Power Electronics VFD

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Summary

Drive Selection Help

Selecting the Right PE VFD or Multi-Vector Drive

Guide to selecting the appropriate drive based on application requirements.

Avoiding Oversized Drive Selection

Explains why PE® drives do not require over-sizing for demanding applications.

PE Drive Compatibility with Single-Phase Power

Addresses compatibility with single-phase power sources and motors.

Using PE Drives with Two-Speed Motors

Details usage with two-speed motors and specific PE® drive models.

Installation Help

Proper PE Drive Mounting

Guidance on correct vertical mounting and ventilation for optimal cooling.

Interpreting P.C. 22 Flashing Display

Explains P.C. 22 flashing, indicating U22 parameter needs setting.

Performing a Gang-Set

Procedure for resetting drive parameters to factory defaults for quick setup.

Adjusting Motor Speed Settings

Details adjusting motor speed, acceleration, and deceleration using 'A' parameters.

General Troubleshooting

PE Drive Unlock Code

Provides the unlock code required to access certain parameter groups.

Drive Behavior During Trip Events

Describes the four events that occur when a trip condition is detected.

Initiating PE Drive Troubleshooting

Initial steps for troubleshooting, focusing on fuses, event codes, and memory.

Accessing Drive Event Code History

Explains how event codes are automatically stored in diagnostic memory locations.

Using Event Codes for Diagnosis

Guidance on interpreting event codes for diagnosing trip conditions.

Resetting the Drive After a Trip Event

Methods for clearing event codes and resetting the drive after a trip.

Troubleshooting Event Codes (F1 - F47)

F0: No F-Code Recorded

Explains F0 indicates no fault was stored or memory was cleared.

F1: Current Trip Troubleshooting

Troubleshooting steps for F1 (Current Trip), a common drive fault.

F1 Trip During Acceleration

Addresses F1 trips occurring during acceleration and potential causes/solutions.

F1 Trip During Deceleration

Addresses F1 trips occurring during deceleration and potential causes/solutions.

F1 Trip at Constant Speed

Addresses F1 trips at constant speed or when a specific speed is reached.

F1 Trip: Motor Not Starting

Addresses F1 trips when the motor doesn't start despite drive command.

Additional F1 Current Trip Causes

Lists additional potential causes for F1 (Current Trip) faults.

F2: Motor Thermal Trip; I^2 T Trip

Diagnosing F2 (Motor Thermal Trip) and I^2T trip events.

F3: Braking Resistor or Low Bus Voltage

Troubleshooting F3 for braking resistor issues or low bus voltage.

F4: Low Bus Voltage

Diagnosing F4 (Low Bus Voltage), a normal trip on power down.

F5: Over Voltage Trip

Diagnosing F5 (Over Voltage Trip) and its causes like high input voltage.

F6;F7: Auxiliary Trip

Diagnosing F6/F7 (Auxiliary Trip) related to external device signals.

F8: A Parameters Out of Spec

Diagnosing F8 (A Parameters Out of Spec) due to logical incompatibility.

F9: CPU Error

Diagnosing F9 (CPU Error) indicating a failure of the drive's CPU.

F10: Memory Error

Diagnosing F10 (Memory Error) due to parameter memory chip malfunction.

F11: Timer

Diagnosing F11 (Timer) when motor runs longer than allotted time.

F12: Hardware Failure

Diagnosing F12 (Hardware Failure) indicating internal component issues.

F13: Overload

Diagnosing F13 (Overload) caused by overload device tripping.

F14: Output Phase Loss

Diagnosing F14 (Output Phase Loss) due to lost line to motor.

F17: Encoder Tracking

Diagnosing F17 (Encoder Tracking) when motor does not match drive command.

F18;F19: Encoder Phase A or B

Diagnosing F18/F19 (Encoder Phase) for power loss in encoder wiring.

F20: Heat Sink Too Hot

Diagnosing F20 (Heat Sink Too Hot) due to excessive drive temperature.

F21: Begin Brake Test Failure

Diagnosing F21 (Brake Test Failure) indicating slipping during the test.

F22: CPU Fault

Diagnosing F22 (CPU Fault) indicating a failure of the drive's CPU.

F23: Brake Control Circuit Open

Diagnosing F23 (Brake Control Circuit Open) due to wiring or fuse issues.

F24: Drive Output Leads

Diagnosing F24 (Drive Output Leads) for lost motor phase during start.

F25: Extra Encoder Pulses

Diagnosing F25 (Extra Encoder Pulses) due to noise or incorrect settings.

F26: Brake Relay Failure

Diagnosing F26 (Brake Relay Failure) indicating an internal brake control relay issue.

F27: Weight Limit Trip (Over Torque)

Diagnosing F27 (Weight Limit Trip) related to over-torque settings.

F28: Power Supply Failure

Diagnosing F28 (Power Supply Failure) affecting supplies, fans, or contactor.

F33: Tracking Error

Diagnosing F33 (Tracking Error) due to speed discrepancy with encoder feedback.

F34: Encoder Tracking Error During Zip-Up

Diagnosing F34 (Encoder Tracking Error) during Zip-Up® function.

F35;F36: Encoder Speed

Diagnosing F35/F36 (Encoder Speed) for encoder running too fast.

F45: Binding

Diagnosing F45 (Binding) after brake test failure, possibly slow DC brake reaction.

F46: No Movement

Diagnosing F46 (No Movement) when the encoder is not moving.

F47: Encoder Problem

Diagnosing F47 (Encoder Problem) for missing encoder pulses.

The Power Electronics® Variable Frequency Drive (VFD) is a sophisticated device designed for precise control of three-phase motors, particularly in demanding applications such as electric overhead cranes and material handling. It offers advanced speed control, troubleshooting capabilities, and a robust design to handle various operational conditions.

Function Description

The VFD's primary function is to convert single-phase line voltage to three-phase output for use with three-phase motors, or to directly control three-phase motors when three-phase power is available. It provides variable speed control, allowing for smooth acceleration and deceleration, which is crucial for applications requiring precise movement and reduced mechanical stress. The drive can be programmed to control either traverse motions (bridge, trolleys, rotation) or hoist motors, with specific models ("H" suffix) pre-programmed for hoist applications. For hoist motors, the VFD can integrate with mechanical load brakes or closed-loop systems using encoders for enhanced control and safety.

The VFD incorporates several protective features to ensure safe and reliable operation. It monitors motor current, temperature, and voltage, tripping out and displaying event codes (F-codes) when abnormal conditions are detected. This self-protection mechanism prevents damage to the drive and the motor. The device also includes brake outputs (B1 and B2) that open during a trip condition, bringing the crane motion to a stop using the brakes.

Usage Features

The VFD offers a range of user-configurable parameters to tailor its operation to specific application needs. These parameters are organized into groups (A, L, U, C, CL) for ease of navigation and adjustment.

Motor Speed and Acceleration/Deceleration Settings (A-parameters): Users can adjust default acceleration time (A1), default deceleration time (A4), low speed setting (A12), and speed settings associated with auxiliary inputs (A13-A16). These adjustments allow for fine-tuning of motor movement, ensuring smooth starts and stops, and preventing issues like load swing.
Unlock Codes: To prevent accidental changes, certain parameter groups (L and U, and C and CL on MX™ and MV™ units) require an unlock code (369) to be entered. This security feature ensures that critical settings are not inadvertently altered.
Gang-Set® Functionality: For quick setup or to return to recommended default values, the VFD offers a Gang-Set function. This reprograms all "A" parameters to factory-chosen values, simplifying initial configuration. Any fine-tuning of individual "A" parameters should be done after performing a Gang-Set.
Two-Speed Motor Compatibility: The VFD can be used with two-speed motors. For Micro-Speed® VFDs, it should be connected to the motor's high-speed windings, with the VFD sized based on the high-speed winding's HP/Amp rating. Smooth-Move® Soft-Start units are also available for two-speed motors.
Single-Phase to Three-Phase Conversion: While primarily designed for three-phase motors, PE® VFDs can convert single-phase line voltage to three-phase output, allowing them to be used in facilities with only single-phase power. Special drive sizing considerations apply in this scenario.
Display and Status Indicators: The VFD features a display that shows operational codes, event codes, and parameter values. For instance, "P.C. 22" flashing indicates that the U22 parameter (total motor FLA) has not been set, preventing control input and power output. "rOFF" or "cOFF" indicate an idle state. "LOC" indicates a locked unit, which can be unlocked by simultaneously pressing the Increase and Decrease buttons from the home screen.
Encoder Integration (MMX/MMV™ models): For closed-loop systems, the VFD integrates with encoders to monitor motor speed and position. Parameters like U30 allow matching the encoder pulse output, and test modes (U49 with U48 set to 17) can detect noise levels or missing pulses from the encoder.
Brake Control: The VFD manages brake outputs (B1 and B2) to ensure controlled stopping. It can perform brake tests (F21) to detect slipping and provides parameters (L26 on CX/MSM) to adjust the dead time for brake setting, preventing starting into a spinning motor.

Maintenance Features

The VFD is designed with troubleshooting and maintenance in mind, offering several features to assist users in diagnosing and resolving issues.

Event Code Display and History: When a trip condition occurs, the VFD displays an event code (e.g., F1 for Current Trip, F2 for Motor Thermal Trip, F5 for Over Voltage Trip). These codes provide immediate insight into the nature of the fault. The drive automatically stores the last four different types of event codes in diagnostic memory locations E1-E4, with E1 holding the most recent trip code and a count of its occurrences. This history is invaluable for diagnosing intermittent problems or conditions related to motor and mechanical issues.
Troubleshooting Guides: The manual and online resources provide detailed troubleshooting steps for each event code. These guides include potential causes, recommended solutions, and specific parameters to check or adjust. For example, for an F1 (Current Trip), the guide suggests checking for shorted output semiconductors, motor problems (bearings, shorts, wiring, voltage/Hz, internal brakes), mechanical brake issues, high voltage boost settings, or mechanical binding.
Resetting the Drive: After an event code is displayed, the drive will not accept control input until it is reset. The reset method can be configured via parameters (L27 for Smart-Move® and CX™ models, C10 for MX/MV™ models), typically by toggling a directional button on the pendant station. Alternatively, removing and restoring mainline power will always reset the drive after the charge light goes off. Note that the F2 code (Motor Thermal Trip) requires the drive to remain powered on for several minutes to allow the motor to cool before it can be reset.
Physical Mounting and Cooling: The VFD is designed for vertical mounting on an electrical panel to optimize cooling through its heat sink fins. Proper spacing in an enclosure and avoiding direct sunlight or radiant heat are recommended for adequate ventilation. If mounted in other orientations or in areas with high ambient temperatures, additional fans or air conditioning may be necessary.
Wiring and Connection Verification: Troubleshooting often involves verifying wiring and connections. For instance, F14 (Output Phase Loss) prompts users to check motor lines with a clamp meter, inspect encoder couplings, and measure DC voltage to the encoder. F23 (Brake Control Circuit Open) requires checking brake wiring diagrams and the brake fuse relay.
Motor Tuning Procedure: For optimal performance, especially after installation, a motor tuning procedure is recommended. This ensures the drive is properly configured for the specific motor characteristics, helping to prevent issues like binding (F45).
Factory Repair and Support: For complex issues or hardware failures (e.g., F9 CPU Error, F12 Hardware Failure, F26 Brake Relay Failure, F22 CPU Fault), the manual advises returning the unit to the factory for repair. Power Electronics® also provides direct support for further assistance, emphasizing the importance of having event code history and product serial numbers available when contacting them.