Danfoss VLT 5000 Crane Series User manual

VLT®5000 Crane
Rev. 2004-03-29
www.danfoss.com/drives
175R0259 MG50N402 *MG50N402*
MG50N402
VLT®5000 Crane Operating Instructions
Operating Instructions

VLT® 5000 Crane
■Contents
Introduction ......................................................................................................... 3
Safety ....................................................................................................................... 4
General Instructions ................................................................................................. 5
Abbreviations and Definitions .................................................................................... 6
Brief Product Description .......................................................................................... 9
Function and System Description ............................................................................. 9
Key Diagram for VLT 5000 Crane 5042, 5102 400-500 V ....................................... 14
Key Diagram for VLT 5000 Crane 5122-5202 400-500 V ....................................... 15
Technical Data .................................................................................................. 16
General Technical Data ........................................................................................... 16
Mains Supply 400 - 500 V ...................................................................................... 20
Mains supply 3 x 400 - 500 V ................................................................................. 20
Fuses ..................................................................................................................... 22
Mechanical Dimensions .......................................................................................... 23
Installation ......................................................................................................... 24
General Warning before Installation ........................................................................ 24
Mechanical Installation ........................................................................................... 24
Installation of VLT 5042–5062 400-500 V Compact IP20/IP00 ............................... 24
Installation of VLT 5072-5202 400-500 V Compact IP20/IP00 ................................ 25
Electrical Installation ............................................................................................... 26
RFI switch .............................................................................................................. 33
LCP - Local Control Panel .......................................................................... 36
Control Panel ......................................................................................................... 36
Display ................................................................................................................... 37
Parameter programming ........................................................................................ 39
Programming .................................................................................................... 42
General Advice on Programming ............................................................................ 42
Operation & Display ................................................................................................ 50
Load and Motor ..................................................................................................... 54
References & Limits ................................................................................................ 58
Inputs & Outputs .................................................................................................... 61
Application Functions ............................................................................................. 68
Service Functions ................................................................................................... 70
Crane Functions ..................................................................................................... 74
Serial communication .................................................................................. 80
Factory Settings ..................................................................................................... 81
Defined Parameters ................................................................................................ 85
All About VLT 5000 Crane .......................................................................... 86
Status Messages .................................................................................................... 86
List of Warnings and Alarms ................................................................................... 87
Warnings ................................................................................................................ 87
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VLT® 5000 Crane
Appendix ............................................................................................................. 92
Trouble-shooting .................................................................................................... 92
Derating for air pressure ......................................................................................... 94
Efficiency .............................................................................................................. 113
General aspects of EMC emissions ...................................................................... 114
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2

VLT® 5000 Crane
Introduction
175ZA522.12
VLT 5000 Crane
Operating instructions
Software version: 20.3x
These operating instructions can be used for VLT 5000
Crane frequency converters with software version 20.3x.
See software version number in parameter 624.
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VLT® 5000 Crane
■Safety
The voltage of the frequency converter
is dangerous whenever the equipment is
connected to mains. Incorrect installation
of the motor or the frequency converter may cause
damage to the equipment, serious personal injury
or death. Consequently, the instructions in this
manual, as well as national and local rules and safety
regulations, must be complied with
■Safety Regulations
1. The frequency converter must be disconnected
from mains if repair work is to be carried out. Check
that the mains supply has been disconnected
and that the necessary time has passed before
removing motor and mains plugs.
2. The [STOP/RESET] key on the control panel of
the frequency converter does not disconnect
the equipment from mains and is thus not to
be used as a safety switch.
3. Correct protective earthing of the equipment
must be established, the user must be protected
against supply voltage, and the motor must be
protected against overload in accordance with
applicable national and local regulations.
4. The earth leakage currents are higher than 3.5 mA.
5. Protection against motor overload is not included
in the factory setting. If this function is desired,
set parameter 128 to data value ETR trip or
data value ETR warning.
Note: The function is initialised at 1.16 x rated
motor current and rated motor frequency. For
the North American market: The ETR functions
provide class 20 motor overload protection
in accordance with NEC.
6. Do not remove the plugs for the motor and mains
supply while the frequency converter is connected
to mains. Check that the mains supply has been
disconnected and that the necessary time has
passed before removing motor and mains plugs.
7. Please note that the frequency converter has more
voltage inputs than L1, L2 and L3, when loadsharing
terminals (linking of DC intermediate circuit) and
external 24 V DC have been installed. Check
that all voltage inputs have been disconnected
and that the necessary time has passed before
repair work is commenced.
■Warning Against Unintended Start
1. The motor can be brought to a stop by means
of digital commands, bus commands, references
or a local stop, while the frequency converter
is connected to mains. If personal safety
considerations make it necessary to ensure
that no unintended start occurs, these stop
functions are not sufficient.
2. While parameters are being changed, the
motor may start. Consequently, the stop key
[STOP/RESET] must always be activated, following
which data can be modified.
3. A motor that has been stopped may start if faults
occur in the electronics of the frequency converter,
or if a temporary overload or a fault in the supply
mains or the motor connection ceases.
4. Immediate stop. Direct stop input (term. 37). When
contact is open, the drive will stop (coast).
175ZA523.11
Warning:
Touching the electrical parts may be fatal - even after the
equipment has been disconnected from mains.
Also make sure that other voltage inputs have been
disconnected, such as external 24 V DC, load-sharing (linkage of
DC intermediate circuit), as well as the motor connection for
kinetic back-up.
Using VLT 5042-5062: wait at least 15 minutes.
Using VLT 5072-5202: wait at least 20 minutes.
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4

VLT® 5000 Crane
Introduction
■General Instructions
These Operating Instructions are intended for
persons who are to install, operate and program
the VLT 5000 Crane.
They comprise the specific technical publications on
the VLT 5000 Crane and are delivered with the product.
When reading these Operating Instructions you come across different symbols that require special attention:
The symbols used are the following:
Indicates a general warning
Indicates a high-voltage warning
NB!:
Indicates something to be noted by the reader
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VLT® 5000 Crane
■Abbreviations and Definitions
■Frequency converter
Abbreviation/Definition Description
IVLT,MAX The maximum output current
IVLT,N The rated output current supplied by the frequency converter
UVLT,MAX The maximum output voltage
■Output
Abbreviation/Definition Description
IMThe current transmitted to the motor
UMThe voltage transmitted to the motor
fMThe frequency transmitted to the motor
Break-away torque
ηVLT The efficiency of the frequency converter is defined as the ratio between the
power output and power input
■NO/NC
Abbreviation/Definition Description
NO Normally open
NC Normally closed
■Input
Abbreviation/Definition Description
Control command
Immediate stop
Stop command
By means of LCP and the digital inputs, it is possible to start and stop the
connected motor.
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6

VLT® 5000 Crane
Introduction
■Motor
Abbreviation/Definition Description
IM,N The rated motor current (nameplate data)
fM,N The rated motor frequency (nameplate data)
UM,N The rated motor voltage (nameplate data)
PM,N The rated power delivered by the motor (nameplate data)
nM,N The rated motor speed (nameplate data)
TM,N The rated torque (motor)
■References
Abbreviation/Definition Description
Analogue ref. A signal transmitted to input 53, 54 or 60. Can be voltage or current
Binary ref. A signal transmitted to the serial communication port
RefMAX The maximum value which the reference signal may have. Set in parameter 205
■Miscellaneous
Abbreviation/Definition Description
ELCB Earth Leakage Circuit Breaker
Trip A state which occurs in different situations, eg. if the frequency converter is subject to a live zero warning.
A trip can be cancelled by pressing Reset
Trip locked A state which occurs in different situations, eg. if the frequency converter is subject to an overtemperature.
A locked trip can be cancelled by cutting off mains and restarting the frequency converter and pressing
Reset
Initializing If initializing is carried out (see parameter 620), the frequency converter returns to the factory setting
LCP The Local Control Panel, which makes up a complete interface for control and programming of VLT 5000
Crane. The control panel is detachable and may, as an alternative, be installed up to 3 metres away from
the frequency converter, ie. in a front panel, by means of the installation kit option
Flux Vector If compared with standard voltage/frequency ratio control, Flux Vector improves the dynamics and the
stability, both when the speed reference is changed and in relation to the load torque
Thermistor A temperature-dependent resistor placed where the temperature is to be monitored (frequency converter
or motor)
Analogue inputs The analogue inputs can be used for controlling various functions of the frequency converter. There are
two types of analogue inputs:
Current input and voltage input
Analogue outputs There are two analogue current outputs
Digital inputs The digital inputs can be used for controlling various functions of the frequency converter
Digital outputs There are four digital outputs, two of which activate relay switches.
Brake resistor The brake resistor is a module capable of absorbing the brake power that is generated in regenerative
braking. This regenerative braking power increases the intermediate circuit voltage and a brake chopper
ensures that the power is transmitted to the brake resistor
Incremental encoder An external, digital pulse transmitter used for feeding back information on motor speed. The encoder is
used in applications where high accuracy in speed control is required
AWG Means American Wire Gauge, ie. the American measuring unit for cable cross-section
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VLT® 5000 Crane
■Miscellaneous- continued
Abbreviations/Definitions Description
Manual initialisation Press the [CHANGE DATA] + [MENU] + [OK] keys at the same time to carry out
manual initialisation. See also Parameter 620.
Note that manual initialisation is only to be used if the reset function does not work!
SFAVM Switching pattern called Stator Flux oriented Asynchronous Vector Modulation
On-line/off-line parameters On-line parameters are activated immediately after the data value is changed.
Off-line parameters are not activated until OK has been entered on the control unit
CT characteristics Constant torque characteristics, used for all applications, such as conveyor belts
and cranes.
MCM Stands for Mille Circular Mil, an American measuring unit for cable cross-section
1 MCM=0.5067mm2
ETR Electronic thermal relay is a thermal load calculation based on present load and
time. Its purpose is to estimate the motor temperature
CP Constant power
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8

VLT® 5000 Crane
Introduction
■Brief Product Description
The VLT 5000 Crane frequency converter supplies
a motor with variable voltage and frequency and
thereby enables infinitely variable speed control of
three-phased standard AC-motors.
The VLT 5000 Crane features the Flux Vector
control system.
The VLT 5000 Crane uses a digital technique
making it possible to program the different control
inputs and signal outputs.
The user can easily program the desired functions
by means of the VLT 5000 Crane control panel or
the user interfaces RS485 and RS232.
The VLT 5000 Crane is protected against the transients
occurring in the mains supply. Furthermore, a
good power factor and low peak current, reducing
the load on the mains installation, are ensured
through intermediate circuit coils.
Current measurement on all three motor phases
perfectly protects VLT 5000 Crane against earthing and
short-circuiting faults on the motor connenction.
Efficient monitoring of the mains supply phases
ensures that the unit stops in case of phase failure.
This eliminates the risk of overloading the inverter and
the capacitors in the intermediate circuit and thereby
prolongs the service life of the frequency converter.
As standard, VLT 5000 Crane features integral
thermal protection. If a situation of thermal overload
occurs, this function cuts out the inverter.
The VLT 5000 Crane features reliable galvanic isolation
on all control terminals and integrated electronic
thermal protection on the motor.
■Function and System Description
With VLT 5000 Crane the speed is infinitely varied in the
whole speed range from standstill (0 RPM) until rated
speed (750 RPM for VLT 5052-5072, 1125 RPM for
VLT 5102) according to the CT characteristic and rated
power up to max. speed (3000 or 4500 RPM).
There is full torque in the whole speed range.
VLT 5000 Crane offers:
•Full utilisation of control range
•130% torque for acceleration
•Fine adjustment at standstill + full load possible
without activating the system brake
■System Description
The sketch on next page shows how a tower crane
works together with VLT Crane Control.
The system consists of the following:
1. VLT 5000 Flux Vector Control
2. Brake resistor
3. Motor
4. Cable drum
5. Angular gear box
6. NC system brake
7. Electric 2-step-gears: Normal load and heavy load
8. Optical encoder: Motor speed information for
flux vector control with closed loop
9. Load signals: VLT 5000 Crane checks on the basis of
load signals that the working range is not exceeded
10. Control signal: Analogue reference as well as
hoist, lowering and position operation
11. Quick stop with brake
12. Digital outputs: For combination of warning
and alarm at your operation
13. Crane ready signal
14. Gear step selection signal
15. VLT ready signal
16. RS 485 bus
17. RS 232 bus
18. Local control panel
Installation and mains connection of brake resistor
and motor are described in Electrical installation
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