YASKAWA CR700 - Technical Manual

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Table of Contents3
Preface and General Precautions13
Receiving14
Glossary14
Registered Trademarks14
Using the Product Safely15
Explanation of Signal Words15
Section Safety15
Warning Label Content and Locations17
Warranty Information18
Exclusion of Liability18
Receiving19
Section Safety20
Crane Application Instructions21
Model Number and Nameplate Check22
Nameplate22
How to Read the Model Number22
Control Method Type and Corresponding Features26
Mechanical & Electrical Installation29
Section Safety30
Installation Environment33
Installation Orientation and Spacing34
Moving the Drive36
Using the Hanging Brackets to Move the Drive36
Instructions on Drive Suspension36
Drive Watt Loss38
Remove and Reattach the Keypad40
Remove the Keypad40
Reattach the Keypad40
Install the Keypad in a Control Panel or Another Device41
Operate the Keypad from a Remote Location41
Connect the Keypad from a Remote Location41
Removing/Reattaching Covers46
Removing/Reattaching the Cover Using Procedure a46
Removing/Reattaching the Cover Using Procedure B47
Change the Drive Enclosure Type51
Remove the Knock-Out Holes51
Attach the Protective Cover (Procedure A)51
Attach the Protective Cover (Procedure B)53
Attach the Protective Cover (Procedure C)55
Attach the Protective Cover (Procedure D)56
Attach the Protective Cover (Procedure E)58
Attach the Protective Cover (Procedure F)61
Attach the Protective Cover (Procedure G)64
Installation Methods67
Electrical Installation71
Standard Connection Diagram71
Main Circuit Wiring74
Motor and Main Circuit Connections74
Configuration of Main Circuit Terminal Block74
Main Circuit Terminal Functions79
Main Circuit Wire Gauges and Tightening Torques80
Main Circuit Terminal and Motor Wiring90
Protection of Main Circuit Terminals93
Main Circuit Terminal Block Wiring Procedure94
Wire the Main Circuit Terminal Block with Procedure a94
Wire the Main Circuit Terminal Block with Procedure B97
Control Circuit Wiring100
Control Circuit Connection Diagram100
Control Circuit Terminal Block Functions101
Terminal Configuration106
Wiring the Control Circuit Terminal108
Switches and Jumpers on the Terminal Board110
Control I/O Connections112
Set Sinking Mode/Sourcing Mode112
Select Input Signals for Multi-Function Analog Input Terminals A1 to A3112
Set Multi-Function Analog Input Terminal A3 to PTC Input113
Select Output Signals for Multi-Function Analog Output Terminals FM, am113
Switch on Termination Resistor for Memobus/Modbus Communications113
Connect the Drive to a PC115
Braking Resistor Installation116
Installing a Braking Resistor: ERF Type116
Installing a Braking Resistor Unit : LKEB Type116
Installing a Braking Unit Connection: CDBR Type117
Connect Braking Units in Parallel123
Dynamic Braking Option Overload Protection123
Drive Wiring Protection125
(Rcm/Rcd)125
Installing a Residual Current Monitoring/Detection (RCM/RCD)125
Dynamic Braking Option, Motor Protection126
Install an Electromagnetic Contactor (MC) at the Input Side of the Drive126
Installing a Thermal Overload Relay on the Drive Output126
Improve the Power Factor128
Connect an AC Reactor or a DC Reactor128
Prevent Switching Surge129
Decrease Noise130
Connect a Noise Filter to the Input Side (Primary Side)130
Connect a Noise Filter to the Output Side (Secondary Side)130
Protect the Drive During Failures132
Factory-Recommended Branch Circuit Protection132
Wiring Checklist134
Motor Application Precautions135
Precautions for Existing Standard Motors135
Precautions Concerning Use of Specialized Motors136
Notes on the Power Transmission Mechanism136
Startup Procedure and Test Run137
Section Safety138
Component Names and Functions139
LCD Display140
Indicator Leds and Drive Status141
Keypad Mode and Menu Displays143
LED Status Ring145
Keypad Operation147
Use the HOME Screen147
Show the Monitor148
Set Custom Monitors149
Show Custom Monitors150
Set the Monitors to Show as a Bar Graph150
Show Monitors as Bar Graphs152
Set the Monitors to Show as Analog Gauges152
Display Monitors as an Analog Gauge153
Set Monitoring Items to be Shown as a Trend Plot154
Show Monitor Items as a Trend Plot157
Change Parameter Setting Values158
Examine User Custom Parameters160
Save the Backup of Parameters161
Write Backed-Up Parameters to the Drive162
Verify Keypad Parameters and Drive Parameters163
Erase Parameters Backed up to the Keypad164
Check Modified Parameters165
Restore Modified Parameters to Defaults166
Show Fault History168
Auto-Tuning the Drive168
Set the Keypad Language Display171
Set the Date and Time171
Disable the Initial Setup Screen173
Start Data Logging174
Configuring the Data Log Content175
Set Backlight to Automatically Turn off177
Show Information about the Drive178
Write Automatically Backed-Up Parameters to the Drive179
Items to Check before Starting up the Drive180
Check before Energizing the Drive180
Check after You Energize the Drive180
Perform the Initial Settings180
Control Method Selection181
Parameter Settings for Operation Without the Brake Sequence181
Setting the Direction of Motor Rotation181
Setting the Encoder (Pulse Generator)182
Application Preset183
Test Run Procedure185
Test Run Flowchart186
Auto-Tuning188
Auto-Tuning for Induction Motors188
ASR and Inertia Tuning189
Precautions before Auto-Tuning190
Load Test Runs193
Perform a No-Load Test Run193
Crane Application Setup Procedure194
External Interlock194
Run Command194
Operation When the External Baseblock Command Is Input and Cleared194
Speed Reference195
Brake Sequence195
Adjusting the Run Command204
Impact Stop Function206
Light-Load Acceleration 1 Function207
Light-Load Acceleration 2 Function210
Overload Detection213
Overtorque Detection214
Travel Limit Function215
Motor Switch Function216
Parameter Switching Function for Reverse Operation220
Crane Maintenance Monitor221
Frequency Reduction Gain223
Rapid Deceleration Function224
Problems that Can Frequently Occur During Setup and Possible Solutions226
Cannot Change Parameter Settings227
The Correct Auto-Tuning Mode Is Not Available227
Crane Sequence Does Not Operate227
Motor Does Not Rotate after Entering Run Command227
The Starting Torque Is Not Sufficient228
Motor Does Not Restart after Power Loss228
Motor Rotates in the Opposite Direction from the Run Command229
Motor Rotates in One Direction Only229
Motor Stops When Operating at the Brake Release Frequency Speed229
Response Is Slow at Start229
Motor Stalls During Acceleration or Accel/Decel Time Is too Long229
Output Frequency Is Not as High as Frequency Reference230
Drive Frequency Reference Differs from the Controller Frequency Reference231
Command231
Large Inconsistency in Stopping Position Due to the Load Rate231
Deceleration Takes Longer than Expected When Dynamic Braking Is Enabled231
The Motor Rotates after the Drive Output Is Shut off231
Suspension Drops (Falls)231
Load Slips at Start232
Load Slips at Stop232
Slipping Occurs During Extremely Fast Inching232
Load Falls When Brake Is Applied232
Excessive Current Occurs at Start232
Excessive Output Current at Constant Speed233
Too Much Output Current, Oscillation233
Start Take too Long233
Excessive Current Flow When Starting to Hoist Immediately after Stopping233
Lowering233
Brake Slips at Start234
Brake Grinding Occurs at Stop234
Impact Stop Is Not Available after the Motor Stops234
Motor Keeps Rotating at the Creep Frequency During Impact Stop Operation234
Accelerates Despite a Heavy Load When Using the Light-Load Acceleration234
Function234
No Acceleration Despite a Light Load When Using the Light-Load Acceleration234
Function235
No Acceleration Despite a Light Load When Using the Light-Load Acceleration235
Excessive Motor Oscillation and Erratic Rotation235
Oscillation Occurs When Lowering in a Hoist/Lowering Crane Without a235
Counterweight235
With a Traverse Crane235
Unexpected Noise from Connected Machinery Occurs When Motor Rotates235
Oscillation or Hunting Occurs When Motor Rotates235
The Motor Is Making an Audible Noise236
The Motor Is too Hot236
Drive236
Residual Current Monitoring/Detection (RCM/RCD) Trips During Run236
Flux Compensation (Current Suppression at Start)236
Controllability Problems and Possible Solutions238
V/F Control and Closed Loop V/F Control238
Open Loop Vector Control Method238
Closed Loop Vector Control240
AOLV Control240
Test Run Checklist242
Standards Compliance245
Section Safety246
European Standards248
CE Low Voltage Directive Compliance248
EMC Directive262
UL Standards273
Area of Use273
Wiring to the Main Circuit Terminal273
Low Voltage Wiring for Control Circuit Terminals288
Drive Motor Overload and Overheat Protection288
China Rohs Compliance293
Information on Hazardous Substances in this Product293
对应中国Rohs指令294
本产品中含有有害物质的信息294
Safe Disable Input295
Safe Disable Specifications295
Precautions296
Using the Safe Disable Function296
Network Communications299
Section Safety300
Field Bus Network Support301
Memobus/Modbus Communications302
Configure Master/Slave302
Communication Specifications302
Communication with the PLC302
Drive Operations by Memobus/Modbus304
Communications Timing304
Message Format305
Examples of Messages for Commands/Responses307
Enter Command311
Self-Diagnostics312
Communications Data Table313
Error Codes332
Troubleshooting333
Section Safety334
Types of Faults, Minor Faults, Alarms, and Errors336
List of Fault, Minor Fault, Alarm, and Error Codes337
Fault342
Minor Faults/Alarms363
Parameter Setting Errors373
Auto-Tuning Errors377
Backup Function Operating Mode Display and Errors381
Diagnosing and Resetting Faults382
Fault and Power Loss Occur at the same Time382
Fault Occurs Without Power Loss382
Fault Reset Procedure382
Periodic Inspection and Maintenance383
Section Safety384
Inspection386
Recommended Daily Inspection386
Recommended Periodic Inspection386
Maintenance388
Replace Cooling Fans and Circulation Fans389
Number of Cooling Fans and Circulation Fans Used389
Fan Replacement (Procedure A)389
Fan Replacement (Procedure B)391
Fan Replacement (Procedure C)394
Fan Replacement (Procedure D)396
Fan Replacement (Procedure E)398
Fan Replacement (Procedure F)400
Fan Replacement (Procedure G)405
Replace the Drive414
About the Control Circuit Terminal Block414
Replace the Keypad Battery419
Storage Guidelines421
Disposal423
Section Safety424
Disposal Instructions425
Specifications427
Section Safety428
Model Specifications (200 V Class)429
Model Specifications (400 V Class)431
Drive Specifications434
Drive Derating437
Carrier Frequency Settings and Rated Current Values437
Altitude Derating438
Drive Exterior and Mounting Dimensions439
IP20/UL Open Type439
IP20/UL Type 1448
Knock-Out Hole Dimensions (UL Type 1)457
Peripheral Devices and Options461
Parameter List465
Section Safety466
How to Read the Parameter List467
Icons and Terms that Identify Parameters and Control Methods467
Parameter Groups468
A: Initialization Parameters469
A1: Initialization469
A2: User Parameters470
B: Application471
B1: Operation Mode Selection471
B2: DC Injection Braking472
B4: Timer Function472
B7: Droop Control473
B9: Zero Servo473
C: Tuning474
C1: Accel & Decel Time474
C2: S-Curve Characteristics475
C3: Slip Compensation475
C4: Torque Compensation476
C5: Auto Speed Regulator (ASR)477
C6: Carrier Frequency478
D: Reference Settings479
D1: Frequency Reference479
D2: Reference Limits480
D3: Jump Frequency480
D4: Frequency Ref Up/Down & Hold480
D6: Field Forcing481
D7: Offset Frequency481
E: Motor Parameters482
E1: V/F Pattern for Motor 1482
E2: Motor Parameters483
E3: V/F Pattern for Motor 2484
E4: Motor 2 Parameters485
E7: Motor 3 Parameters485
F: Options487
F1: Encoder Option Setup487
F2: Analog Input Option488
F3: Digital Input Option489
F4: Analog Output Option490
F5: Digital Output Option490
F6: Communication Options491
F7: Communication Options494
10.10 H: Terminal Functions499
H1: Digital Inputs499
H2: Digital Outputs503
H3: Analog Inputs509
H4: Analog Outputs511
H5: Memobus/Modbus Communications512
H7: Virtual Inputs / Outputs513
10.11 L: Protection Functions515
L1: Motor Protection515
L2: Power Loss Ride through515
L3: Stall Prevention516
L4: Speed Detection517
L7: Torque Limit518
L8: Hardware Protection518
L9: Drive Protection 2520
10.12 N: Special Adjustment521
N1: Hunting Prevention521
N2: Auto Freq Regulator (AFR)521
N3: Overexcitation Deceleration522
N4: Adv Open Loop Vector Tune522
N5: Feed Forward Control523
N6: Online Resistance Tuning523
10.13 O: Keypad-Related Settings524
O1: Keypad Display524
O2: Keypad Operation526
O3: Copy Keypad Function527
O4: Maintenance Monitors527
O5: Log Function528
10.14 S: Crane Parameters530
S1: Brake Sequence530
S2: Run Command Tuning, Maintenance Monitors, Frequency Derating Gain, Rapid532
Deceleration532
S3: Impact Stop533
S4: Light-Load Acceleration533
S5: Overload Detection535
S6: Overtorque Detection535
10.15 T: Motor Tuning537
T0: Tuning Mode Selection537
T1: Induction Motor Auto-Tuning537
T3: ASR and Inertia Tuning538
10.16 U: Monitors539
U1: Operation Status Monitors539
U2: Fault Trace541
U3: Fault History543
U4: Maintenance Monitors544
U6: Operation Status Monitors548
Parameters that Change from the Default Settings with A1-02551
Selection551
Parameters that Change from the Default Settings with E3-01554
Mode Selection]554
Parameters Changed by E1-03 [V/F Pattern Selection]555
Parameters Changed by O2-04 [Drive Model (KVA) Selection]557
Class557
Class561
Parameter Details567
Section Safety568
A: Initialization Parameters569
A1: Initialization569
A2: User Parameters582
B: Application584
B1: Operation Mode Selection584
B2: DC Injection Braking593
B4: Timer Function595
B7: Droop Control597
B9: Zero Servo598
C: Tuning600
C1: Accel & Decel Time600
C2: S-Curve Characteristics604
C3: Slip Compensation605
C4: Torque Compensation609
C5: Auto Speed Regulator (ASR)612
C6: Duty & Carrier Frequency620
D: References622
D1: Frequency Reference622
D2: Reference Limits628
D3: Jump Frequency629
D4: Frequency Ref Up/Down & Hold630
D6: Field Forcing631
D7: Offset Frequency632
E: Motor Parameters633
E1: V/F Pattern for Motor 1633
E2: Motor Parameters641
E3: V/F Pattern for Motor 2644
E4: Motor 2 Parameters646
E7: Motor 3 Parameters649
F: Options651
F1: Encoder Option Setup651
F2: Analog Input Option656
F3: Digital Input Option658
F4: Analog Monitor Option662
F5: Digital Output Option664
F6, F7: Communication Options667
H: Terminal Functions686
H1: Digital Inputs686
MFDI Function Selections690
H2: Digital Outputs701
H2 MFDO Parameters704
MFDO Setting Values711
H3: Analog Inputs724
H3: MFAI Parameters725
Multi-Function Analog Input Terminal Settings730
H4: Analog Outputs734
H5: Memobus/Modbus Communication737
H7: Virtual MFIO Selection741
L: Protection Function745
L1: Motor Protection745
L2: Power Loss Ride through750
L3: Stall Prevention750
L4: Speed Detection757
L7: Torque Limit759
L8: Drive Protection762
L9: Drive Protection 2768
11.10 N: Special Adjustment769
N1: Hunting Prevention769
N2: Auto Freq Regulator (AFR)771
N3: Overexcitation Braking772
N4: Adv Open Loop Vector Tune774
N5: Feed Forward Control777
N6: Online Tuning780
11.11 O: Keypad-Related Settings781
O1: Keypad Display Selection781
O2: Keypad Operation788
O3: Copy Function791
O4: Maintenance Mon Settings792
O5: Log Function795
11.12 T: Auto-Tuning800
T0: Tuning Mode Selection800
T1: Induction Motor Auto-Tuning800
Revision History816
Basic Specifications817
Function Details818
3.1 Wire Length Detection818
Cargo Swing Suppression (Anti Swing Control)821
Revision History837
Basic Specifications838
Synchronous Control839
3.1 Overview839
3.2 Application Precautions839
3.3 System Configuration840
3.4 Block Diagram841
3.5 Descriptions of Parameters842
Parameter List861
F1: PG Option Setup (Encoder)861
4.2 H1: Multi-Function Digital Input Settings861
4.3 H2: Multi-Function Digital Output Settings863
H3: Multi-Function Analog Input Settings863
4.5 SA: Crane Special Func863
4.6 U9: Crane Monitors868
4.7 Troubleshooting870
Revision History872
Basic Specifications873
Function Details873
Parameter List884

YASKAWA CR700 - Technical Manual

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