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Hitachi P1 Instruction Manual

Hitachi P1 Instruction Manual

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HITACHI P1 BASIC INSTRUCTION MANUAL
DETROIT HOIST PROGRAM V30
Detroit Hoist & Crane LLC, Co.
6650 Sterling Drive North, Sterling Height Michigan 48312
+1 586-268-2600
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  • Page 1 HITACHI P1 BASIC INSTRUCTION MANUAL DETROIT HOIST PROGRAM V30 Detroit Hoist & Crane LLC, Co. 6650 Sterling Drive North, Sterling Height Michigan 48312 +1 586-268-2600 Page 1...
  • Page 2 Stop Read First! IMPORTANT! – This manual was created based on Detroit Hoist program version 30. Please verify the program number before using this manual by navigating to VFD parameter db-02. Step Instruction Power up the VFD. Press the #1 button on the display one time and the screen will change to a menu listing with scroll mode at the top of the screen.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS BASIC SPECIFICATIONS ................................ 6 POWER CIRCUIT WIRING ..............................7 CONTROL CIRCUIT WIRING ..............................8 CONFIGURING SPEED CONTROL METHOD ........................10 CONFIGURING SPEEDS / FREQUENCIES ..........................11 MULTI-STEP SPEED COMMAND ............................12 0-10V ANALOG SPEED CONTROL ............................13 ALTERNATE SPEED CONTROL METHOD SWITCHING ......................
  • Page 4 EZCOM PARAMETERS ................................ 36 EZCOM V27-29 TO V30 TRANSLATION ..........................37 EZCOM CIRCUIT WIRING ..............................38 HOOK BLOCK SYNCING / PULSE TRAIN POSITION COMMAND (CLV) ................39 PULSE TRAIN POSITION COMMAND PARAMETERS (CLV) ....................39 PULSE TRAIN POSITION COMMAND WIRING EXAMPLE (CLV) ..................40 TROUBLESHOOTING PULSE TRAIN POSITION COMMAND (CLV) ..................
  • Page 5 FAULT / ERROR CODES DESCRIPTION ..........................61 VIEW FAULT HISTORY ................................ 63 CLEARING FAULT HISTORY ..............................64 USING THE KEYPAD ................................65 MANUAL REVISIONS................................75 Page 5...

  • Page 6: Basic Specifications

    Please contact Detroit Hoist for further information on single phase applications. • 380-480Vac (400v class models P1-*****-H). Nominal voltage 460-480V | maximum rated voltage 500V • 208-240Vac (200v class models P1-*****-L). Nominal voltage 210-230V | maximum rated voltage 240V •...

  • Page 7: Power Circuit Wiring

    POWER CIRCUIT WIRING Risk of electric shock! Risk of electric shock! • Before inspecting the inverter, be sure to turn off • Before inspecting the inverter, be sure to turn off the power supply and wait for more than 10 or 15 the power supply and wait for more than 10 or 15 minutes depending on the invertor model minutes depending on the invertor model...

  • Page 8: Control Circuit Wiring

    CONTROL CIRCUIT WIRING Below is a basic example of the control circuit for the Hitachi P1 with the DH firmware and may differ from the actual configuration please reference the provided electrical drawing. Please consult Detroit Hoist if you plan to make changes to the control circuit for specific functions to ensure compatibility with the DH firmware.
  • Page 9 Terminal Symbol Description Internal 24V power supply COM 1 - 9 24v digital inputs for command functions. 5.6mA * 7 not configurable Terminal 4, 6, 8, 9 can be configured for allowed functions. 0v ground reference for 24v control circuit A, B 24v Encoder input for control main body.

  • Page 10: Configuring Speed Control Method

    CONFIGURING SPEED CONTROL METHOD Detroit Hoist VFD controls come factory pre-configured for 2-Step speed control unless otherwise specified during the ordering process. Use the chart below to configure the speed control method that is required. If additional inputs are required for the desired speed control method, you will need to add the appropriate circuit if one is not present on the panel.

  • Page 11: Configuring Speeds / Frequencies

    CONFIGURING SPEEDS / FREQUENCIES Speed / frequency values are stored as whole numbers (example is 15.25 Hz = 1525). Use the chart below to configure the speeds / frequencies for the configured speed control method. NOTE – If operating at low frequencies for an extended amount of time an external motor cooling device may be required to prevent motor overheating.

  • Page 12: Multi-Step Speed Command

    MULTI-STEP SPEED COMMAND Multi-Step speed command can be configured up to 16 speeds. Only use multi-step speed command when speed control greater than 3-steps is required. In the multi-step speed command, 4 inputs as a binary combination of 0 (OFF) and 1 (ON) will determine the command frequency, reference the chart below for configuring the steps and speeds.

  • Page 13: 0-10V Analog Speed Control

    0-10V ANALOG SPEED CONTROL When using 0-10V or 4-20mA the low-speed frequency will be 0V or 4mA. If the 0-10V is supplied from a radio that has its own 10V supply, then you will only need to connect the radio’s 0V / COM reference to terminal L and the radio’s 0-10V output signal to Ai1 terminal.

  • Page 14: Alternate Speed Control Method Switching

    ALTERNATE SPEED CONTROL METHOD SWITCHING It is possible to switch between two different speed control methods using a digital input on the VFD. The Alternate Speed Control Method does not support Multi-Step Speed Control and can only be assigned to the Standard Speed Control Method.

  • Page 15: Acceleration / Deceleration Times

    ACCELERATION / DECELERATION TIMES When adjusting the deceleration times be sure to check the hook block limit for over travel. If over travel occurs either lower the deceleration time or adjust the limit zones. Changing the acceleration time to a shorter time can cause an E01 over-current or E05 over-load fault /trip, if this occurs due to a short acceleration time increase the acceleration time and test again.

  • Page 16: Alternate Acceleration / Deceleration Times

    ALTERNATE ACCELERATION / DECELERATION TIMES The alternate acceleration and deceleration function can be used to switch from the standard acceleration and deceleration times to an alternate acceleration and deceleration time based on a digital input, frequency break point, or reversal of direction command (aka reverse plugging). If you plan to use switch by input [2CH] you will need to configure an available digital input function for 31:[2CH] (example CA-06 = 31) and add the 24v circuit for that input.

  • Page 17: Micro-Speed Function

    MICRO-SPEED FUNCTION Micro-speed is designed to temporarily restrict or lower the speed set until the function is released. The micro-speed function can be configured for two different modes. Min-Max Mode – This mode will limit the low speed and high-speed frequency range to the values supplied in UE-10 for low-speed and UE-15 for high-speed.

  • Page 18: Automatic Adaptive Auto-Speed Function (Aaas)

    AUTOMATIC ADAPTIVE AUTO-SPEED FUNCTION (AAAS) The automatic adaptive auto-speed (AAAS) function will automatically increase the frequency to the fastest possible frequency while keeping the output motor current 10% below the overload / over-weight high speed current settings CE107 to prevent trips and false over-weight detections. The auto-speed does not function when micro-speed is active, or when in tandem mode / sync mode.

  • Page 19: 125% Field Load Testing / Over-Weight Bypass

    125% FIELD LOAD TESTING / OVER-WEIGHT BYPASS Each hoist is factory load tested prior to shipment. If a field load test is required, you will need to bypass the over-weight signal. To bypass the over-weight signal, locate the bypass terminal knife disconnect it should be labeled “BPS” (use images below as reference) and pull the yellow/orange tab to open.

  • Page 20: Hoist Over-Weight Function

    HOIST OVER-WEIGHT FUNCTION The VFD is setup to use the output current to the motor as the over-weight function. The VFD uses (2) over-weight current parameters. Over-weight (1) is when operating less than or equal to the low-speed frequency and over-weight (2) is when operating above low-speed frequency.

  • Page 21: Hoist Over-Weight Parameters

    HOIST OVER-WEIGHT PARAMETERS Function Parameters Example Value 0 = External Momentary Over-Weight Signal Output Type UE-54 1 = External Maintained 2 = Internal Over-Weight Detection Delay Time UE-55 150 = (1.5 seconds) Over-Weight Reset Time UE-56 200 = (2.0 seconds) Over-Weight (2) Switch Over Frequency UE-57 1200 = (12.00Hz)

  • Page 22: Setting Hoist Over-Weight

    SETTING HOIST OVER-WEIGHT Each hoist’s over-weight settings will be set at the factory prior to shipment. In some cases, field adjustments may be required. Use the step chart below to set the hoist’s over-weight settings. NOTE – If you are setting the alternative over-weight parameters use steps 6A and 7A. Step Instruction Locate the terminal knife disconnect labeled “BPS”...

  • Page 23: Outut For Fault Signal

    OUTUT FOR FAULT SIGNAL The VFD will come from Detroit Hoist with output 16 (dry contact) already configured for fault alarm signal. If you need to switch the fault alarm signal to a different output. Function Parameters Value CC-01 thru CC-05 (24vdc digital i/o) Fault Alarm Signal 017 = AL (Alarm) CC-06 (16 relay dry contact)

  • Page 24: Output 0-10V / 4-20Ma

    OUTPUT 0-10V / 4-20mA The output analog can be configured for multiple functions. Listed below are the most common functions used for hoist and crane applications. If the function is not present, please contact Detroit Hoist for further assistance. Function Parameters Value Description...

  • Page 25: Electronic Motor Thermal Protection

    ELECTRONIC MOTOR THERMAL PROTECTION The VFD has a built-in electronic motor thermal protection function and is configured for constant torque loading. When the output current exceeds the value in bC110 for a calculated time based on frequency, time and a reduction ratio. The electronic thermal protection function also can save the current data and calculate it based on output current and time.

  • Page 26: Shock-Load Prevention / Detection (Clv)

    SHOCK-LOAD PREVENTION / DETECTION (CLV) Shock-Load Protection – The VFD will set a reserved forward driving torque limit. The reserve torque limit is calculated from the required torque and the addition of the torque padder value either at constant speed or at acceleration. This will provide the motor with the minimum amount of torque required to operate and allow for a torque limited stall if the torque rises abruptly.

  • Page 27: Motor Brake Parameters

    MOTOR BRAKE PARAMETERS While operating in closed loop vector mode (AA121 = 10) the motor brake release and set frequencies are controlled automatically and typically do not require adjustment. When operating in open loop mode (AA121 = 1 thru 9) the motor brake release and set frequencies are controlled by parameters that can be adjusted but typically do not require adjustment.

  • Page 28: Encoder-Based Operational Hook Block Limits (Clv)

    ENCODER-BASED OPERATIONAL HOOK BLOCK LIMITS (CLV) The VFD has the capability to utilize the motor encoder to create digital upper and lower operational hook block limits. This is done with the use of the encoder from the motor while operating in closed loop vector control only (AA121 = 10) and with the encoder-based limits enabled (UE-33 = 1 or 2).

  • Page 29: Setting Encoder-Based Limits (Clv)

    SETTING ENCODER-BASED LIMITS (CLV) Use the step chart below to set the encoder-based limits. If using switches from the factory use the image below of the blue terminal knife disconnect as reference. IMPORTANT NOTE – New with V29 if the PP switch is left open and power is cycled the PP switch will need to be closed and opened again in order to enter Program Position mode.

  • Page 30: Output Signal For Encoder Limits (Clv)

    OUTPUT SIGNAL FOR ENCODER LIMITS (CLV) When using the encoder-based limits it is possible to configure available digital outputs for upper and lower limit indication outputs. Use the chart below. A separate external 24vdc supply is required to be added to power the additional outputs.

  • Page 31: Encoder Parameters (Clv)

    In most applications the encoder will terminate at the main body digital input terminals and the parameters with Main Body will apply. In some cases, an external feedback card will be installed and the parameters with P1-FB will apply. In the case of the P1-FB card CA-90 will need to = 00: disabled.

  • Page 32: Load Float (Clv)

    LOAD FLOAT (CLV) Load float is a term used in closed loop vector control where the VFD can hold the motor / load in a servo-lock state at 0hz / 0 speed without the use of the motor brake. This function is available when operating in closed loop mode (AA121 = 10) and will increase the life of the motor brake by only using the motor brake as a static holding/parking brake and not a dynamic brake during normal operation.

  • Page 33: Motor Torque Proving (Clv)

    MOTOR TORQUE PROVING (CLV) Motor torque proving function is a safety check feature that checks to make sure the motor can generate sufficient torque to current ratio before releasing the motor brake. Motor torque proving function is only available when operating in closed loop vector control only (AA121 = 10).

  • Page 34: Motor Brake Slip Detection (Clv)

    MOTOR BRAKE SLIP DETECTION (CLV) Motor brake slip detection function is a safety check feature that checks for motor rotation / brake slip after the motor brake has been set and will hold the load if rotation / slip is detected. Motor brake slip detection function is only available when operating in closed loop vector control only (AA121 = 10).

  • Page 35: Ezcom Rs485 Sync (Speed & Command Syncing)

    EZCOM RS485 SYNC (SPEED & COMMAND SYNCING) EZCOM can be used when 2 VFD’s are used in tandem operation and require synced operation of the frequency, command status, and fault status. The VFD’s will need to be configured to allow peer to peer communication between each other.

  • Page 36: Ezcom Setup Guide

    EZCOM SETUP GUIDE Step Instruction Configure the VFD’s parameters using the EZCOM parameter chart. Most of the parameters should already be configured and only the ones highlighted in yellow should need to be changed. Power down both VFD’s and connect the 2-wire shielded cable to the corresponding SN & SP terminals as shown in the EZCOM circuit wiring example on the next page.

  • Page 37: Ezcom V27-29 To V30 Translation

    EZCOM V27-29 TO V30 TRANSLATION If using Ezcom with an existing P1 with firmware version 27-29 then you will need to modify the Ezcom destination parameters on both VFD’s. See the chart below. Decimal Value Parameter Hex Value P1 V27-29 Ezcom Dest.

  • Page 38: Ezcom Circuit Wiring

    EZCOM CIRCUIT WIRING EZCOM wiring example circuit. Make sure the VFD#2 has the RS485 termination jumper installed between RP and SN as shown below. Make sure to bond terminals CM1 as shown below. Ground the shield of the communication cable only at one end.

  • Page 39: Hook Block Syncing / Pulse Train Position Command (Clv)

    HOW IT WORKS – The VFD’s use the SN/SP RS485 terminals to send frequency reference, drive status, and command status Modbus registers values between each other. The VFD’s also required the external encoder feedback card (P1-FB) connected in order to send the 1:1 pulse train encoder signal. The main hoist will send a 1:1 pulse train from the encoder card to the pulse train input on the follower encoder card.

  • Page 40: Pulse Train Position Command Wiring Example (Clv)

    PULSE TRAIN POSITION COMMAND WIRING EXAMPLE (CLV) The external encoder card P1-FB will need to be installed in the center option card slot #2 on both VFD’s. The reference image below is based on a non-inverted encoder signal connection. If the connected encoder signal is inverted then the connections from AP, AN, BP, BN to SAP, SAN, SBP, SBN will need to be inverted as well.

  • Page 41: Troubleshooting Pulse Train Position Command (Clv)

    TROUBLESHOOTING PULSE TRAIN POSITION COMMAND (CLV) After the wiring and parameters have been set if the follower hoist does not rotate in the correct direction, then you will need to reverse the pulse train connection phase by switching the position of the SAP & SAN wires to the position of SBP &...

  • Page 42: Vfd Control Modes

    VFD CONTROL MODES If you need to change the VFD control mode for testing, troubleshooting, or changing an open loop hoist to closed loop reference the parameter chart below. Only choose the options provided below that are verified to be compatible with the DH firmware.

  • Page 43: Auto-Tuning

    AUTO-TUNING Field auto-tuning is generally not required. The VFD will be configured from the factory for the connected motor. If field auto-tuning is required, please use the step chart below. NOTE – The E-stop / maximum upper limit will retain function to prevent over-travel into the frame. The VFD will automatically control the brake release command during auto-tuning.

  • Page 44: Speed Deviation (Clv)

    SPEED DEVIATION (CLV) The speed deviation error detection function judges that the deviation is excessive if the deviation between the frequency command and the feedback speed becomes large. Speed deviation is the difference between [dA-12] Output frequency monitor and [dA-08] detected frequency monitor. When the absolute value of speed deviation has exceeded [bb-83] Speed deviation error detection level and [bb-84] Speed deviation error detection time has elapsed, it is judged as a speed deviation error.

  • Page 45: Dynamic Braking

    DYNAMIC BRAKING Dynamic braking is used to electronically brake the motor during deceleration. Dynamic braking requires the use of a braking resistor or a regenerative converter. The parameters below only apply when using a resistor. Load-Brake – The internal load-brake absorbs 99% of the dynamic braking. The dynamic braking usage ratio should be set to 3% to detect when the load-brake becomes worn, and maintenance is required.

  • Page 46: Over-Speed (Clv)

    OVER-SPEED (CLV) The over-speed error detection function judges that the speed is excessive if the feedback speed exceeds the over-speed level. Whether the speed is excessive is determined according to the feedback frequency displayed on [dA-08] Detected frequency monitor. When the speed has exceeded [bb-80] Over-speed error detection level and [bb-81] Over-speed error detection time has elapsed, it is judged as an over-speed error.

  • Page 47: Input Phase Loss Protection

    INPUT PHASE LOSS PROTECTION When [bb-65] input phase loss selection is set to 01, when a missing phase is detected in input line, the inverter turns OFF its output. This protection function is used to prevent system failure due to unstable motor operation when a phase loss occurs by breakage of the input power cable.

  • Page 48: Input Power Supply Over-Voltage Protection

    INPUT POWER SUPPLY OVER-VOLTAGE PROTECTION This function will output an error [E015] when the P-N voltage exceeds the voltage level set in the incoming overvoltage level selection [bb-62] for 100 seconds continuously due to incoming voltage. Function Parameter Example Value 0 = warning Power supply over-voltage error bb-61...

  • Page 49: Monitor Digital Inputs

    MONITOR DIGITAL INPUTS The Hitachi VFD’s have a monitor function that will display the status of the 24vdc digital inputs 1 through 9 & A, B. Unlike the WJ200 the P1 has a GUI screen and supports up to (3) monitors on the main screen. By default, the digital input monitor should be located on the bottom of the main screen on power up.

  • Page 50: Monitor Parameters

    MONITOR PARAMETERS Monitor Parameter Brief Description Output Frequency dA-01 The commanded output frequency. Output Current dA-02 Displays the output current to the motor. Actual Rotation Direction dA-03 Output rotation direction (f = forward / r = reverse) Encoder Detected Speed dA-08 Displays the detected speed from the encoder Output Torque...

  • Page 51: Troubleshooting E50 Fault

    TROUBLESHOOTING E50 FAULT WHAT IS AN E50 FAULT - An E50 fault is a brake slip detection fault. This will occur when a brake slip is detected, and the next brake slip detection test has passed usually when a load is removed or on the ground. This fault is used to alert and track that a brake slip has been detected and the motor brake should be inspected immediately before using the hoist again.

  • Page 52: Troubleshooting E51 Fault

    TROUBLESHOOTING E51 FAULT WHAT IS AN E51 FAULT - An E51 fault is a motor torque proving fault. The motor responded with less than the anticipated motor current. HOW IS AN E51 FAULT DETERMINED – When the VFD is operating in closed loop vector control only (AA121 = 10) at the start of a lift cycle the VFD applies a calculated output torque to the motor and allows a specific amount of time UE-32 for the motor to respond with the motor current.

  • Page 53: Troubleshooting E52 Fault

    TROUBLESHOOTING E52 FAULT WHAT IS AN E52 FAULT - An E52 fault is a speed deviation fault. The encoder detected speed deviated from the output commanded set-frequency. HOW IS AN E52 FAULT DETERMINED – When the VFD is operating in closed loop vector control only (AA121 = 10) the VFD is constantly comparing the detected frequency from the encoder to the commanded frequency while running.

  • Page 54: Troubleshooting E53 Fault

    TROUBLESHOOTING E53 FAULT WHAT IS AN E53 FAULT - An E53 fault is a over-torque fault. HOW IS AN E53 FAULT DETERMINED – When the VFD is operating in a control mode of (AA121 = 8, 9, or 10) the VFD will use the torque monitor to determine if the output torque becomes greater than the values in over-torque level parameters CE120 –...

  • Page 55: Troubleshooting E054 Fault

    TROUBLESHOOTING E054 FAULT WHAT IS AN E54 FAULT - An E54 fault is a shock-load snag detection fault. HOW IS AN E54 FAULT DETERMINED –When the VFD reaches a constant speed above the low-speed frequency setting, the VFD will monitor the required torque and set the forward driving torque limit to the required torque + a torque padder value.

  • Page 56: Troubleshooting E055 Fault

    TROUBLESHOOTING E055 FAULT WHAT IS AN E55 FAULT - An E55 fault is when the motor torque test failed because there was motion / brake slip during the motor torque test and was the reason for the failure. HOW IS AN E55 FAULT DETERMINED –When the motor torque proving test is started the VFD will monitor the detected speed from the motor encoder and if the detected speed is greater than zero speed parameter value the VFD will fail the motor torque proving test with an E55 fault.

  • Page 57: Troubleshooting E001 / E005 / E039 Faults

    TROUBLESHOOTING E001 / E005 / E039 FAULTS WHAT IS E001, E005, and E039 FAULT – The 3 faults are all over-current type faults. • If operating in closed loop AA121 = 10 then check the encoder shaft collar is tight on the shaft and the encoder tether is secure.

  • Page 58: Troubleshooting E007 Fault

    TROUBLESHOOTING E007 FAULT WHAT IS AN E007 FAULT – An E007 fault is a dc-bus over-voltage fault. • Check the dynamic braking resistor circuit. Check that the resistor is connected to the correct terminals RB & P+. Check if the resistor is open using a multimeter. •...

  • Page 59: Troubleshooting E016 Fault

    TROUBLESHOOTING E016 FAULT WHAT IS AN E016 FAULT – An E016 fault is an instantaneous power failure fault. When the power is removed and restored within a very short period the VFD will detect that as an instantaneous power failure and will fault to protect the VFD and motor.

  • Page 60: Troubleshooting Blank Screen / Display

    TROUBLESHOOTING BLANK SCREEN / DISPLAY If the VFD’s screen / display is blank, it usually means the internal 24v power supply is shorted or damaged. In most cases if a connected circuit is causing the short, disconnecting that circuit will restore 24v power to the screen / display. •...

  • Page 61: Fault / Error Codes Description

    FAULT / ERROR CODES DESCRIPTION Fault / Error Code Description E001 Over-current error E005 / E039 Electronic thermal overload error (motor current > bC110) E006 Dynamic braking resistor over used error E007 DC-Bus over-voltage error E008 / E011 Memory error / CPU error E009 Undervoltage error E010...
  • Page 62 Option card slot 3 connection error E090 – E096 STO path error / FS option error E100 Encoder disconnection error when using P1-FB option card Position control range error E104 The encoder position data exceeded (268435455 | -268435455) pulses E105...

  • Page 63: View Fault History

    VIEW FAULT HISTORY To view the fault history, use the step chart below. Step Instruction Power on the VFD. Press the left arrow button 2 times to view the fault history list. Use the up and down arrow buttons to scroll through the fault history list and use the center dot button to select the fault and view information as in date / time / fault / status / output current / dc-buss / ext.

  • Page 64: Clearing Fault History

    CLEARING FAULT HISTORY To clear the fault history, use the step chart below. Step Instruction Power on the VFD. Press the #1 button one time to view the menu screen. Use the arrow buttons to highlight “SCROLL MODE” and press the center dot button to enter the “SCROLL MENU”.

  • Page 65: Using The Keypad

    USING THE KEYPAD Page 65...
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  • Page 76: Manual Revisions

    MANUAL REVISIONS Manual Firmware Date What Changed Version# Version# 6/25/2024 • Initial release for firmware version 30 Page 76...
  • Page 77 FIRMWARE REVISIONS CHANGE LOG What changed from V29 to V30 Detroit Hoist firmware for the Hitachi P1? • The auto-speed function has been revamped and only features the adaptive auto-speed function. The auto-speed activation level from V29 was reused for the adaptive auto-speed function to still allow for auto-speed activation based on a specified load and is now based on the motor output current instead of the VFD’s output current...

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