ZIEHL-ABEGG ZETADYN 1DV Series User guide

ZETADYN 1DV
Control System for Elevators,
High-bay Storage and Retrieval
Systems, Cranes and Conveyors
System Description ASK8.T-E0197
ZIEHL-ABEGG
ZETADYN 1DV
P
ZETADYN 1DV
ZIEHL-ABEGG

http://www.bzxindaxin.com http://www.gk-world.com
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http://www.bzxindaxin.com http://www.gk-world.com

http://www.bzxindaxin.com http://www.gk-world.com

http://www.bzxindaxin.com http://www.gk-world.com

INTRODUCTION
The following equipment is described in this documentation:
Controller Series ZETADYN 1DV
from Serial No. 39432xxxxx/xxxx
with control software as from version 3.02
It contains important information on
•Controller construction
•Connections
•Operation
•Control
•Commissioning
•Service
of the ZETADYN 1DV controller.
The Appendix contains suggested a wiring diagram and a setting data card.
The information contained within this documentation describes the features of our products
without guaranteeing the operation. We reserve the right to introduce changes without notice.
It is particularly important that you observe the following for your own safety:
Information on safe operation of the equipment.
Important information

Safety information
The electrical equipment and machines
described in this documentation are designed
for use in industrial heavy current systems. They
have parts which move or rotate and carry
dangerous voltages during operation. Therefore,
danger to health and property may be created if
the necessary guards of safety covers are
removed where this should not be done or if the
necessary maintenance work is neglected.
Consequently, those responsible for the safety
of the equipment must observe the following
rules:
- Only suitably qualified personnel* may be
entrusted with any work which needs to be
done on this equipment and machinery.
- Personnel working on this equipment and
machinery must have access to the operating
instructions and all product documentation
supplied and must observe the relevant
instructions contained therein.
- Unskilled personnel must not be allowed to
work on this equipment and machinery or in
the vicinity of it.
(*Definitions as in VDE 105 or IEC 364)
These safety instructions are not claimed to
cover all aspects of safety.
Notes
The information on processes and sections of
the circuitry contained in this documentation
must be regarded as such without further
implications. Their adaptation to other
applications must be investigated; ZIEHL-
ABEGG does not guarantee their suitability in
such circumstances.
The assemblies comprise components which
may be electro-statically endangered. The body
of the person touching them must first be
electrically neutralized, for example by first
touching a conductive, earthed object (e.g.
bright metal parts of an electrical cabinet or
earthing contact of a plug socket).
Written out as:
All settings at the unit are carried out with the
help of parameters grouped in menus.
Example: The running speed is determined
by the Parameter V_3 in the
TRAVELLING menu.
Written out as: /TRAVELLING/ V_3.
During electrical installation the following rules have to be observed:
VDE 0100 - Bestimmung für das Errichten von Starkstromanlagen mit Nennspannung bis 1000V
VDE 0113 (EN 60204) - Bestimmung für die elektrische Ausrüstung von Be- und Verarbeitungs-
maschinen.
VDE 0160 - Ausrüstung von Starkstromanlagen mit elektrischen Betriebsmitteln.
In special applications additional rules or directions must be observed.

ZETADYN 1DV System Description
Contents Page
0. Introduction
1. ZETADYN 1DV system information - Summary..............................................6
1.1 Applications ........................................................................................................6
1.2 Functions and features .......................................................................................6
1.3 Requirements......................................................................................................8
2. Mounting............................................................................................................9
2.1 Construction .......................................................................................................9
2.2 Installing the controller ........................................................................................ 9
2.3 Connecting and occupation of terminals ........................................................... 10
2.3.1 Mains .................................................................................................... 10
2.3.2 Motor ..................................................................................................... 11
2.3.3 Control inputs ........................................................................................ 12
2.3.4 Control outputs ...................................................................................... 13
3. Control and controller functions ...................................................................14
3.1 Controlling of ZETADYN 1DV ........................................................................... 15
3.2 Description of controller functions...................................................................... 16
3.2.1 Switching ON and OFF ......................................................................... 16
3.2.2 Start and accelaration ........................................................................... 16
3.2.3 Distance-controlled deceleration - Arch travel........................................17
3.2.4 Time based deceleration ....................................................................... 18
3.2.5 Distance-corrected deceleration ............................................................ 18
3.2.6 Normal slow down.................................................................................. 19
3.2.7 Quick stop.............................................................................................. 19
3.2.8 Readjustment ........................................................................................ 20
3.2.9 Direction reversal .................................................................................. 20
3.2.10 Short travel............................................................................................. 21
3.2.11 Troubles................................................................................................. 22
3.3 To ensure safe operation of the controller ........................................................ 23
4. Operation and settings...................................................................................24
4.1 Operating through keyboard and LCD display .................................................. 24
4.2 Remote operation with PC and ZETAMON software ........................................ 26
4.3 Summary of parameters ................................................................................... 27
4.3.1 The menu "Monitor" ..............................................................................28
4.3.2 The menu "Distances & Times" ............................................................. 29
4.3.3 The menu "Statistic" .............................................................................. 30
4.3.4 The menu "Travelling" ........................................................................... 31
4.3.5 The menu "Accelerating"........................................................................ 32
4.3.6 The menu "Decelerating" ....................................................................... 33
4.3.7 The menu "Controller" ........................................................................... 33
4.3.8 The menu "Operating" ........................................................................... 34
4.3.9 The menu "Installation".......................................................................... 35
4.3.10 The menu "Interfaces" ........................................................................... 37
4.3.11 The menu "ZA-Intern" ...........................................................................38

Contents Page
5. Commissioning...............................................................................................39
5.1 Requirements ................................................................................................... 39
5.2 Quick setup for mounting travels.......................................................................40
5.3 Setting of the "Switch off contacts" in the shaft.................................................. 41
5.4 Adjustment ........................................................................................................ 42
5.5 Final of setting up ............................................................................................. 44
6. Service .............................................................................................................45
6.1 Maintenance ..................................................................................................... 45
6.2 Troubleshooting ................................................................................................ 45
6.3 Repair................................................................................................................ 45
see appendix A9
APPENDIX:
A1 Technical data
A2 Denotation of controller types
A3 Dimension sheet
A4 Errorlist
A5 Error tracing plan
A6 Accessories
A7 Changes and new functions
A8 Schematic diagram
A9 HOTLINE-NOTIC
A10 Setting data card

6 System information ZETADYN 1DV
1. ZETADYN 1DV System Information - Summary
1.1 Applications
ZETADYN 1DV controllers are designed for up to 33 KW drives (motor rated current 90A) where high
positioning accuracy is required.
They are mainly used in •Passenger and goods lifts
•High-bay storage and retrieval systems
•Cranes and material handling plants.
ZIEHL-ABEGG supplies complete AC drives with asynchronous motors, digital encoders
and ZETADYN 1DV controllers.
1.2 Functions and features
A microprocessor controls the drive in accordance with the time and distance related programs selected
by main control system. Fully digital 4-quadrant motor speed control is accomplished by lowering the
voltage at constant frequency. The whole drive cycle is controlled from start to stop.
Features of the digital ZIEHL-ABEGG drive control system:
•accurate control response with good dynamics and a high positioning accuracy
•simple to commission and operate
•comprehensive diagnostic system and data protection functions
•high level of safety achieved by multiple monitoring systems
•in case of maintenance, replacement of the device without new adjustment of the control device
Figure 1.1 Schematic ZETADYN 1DV
Mains
PLC &
Software
Inputs
Outputs
Power supply
Power stage
Revolution
counter
temperature
Motor
controlling
Terminal
Zetadyn 1DV
Interface
RS232C
ZETAMON
P↓↑
ZIEHL-ABEGG
ZETADYN 1DV


Microprocessor

System information ZETADYN 1DV 7
The logic design allows the equipment to be easily adapted to various applications.
1. Controls
The superior control system communicates with
the controller through floating inputs and
outputs. Time and distance related control
programs are selected by activating optically
coupled inputs. The operating condition of the
drive is continually signalled back to the controls
through floating relay outputs.
2. Parameterizing
Commissioning, service and documentation are
supported by digital computer technique:
speeds, accelerations and other parameters
specific to the system can be entered through
text dialogue by using the integral display and
operating unit. A password protects the system
against misadjustments. It is also possible to
parameterize through a PC or the ZETAMON
software with user guide, which is available as
one of the accessories.
3. Regulation
All programs are run at regulated speeds and
independent of the load. The regulating control
system can be used for speeds up to 3.5 m/s.
The regulating range up to 1:100 allows a high
degree of positioning accuracy.
4. Drive
A high degree of stability of a drive at low load
torques can only be achieved by continuous
transition of drive and braking conditions.
ZIEHL-ABEGG asynchronous motors for
variable drives have two electrically separated
windings.
The AC winding produces the drive torque
and the DC winding the braking torque.
Figure 1.2 Torque generation
Both windings in the motor are activated
separately, a three-phase thyristor speed
controller feeds the AC winding, a semi-
controlled DC bridge the DC winding (see Figure
1.3).
Figure 1.3 Schematic diagram control circuit
This ensures perfect running response in all load
situations.
No brake wear occurs in control operation up to
STOP. The drive operates very quietly.
n
drive
brake
M
Zetadyn 1DV
M
3
TB
TB
Digital
4-Q-
speed
controller
PLC
brake
drive
Encoder
set point
generator

8 System information ZETADYN 1DV
1.3 Requirements
Ziehl-Abegg provides you with an optimally tuned D.C. drive with asynchronous motor, digital speed
transmitter and controller ZETADYN 1DV.
If you only purchase the controller - for example when retrofitting an old installation - please observe the
following.
Motorselection:
Suitable devices are all pole-changing elevator
motors having a pole ratio of 4/16.
Pole pair ratios of 4/24 and 6/24 are partly
suitable. For these motors, the course of the
characteristic line for the d.c. injection brake
(low-speed winding) in the range of speed 0 is a
bit more unfavourable and there can be a small
stopping jerk in the direction "EMPTY UP".
Additional balance weights are to be removed, if
necessary. An existing massive handwheel
should be exchanged against a plastic
handwheel. Besides the energy saving,
additional reserves are liberated for the speed
regulation.
Prior to the retrofitting (projecting phase) it is
necessary to check whether the motor works
properly in the pole-changing areas in all
operating states. The motor as well as the gear
have to work calm, i.e. without out-of-balance
and clearance. Mechanical weaknesses cannot
be improved by a control but can possibly make
a controlled operation impossible.
Controllerselection:
The rated current of the controller has to be
higher or equal to the rated current of the high-
speed motor winding.
Installation of a encoder:
Provided that no sleeve shaft encoder (e.g.
Ziehl-Abegg -ET3R-1024) can be installed, there
are three possibilities:
1. Installation of a encoder linked to the motor
shaft by means of a toothed belt.
Documentation: LEM6.06.385 and
LEM6.06.815. "Installation of an encoder
G58H-1024"
2. In case of gauges provided for the
installation of an analog tacho with Euro-
flange, it is possible to use an incremental
encoder of the same construction
G71-xx/30. The tacho can be supplied with
a shaft diameter (XX) of 07 and 11 mm.
3. It is also possible to install an incremental
encoder direct to same gears.
Note:
In case of own constructions, you have to pay
attention to the fact that the encoder is mounted
to the motor (gear) without any clearance,
without any axial offset and solid as to the
mechanical link.
Preferably you have to choose an encoder with
a resolution of 1024 increments/track.
ZIEHL-ABEGG can be asked for documentation
concerning the connection possibilities of
encoders of external manufacturers.

Mounting 9
2. Mounting
2.1 Construction
ZETADYN 1DV controllers are designed for easy operation and maintenance. They are built to safety
standard IP 00 and fulfil the requirements of VBG 4.
The controller consists of the following components
- shell
- power section
- controller circuit board
- terminal.
The control unit with a two-line illuminated LCD display, p.b. panel and the RS 232 C interface are flush-
fitted in the front panel.
All connection terminals are not covered so that it is not necessary to remove the front plate.
Figure 2.1 Controller ZETADYN 1DV
2.2 Installing the controller
For the ambiance of the device, the conditions mentioned in appendix A1 "Technical Data" are valid.
Mount the controller in switchgear cabinets vertically with the terminals at the bottom.
-> Dimensions of the controller: see Appendix A3.
It is essential to provide adequate air cooling! The minimum distances shown in Appendix A3
must not be reduced.
ZIEHL-ABEGG
ZETADYN 1DV
P
ZETADYN 1DV
ZIEHL-ABEGG

10 Mounting
2.3 Connecting and occupation of terminals
The controller must be connected up in accordance with the wiring diagram (see Appendix A8)
Control cables must be separated from power cables. All controller inputs and outputs are floating,
suitable for relay controls or memory programmable controls and carried through screw terminal
connections.
When connecting the control device, please observe the technical data (appendix A1).
The controller ZETADYN 1DV corresponds to the safety class 1, of the DIN VDE 0558, Teil 1,
Pkt.5.4.3.1.1.
2.3.1 Mains
Prior to the connection of the supply voltage, you have to check whether the indications made on
the identification plate of the control device are the same as those of the necessary connection
values.
The current supply is to be connected according to figure 2.2:
"PE-L1-L2-L3" Connection of the supply voltage of the power stage
The system can be protected (F1-3) by means of slow-acting fuses to suit the rated
current.
"L1-L2-L3" Connection of the supply voltage of the controller board
As power safety, time-lag fuses (F4-6, rated current > 1A) are to be used.
"11-12" Connection of the cooling fan
Voltage: AC 230V, 50/60 Hz.
In case of devices starting with a rated current of 80A, an additional fan for cooling the
power stage is incorporated. The fan is switched by means of an integrated thermal
contact. Use a slow-acting fuse (rated current >1A) for protection. In case of devices
with a rated voltage of 400V, the fuse protection can be effected by one of the fuses
F4-F6.
Figure 2.2 Connection of the voltage supply
The employment of an interference filter is disregarded.
See figure A8 / schematic diagram and also A6 / accessories.
The controller circuit board must be connected in the same phase sequence as the power
section! Connection must be made in front of the main contactor "KO".
power stage
controller board
1
3
5
2
4
6
main contactor
K0
F1
F2
F3
L3
L2
L1
PE
N
L3
L2
L1
F4 F5 F6
M
1fan (only
1DV80 &1DV90)
11
12
ZETADYN 1DV
mains
T
.
L3
L2
L1
1
3
5
2
4
6
K0´

Mounting 11
2.3.2 Motor
Connect terminals on the control unit and the ZIEHL-ABEGG motor with the same coding (see figure 2.3).
"U1-V1-W1" AC winding
AC winding in the motor terminal box is marked "2U1-2V1-2W1".
"F1-F2" DC winding
"ET1-ET5" Encoder
Connection of the ZIEHL-ABEGG-encoder. Use a five-core, screened cable. The
correct connection of the monitor has to be ensured.
"MB1-MB2" Spring-loaded safety brake
This exit switches the spring-loaded safety brake by means of an external contactor
relay K*.
In order to achieve an optimum start-up and positioning reaction, the control
has to open and close the brake without delay via this contact.
"P1-P2" PTC thermistor
Connecting PTC thermistor in accordance with DIN 44 081, for monitoring the motor
temperature. If the monitoring is not to be effected via the control device, a jumper has
to be installed between these two terminals.
The maximum
permissible test voltage for the
PTC thermistor is 2.5V. Take
care when using electrical
continuity testing equipment.
Figure 2.3 Connection of motor,
encoder and brake.
brown
green
white
brown
green
white
yellow
grey
pink
V1
ET
GU5
GU6
GU7
ET1
ET2
ET3
ET4
a
bU
varistor
motor windings
1U1 1U2
1V2
1W2
2V1
1V1
1W1
F2
F1
PTC
P2
P1
9U1
9U2
M
1
fan
ET1ET2ET3ET4ET5 MB1
5
F2
F1
rectifier
K*
K*
P2
P1
L1
N
power stage
controller board
ET5
ET6
+
-
U1 2U1
W1 2W1
ZETADYN 1DV MOTOR
encoder
thermistor
brake
MB2
.
K*

12 Mounting
2.3.3 Control inputs
The inputs are coupled optically.
For selecting the inputs there are two possibilities (figure 2.4):
a) By means of a potential-free contact, the higher
control links the terminal of the control voltage
"U0" to the corresponding input.
b) The higher control feeds an external voltage of
+24V to the input. The terminal "GND" serves as
reference potential.
Figure 2.4 Triggering possibilities
Control inputs:
"GND" Reference potential
"U0" Control voltage
DC output of approx. 21V for activating the inputs.
"RF" Controller release
The input "RF" has to be triggered during running.
"V1" Positioning speed
"V2" Intermediate speed
"V3" Travel speed
"VZ" Readjustment speed
"ZE1" Additional speed V_ZE1
"ZE2" Additional speed V_ZE2
"ZE3" Additional speed V_ZE3
These inputs are provided for triggering various functions in the controller. The adjustment is
effected in the menu /INTERFACES. The additional speeds V_ZE1, V_ZE2 and V_ZE3 of the
same name are selected by the manufacturer.
Preferably these speeds are to be used for inspection run and restoring control.
"RV1" Predirection 1 UP
"RV2" Predirection 2 DOWN
If the controller is connected up as suggested in circuits A8 (in the Appendix), the motor will run
(with works setting) anti-clockwise when the "RV1" input is activated and clockwise when the
"RV2" input is activated (viewed from the drive end of the shaft).
a)
RV1VZV3
V2
RFU0GND V1 RV2 ZE1 ZE2 ZE3
b)
RV1VZV3
V2
RFU0GND V1 RV2 ZE1 ZE2 ZE3
GND
+24V

Mounting 13
2.3.4 Control outputs
The relay outputs are in the form of floating change-over contacts or NO contacts.
The special contacts "SK1"-"SK3" can be programmed in the menu /INTERFACES in another way than in
the factory setting and can be assigned with other functions.
In this menu, it is also possible to invert the function of "RB".
"ST"- Fault
Contact ST1-ST2 is closed when no failure occurs.
"SK1"- Special contact 1
Contact K11-K12 is closed when the speed is higher than 0.3 m/s.
"SK2"- Special contact 2
Contact K21-K22 is closed when the rated speed is exceeded by 10%.
"SK3"- Special contact 3
Contact K34-K31 is open when the motor temperature control triggers off.
"RB"- Controller active
When closing the contact RB1-RB2, the control is to switch the main contactor K0 without
delay.
"MB"- Spring-loaded safety brake
When closing the contact MB1-MB2, the control is to switch the spring-loaded safety brake
without delay.
Figure 2.5 Control outputs
ST1 ST2 K14 K11 K12 K24 K21 K22 RB1 RB2 MB1 K34MB2
Fault special contact 1 special contact 2 controller active
(main contactor control) brake special contact 3 (V > 0.3 m/s) (V > 1.1* V_NENN) (mot. temp. control)
ST SK1 SK2 RB MB SK3
K31

14 Control and controller functions
3. Control and controller functions
The functional equipment of the controller ZETADYN 1DV makes it possible to adapt to the various
applications. In the following, we give a short description of the factory presetting.
3.1 gives a general description of the control of the controller.
3.2 gives a detailed description of specific functions of the device.
Table: factory presetting
Normal running mode:
Run at high running speed "V3" and positioning run at "V1"
Run at intermediate speed "V2" and positioning run at "V1"
In both cases, the decelerating distance is driven depending on the path, i.e. when the driving
command "V3" or "V2" respectively is switched off, it is always the same decelerating distance
that is travelled independent from the actual speed achieved at the moment (arch travel).
Readjustment:
Readjustment possibility with speed "VZ".
Manual and service operation:
In addition, three speeds "V_ZE1", "V_ZE2" and "V_ZE3" are available which are not regulated
depending on the path.
Output: Controller active - "RB"
With the output "RB" the control device switches the main contactor to the currentless state.
Output: Mechanical brake - "MB"
With the output "MB" the control device switches the mechanical stopping brake.
Monitoring functions:
Checking the input speed (0.3m/s) by means of output "SK1".
Checking of the maximum speed by means of output "SK2".
Checking of the motor temperature by means of output "SK3".
Fault message:
The control device indicates a fault at the output "ST".
The following functions are monitored:
- power outage
- cyclic change
- heat sink excess temperature
- motor temperature
- encoder breakage
- start-up monitoring
- parameterization
- deceleration monitoring
Additional functions:
The inputs "ZE1", "ZE2" and "ZE3" as well as the outputs "SK1", "SK2" and "SK3" can be programmed
with special functions in another way than in the factory setting.
Examples: •Changing over between two completely separated parameter sets.
•Switching off the forced air cooling of the motor with the function of the after-running time-
relay.
•Switch output for the monitoring of a freely adjustable speed limit.

Control and controller functions 15
3.1 Controlling of ZETADYN 1DV
Figure 3.1 shows control of a simple travel between two stops, referred to as NORMAL TRAVEL. Please
observe that the wiring plan shown in appendix A8 is met by the control.
Figure 3.1 Normal travel
(1) The higher control sets the direction of
motion for the inputs "RV1/RV2" and
triggers the inputs for the running speed (in
this case "V1" and "V3"). The "controller
release -RF" can already be fed. It is also
possible to connect it only when the
direction and the speed are fed.
By means of the output "Controller active -
RB" the control device indicates that the
input signals have been accepted and that
it is ready for a new run. When switching
"RB" the main contactor K0 has to be
closed.
When switching the output "Mechanical
brake -MB" the control of the brake has to
open immediately and without delay.
(2) The drive accelerates until the preset speed
is reached.
(3) A travel at a constant speed follows, until
the activation of the travel speed ("V3") is
cancelled.
(4) The drive decelerates to the positioning
speed "V_1".
(5) After a short distance covered, the
positioning speed is switched off.
(6) The drive continues to decelerate.
(7) The control device disconnects the output
"MB". The control is to close the brake
without delay.
(8) The main contactor "K0" has to be switched
on until the contactor "RB" is switched off.
The spring-loaded safety brake is to be switched on and off by means of the relay "MB".
This is the only guarantee that the control device is able to control start-up and stopping
without jerk.
The main contactor "K0" is to be switched on and off by means of the relay "RB". This is the
only guarantee that the main contactor is switched in the currentless state and enables start-
up and stopping without jerk.
In case of trouble, i.e. when the relay "ST" is released, the control has to make sure that the
mechanical brake and the main contactor are immediately switched off.
V
t
RF
V1
V3
RV1
MB
inputs
outputs
56 78
4321
RV2
V1
V3
RB
normal slow down
const. speed
deceleration
const. speed
acceleration
start