Related Manuals for Hitachi WJ-C1
Summary of Contents for Hitachi WJ-C1
- Page 1 HITACHI WJ-C1 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 ESC button one time and the screen will change to dA-01. Scroll to db-02 by turning the jog rotary dial clockwise until you get to db-02.
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Page 3: Table Of Contents
TABLE OF CONTENTS BASIC SPECIFICATIONS ................................ 5 POWER CIRCUIT WIRING ..............................6 CONTROL CIRCUIT WIRING ..............................7 CONFIGURING SPEED CONTROL METHOD ......................... 9 CONFIGURING SPEEDS / FREQUENCIES ..........................10 MULTI-STEP SPEED COMMAND ............................11 0-10V ANALOG SPEED CONTROL ............................12 ALTERNATE SPEED CONTROL METHOD SWITCHING ...................... - Page 4 EZCOM WJ200 TO WJ-C1 TRANSLATION .......................... 35 VFD CONTROL MODES ..............................36 MANUAL TORQUE BOOST / AUTOMATIC TORQUE BOOST PARAMETERS ............... 36 AUTO-TUNING ................................... 37 MOTOR CONSTANTS ................................. 37 SPEED DEVIATION ................................38 DYNAMIC BRAKING ................................39 OVER-SPEED ..................................40 CARRIER FREQUENCY ................................
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Page 5: Basic Specifications
BASIC SPECIFICATIONS For specifications that are not listed please contact Detroit Hoist for further information. • Input power 3-phase 50/60hz (recommended). • Single phase applica�ons must use an input line noise filter and derate VFD to 65% and may require a larger VFD to supply the required motor current. -
Page 6: 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 7: Control Circuit Wiring
CONTROL CIRCUIT WIRING Below is a basic example of the control circuit for the Hitachi WJ-C1 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 8 Terminal Symbol Description Internal 24V power supply. Maximum current 100mA Common for inputs 1 – 8. Sink / Source logic switch. Sink logic: short-circuit to [P24] terminal Source logic: short-circuit to [L] terminal 24v digital inputs for command functions. 5mA Terminal 4, 5, 6, 7, 8 can be configured for allowed functions.
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Page 9: 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 10: 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 11: 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 12: 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 13: 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 14: 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 15: 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 the alternate acceleration deceleration switching by input [2CH] you will need to configure an available digital input function for 31:[2CH] (example CA-08 = 31:2CH) and add the 24vdc circuit for that input. -
Page 16: 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. This function is factory configured using digital input 4. 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 17: Limit To Low-Speed Function
LIMIT TO LOW-SPEED FUNCTION For applications where it is required to limit the VFD to low-speed frequency you can configure an available digital input for that function. This is typically used for travel limits or when approaching an upper / lower hook limit. This function, when enabled, will prevent high speed operations and force the VFD to the configured low speed frequency. -
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 functions are available when using 0-10V/4- 20mA speed control methods, when micro-speed is active, and or when in tandem mode sync mode. -
Page 19: Hoist 125% Field Load Testing / Over-Weight Bypass
HOIST 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: 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. Step Instruction Locate the terminal knife disconnect labeled “BPS” and pull the top of the yellow/orange tab outwards, this will bypass the over-weight circuit. -
Page 22: Outut Signal For Fault Signal
OUTUT SIGNAL FOR FAULT SIGNAL The VFD will come from Detroit Hoist with output 12 already configured for fault alarm signal. If you need to switch the fault alarm signal to a different output. Function Parameters Value Fault Alarm Signal CC-01 CC-02 (24vdc digital i/o) 017 = AL (Alarm) RESET FAULT USING INPUT... -
Page 23: 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 24: 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 25: Motor Brake Parameters
MOTOR BRAKE PARAMETERS Brake Release Max Wait Time – The brake release max wait time UE-28 is used to compensate for delayed brakes to help prevent driving through the motor brake. This is the maximum amount of time the VFD will wait before accelerating to the commanded frequency. -
Page 26: Encoder Parameters
ENCODER PARAMETERS The VFD can use encoder feedback for speed compensation and absolute position control. When CA-90 is set to 02: Feedback digital inputs 7 and 8 will be configured for encoder signal inputs [7]: Sig B, [8]: Sig A and cannot be configured for any functions. -
Page 27: Gearbox Mounted Encoder
GEARBOX MOUNTED ENCODER In some applications the encoder may be mounted to the output shaft of a gearbox and will need to be electronically compensated to detect the correct speed of the motor. This function should NOT be used when using AA124 = 01 speed compensation with encoder feedback. -
Page 28: Using An Encoder Feedback For Speed Compensation
USING AN ENCODER FEEDBACK FOR SPEED COMPENSATION The VFD has the capability to utilize a motor encoder for speed compensation. This is in no way a closed-loop flux vector. The VFD can operate in sensorless vector and automatic torque boost with encoder feedback for speed compensation but lacks torque proving, brake slip detection and load floating capabilities. -
Page 29: Using Encoder-Based Operational Travel Limits
USING ENCODER-BASED OPERATIONAL TRAVEL LIMITS The VFD has the capability to utilize the motor encoder to create digital forward/upper and reverse/lower operational travel limits. The VFD will store the pulse data on power cycle. If power is removed during operation or the motor is rotated without power on the VFD, the encoder limit areas may shift and will need to be reset. -
Page 30: Setting Encoder-Based Limits
SETTING ENCODER-BASED LIMITS Use the step chart below to set the encoder-based limits. Step Instruction Navigate to VFD parameter UE-66 and set the value to 1 and save it. Run the hook block to the desired upper limit position and wait for the motor brake to set. Navigate to VFD parameter UE-66 and set the value to 2 and save it, wait 2 seconds, and change it back to 1. -
Page 31: Using Encoder For Absoulte Position Control
USING ENCODER FOR ABSOULTE POSITION CONTROL Please contact Detroit Hoist for more information regarding this information. MULTIPOSITION ABSOULTE POSITION CONTROL Please contact Detroit Hoist for more information regarding this information. Page 31... -
Page 32: 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 33: 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 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 34: Ezcom Circuit Wiring
EZCOM CIRCUIT WIRING EZCOM wiring example circuit. Make sure that VFD#2 has the RS485 termination switched to the on position shown below. Make sure to bond terminals L & PLC as shown below. Ground the shield of the communication cable only at one end. -
Page 35: Ezcom Wj200 To Wj-C1 Translation
EZCOM WJ200 TO WJ-C1 TRANSLATION If using Ezcom with an existing WJ200 then you will need to modify the Ezcom destination parameters on both VFD’s. See the chart below. Decimal Value Parameter Hex Value WJ200 Ezcom Dest. Register 1 18443... -
Page 36: Vfd Control Modes
VFD CONTROL MODES Function Parameters Value 00: V/F Control Constant Torque VFD Control Mode AA121 03: V/F Control Automatic Torque Boost 08: Sensorless Vector Control MANUAL TORQUE BOOST / AUTOMATIC TORQUE BOOST PARAMETERS The manual and automatic torque boost parameters are only valid for VFD control modes 00 CT and 03 ATB. Function Parameter Example Value... -
Page 37: 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 38: Speed Deviation
SPEED DEVIATION 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 39: 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 40: Over-Speed
OVER-SPEED 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 41: 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 42: 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 43: Monitor Digital Inputs
1 through 8. The image below is a reference image to the WJ-C1 digital input monitor. This example shows digital input 5 and 6 is the only active digital input. Again, the screen reads right to left, digital input 1 is the 1 line from the right. -
Page 44: 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 45: 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 with encoder speed feedback (CA-90 = 02) the VFD is constantly comparing the detected frequency from the encoder to the commanded frequency while running. -
Page 46: 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) 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 47: 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 opera�ng in closed loop AA121 = 10 then check the encoder sha� collar is �ght on the sha� and the encoder tether is secure. -
Page 48: 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 mul�meter. •... -
Page 49: 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 50 E043 / E044 / E045 Internal Program illegal instruction error E052 Speed Deviation error E053 Over-Torque 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 51 MANUAL REVISIONS Manual Firmware Date What Changed Version# Version# • Ini�al release for firmware version 30 for new WJ-C1. Used version 30 as a star�ng 6/25/2024 point since the WJ200 le� off at V29 in beta. Page 51...