motion 2.5 Control methods There are three different control methods (8 control modes) available: 1 EP Electronic potentiometer function. - Stepless control using a 2-step controller. - EP3 stepless control using a 3-step controller. 2 MS Multistep control (up to 5 steps) - Requires programmable digital inputs for speed reference steps 3 AU Automation control for any control device with an output in the range of 0 – 10V - E.g. radio controls, process computers. All control methods are available without any changes in the hardware or software.The control mode of XS is selected by parameter P1.1.11 Input set, which has eight alternative settings: MS2 (stop-limit), MS2/MS3 (slow-limit), EP2 (stop- limit), EP2 (slow-limit), EP3, MS4, MS5 and AU (automation control). (See Chapter 5: parameter descriptions.) The parameter assigns digital inputs S1, S2 and DID3-DID5. It is not possible to change the functions of the inputs separately. Digital inputs DID1 and DID2 are for direction commands, so DID1 = S1, DID2 = S2 in every case. Digital inputs (DID3-DID5) are automatically assigned according to the selected mode. The state of inputs can be checked from parameter V2.3. Control Mode MS2 (stop- lim) MS2 (slow- lim) EP2 (stop- lim) EP2 (slow- lim) EP3 MS4 MS5 AU (Ain1) Parameter P1.1.11 0 1 2 3 4 5 6 7 Signal S1 S1 S1 S1 S1 S1 S1 S1 S1 S2 S2 S2 S2 S2 S2 S2 S2 S2 DID3 MAX MAX AP AP AP MS2 MS2 S11/S21 DID4 S12 S11/S21 S12 S11/S21 HOLD MS3 MS3/MAX S12 DID5 S22 ES S22 ES S11/S21 MAX MS4 S22 S1 Drive command forward S2 Drive command reverse AP Acceleration command HOLD Hold speed command S11 Slowdown limit forward S21 Slowdown limit reverse S12 Stop-limit forward S22 Stop-limit reverse S11/S21 Common slowdown limit MS2 Multistep Frequency2 MS3 Multistep Frequency3 MS4 Multistep Frequency4 MAX Maximum frequency ES External stop Desired speed levels for multi-step control mode are selected with following parameters Speed Parameter Input Speed 1 P1.1.4 S1/S2 Speed 2 P1.1.8 MS 2 Speed 3 (only available in MS4) P1.1.9 MS 3 Speed 4 (only available in MS5) P1.1.10 MS 4 Speed 5 P1.1.5 MAX �������� �� �������� �� �������� �� �������� �� rev 6.0 with software D2S2V051 8/36 Drivecon Inc. reserves the right to alter or amend the above information without notice. 2.6 Description of the control modes 2.6.1 MS2-control c_coms2a A. Pushbutton / controller position B. Speed 0) “decelerate to zero” 1) step 1 “drive minimum speed” 2) step 2 “drive maximum speed” 2.6.2 EP2-control c_coep2a A. Pushbutton / controller position B. Speed 0) “decelerate to zero” 1) while starting “drive minimum speed” while running “hold speed” 2) while running “accelerate” while running at maximum speed “hold speed” 2.6.3 EP3-control c_coep3a A. Pushbutton / controller position B. Speed 0) “decelerate to zero” 1) step 1 “drive minimum speed” 2) step 2 “hold speed” 3) step 3 while running “accelerate” while running at maximum speed “hold speed” �������� �� �������� �� �������� �� �������� �� rev 6.0 with software D2S2V051 9/36 Drivecon Inc. reserves the right to alter or amend the above information without notice. 2.6.4 MS4-control c_coms4b A. Controller position B. Speed 0) “decelerate to zero” 1) step 1 “drive minimum speed” 2) step 2 “drive speed2” 3) step 3 “drive speed3” 4) step 4 “drive maximum speed” 2.6.5 MS5-control c_coms5b A. Controller position B. Speed 0) “decelerate to zero” 1) step 1 “drive minimum speed” 2) step 2 “drive speed2” 3) step 3 “drive speed3” 4) step 4 “drive speed4” 5) step 5 “drive maximum speed” 2.6.6 AU/PO-control S1 S2 c_coms6a A. Reference B. Speed AU control may be used with control device with an output in the range of 0 V – 10 V (for example radio or PLC). PO control may be used with a controller with potentiometer. The operation is as follows: -Driving command S1 or S2 is given separately and means “drive minimum speed” -The speed linearly follows the analog input signal. �������� �� �������� �� �������� �� �������� �� rev 6.0 with software D2S2V051 10/36 Drivecon Inc. reserves the right to alter or amend the above information without notice. 2.7 Slowdown-limit Operation The slowdown function is available in MS2- (slow-lim), EP2- (slow-lim), EP3- and AU-control modes. It can reduce maximum frequency at the both ends of the crane runway. When the function is active, the reference slowdown frequency is set automatically by parameter P1.1.8 “Multistep freq2/Slowdown”. The action in slowdown-limit area depends on parameter P1.5.1 “Slowdown Mode” settings. The description on “Slowdown Mode” selections is shown as follows: Parameter value Action 0 = Slow When the limit switch circuit is opened, the maximum speed is limited in both directions until the limit switch circuit is closed. 1 = Fast When the limit switch circuit is opened during running the slowdown function is activated and the maximum speed is limited in the present running direction. If the limit switch circuit is open when power is turned on, the maximum speed is limited in both directions until the limit switch circuit is closed. 2 = Fast power up When the limit switch circuit is opened during running the slowdown function is activated and the maximum speed is limited in the present running direction. When power is turned off, the limit switch status is saved in EEPROM. When power is turned back on and limit switch circuit is open, driving is allowed the maximum speed in opposite direction. 2.8 Stop-limit operation Stop-limit function is available in MS2- (stop-lim), EP2- (stop-lim), and AU-control modes. Normally these inputs (S12 and S22) are "high" (limit switch closed, voltage present in the input). When either of these signals goes “down” (no voltage in the input), the motion is stopped by switching the motor current off immediately and by opening the relay contact ROD1 (mechanical brake closes). Restart may occur only after one second. Restart is only allowed to the direction opposite to the stop-limit switch circuit being off. If both of these inputs are off restart is not permitted. Restart may be initiated only by a run command changing from off to on (= before restart both run commands must be off after the one-second time has passed). 2.9 Mechanical brake control XS panels have a brake contactor to control electromechanical disk brake of the traveling motor. When there is no voltage present, the brake is closed and is kept closed by spring force. The brake is controlled so that during starting the motor generates torque first and after that the brake is opened. The same applies for stopping; while the brake is being closed, the motor still generates torque. During a direction change, the brake is kept held open. The inverter decelerates the motor to a stop according to the set deceleration time when the run command is switched off; so the brake is used only as a holding brake. This way brake wear is minimized. Only if a failure occurs, the emergency stop button is pushed, or a stop limit is triped will cause the brake to close immeadiately which stops the motor. �������� �� �������� �� �������� �� �������� �� rev 6.0 with software D2S2V051 11/36 Drivecon Inc. reserves the right to alter or amend the above information without notice. 2.10 EMC The abbreviated "EMC" stands for the Electromagnetic Compatibility. According to the European EMC directive "the apparatus shall be so constructed that: The electromagnetic disturbance it generates does not exceed a level allowing other apparatus to operate as intended The apparatus has an adequate level of intrinsic immuni