SOLUTION

Hoist appliction
Kinda frequency inverter applied in hoist applications


1, Features of traditonal system
(1) The traditional system works at heavy load for long time, forward and reverse run frequently, the lifetime of the
      system is short;

(2) High failure ratio.
(3) Low efficiency, the power factor is less than 0.8.
(4) The safety performance is bad.

.
2,  Requests for frequency inverters (VFD)
(1) Big output torque at low frequency, it should run smoothly during working.

(2) Big overload capacity.
(3) Less failure ratio, run stably.
(4) Braking unit and braking resistor should be added.

3,  Real application (Tower crane)
   3.1 system introduction

   The hoist motor in the system is 55kW/380V, the load type is constant torque, to consider its heavy duty characteristic,
   the frequency inverter should be selected two sizes higher as below:

   3.2 system diagram





 3.3 control logic

   (1) The tower crane control system provide the forward and reverse signals, while MI1 and DCM closed, the tower
         crane runs forwardly, and while MI2 and DCM closed, the tower crane runs reversely:

   (2) The  running speed of crane is controlled by ON/OFF conditions of MI3, MI4 and MI5, details as below:

MI5MI4MI3Speed
OFFOFFOFFSpeed 0 (FD-00)
OFFOFFONSpeed 1 (FD-01)
OFFONOFFSpeed 2 (FD-02)
OFFONONSpeed 3 (FD-03)
ONOFFOFFSpeed 4 (FD-04)
ONOFFONSpeed 5 (FD-05)

  (3) The inverter output a fault signal to the crane control system, while fault happen, the system will brake and stop
        immediately.

  (4) There is an output FDT1 (controlled by F8-19 and F8-20) ON/OFF signal, while the inverter  runs to the setting
        frequency, this signal will control the brake to open, to avoid the reverse run happen.

 3.4 autotuning

    For this kind of heavy duty system, it is better to use Sensorless Vector Control (SVC) mode, it will get better output
    torque performance.
    Before using SVC mode, please perform motor autotunning, do it as below steps:

   1) Set F0-02=0 (keypad), set correct value of F2-01 ~ F2-05 (based on motor nameplate);
   2) If the load can be removed from motor, please set F2-11=2 (Rotation autotuning, get better performance), if the
        load cannot be removed from motor, please set F2-11=1 (Static autotuning). The keypad will display “TUNE”.
   3) Press the RUN button, wait until the autotuning finish automatically.
   4) Change the value of F0-01=0 (Sensorless vector control)

 3.5 Parameters setting

No.Function codesDefaultSetting valueExplanation
1F0-0120Sensorless Vector Control
2F0-0201External singal start / stop
3F0-0316Multi-step speed
4F0-17Model depend5sAcceleration time (adjustable)
5F0-18Model depend0.5sDeceleration time (adjustable)
6F3-10150%200%Torque uppee limit
7F5-0011Forward
8F5-0122Reverse
9F5-02012Multi-step speed termnial 1
10F5-03013Multi-step speed termnial 2
11F5-04014Multi-step speed termnial 3
12F6-0222Fault output
13F6-0503FDT1 output
14F8-1950.00Hz3.00HzSetting FDT1 output frequency 
15FD-000.0%16%Multi-step speed 0 (adjustable)
16FD-010.0%16%Multi-step speed 1 (adjustable)
17FD-020.0%30%Multi-step speed 2 (adjustable)
18FD-030.0%50%Multi-step speed 3 (adjustable)
19FD-040.0%70%Multi-step speed 4 (adjustable)
20FD-050.0%82%Multi-step speed 5 (adjustable)
 

3.6 Problems faced during commissioning

(1)  For KD330-09000T4, it needs connect additional braking unit and braking resistor to consume the regenerated
       energy. The parameter of  FA-04 is the braking threshold, the default value is 135%. The stand DC bus voltage is
       540V, 540*135%=729V, that means while the DC bus voltage reach to 729V, the Braking unit will start work.
       Sometimes, the fault of over voltage will happen, please reduce the value of FA-04 to avoid it.

(2)  Cause the tower working distance is too long, during down running, the inverter works at regenerated status for
       long time, so the braking resistor should be selected bigger, to get better performance. In this system, it is
       select as 4ohm, 10kW.


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