AN-GS-014: Mine elevator application note using GS3 drive
Contents
1. Multi function Digital Inputs DURAPULSE PLC controlling elevator Output Contact G e 24V Power Source R1 e 20mA max AG DE una Going up Stop grp e D o RiCe ive PUNANG i Input Mode Setting Lom Going down Stop o o DI2 Sink oR10g o To of 24 V power supply External Reset ils o 0 _ D13 Source Digital Outputs 7 Multi Speed 1 4 o 6 r D4 DOI es oe Multi Speed 2 4 0o 0 DI5 ED AG Driveireut JOG o 6 I Die joz H D17 ee At Speed e External Fault N C O_O o Dis G DO3 I DI9 Encoder loss 2 DI10 Diii Tpoc Digital Output Com DCM Digital Output Com Digital Signal Com Power supply 24 VDC Analog Inputs ie ian Aral oi o or ae 10V Power Source ulti function Analog Output 20mA max AO o Scale 0 10VDC Indicates Output e l Current of VFD aS 0 to 10V ACM sd 0 10VDC 2mA LiL2L3 2 11273 lt O l J Motor Incoming supply Braking unit i 480V 10 i 60Hz 5 Lr o _ Overtemperature Masistor Motor outlet A GS3 FB A aw Encoder output 12VDC OC Open collector TP totem pole TP SV Note that it is necessary to determine the motor parameters for use with sensorless vector control This is done with the auto tuning procedure The auto tuning procedure should be done during the start up procedure This is not described here Refe2. 527 179 38 No load 1444 0 109 365 G 132 52 0 17 6 38 No load 1444 0 109 365 1278 H 32 J0 0 0 0 0 42 0 0 0 0 0 75100 4 Hise SO AN Agee ee a ALTONA TIONDIREGN COM TECHNICAL SUPPORT IS SUPPLIED AS IS Application note DURApulse Drives AN GS 014 Parameter configuration In order to fulfill the requirements of this application the parameters must be set as follows P 0 00 Motor Nameplate Voltage Value 460 Range 200V class 200 208 220 230 240 Default 240 460V class 380 400 415 440 460 480 Default 480 The value of this parameter is defined on the nameplate of the motor Motor Nameplate Amps Value 115 Range AC drive rated currentx 0 1 to 1 0 Default Iypp A The value of this parameter is defined on the nameplate of the motor WORA Motor Base Frequency Value 60 Range 50 60 400 Default 60 The value of this parameter is found on the nameplate of the motor WAEI Motor Base RPM Value 1785 Range 375 to 24 000 RPM Default 1750 The value of this parameter is defined on the nameplate of the motor P 0 04 Motor maximum RPM Value 1800 Range P 0 03 to 24 000 RPM Default P 0 03 The value of this parameter is determined by the requirements of the application P 1 00 Stop Methods Value 00 Default 00 Range 00 Ramp to stop 01 Coast to stop This parameter causes the motor to stop in a fixed time Acceleration time 1 Value 5 0 Range 0 1 to 600 sec Default 10 sec The motor must accelerate
3. 0 5s P121 05s ON OFF Operation S command DE Injection level zz P1 18 RSS WAL Control mode Value 03 Range 00 V Hz open loop control Default 00 01 V Hz closed loop control 02 Sensorless vector 03 Sensorless vector with external feedback This parameter determines the method of control of the drive We selected mode 03 to have better torque control compared to Volt Hertz mode WERI Source of operation command Value 02 Default 00 Settings 00 Operation determined by Digital Keypad 01 Operation determined by external control terminals Keypad STOP is enabled 02 Operation determined by external control terminals Keypad STOP is disabled 03 Operation determined by communication interface Keypad STOP is enabled 04 Operation determined by communication interface THIS INFORMATION PROVIDED BY AUTOMATIONDIRECT COM TECHNICAL SUPPORT IS SUPPLIED AS IS WITHOUT ANY GUARANTEE OF ANY KIND Application note DURApulse Drives AN GS 014 Keypad STOP is disabled e This parameter defines the source of the operation command for the variable frequency drive In this case the PLC and possibly some sensors will define the commands Multi function input terminals DI DI2 Value 00 DI1 FWD STOP Default 0 0 DI2 REV STOP puns This parameter defines the input source for the operation commands of the variable frequency drive We want the skip to begin movement when the operator presses the button that
4. Range 00 Disable Default 00 01 Single Phase 02 Quadrature FWD CCW 03 Quadrature FWD CW This parameter is used to specify encoder signal type Settings 02 and 03 are used to distinguish motor rotation in relation to the quadrature type encoder signal Error message ENC SIGNAL ERROR will come up if motor rotation does not match quadrature settings etka Proportional Control Value 1 00 Range 0 0 to 10 0 Default 1 00 This parameter specifies Proportional control and associated gain I used for vector control with encoder feedback Leave as default THIS INFORMATION PROVIDED BY AUTOMATIONDIRECT COM TECHNICAL SUPPORT IS SUPPLIED AS IS WITHOUT ANY GUARANTEE OF ANY KIND 1 1 Application note DURApulse Drives AN GS 014 Note The diagram on the following page shows the output control relationship of j P 10 02 P 10 03 and P 10 04 CRs Integral Control Value 1 00 Range 0 0 to 100 0 sec Default 1 00 This parameter specifies integral control and associated gain I Leave as default mtn Speed Control Output Speed Limit Value 7 5 Range 0 0 to 20 0 Default 7 5 This parameter limits the amount of correction by the PI control on the output frequency when controlling speed It can limit the maximum output frequency P 10 05 Encoder Loss Detection Value 00 Range 00 Warn and continue operation Default 00 01 Warn and RAMP to stop 02 Warn and COAST to stop This parameter governs the respon
5. changes On the following table we study the torque on every segment of the torque curve we determine the of torque related to the motor rated torque and then estimate the same increase on the current since The I2R losses are proportional to the square of the current we have to find the factor to multiply the basic losses at full load shown on line A Having that we can determine the watts the energy in Joules corresponds to the watts by seconds that the motor keeps running since they are not constant on time we do the average value of the end values on each segment for example for the segment 3 5 and 28 5 the average value of the losses are 797 107 Watt 2 and this is multiplied by the time This is an approximation but it is close enough as we will see from the result The result shows that the energy in the cycle is considerably less than if the motor runs continuously If the calculation has errors the error can be as high as 107000 Joule This proves that the motor will not get too hot Item Time Torque Torque Current Squared Factor Losses Losses Joules second lb ft per cent A A A in Watt in Joules sum A Rated 295 100 115 13225 1inp u 3345 n a B 0 433 146 8 168 8 28492 2 154 7205 C 3 5 432 146 4 168 4 28361 2 144 TA 25160 D 3 5 283 9 96 2 110 7 12247 0 926 INS E 28 5 144 48 8 56 1 3153 0 238 796 48662 F 28 5
6. setting DC Current Braking please notice that 100 is equal to the rated current of the drive It is recommended to start with low DC Current Braking Level and then increase until proper holding torque has been attained DC Injection time during starting Value 0 5 Range 0 0 to 5 0 s Default 0 0 This parameter determines the period in which the DC injection is applied to the motor during starting of the frequency drive The DC braking will be applied for the time set in this parameter until the minimum frequency is reached This is done to avoid the elevator cage dropping when the mechanical brake is released THIS INFORMATION PROVIDED BY AUTOMATIONDIRECT COM TECHNICAL SUPPORT IS SUPPLIED AS IS WITHOUT ANY GUARANTEE OF ANY KIND Application note DURApulse Drives AN GS 014 aval DC Injection during stop Value 0 5 Range 0 0 to 25 0 s Default 0 0 This parameter determines the duration for which the injection voltage will be applied to the motor during stopping If it is planned to stop with DC braking then P1 00 must be set as Ramp to stop 00 WWA Start point for DC injection Value 1 5 Range 0 0 to 60 0 Hz Default 0 0 This parameter determines the frequency where the DC injection braking during the deceleration We want to apply DC so that when the mechanical brake get released there is already a resistive torque in the motor Main frequency 1Hz Start point for DC braking sl time P1 20
7. 03 This output terminal is programmed as Encoder loss and will go to the PLC This signal will tell the PLC that the skip will wait for repair on one of the end travel positions THIS INFORMATION PROVIDED BY AUTOMATIONDIRECT COM TECHNICAL SUPPORT IS SUPPLIED AS IS WITHOUT ANY GUARANTEE OF ANY KIND 9 Application note DURApulse Drives AN GS 014 P 4 00 Source of Frequency Command Value 02 Default 01 Settings 01 Frequency determined by digital keypad up down 02 Frequency determined by 0 to 10V input on Al1 terminal We will set the analog setpoint for frequency with mode 02 P 4 11 Analog Output Signal Value 01 Range 00 Frequency Hz Default 00 01 Current A 02 PV This parameter selects current to be the output on the 0 to 10V AO output eK 86 jog Value 3 1 Range 0 0 to 400 0 Hz Default 6 0 The Jog Command is selected by to Multi Function Input Terminal P 3 04 set to the Jog Function 09 that corresponds to 92 RPM Multi Speed 1 Value 60 5 Default 00 The multi speed 1 value is defined as 60 5 Hz that corresponds to 1800 rpm and will be used at the normal speed of the skip Multi Speed 2 Value 3 0 Default 00 P 6 00 The multi speed 2 value is defined as 3 0 Hz that corresponds to 89 rpm and will be used at the creep speed of the skip Thermal Overload type selection Value 00 Modes 00 Use with inverter duty motor Default 00 01 Use with standard fan cooled motor 02 Inactive T
8. Application note DURApulse Drives AN GS 014 il Small mine hoist type loads In this application note we will size and configure a DURApulse variable frequency drive for a small mine ae Motor hoist A mine hoist lifts mineral ore from one level to one Ne up in underground mines The transport capacities are variable with motors ranging from hundreds of HP to i Cage some in the thousands ase In this case we have a vertical shaft small hoist with 2 cages or skips in such a way that when one loaded skip goes up the other empty goes down The loading and unloading happens simultaneously by mechanical means See adjacent diagram The requirements are to have a daily lifting output of 1200 short tons in 15 5 hours for a distance of 350 feet With the mechanical design is has been determined that the unloaded cage weight is 2250 Ib and the cable is 462 Ib total That results in a cycle of 86 liftings per hour and since the load unload time is 10 second the total travel time is 41 8 s Acceleration and deceleration are equal to 3 5 second The calculations done by the mechanical engineering has issued a curve of torques versus time referred to the motor shaft operation from the point of view of the drive Safety factors are already included The control is done with a PLC not shown in this example The task in this example is to design the drive components and configure the parameters We will make a list of the requi
9. ED AS IS WITHOUT ANY GUARANTEE OF ANY KIND Application note DURApulse Drives AN GS 014 is designed for maintenance operations WEA Multi function Input terminal DI7 Value 99 Default 00 This terminal does not have any input Input disabled WAA Multi function Input terminal DI8 Value 01 Default 00 This terminal has a contact from a master relay that will open in case of voltage shutdown as well as any other emergency situation This master relay shall also remove energy from the drum brake to cause an immediate stop of the skip Multi function Input terminal DI9 Value 99 ae 60 Default 00 This terminal does not have any input Input disabled Multi function Input terminal DI10 Value 99 Default 00 This terminal does not have any input Input disabled WAL Multi function Input terminal DI11 Value 99 Default 00 This terminal does not have any input Input disabled J pe Multi function Output Terminal 1 Relay Output Value 00 Default 00 This output terminal is programmed as AC drive running and will go to the PLC ems Multi function Output Terminal 2 DO1 Value 01 Default 01 This output terminal is programmed as AC drive Fault and will go to the PLC WAE Multi function Output Terminal 3 DO2 Value 02 Default 02 This output terminal is programmed as AC drive At Speed and will go to the master relay WAC Multi function Output Terminal 4 DO3 Value 15 Default
10. ally closed contacts to determine overtemperature that are wired to the PLC The corresponding drive is the GS3 4100 with up to 150A rated current We will also select the braking resistor of the GS3 4100 BR type and a GS 4DBU braking unit The braking resistor allows the drive to brake up to 125 of the motor torque which is enough since we need only 52 7 ft lb This corresponds to about 19 of the motor rated torque 2 THIS INFORMATION PROVIDED BY AUTOMATIONDIRECT COM TECHNICAL SUPPORT IS SUPPLIED AS IS WITHOUT ANY GUARANTEE OF ANY KIND Application note DURApulse Drives AN GS 014 AN GS 014 SG We will select the sensorless vector method with feedback to have a better torque behavior which is needed to perform the cycle consistently every time The motor heating calculation should be verified with the method of RMS power during a complete cycle or other method shown later in this note The line reactor to be used is the GS 4100 LR for 460 Volt and the fuse kit including the fuses is the GS 4100 FKIT Please note that the fuse is sized for 600A 600 Volt and is fast blow to protect the drive and not the wire feeding the drive In general the branch circuit fusing is of a lower rating than that sized to protect the AC drive Next we show the Durapulse wiring diagram for this specific application PLC input module
11. from 0 RPM to the maximum speed of the motor P 0 04 in 5 seconds THIS INFORMATION PROVIDED BY AUTOMATIONDIRECT COM TECHNICAL SUPPORT IS SUPPLIED AS IS WITHOUT ANY GUARANTEE OF ANY KIND 5 Application note DURApulse Drives AN GS 014 RY Deceleration time 1 Value 5 0 Range 0 1 to 600 s Default 30 sec This parameter is used to define in 5 seconds as the deceleration time that the frequency drive is going to impose The speed change is linear unless the S curve is activated This is a typical value for low speed elevators Acceleration with S curve Value 03 Range 00 to 07 Default 00 This parameter is used whenever the motor and the load need a smoother acceleration The acceleration with S curve is set in 03 This is necessary to avoid abrupt accelerations of the skip and the cable Deceleration with S curve Value 3 Range 00 to 07 Default 00 This parameter is used whenever the motor and the load need a smoother deceleration The deceleration with the S curve is set in 03 and will be activated when the contact to stop is deactivated This contact opens when the limit switch of the stop level is activated before reaching that level The PLC will make the corresponding logic Frequency Ji te Time Sees Characteristic of S curve of S curve DC Current injection Value 10 Range 00 to 100 Default 00 This parameter determines the DC current of motor braking applied during starting and stopping When
12. he mode 00 uses the normal inverse time thermal overload protection over the full speed range tripping at 100 of motor current with tripping 150 in one minute The mode 01 is used to derate the thermal protection at lower speeds in such a way that there is a linear derating from rated speed to speed zero The current to trip at 0 Hz is 40 We use constant torque in this case AE Reverse Operation Inhibit Value 00 Default Setting 00 THIS INFORMATION PROVIDED BY AUTOMATIONDIRECT COM TECHNICAL SUPPORT IS SUPPLIED AS IS 1 0 WITHOUT ANY GUARANTEE OF ANY KIND Application note DURApulse Drives AN GS 014 Settings 00 Enable Reverse Operation 01 Disable Reverse Operation This parameter determines whether the AC Motor Drive can operate in the reverse direction In this case we clearly will enable reverse operation immu User Defined Display Function Value 00 Default 00 Settings 00 Output Frequency Hz 01 Motor Speed RPM 02 Scaled Frequency 03 Output Current A 04 Motor Load 05 Output Voltage V 06 DC Bus Voltage V 07 PID Reference 08 PID Feedback PV 09 Frequency Reference This value is the Default to indicate the Output Frequency P 10 00 Encoder Pulse Per Revolution Value 1024 Range 01 to 20000 Default 1024 An encoder is used as a transducer to feed back the motor speed and this parameter defines the number of pulses for each cycle of the PI control P 10 01 Encoder Type Input Value 02
13. r to the auto tune procedure in Chapter 3 of the DURApulse user manual THIS INFORMATION PROVIDED BY AUTOMATIONDIRECT COM TECHNICAL SUPPORT IS SUPPLIED AS IS WITHOUT ANY GUARANTEE OF ANY KIND 3 Application note DURApulse Drives AN GS 014 Motor heating calculation There are several methods to check that the motor does not get too hot Here is one method The motor has a rated efficiency at full load of 94 5 respecting class F insulation This means that the losses at rated current 115A are 4 34 kW These continuous operation losses will maintain the temperature below the limit of class F 155 C in the hottest point Since there is no continuous current we will have to estimate the heating effect during a cycle The motor losses are comprised of friction cooling losses caused by the fan iron losses and the losses I2R on the copper The I7R losses can be estimated because we have the values R1 and R2 from the tables published on the AutomationDirect Web site R1 0 034 Ohm and R2 0 0219 Ohm the value for the copper losses 12R are about 3345 Watt the rest should be the constant losses 995 Watt The iron losses and friction can be considered constant The energy during the cycle is about 42 seconds That is if constant the motor will loose 4340 Watt x42 s 182280 Joule In the case of this hoist we can say with certain approximation that the current will change in the same way as the torque
14. rements of the application in order to decide which parameters need modifications Application requirements eSee the concept of control in the diagram on the next page eThe drive will control a 460 Volt motor horsepower to be determined eThe maximum speed of the motor is 1800 RPM connected to a reducer eThe motor must accelerate to the maximum speed in 3 5 seconds preferably with an S curve profile The motor must stop with a deceleration of 3 5 seconds when the mechanical brake will be applied eThe operation of the system start stop etc will be controlled by a controller which could be a PLC eThe frequency of the VFD will be preset by an external contact The command to raise the hoist skip will be from one contact and the command to lower it will be from another contact eThe analog signal output of the VFD will indicate the motor current when it is working eThe mine hoist is stopped with drum brakes not controlled by the VFD but by a master relay a safety control device THIS INFORMATION PROVIDED BY AUTOMATIONDIRECT COM TECHNICAL SUPPORT IS SUPPLIED AS IS 1 WITHOUT ANY GUARANTEE OF ANY KIND Application note DURApulse Drives AN GS 014 ij e The system will incorporate dynamic braking eThe system will utilize DC injection to p s hold the motor when the mechanical ZN brake is released UUN e The drive will change to the creep speed XS right before the stop point to allow for a e
15. se of the drive to the feedback signals such as the analog or encoder pulse signals when they are performing abnormally Closed Loop Tuning Diagram THIS INFORMATION PROVIDED BY AUTOMATIONDIRECT COM TECHNICAL SUPPORT IS SUPPLIED AS IS WITHOUT ANY GUARANTEE OF ANY KIND f These documents are provided by our technical support department to assist others We E do not guarantee that the data is suitable for your particular application nor we assume any responsibility for them in your application 1 2 THIS INFORMATION PROVIDED BY AUTOMATIONDIRECT COM TECHNICAL SUPPORT IS SUPPLIED AS IS WITHOUT ANY GUARANTEE OF ANY KIND
16. will close a contact on the PLC and we want to stop when near the other level The operation can also be automatic The stop function will be reached with 2 preset speeds one at 60 5 Hz and the other at 3 Hz The low speed is the creep speed to allow the skip to stop just in front of the level Settings amj ge r Goin i p Stop DH Going Down Stop po Value 02 Default 00 Multi function input terminal DI3 This is a button in the machine room that will reset the drive in case of a failure The PLC should check that every safety element is in compliance before resetting the drive Value 03 Default 00 This parameter will define multi speed 1 This speed will be defined as the normal speed of the cage and corresponds to 1800 rpm The value is to be set with P5 01 Multi function input terminal DI4 Value 04 Default 00 Multi function input terminal DI5 This parameter will define multi speed 2 This speed will be defined as the creep speed of the skip and corresponds to 89 rpm The value is to be set with P5 02 This speed is applied for the last few feet close to the level to allow for an exact positioning of the cage Value 09 Default 00 Multi function input terminal DI6 This parameter will define the jog command This speed will be defined to correspond to 92 rpm The value is to be set with P5 00 This speed THIS INFORMATION PROVIDED BY AUTOMATIONDIRECT COM TECHNICAL SUPPORT IS SUPPLI
17. xact application of the mechanical brake That creep speed will be n See determined by the PLC based on position limit switches or proximity sensors incoming Inputs power The adjacent figure shows the concept of ene DURApulse control The shaft will have position limit switches and there is a central control room where is is commanded to start and sensors 100 HP motor commands stop ae Next we show the required torque at the input of the gearbox through the cycle Motor Frequency Deceleration Acceleration 60 5 Hz Load Torque 144 ft lb Loading unloading Loading unloading Skip 1 going up Skip 1 going down 52 7 ft lb 433 ft lb 284 ft lb As the maximum torque required is 433 ft lb and the DURApulse can supply up to 150 of the motor rated torque we will use a motor with a rated torque of at least 289 ft lb The closest we have is a 100 HP 1785 rpm 295 ft Ib We sell several different inverter duty type 100 HP motors We select the Marathon inverter duty motor Y575 A774 Blue Max with 115A of rated current at 460 Volt with an encoder of 1024 pulses per revolution to assure stable speed non dependent on the possibilities to change slip if the load is variable This is a possibility because the density or even the load may not be exactly the same quantity during one load The motor has 3 norm
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