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  HITACHI WJ BASIC INSTRUCTION MANUAL DH PROGRAM #27 Detroit Hoist & Crane LLC, Co. 6650 Sterling Drive North, Sterling Height Michigan 48312 +1 586-268-2600 Page 1…
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  Stop Read First! Important! – This manual is for program number #27 from Detroit Hoist. Please verify the program number before using this manual by navigating to VFD parameter d024. To navigate to d024 and check your VFD’s program number follow the steps chart below. Step Instruction Power up the VFD.

• Page 3: Table Of Contents

  Contents BASIC SPECIFICATIONS …………………………….4 POWER CIRCUIT WIRING …………………………….5 CONTROL CIRCUIT WIRING …………………………….6 CONFIGURING SPEED CONTROL METHOD ……………………….7 CONFIGURING SPEEDS / FREQUENCIES …………………………8 ACCELERATION / DECELERATION TIMES …………………………. 9 ALTERNATE ACCELERATION / DECELERATION TIMES ……………………..9 MICRO-SPEED FUNCTION …………………………….

• Page 4: 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 derate VFD to 70% and may require a larger VFD to supply the required motor current. •…

• Page 5: 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 6: Control Circuit Wiring

  CONTROL CIRCUIT WIRING Below is a basic example of the control circuit for the Hitachi WJ 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 7: 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. Speed Control Method Parameters Values 2-Step P108 2-Step Infinitely Variable…

• Page 8: 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. If operating at frequencies below or at 5hz for an extended amount of time an external motor cooling device may be required to prevent motor overheating.

• Page 9: Acceleration / Deceleration Times

  ACCELERATION / DECELERATION TIMES Changing the acceleration time to a shorter time can cause a E01, E02, or E03 over-current and or E05 over-load fault /trip, if this occurs due to a short acceleration time increase the acceleration time and test again. Changing the deceleration time to a shorter time can cause a E07 over-voltage fault/trip, if this occurs due to a short deceleration time increase the deceleration time and test again.

• Page 10: Micro-Speed Function

  MICRO-SPEED FUNCTION Micro-speed is designed to temporarily restrict the speed of the hoist to a lower speed and to prevent high speed operations until the function is released. The micro-speed function can be configured two ways. 2-STEP MAINTAINED MODE – This mode will switch to a 2-Step maintained speed set. This is helpful where the micro-speeds need to be specific.

• Page 11: Auto-Speed 90Hz Function

  AUTO-SPEED 90HZ FUNCTION The auto-speed function will allow the VFD to increase the high speed to up to 90Hz when there is an empty hook or a light load. You can set this function for automatic or for input activation. The auto-speed function is not available when using 0-10V/4-20mA speed control methods, when micro-speed is active, and or when in tandem mode.

• Page 12: 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 13: 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 14: 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 15: Carrier Frequency

  CARRIER FREQUENCY The carrier frequency is adjustable from 2.0kHz to 15kHz. The audible sound decreases at the higher frequencies, but RFI noise and leakage current may be increased. It is recommended that the carrier frequency is 2.3kHz or greater when operating in sensorless vector A044 = 03.

• Page 16: Reset Fault Using Input

  RESET FAULT USING INPUT Resetting a fault remotely using an input to the VFD can be done by configuring one of the available digital inputs for reset. Use the chart below. Function Parameters Value Fault reset C006 – C007 18 = RS OUTPUT SIGNAL WHEN FAULT OCCURS You can configure a 24v digital output to turn on when a fault occurs.

• Page 17: Motor Brake Parameters

  MOTOR BRAKE PARAMETERS The motor brake parameters ca be adjusted based on the application needs. Brake wait time for release – After the Brake Release Frequency Setting is reached, the inverter waits for the braking wait time (b121) Brake wait time for acceleration – The inverter waits for the Brake Wait Time for Acceleration (b122), and then starts accelerating the motor up to the set acceleration frequency.

• Page 18: Constant Torque Control Mode / Manual Torque Boost

  CONSTANT TORQUE CONTROL MODE / MANUAL TORQUE BOOST Manual Torque Boost – The Constant and Variable Torque algorithms feature an adjustable torque boost curve. When the motor load has a lot of inertia or starting friction, you may need to increase the low frequency starting torque characteristics by boosting the voltage above the normal V/f ratio (shown below).

• Page 19: Constant Torque Control Mode / Automatic Torque Boost

  CONSTANT TORQUE CONTROL MODE / AUTOMATIC TORQUE BOOST In constant torque using automatic torque boost the starting torque boost value and frequency break point are used as starting points for automatic torque boost. Voltage compensation gain and slip compensation gain are used for fine tuning adjustments. Using parameters A046 and A047, you can obtain better performance under automatic torque boost mode (A041=01).

• Page 20: Sensorless Vector Control Mode

  SENSORLESS VECTOR CONTROL MODE Sensorless vector control can achieve high torque performance (200% torque at 0.5Hz of output frequency) without motor speed feedback (encoder feedback). Sensorless vector control enables the inverter to accurately operate the motor with a high starting torque, even at low speed.

• Page 21: Fine Tuning Sensorless Vector

  FINE TUNING SENSORLESS VECTOR In most cases fine tuning is not required with the standard motor constants that are supplied when selecting the correct motor constant profile in parameter H003. Before making adjustments, try selecting a motor constant profile (1) smaller or larger than the combined connected motors in kW’s in parameter H003.

• Page 22: Auto-Tuning

  AUTO-TUNING In some cases, performing an auto-tune to get the proper motor constant will help in providing optimal performance when operating in sensorless vector control mode A044 = 03. Before auto-tuning make sure that parameter H003 is set to a value of the combined connected motors in kW’s, in some cases this value might be (1) size larger or smaller.

• Page 23: Reduced Load Swing

  REDUCED LOAD SWING In traverse applications it is possible to reduce the chance of load swing by configuring the VFD for sensorless vector control and using the torque limits to help reduce starting load swing. Also, you will use the alternate acceleration and deceleration functions to reduce load swing when accelerating and decelerating to and from high speeds.

• Page 24: Tandem Hoist / Trolley Ezcom (Speed / Command Syncing)

  TANDEM HOIST / TROLLEY EZCOM (SPEED / COMMAND SYNCING) Tandem hoist / trolley EZCOM can be used when 2 hoists / trolleys are used in tandem operation and require the frequency, command status, and run status to sync between each hoist. The VFD’s will need to be configured to communicate between each other and the internal logic activated.

• Page 25: 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 26: Ezcom Circuit Wiring

  EZCOM CIRCUIT WIRING EZCOM wiring example circuit. Make sure the BVFD has the RS485 termination resistor dip switch toggled to the right. MDSW1 Dip switch for termination RS-485 (Modbus) Page 26…

• Page 27: View Fault History

  VIEW FAULT HISTORY To view the fault history, use the step chart below. Step Instruction Power on the VFD. Press ESC button and use the arrow buttons to navigate to d081 – d086. Press the SET button to view the fault. NOTE d081 will always be the most recent fault.

• Page 28: Clearing Fault History

  CLEARING FAULT HISTORY To clear the fault history, use the step chart below. Step Instruction Power on the VFD. Press the ESC button 4 times or until the screen displays b001. Use the arrow buttons to navigate to parameter b084. Press the SET button to enter the parameter, use the UP arrow to set the value to 01 and press the SET button to save the change.

• Page 29: Fault / Error Codes Description

  FAULT / ERROR CODES DESCRIPTION Fault / Error Code Description Over-current event while at constant speed Over-current event during deceleration Over-current event during acceleration Over-current event during other conditions Electronic thermal overload protection (motor current > b012) Dynamic braking resistor over used error. Check incoming voltage for spikes. DC-Bus over-voltage error.

• Page 30
  REVISIONS Version Date Changes / Updates 1/7/2022 Initial release Page 30…

Basic System Description

A motor control system will obviously include a motor and inverter, as well as a circuit breaker or fuses for safety. If you are connecting a motor to the inverter on a test bench just to get started, that’s all you may need for now. But a system can also have a variety of additional components. Some can be for noise suppression, while others may enhance the inverter’s braking performance. The figure and table below show a system with all the optional components you might need in your finished application.

Determining Wire and Fuse Sizes

The maximum motor currents in your application determines the recommended wore size. The following table gives the wire size in AWG. The “Power Lines” column applies to the inverter input power, output wires to the motor, the earth ground connection, and any other components shown in the “Basic System Description” on page 9. The “Signal Lines” column applies to any wire connecting to the two green connectors just inside the front cover panel.

18 to 28 AWG / 0.14 to 0.75 mm2 shielded wire (see Note 4)

Note 1: Field wiring must be made by a UL-Listed and CSA-certified closed-loop terminal connector sized for the wire gauge involved. Connector must be fixed by using the crimping tool specified by the connector manufacturer.

Note 2: Be sure to consider the capacity of the circuit breaker to be used.

Note 3: Be sure to use a larger wire gauge if power line length exceeds 66ft. (20m). Note 4: Use 18 AWG / 0.75mm2 wire for the alarm signal wire ([AL0], [AL1], [AL2]

terminals).

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Wire the Inverter Input to a Supply

In this step, you will connect wiring to the input of the inverter. First, you must determine whether the inverter model you have required three-phase power only, or single-phase power only. All models have the same power connection terminals [R/L1], [S/L2], and

[T/L3]. So you must refer to the specifications label (on the side of the inverter) for the acceptable power source types! For inverters that can accept single-phase power and are connected that way, terminal [S/L2] will remain unconnected.

Note the use of ring lug connectors for a secure connection.

RB +1 + —

RB PD/+1 P/+ N/—

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You can see from the following page how to monitor and/or program the parameters.

Keypad Navigation Map

The WJ200 Series inverter drives have many programmable functions and parameters. Chapter 3 will cover these in detail, but you need to access just a few items to perform the powerup test. The menu structure makes use of function codes and parameter codes to allow programming and monitoring with only a 4-digit display and keys and LEDs. So, it is important to become familiar with the basic navigation map of parameters and functions in the diagram below. You may later use this map as a reference.

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ESC Data display

When data is changed, the display starts blinking, which means that new data has not been activated yet.

Press the both up and down key at the same time in func. code or data display, then single-digit edit mode will be enabled.

Refer to 2-34 for further information.

NOTE: Pressing the [ESC] key will make the display go to the top of next function group, regardless the display contents. (e.g. A021 [ESC] b001)

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[Setting example]

After power ON, changing from 0.00 display to change the A002 (Run command source) data.

Press [ESC] key to move on to the function group F001

F001

ESC

Press [ESC] key Once to move on to the function group A001.

A002

ESC

Press up key to increase the data (02 01)

SET

Press SET key to set and save the data

When data is changed, the display starts blinking, which means that new data has not been activated yet.

SET :Fix and stores the data and moves back to the function code

ESC :Cancels the change and moves back to the function code

Function code dxxx are for monitor and not possible to change.

Function codes Fxxx other than F004 are reflected on the performance just after changing the data

(before pressing SET key), and there will be no blinking.

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Connecting to PLCs and Other Devices

Hitachi inverters (drives) are useful in many types of applications. During installation, the inverter keypad (or other programming device) will facilitate the initial configuration. After installation, the inverter will generally receive its control commands through the control logic connector or serial interface from another controlling device. In a simple application such as single-conveyor speed control, a Run/Stop switch and potentiometer will give the operator all the required control. In a sophisticated application, you may have a programmable logic controller (PLC) as the system controller, with several connections to the inverter.

It is not possible to cover all the possible types of application in this manual. It will be necessary for you to know the electrical characteristics of the devices you want to connect to the inverter. Then, this section and the following sections on I/O terminal functions can help you quickly and safely connect those devices to the inverter.

CAUTION: It is possible to damage the inverter or other devices if your application exceeds the maximum current or voltage characteristics of a connection point.

2.Make sure that the logic sense (active high or active low) of any ON/OFF connection is correct.

3.Check the zero and span (curve end points) for analog connections, and be sure the scale factor from input to output is correct.

4.Understand what will happen at the system level if any particular device suddenly loses power, or powers up after other devices.

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