WEG CFW-11 Applications Manual
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WEG CFW-11 Applications Manual

Crane horizontal motion
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Motors | Automation | Energy | Transmission & Distribution | Coatings
Crane Horizontal Motion
CFW-11
Application Manual
Language: English
Document: 10001257504 / 01

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  • Page 1 Motors | Automation | Energy | Transmission & Distribution | Coatings Crane Horizontal Motion CFW-11 Application Manual Language: English Document: 10001257504 / 01...
  • Page 3 Crane Horizontal Motion Application Manual Series: CFW-11 Language: English Document Number: 10001257504 / 01 Publication Date: 04/2017...

  • Page 4: Table Of Contents

    Contents CONTENTS ABOUT THE MANUAL .................. 6 ABBREVIATIONS AND DEFINITIONS ......................6 NUMERICAL REPRESENTATION ....................... 6 QUICK PARAMETER REFERENCE, FAULTS AND ALARMS ..... 7 FAULTS AND ALARMS ................9 1 INTRODUCTION TO THE CRANE ............10 1.1 CRANE HORIZONTAL MOTION ......................10 1.2 CRANE VERTICAL MOTION ........................
  • Page 5 Contents 6.1 LADDER DIAGRAMS ..........................59 6.2 APPLICATION CONFIGURATION WIZARD ..................60 6.2.1 Tittle ................................60 6.2.2 Input Value for Parameters ........................60 6.2.3 Info ................................. 60 6.2.4 Browse Buttons ............................60 6.3 MONITORING DIALOG BOXES ......................61 6.4 TREND VARIABLES DIALOG BOXES ....................61 6.5 PARAMETER VALUE DIALOG ......................

  • Page 6: About The Manual

    This manual provides the necessary description for the crane horizontal motion application configuration developed of the CFW-11 frequency inverter SoftPLC function. This manual must be used together with the CFW-11 user manual, the SoftPLC function manual and the WLP software manual.

  • Page 7: Quick Parameter Reference, Faults And Alarms

    Quick Parameter Reference, Faults and Alarms QUICK PARAMETER REFERENCE, FAULTS AND ALARMS Factory User Parameter Description Adjustable Range Properties Groups Page Setting Setting P1010 Crane Horizontal Motion Version 0.00 to 10.00 P1011 Last Alarm 0 to 999 P1012 Last Alarm Date 01.01 to 31.12 P1013 Last Alarm Time...
  • Page 8 Quick Parameter Reference, Faults and Alarms Factory User Parameter Description Adjustable Range Properties Groups Page Setting Setting P1025 Limit Switches Configuration 0 = Without Limit Switches 1 = Forward Slowdown via DI7 and Reverse Slowdown via DI8 2 = Forward Slowdown via DI7 and Stop Forward via DI8 3 = Reverse Slowdown via DI7 and Stop Reverse via DI8...

  • Page 9: Faults And Alarms

    Quick Parameter Reference, Faults and Alarms FAULTS AND ALARMS Fault/Alarm Description Possible causes A750: The Crane Horizontal Motion application is The motor speed is greater than P1039 and the Lightweight Operation operating in the lightweight mode. motor current is less than P1038 when a load forward or reverse command is being executed.

  • Page 10: Introduction To The Crane

    Introduction to the Crane 1 INTRODUCTION TO THE CRANE The applicatives for crane developed for the CFW-11 SoftPLC function provides flexibility to the user in the system use and in its configuration. It uses the tools already developed for the WLP programming software, together with configuration wizards and monitoring dialog boxes.

  • Page 11: Frequency Inverter Use Advantages

    Introduction to the Crane 1.3 FREQUENCY INVERTER USE ADVANTAGES We are able to evaluate the advantages of the variable frequency inverter use for crane horizontal motion or for crane vertical motion, under the following aspects: ■ Elimination of the electrical line disturbances: with the use of the inverter, by maintaining the motor flux constant (varying both frequency and voltage), it is possible to have the motor rated torque in the entire speed range.

  • Page 12: Frequency Inverter And Braking Resistor Selection Criteria

    = Motor rated power (kW); %ED = Braking duty cycle. NOTE! Refer to the CFW-11 user's guide, table 3.3, to verify the ohmic value of the braking resistor to be used according to the frequency inverter model. 1.5.2 Vertical Motion The inverter must be selected according to its heavy duty rated current (I ■...

  • Page 13: General Notes

    = Motor rated power (kW); %ED = Braking duty cycle. NOTE! Refer to the CFW-11 user's guide, table 3.3, to verify the ohmic value of the braking resistor to be used according to the frequency inverter model. 1.5.3 General Notes ■...

  • Page 14: Crane Horizontal Motion

    The crane horizontal motion control developed for the CFW-11 SoftPLC presents the following characteristics: ■...

  • Page 15: Speed Reference Via Electronic Potentiometer (Ep)

    It is necessary to install the IOC-01 or IOC-02 accessory module in case the DI9, DI10, DI11 and DI12 digital inputs and/or the DO6 and DO7 digital outputs use is required. Refer to the CFW-11 frequency inverter manual for more information on accessory modules.

  • Page 16: Speed Reference Via Digital Inputs

    It is necessary to install the IOC-01 or IOC-02 accessory module in case the DI9, DI10, DI11 and DI12 digital inputs and/or the DO6 and DO7 digital outputs use is required. Refer to the CFW-11 frequency inverter manual for more information on accessory modules.

  • Page 17: Speed Reference Via Analog Input Ai1

    It is necessary to install the IOC-01 or IOC-02 accessory module in case the DI9, DI10, DI11 and DI12 digital inputs and/or the DO6 and DO7 digital outputs use is required. Refer to the CFW-11 frequency inverter manual for more information on accessory modules.

  • Page 18: Speed Reference Via Communication Networks

    It is necessary to install the IOC-01 or IOC-02 accessory module in case the DI9, DI10, DI11 and DI12 digital inputs and/or the DO6 and DO7 digital outputs use is required. Refer to the CFW-11 frequency inverter manual for more information on accessory modules.

  • Page 19: Brake System

    2.2.1 Connection Diagram NOTE! The following connection diagrams shown are valid for WEG brake motors. The same must be suitable for other types of brake or brake motor. 2.2.1.1 AC Power Supply Usually brake motors admit two braking systems: normal and fast.
  • Page 20 Crane Horizontal Motion ■ Fast Braking: the interruption of DC power to brake closing is done directly in the direct current source to terminals 3 and 04 keeping the terminals 1 and 2 on AC power supply. Figure 2.6 – Connection diagram of the bridge rectifier for fast braking 2.2.1.2 DC Power Supply The connection must be made directly on the brake terminals as the voltage on the brake power nameplate.

  • Page 21: Parameters Description

    LOCAL Situation: It allows the user to command the motor of crane driven by the CFW-11 inverter disregarding the control logics. REMOTE Situation: It enables the crane horizontal motion control logics, according to the programming performed by the user.
  • Page 22 NOTE! Refer to the CFW-11 programming manual for more information on the stop mode. P1024 – Enable use of a Filter in the Forward and Reverse Commands...

  • Page 23: Ramps

    Parameters Description P1027 – Motor Demagnetization Time Adjustable 0 to 65000 s Factory Setting: 600 s Range: Proprieties: Access groups via HMI: 01 PARAMETER GROUPS ∟ 50 SoftPLC ..Description: This parameter defines the period without load forward or reverse commands that has to elapse before the inverter general enable command is removed, thus demagnetizing the motor.

  • Page 24: Speed Limits

    This parameter defines the source of the command that will select between the 1st and the 2nd ramp, which is only SoftPLC for the crane horizontal motion applicative. NOTE! Refer to the CFW-11 programming manual for more information on the ramp parameters. 3.3 SPEED LIMITS This parameter group allows the user to configure the motor speed limits.

  • Page 25: Dynamic Braking

    Parameters Description NOTE! Refer to the CFW-11 programming manual for more information on the speed limit parameters. 3.4 DYNAMIC BRAKING This parameter group allows the user to configure the braking resistor to be used for dynamic braking. P0154 – Dynamic Braking Resistor P0155 –...
  • Page 26 Parameters Description When the speed reference is selected through the logic combination of the DI4, DI5 and DI6 digital inputs, the following truth table must be applied to obtain the speed reference. Table 3.2 – Speed reference truth table with the logical combination of DI4, DI5 and DI6 digital inputs P1031 - Speed P1032 - Speed...
  • Page 27 Parameters Description ■ P1023 = 6, it defines the minimum speed reference value for the crane horizontal motion applicative. In other words, it is the initial speed reference value when the value read at the analog input is 0 V, 0 mA or 4 mA. ■...
  • Page 28 Parameters Description P1034 – Speed Reference 4 Adjustable 0.0 to 1020.0 Hz Factory Setting: P1023 = 0: 0.0 Hz Range: P1023 = 1: 0.0 Hz P1023 = 2: 0.0 Hz P1023 = 3: 0.0 Hz P1023 = 4: 60.0 Hz P1023 = 5: 45.0 Hz P1023 = 6: 0.0 Hz P1023 = 7: 0.0 Hz...

  • Page 29: Control Word

    Parameters Description 3.6 CONTROL WORD P1022 – Communication Network Control Word Adjustable 0000h to FFFFh Factory Setting: 0000h Range: Proprieties: Access groups via HMI: 01 PARAMETER GROUPS ∟ 50 SoftPLC ..Description: This parameter defines the control word for the crane horizontal motion applicative when the speed reference control via communication networks has been selected (P1023 = 7).

  • Page 30: Digital Inputs

    Parameters Description ■ Reverse Slowdown (speed reduction): With an active reverse command and activated sensor (logical level “0”), It decelerates the motor down to the minimum speed defined at P0133 respecting the ramp defined at P0101. ■ Stop Forward: With an active forward command and activated sensor (logical level “0”), it causes an normal stop respecting the ramp defined at P0101.
  • Page 31 Parameters Description NOTE! When the speed reference control is programmed for communication networks (P1023 = 7), then the digital input DI2 does not have a specific function for the crane horizontal motion applicative P0265 – DI3 Function Adjustable 0 to 31 / 0 = Not Used Factory Setting: Range: 2 = Coast to Stop...
  • Page 32 Parameters Description P0266 – DI4 Function Adjustable 0 to 31 / 21 = Acceleration (PLC Use) Factory Setting: P1023 = 0: 21 Range: 21 = 1st Speed Reference Digital Input (PLC Use) P1023 = 1: 21 21 = 1st Speed Reference Digital Input (PLC Use) P1023 = 2: 21 21 = 1st Speed Reference Digital Input (PLC Use) P1023 = 3: 21...
  • Page 33 Parameters Description ■ P1023 = 0, 1, 2, 6 or 7 and P1025 = 1 or 2: These options define that the function of the DI5 is “Forward Slowdown Limit Switch”. With logical level “0” (sensor actuated) and with a load forward command present, it decelerates the motor down to the minimum speed defined in P0133.
  • Page 34 3. 3. NOTE! Refer to the CFW-11 programming manual for more information on the digital input parameters. Some parameter options have been removed from the configuration wizard. DI9 Function...

  • Page 35: Digital Outputs

    Refer to the section 3.12 in this application manual for more information on the brake control logic. NOTE! Refer to the CFW-11 programming manual for more information on the digital output parameters. Some parameter options have been removed from the configuration wizard.

  • Page 36: Analog Input

    ..Description: This parameter configures the type of signal (voltage or current) that will be read by the analog input AI1. Adjust the CFW-11 control board DIP switch S1.4 according to the selected option. Crane Horizontal Motion | 36...

  • Page 37: Lightweight Mode

    AI1. NOTE! Refer to the CFW-11 programming manual for more information on the analog input parameters. Some parameter options have been removed from the configuration wizard. 3.11 LIGHTWEIGHT MODE This parameter group allows the user to adjust the lightweight mode operation conditions.
  • Page 38 Parameters Description Description: This parameter configures the motor current threshold for lightweight detection. In other words, when the actual motor current is below the adjusted value, this indicates that it is with lightweight. P1039 – Speed Threshold for Lightweight Detection Enabling Adjustable 0.0 to 1020.0 Hz Factory Setting:...
  • Page 39 Parameters Description Figure 3.1 – Lightweight detection operation mode Description of the identified moments: 1 – The load forward command is given through the digital input DI1. The motor becomes magnetized, and voltage and frequency are applied to it 2 – The motor is accelerated to the speed reference 1 value set in P1031. 3 –...

  • Page 40: Brake Control

    Parameters Description 3.12 BRAKE CONTROL P1041 – Brake Release Frequency Threshold Adjustable 0.0 to 500.0 Hz Factory Setting: 4.0 Hz Range: Proprieties: Access groups via HMI: 01 PARAMETER GROUPS ∟ 50 SoftPLC ..Description: This parameter define the motor frequency threshold to release the brake. In other words, if the total speed reference (as motor frequency) after the ramp is higher than or equal to the adjusted value, then the brake release command is permitted.
  • Page 41 Description: This parameter defines the brake response time to release, or how long the brake takes to release after receiving the command from the digital output of the CFW-11, and thus be mechanically released. NOTE! In time for the brake release, the speed reference is kept in the brake release frequency threshold if it is enabled (P1041 ≠...
  • Page 42 This parameter defines a time after the command to brake closing has been executed via the digital output of the CFW-11, so that a new command to load forward or load reverse is accepted and thus the brake can be released again thus preventing a new command to be generated without the brake being closed mechanically.
  • Page 43 Parameters Description Figure 3.2 – Logic block diagram for the mechanical brake control through the digital output DO3 The brake control operation diagram considering that the crane horizontal motion has been configured for two speed references obtained from the digital input logic, and that the evaluations of motor frequency and motor current for the control of the mechanical brake are enabled, is presented next.
  • Page 44 Parameters Description Figure 3.3 – Brake control operation Description of the identified moments: 1 – The load forward command is given through the digital input DI1. The motor becomes magnetized, and voltage and frequency are applied to it. The brake remains closed. 2 –...

  • Page 45: Momentary Overload

    Parameters Description 5 – The speed reference 2, programmed in P1032, is selected through the digital input DI4. The load is then accelerated to that speed reference 2 selected through the digital input DI4. Note that the motor current increases, but momentary overload is not detected while forward the load. 6 –...
  • Page 46 Parameters Description P1054 – Momentary Overload Alarm (A770) Delay Time Adjustable 0.00 to 650.00 s Factory Setting: 1.00 s Range: Proprieties: Access groups via HMI: 01 PARAMETER GROUPS ∟ 50 SoftPLC ..Description: This parameter defines a delay time after the motor current becomes greater than or equal to the threshold defined in P1052, during a load forward or load reverse command, before the alarm “A770: Momentary Overload”, is generated.

  • Page 47: Inverter In Torque Limit Detection

    Inverter in Torque Limit is an abnormal condition detected in the crane horizontal motion operation, when the CFW-11 frequency inverter is not able to execute the motion in the desired manner (with controlled speed), i.e., operating in a torque limit condition.

  • Page 48: Improper Operation

    Parameters Description Description: These parameters limit the motor current component that produces positive (P0169) or the negative (P0170) torque. The adjustment is expressed as a percentage of the rated motor torque current. P1028 – Speed Hysteresis for Inverter in Torque Limit Detection Adjustable 0.0 to 50.0 % Factory Setting:...

  • Page 49: Motor Umbalanced Current

    P0206 – Reading Parameter Selection 2 P0207 – Reading Parameter Selection 3 NOTE! Refer to the CFW-11 programming manual for more information on the HMI parameters. Some parameter options have been removed from the configuration wizard. Crane Horizontal Motion | 49...

  • Page 50: Read-Only Parameters

    Parameters Description 3.18 READ-ONLY PARAMETERS P1010 – Crane Horizontal Motion Version Adjustable 0.00 to 10.00 Factory Setting: Range: Proprieties: Access groups via HMI: 01 PARAMETER GROUPS ∟ 50 SoftPLC ..Description: This parameter indicates the version of the applicative developed for the crane horizontal motion. 3.18.1 Alarm History This parameter group allows to the user to visualize the last three alarms that have occurred in the inverter, together with their time and date information.

  • Page 51: Status Word

    01 PARAMETER GROUPS ∟ 50 SoftPLC ..Description: This parameter allows the status monitoring of the CFW-11 frequency inverter and of the crane horizontal motion commands. Each bit represents a specific status. Table 3.4 – Status word 1 description Bits...
  • Page 52 Parameters Description Bit 8 0: No load reverse command Load Reverse 1: It indicates that a load reverse command is being executed. Command Bit 9 0: It indicates that a brake closing command is being executed. Brake Release 1: It indicates that a brake release command is being executed. Command Bits 10 to 15 Reserved.

  • Page 53: Creation And Download The Application

    In order to configure the CFW-11 inverter for Crane Horizontal Motion application, it is necessary to create the ladder application on the WLP and then download it to the SoftPLC function of the CFW-11 inverter, as well as the parameter values configured on the configuration wizard.
  • Page 54 Creation and Download the Application Step: Adjust the configuration of the WLP communication interface with the equipment, can be via USB or serial port (COM1..COM8). For this, select Communicate and then click Configuration (Shift + F8); Figure 4.3 – Adjust the communication interface in the new project Step: Download the ladder application and user’s parameter.
  • Page 55 Then click “Ok” to start the transfer to the CFW-11 inverter; Figure 4.5 – Ladder application download dialog Step: Download the ladder application to the CFW-11 inverter. For this, after the project is compiled and the CFW-11 inverter is identified, click "Yes" to start the download;...
  • Page 56 Creation and Download the Application Step: Start the configuration wizard setup for Crane Horizontal Motion application. For this, click the Configuration Wizard “Crane Horizontal Motion” in the project tree bar; Figure 4.9 – Select the configuration wizard for Crane Horizontal Motion application Step: Click "Finish"...
  • Page 57 Step: Send the values of the parameters configured in the configuration wizard of Crane Horizontal Motion for the CFW-11 inverter. For this, click "Yes" to start sending the values. Figure 4.11 – Dialog for download the values of configuration wizard...

  • Page 58: Download Dialog Boxes

    Through the WLP it is possible to download the user´s ladder program, the configuration of user´s parameters and the values configured in the configuration wizard. Below is a presentation of the main download dialogs to the CFW-11 inverter. NOTE! Refer to the help topics in the WLP programming software for more details on the download.

  • Page 59: Project Tree On Wlp

    Application, configure the parameters through the Configuration Wizards (2), monitor parameters and variables through the Monitoring Dialogs (3), monitor variables through Trend Variables Dialogs (4), and upload/download drive parameters CFW-11 through the parameter Values Dialogues (5). The figure 6.1 presents the project tree where the functions mentioned before.

  • Page 60: Application Configuration Wizard

    When powering up the inverter for the first time follow the steps described in the chapter 5 “First time Power-up and Start-up” of the CFW-11 user´s guide inverter. It is recommended to use the V/f control mode for this type of application! Figure 6.3 –...

  • Page 61: Monitoring Dialog Boxes

    Project Tree on WLP 6.3 MONITORING DIALOG BOXES It is possible to monitor and change the parameters of the Crane Horizontal Motion application through the WLP. Figure 6.4 – Monitoring dialog of the Crane Horizontal Motion application 6.4 TREND VARIABLES DIALOG BOXES It is possible to monitor variables of the Crane Horizontal Motion application through the WLP.

  • Page 62: Parameter Value Dialog

    Project Tree on WLP 6.5 PARAMETER VALUE DIALOG Through the WLP, it is possible to save the parameters of the Crane Horizontal Motion applicative. Figure 6.6 – Parameter value dialog NOTE! Refer to the WLP programming software help topics for more information on the use of the parameter value dialog box.

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