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SERVICE MANUAL FOR FREQUENCY CONTROL SYSTEM

1. 030F 045F 055F Weight 47 kg 102 Ibs Weight 80 kg 176 Ibs a o Z2 G1 O fo fo Wesen 8 d E M F7 K7 E 8 He sess S 78 i NW LO Al 6 Elooo e 28 G d 0 9 4 37 z 4 8 5 j HE 8 x1i CM1 2 8 IECH z2 2 es d E LJ Ed M cra IR 453 5 mm 17 85 in Z3 74 m 0 28 in 467 5 mm 18 41 in Ai Ej F7 F71 K ok E BloooBlooo FEED Liem X1 UHele ejyejeyeTo o E 7mm 453 5 mm 17 85 in E B 0 28 iny 467 5 mm 18 41 in 4 3 Circuit diagrams 002F 005F 007F 011F 015F 045F 055F 4 3 1 Internal wirings Other single Screened FE B B g D wires cables 002F 011F 002F 011F 002F 018F 002F 055F 002F 055F 002F 055F 002F 055F 2 5 mm 2 5 mm 2 5 mm 2 5 mm 1 5 mm 0 75 mm 8x0 5 mm AWG 14 AWG 14 AWG 14 AWG 14 AWG 16 AWG 20 8 x AWG 20 015F 018F 015F 018F 6 mm 6 mm AWG 10 AWG 10 022F 037F 022F 022F 10 mm 10 mm 6 mm AWG 8 AWG 8 AWG 10 030F 037F 030F 045F 16 mm 10 mm AWG6 AWG 8 67 83 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice 4 3 2 R amp M MATERIALS R amp M Materials Handling Inc 4501 Gateway Boulevard
2. 1 4 Functional description Operation when power is switched on Stop limit switches S12 amp S22 and slow down limit switches S11 amp S21 are assumed to be normally closed as well as the emergency stop button ES The control voltage is supplied to X1 37 The main voltage is connected to inverter power supply and inverter wakes up If the control voltage is connected to RDY signal and the fault circuit is OK inverter is ready to operate in about 1 2 seconds If either of the direction signals S1 or S2 is on the display shows F6 and driving can begin only after the direction signals have been off for a while Normal operation For the description of the speed reference setting see chapter Control methods Hoisting lowering starts when switch S1 S2 closes Closing the contact ROB2 on A1 energizes K7 which opens the brake in model 055 the brake can be controlled also by K71 Motor accelerates according to the acceleration ramp setting to the selected speed When the switch S1 S2 opens motor stops according to the deceleration ramp setting and the brake closes H1 dissipates the regenerated energy during lowering periods The power supply to R1 is controlled by A1 If the braking resistor fan s are included in external resistor unit they start to operate when power is supplied to the braking resistors The cooling continues about 4 5 minutes after electrical
3. Standard connection with sensor bearing KAE 234 D2L AN gt 6 3 red BROWN A 1 S a white WHITE B z lue m G E m kd 2 7 DN Oo black GREEN Standard connection with sensor bearing Two channels connected for Synchro M D2L xi E 55 red BROWN 1 T 24V A Oo o 51 white WHITE EA EN 53 z EB m e 52 3 EA m 54 EB DN zs sd 56 black GREEN ov _ KAE 234 6 3 O O B is 4 blue YELLOW R 2 7 ae e Standard connection with encoder 24 ppr terminal box D2L x1 V 55 red 24V A e 51 yellow EA _ RE G EB m O 52 15 EA B D EB 0v 56 blue ov Standard connection with encoder 600 ppr or more terminal box D2L x1 V 55 red 24V A S 51 L ew EA 53 z G reen EB m A 52 4 black EA B B 54 white EB ov 56 blue DV 82 83 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice A BAM Materials Handling Inc R amp M 4501 Gateway Boulevard MATERIAIS Springfield Ohio 45502 ANDLING E P 937 328 5100 INC FAX 937 325 5319 Standard connection with proximity switch Baumer Sch nbuch KAE 234 D2L xi AN 6 3 brown 1 4 24V A S Oo 51 black EA _ 53 2 G rae m kd ge 2 et blue L Standard connection with proximity switc
4. 23 IA NEE SIDA e errr 24 2 83 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice A BAM Materials Handling Inc R amp M 4501 Gateway Boulevard MATRAS Springfield Ohio 45502 TANDING P 937 328 5100 INC FAX 937 325 5319 2 PARAMETER ADJUSTMENTS cessciccicscuttcrnacedicenstuniannadsciniasnentetmrienanunttenteunbsscennwsaentenersecinunstuntenmenues 25 21 nhhedisplay panel wise bee A ei c ete te eee t eR nne e ve ec 25 2 1 1 Navigation on the control kevpad nennen nennen nennen inen nnns 26 2 1 2 Value se SUTIN Ge 5 8 cr roter ee ore odere ne e nn e ere ee m Eee ree eu 26 2 2 Storing and restoring Darameierg nennen nennen sse n nnn nnn nsns 27 2 2 1 User parameters cer toe vete te uoto Pte ver ost Eeer eT sb Perte ert 27 2 2 2 Default Parameters eene nnenn ssh nsn nnn i nets siens nnn nra setis setis n nnn annes nsns 27 2 2 3 IKeypad settlnags anerter rnt e n tm ne t t n m n n re reci 27 2 2 4 leed ET 27 3 PARAME ere li an LEE 28 4 FACTORY DEFAULT PARAMETERS wiscicccssccsiictsscccccccccatsecccenccecccesctesscescsccecesetececentecesdeuttestdesceceeses 36 2 3 Factory default parameters for 100Hz motors nennen nnne nnn nnns 36 2 4 Factory default parameters for 120Hz motors nennen nnne nennen 40 5 SPEED SUPERVISION SET TINGS E 44 2 5 Standard RE d CN 44 2 5 1 Settings for e ln e EE 44 2 5 2 Settings for pulse wheel speed se
5. Springfield Ohio 45502 G EE P 937 328 5100 INC FAX 937 325 5319 045F 045F 16 mm 25 mm AWG6 AWG A 055F 075F 055F 055F 25 mm 35 mm 16 mm AWG 4 AWG 2 AWG 6 Wiring colours Single wires Screened cable board A Screened cable board C PE Green Yellow PUR Grey EA Grey A Black 15V Pink EA Pink B Black AIN1 Green EB Green ONE White AIN2 Yellow EB Yellow Others Red AIN Blue 24V Brown AOUT2 Red DV White DV White 24V Brown 68 83 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M MATERIALS HANDLING INC R amp M Materials Handling Inc 4501 Gateway Boulevard Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 D2HRO4F90ROS4 PET 1 E A Zi Z2 B 90 ohm SS F R e pe e L10 L1 Z3 A E Musee d EEMISCE 21 O 22 CM1 Z1 Z2 Z3 AND CM1 NOT Xl i Eo oe INCLUDED IN STANDARD OR G 23 IT MODELS oM 27 p e 25 1 18 K7 2 4 23 4 G A 26 K7 6 8 L1 L2 AC a 5 7 ad pc IB A27 G1 o e D 57 X13110 032 O ee m Pe Pg ce ee xi 1 8 3 11 S1 xi S805 1 E Q 12 s2 ie
6. E D Power supply phase 1 L2 L2 Power supply phase 2 L3 L3 Power supply phase 3 B B Braking resistor R R Braking resistor U T1 U T1 Motor output phase 1 V T2 VITZ Motor output phase 2 W T3 W T3 Motor output phase 3 No Name Description signal level No Name Description signal level 1 BL1 AC brake supply phase 1 31 BD1 DC brake supply 1 2 BL2 AC brake supply phase 2 32 BD2 DC brake supply 2 3 BL3 AC brake supply phase 3 33 Ti Thermistor input 4 T12 Reserved for thermistors connections 34 T2 Thermistor input 5 OLE External control voltage 42 48 115 230Vac 35 ONE Neutral of external control voltage OLE 6 OLE External control voltage 42 48 115 230Vac 36 ONE Neutral of external control voltage OLE 7 RDY Stop with brake 37 ES External Stop 8 S1 Direction 1 run command 38 DID1 Free input 9 S2 Direction 2 run command 39 DID2 S11 Slowdown signal direction 1 0 DIA3 Accelerate speed 2 40 DID3 S21 Slowdown signal direction 2 1 DIA4 Not used hold speed 3 41 DID4 S12 Stop limit signal direction 1 2 DIA5 Not used speed 4 42 DID5 S22 Stop limit signal direction 2 3 43 4 44 5 K7 A1 Coil of brake contactor K7 45 ROB1 21 Not used 6 ROB1 22 Not used 46 ROB1 23 Not used 7 ROD1 28 Free NO contact of relay ROD1 47 RO
7. 011 4501 Gateway Boulevard Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 015 R amp M Materials Handling Inc 018 022 T5 MF11MB200 400V 100Hz T6 MF13Z 200 400V 100Hz T7 MF13ZA200 400V 100Hz T8 MF13ZB200 400V 100Hz Label Code Default Label Code Default Label Code Default Label Code Default G 2 1 General Parameters G 2 1 General Parameters G 2 1 General Parameters G 2 1 General Parameters P 2 1 10 Accel Time 1 1 5 Accel Time 1 1 5 Accel Time 1 1 5 P 2 1 10 Accel Time 1 1 5 Decel Time 1 1 5 Decel Time 1 1 5 Decel Time 1 1 5 Decel Time 1 1 5 r Parameters r Parameters r Parameters r Parameters Motor Nom Volt 400 Motor Nom Volt 400 Motor Nom Volt 400 Motor Nom Volt 400 Motor Nom Freq 100 Motor Nom Freq 100 Motor Nom Freq 100 Motor Nom Freq 100 Motor Nom Speed 2830 Motor Nom Speed 2910 Motor Nom Speed 2890 Motor Nom Speed 2890 Motor Nom Curr 21 Motor Nom Curr 31 Motor Nom Curr 36 Motor Nom Curr 42 Nom Flux Curr 12 Nom Flux Curr 15 Nom Flux Curr 15 Nom Flux Curr 17 Start Current 24 Start Current 32 Start Current 42 Start Current 48 Current Limit 31 Current Limit 46 Current Limit 54 Current Limit 63
8. 59 c MEE IUIS nes 59 9 TROUBLESHOOTING TABLE rnra rura pat rho bep RR rbRE tuu PER bx xE FEX ErkxE PER ER nk FEM EREME ERU FEREP MEINE PERDU E rfREE 60 E Te EE 61 10 SPARE PARTS LIST FOR HOISTING INVERTER esses nnn 62 11 DRAWINGS 64 4 1 Descripionor termilidissss tiere rer e EET EP aes ai an aa 64 4 1 1 Power classes 002F 01 VF i e eem entente dee dE dete reve ve ere ri vae ees 64 4 1 2 Power classes 015F O55F sssssssssssssssssssseesseeene nne nnnnnerr isse nent h n nnner isse nennt rennen nsn nnn 65 4 2 Layouts dimensions and Weights AAA 65 GE eege Ee LE Tu 67 4 3 1 Internal ll ue EE 67 4 3 2 Wiring colour S nnc a 68 3 83 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc R amp M 4501 Gateway Boulevard EUER Springfield Ohio 45502 HANDLING P 937 328 5100 FAX 937 325 5319 INC 4 4 Circuit diagrams for braking resistors nennen nemen iss nnan n nennen nnns 77 4 4 1 Internal WINNS m 77 4 5 Standard connections for pulse sensors sssssssssssssssssssseeeeeeeeneennn nennen nennen rsen nnn nnne 82 L E d E d GS L This manual rev 7 0 is for inverter D2L with software Ind3 V114 Before starting read the instructions carefull
9. D Du dt filter should be as near inverter as possible D Note All control cables must be placed as far from the motor and braking resistor cables as possible 14 83 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice A BAM Materials Handling Inc R amp M 4501 Gateway Boulevard MATRAS Springfield Ohio 45502 HANDLING Esas dte P 937 328 5100 INC FAX 937 325 5319 1 12 Signal cabling 1 12 1 Shielded signal cable It s recommended to use twisted pair and braided shielded signal cables Foil type shield is not sufficient enough in crane applications because of poor mechanical durability Cable insulation material effects to cable capacitance Recommended cable capacitance between signal signal and signal ground is equal or less than 100pF m 31pF ft It is not recommended to use shielded flat cable because its capacitance is extremely high and this may cause high frequency interference 1 12 2 Reference signals Shielded round cables must be used for analog reference signals The shield is to be grounded only at one end of the cable 1 12 3 Sensor bearing The cable for the sensor bearings must be shielded round cable and grounded 260 at both ends 1 12 4 Encoder The encoder connections may be split into two cables then the signal conductors 4pcs should go together in one cable and the supply and common 24V 0V together in another cable The encoder ca
10. 1 5 r Parameters r Parameters Motor Nom Volt 400 Motor Nom Volt 400 Motor Nom Freq 100 Motor Nom Freq 100 Motor Nom Speed 2890 Motor Nom Speed 2880 Motor Nom Curr 84 Motor Nom Curr 110 Nom Flux Curr 34 Nom Flux Curr 44 Start Current 90 Start Current 110 Current Limit Current Limit 165 Min Freq S1 10 Min Freq S1 10 Min Freq S2 5 Min Freq S2 5 Max Freq S1 Max Freq S1 Max Freq S2 Max Freq S2 Max ESR Freq Max ESR Freq Drive Selection Drive Selection Pulse Number Pulse Number Zero Freq Volt Zero Freq Volt U f Mid Volt U f Mid Volt U f Mid Freq U f Mid Freq Torque Boost On Torque Boost On Rs Voltage Drop 100 Rs Voltage Drop 100 Stop Function Ramping Stop Function Ramping rt rt Flux Current Kp 4000 Flux Current Kp 4000 Flux Current Ti 25 Flux Current Ti 25 S2 Flux Control 100 S2 Flux Control 100 Freq 0 1 Freq 0 1 Freq 1 3 Freq 1 3 Freq 2 S1 10 Freq 2 S1 10 Freq 3 S1 20 Freq 3 S1 20 Zero Flux Curr 80 Zero Flux Curr 80 Stray Flux Curr 40 Stray Flux Curr 40 Freq 2 S2 10 Freq 2 S2 10 Freq 3 S2 40 Freq 3 S2 40 Zero Speed Curr Zero Speed Curr Min
11. Buffer amplifier pulse output can be measured 24V 1V during driving The picture beside presents the pulse output 0x 1V 1 17 Brake controllers 1 17 1 REC12 Brake control unit REC12 is a line voltage half wave rectifier for DC brakes AC Line Voltage Voltage range 200 690Vac K7 K7 Output voltage Upc Half wave 0 45 x Uac Maximum current 1 25Adc When the brake is opened the brake contactor K7 connects two phases of mains voltage to terminals L1 and L2 In addition the brake contactor shorts terminals a and b thus making the DC circuit To close the brake the brake contactor disconnects the supply to terminals L1 and L2 The released brake contactor also opens the brake coil DC circuit which speeds closing of the brake The purpose of the varistor there is overvoltage protection for K7 contacts and the brake coil 23 83 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice A BAM Materials Handling Inc R amp M 4501 Gateway Boulevard MATERIALS Springfield Ohio 45502 G E P 937 328 5100 INC FAX 937 325 5319 17 2 ESD141 Brake control unit ESD141 is a line voltage full half wave rectifier for DC brakes pe Voltage Voltage range 200 690Vac Full wave 0 90 x Uac eT Half wave 0 45 x Unc jd Maximum current 1 25Adc continuous and 2 5Adc at ED5 Output voltage Upc Set 0 3s When the brake is
12. SSU LED s If the fault comes again contact service F66 SSUOverspeed SSU overspeed limit has been set over Check Limit 140 of maximum frequency set SSU overspeed limit under 14096 of maximum frequency 57 83 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc R amp M 4501 Gateway Boulevard Hil Springfield Ohio 45502 EE P 937 328 5100 INC FAX 937 325 5319 motor type plate parameters maximum frequency parameters F70 Multicare Fault Other inverter has tripped to fault or brake Check other hoisting inverter of other inverter has not been opened fault history Fault is not stored into fault history brake operation F71 Brake Control Load information from hoist control unitis Check Fault out of operation window Ain2 wiring settings of load measuring device F73 Both Dir Active Both direction signals are active at same Check time gt 500ms controller operation wiring of direction signals F90 SystemBus fault Communication error in SystemBus Check SystemBus wiring SystemBus boards connections into the control units Parameters P2 4 1 P2 4 2 and P2 4 3 in all drives F91 SystemBus Brake All units are not giving brake opening or Check supervision closing information during 500ms That each active drive gets direction signals S1 S2 That ramp times are similar in each drive F92 Synchroniza
13. Start Freq S2 Brake Stop Freq Brake Stop Freq ESR Point Freq ESR Point Freq ESR Point Volt ESR Point Volt IrAdd Motor IrAdd Motor IrAdd Generator IrAdd Generator Ramp Stretching Ramp Stretching Switching Freq Switching Freq DeadTime Comp DeadTime Comp DeadTimeCurrLim DeadTimeCurrLim 43 83 Brake Chopper Brake Chopper R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice A BAM Materials Handling Inc R amp M 4501 Gateway Boulevard pner Springfield Ohio 45502 HANDLING iab eed P 937 328 5100 INC FAX 937 325 5319 5 SPEED SUPERVISION SETTINGS SSU is a hoist motion speed supervision unit which reads the pulse frequency from the hoist motor sensor bearing encoder or pulse sensor This pulse frequency is compared with a fixed oscillator frequency and inverter frequency reference As a result of frequency comparison there are three different speed supervision functions available overspeed supervision rush control stall supervision speed difference supervision Overspeed supervision F61 is totally implemented by hardware Switches S2 2 and S2 3 divide the full frequency range to four frequency areas Selected frequency area is the same for normal and ESR speeds The four frequency areas are each divided to lower and upper frequency ranges Switch S2 1 selects the
14. 32 2 12 2 um 344 A DAS ron 13 DIAS eae 145 L Dad An 44 DIAA O 4 DIAS BEE 46 6 16 OK O ONEO SS WEI gt OK xi KAE234 38 O51 A O O EI L ops S11 4 39 520 L DID3 S21 4 40 53 xi L DID4 12 La 54 5 OLE e Q 4 DIDS S22 4 42 55 ls 36 E ONEO igo tr lg Xib3 Lu m ot dur SET 0 38 Le ES ESA 37 A oun X8 Dk BRT4 9 RDY 7 F7 X16 18 a 48 Oo 153 154 Sos Xigyi9 lt 3 495 163 164 72 83 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice i R amp M Materials Handling Inc R amp M 4501 Gateway Boulevard MATRAS Springfield Ohio 45502 HANDLING E P 937 328 5100 INC FAX 937 325 5319 D2FR18F21R382 pe Z1 A1 Z2 B 21 ohm is ad B i20 D RRE L2 O L1 Q E Aa m Z3 A L30 B U L2 0792 U O SE rer LE v av Y Sp ee TE LI ow 7 21N O F7 1 la js W 22 is i a CM1 Z1 Z2 Z3 AND CM1 NOT Di Il fa Ma f 12 1 INCLUDED IN STANDARD OR 2 la le o 323 IT MODELS or 27 S p G h25 1 8 K7 2 j4 23 G Lag K7 K7 16 18 ser 24 1 l2 0 3s 56 3 AC 4 5 7 5 d 4 DC BE
15. Flux Current Kp 4000 Flux Current Kp 4000 Flux Current Kp 4000 Flux Current Ti 25 Flux Current Ti 25 Flux Current Ti 25 Flux Current Ti 25 S2 Flux Control 100 S2 Flux Control 100 S2 Flux Control 100 S2 Flux Control 100 Freq 0 1 Freq 0 1 Freq 0 1 Freq 0 1 Freq 1 3 Freq 1 3 Freq 1 3 Freq 1 3 Freq 2 S1 10 Freq 2 S1 10 Freq 2 S1 10 Freq 2 S1 10 Freq 3 S1 20 Freq 3 S1 20 Freq 3 S1 20 Freq 3 S1 20 Zero Flux Curr 80 Zero Flux Curr 80 Zero Flux Curr 80 Zero Flux Curr 80 Stray Flux Curr 40 Stray Flux Curr 40 Stray Flux Curr 40 Stray Flux Curr 40 Freq 2 S2 10 Freq 2 S2 10 Freq 2 S2 10 Freq 2 S2 10 Freq 3 S2 40 Freq 3 S2 30 Freq 3 S2 40 Freq 3 S2 40 Zero Speed Curr Zero Speed Curr Zero Speed Curr Zero Speed Curr Min Current Ref 90 Min Current Ref 90 Min Current Ref 90 Min Current Ref 90 Accel Comp TC 0 1 Accel Comp TC 0 1 Accel Comp TC 0 1 Accel Comp TC 0 1 Ref Angle S1 Ref Angle S1 Ref Angle S1 Ref Angle S1 Ref Angle S2 Ref Angle S2 Ref Angle S2 Ref Angle S2 Flux Curr Damp Flux Curr Damp Flux Curr Damp Flux Curr Damp Stop DC Freq Stop DC Freq Stop DC Freq Stop DC Freq Sta
16. G1 CH 6 7 D DA s Xt314 4 32 oO 11 S1 xi 33 E l 82 3 12 S2 l cn 3 BAL A HI en 18 DIA3 Sis Ned 45 4 DIAS on 14 DIA4 O 4 DIAS BEE 46 gt 16 OK O ONE 35 15 gt OK e KE f A C O38 X516 lu 4 DID2 S11 4 39 52 4 pips S21 4 40 58 xi KL DIDA S12 4 41 54 5 OLE me A DID5 S22 1 42 55 m 36 e ONE GTO AA Xd 3 Lux m Aur SET 03s Lo ES ESA 37 1 z az pp X18 A2 BRT1 RDY 7 F7 xi Q18 lt A8 O ei SE 158 154 Xo 349 163 164 73 83 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice A BAM Materials Handling Inc R amp M 4501 Gateway Boulevard MATERIALS Springfield Ohio 45502 G eee P 937 328 5100 INC FAX 937 325 5319 D2FR24F16R482 oo Z1 A1 Z2 B 16 ohm B Q 20 E EUR A L2 Q O Li Q S A A Z3 A L30 U nea d IN Ta Ot se O C WITH MULTICARE V i E L L owy Zi 21 O F7 h la 5 W 22 is i fs CM1 Z1 Z2 Z3 AND CM1 NOT Di Il ta Xo f eech INCLUDED IN STANDARD OR 2 4 6 O L o2 IT MODELS SE 27 D g A 25 D gt 1 15 K7 2 j4 23 r G A 26 K7
17. Max ESR Freq Max ESR Freq Max ESR Freq Max ESR Freq Drive Selection Drive Selection Drive Selection Drive Selection Pulse Number Pulse Number Pulse Number Pulse Number Zero Freq Volt Zero Freq Volt Zero Freq Volt Zero Freq Volt U f Mid Volt U f Mid Volt U f Mid Volt U f Mid Volt U f Mid Freq U f Mid Freq U f Mid Freq U f Mid Freq Torque Boost On Torque Boost Torque Boost Torque Boost On Rs Voltage Drop 150 Rs Voltage Drop Rs Voltage Drop Rs Voltage Drop 100 Stop Function Ramping Stop Function Stop Function Stop Function Ramping rt rt rt rt Flux Current Kp 4000 Flux Current Kp Flux Current Kp Flux Current Kp 4000 Flux Current Ti 25 Flux Current Ti Flux Current Ti Flux Current Ti 25 S2 Flux Control 100 S2 Flux Control S2 Flux Control S2 Flux Control 100 Freq 0 1 Freq 0 Freq 0 Freq 0 1 Freq 1 3 Freq 1 Freq 1 Freq 1 3 Freq 2 S1 10 Freq 2 S1 Freq 2 S1 Freq 2 S1 10 Freq 3 S1 20 Freq 3 S1 Freq 3 S1 Freq 3 S1 20 Zero Flux Curr 80 Zero Flux Curr Zero Flux Curr Zero Flux Curr 80 Stray Flux Curr 40 Stray Flux Curr Stray Flux Curr Stray Flux Curr 40 Freq 2 S2 10 Freq 2 S2 Freq 2 S2 Freq 2 S2 10 Freq 3 S2 40 F
18. Min Freq S1 10 Min Freq S1 10 Min Freq S1 10 Min Freq S1 10 Min Freq S2 5 Min Freq S2 5 Min Freq S2 5 Min Freq S2 5 Max Freq S1 Max Freq S1 Max Freq S1 Max Freq S1 Max Freq S2 Max Freq S2 Max Freq S2 Max Freq S2 Max ESR Freq Max ESR Freq Max ESR Freq Max ESR Freq Drive Selection Drive Selection Drive Selection Drive Selection Pulse Number Pulse Number Pulse Number Pulse Number Zero Freq Volt Zero Freq Volt Zero Freq Volt Zero Freq Volt U f Mid Volt U f Mid Volt U f Mid Volt U f Mid Volt U f Mid Freq U f Mid Freq U f Mid Freq U f Mid Freq Torque Boost On Torque Boost Torque Boost Torque Boost On Rs Voltage Drop 150 Rs Voltage Drop Rs Voltage Drop Rs Voltage Drop 100 Stop Function Ramping Stop Function Stop Function Stop Function Ramping rt rt rt rt Flux Current Kp 4000 Flux Current Kp Flux Current Kp Flux Current Kp 4000 Flux Current Ti 25 Flux Current Ti Flux Current Ti Flux Current Ti 25 S2 Flux Control 100 S2 Flux Control S2 Flux Control S2 Flux Control 100 Freq 0 1 Freq 0 Freq 0 Freq 0 1 Freq 1 3 Freq 1 Freq 1 Freq 1 3 Freq 2 S1 10 Freq 2 S1 Freq 2 S1 Freq 2 S1 10 Freq 3 S1 20 Freq 3 S1 Freq
19. Ohio 45502 NDLING EE P 937 328 5100 INC FAX 937 325 5319 D2FR18FR3S2 3x 32 ohm WIRING A 6 mn B 2 5 mm OTHERS 0 75 mm IL Cu l C12 6 O T BLU BRN BLK M11 as 3 ONS X11 8 F11 BRT1 BRT2 O G 33 34 9 O 80 83 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice i R amp M Materials Handling Inc R amp M 4501 Gateway Boulevard MATRAS Springfield Ohio 45502 ANDLING eee P 937 328 5100 INC FAX 937 325 5319 D2FR24FR4S2 4x 32 ohm WIRING A 10 mm B 2 5 mm OTHERS 0 75 mm xi ER C12 6 O T BLU BRN BLK M11 PE 3 c X11 8 F11 BRT1 BRT2 Q 33 34 9 CH 81 83 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice A BAM Materials Handling Inc R amp M 4501 Gateway Boulevard pner Springfield Ohio 45502 HANDLING iai ed P 937 328 5100 INC FAX 937 325 5319 4 5 Standard connections for pulse sensors
20. Switching Freq Switching Freq DeadTime Comp DeadTime Comp DeadTime Comp DeadTime Comp DeadTimeCurrLim DeadTimeCurrLim DeadTimeCurrLim DeadTimeCurrLim 37 83 Brake Chopper Brake Chopper R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice Brake Chopper Brake Chopper R amp M MATERIALS HANDLING INC 030 037 R amp M Materials Handling Inc 4501 Gateway Boulevard Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 037 037 T9 MF13ZC200 400V 100Hz TA MF13X 200 400V 100Hz 2 T6 2 MF13Z 200 400V 100Hz 2 T7 2 MF13ZA200 400V 100Hz Label Code Default Label Code Default Label Code Default Label Code Default G 2 1 General Parameters G 2 1 General Parameters G 2 1 General Parameters G 2 1 General Parameters Accel Time 1 1 5 Accel Time 1 1 5 Accel Time 1 1 5 Accel Time 1 1 5 Decel Time 1 1 5 Decel Time 1 1 5 Decel Time 1 1 5 Decel Time 1 1 5 r Parameters r Parameters r Parameters r Parameters Motor Nom Volt 400 Motor Nom Volt 400 Motor Nom Volt 400 Motor Nom Volt 400 Motor Nom Freq 100 Motor Nom Freq 100 Motor Nom Freq 100 Motor Nom Freq 100 Motor Nom Speed 2880 Motor Nom Speed 2880 Motor Nom S
21. Synchro functions normally V2 4 10 1 master does not show position error but between hooks there comes position error System does not register position error between hooks because Speed in one or more dri accurate enough P2 2 2 Nominal ves is not correct or Check P2 4 4 Nominal speed in all drives One or more drives are vibrating especially after acceleration or deceleration Too high gain level Speed correction is overshooting Reduce P2 4 6 SystemBus Synchro gains value in master drive Position error between hooks especially after acceleration deceleration or stopping Different ramp times or stop function Check that Ramp time and Stop method parameters P2 1 10 P2 1 11 and P2 2 20 have similar value in every drive 49 83 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice A BAM Materials Handling Inc R amp M 4501 Gateway Boulevard pner Springfield Ohio 45502 ANDLING E P 937 328 5100 INC FAX 937 325 5319 7 MULTICARE FUNCTION Two inverter drives can be operated simultaneously in tandem mode by utilizing the multicare function The two drives are connected together using their analog outputs and analog inputs The analog output of one drive is connected to the analog input of the other drive and vice versa Both drives alter the voltage value of their own analog output signal according to run c
22. not be used 2 1 1 Navigation on the control keypad ck ve gn A Lei ae A roue _ Fault History lt P 57 Thermistor lt P Operation days v HoHx 5 YF T3525 Y 0 A germ kv _ Active Faults v ve A S61 fh _ System Menu lt gt Application v S15S9 gt Y Crane A eee A T Panel Control lt A gt Panel Control v B1sR2 gt Y Off a A V4 19 fh _ Monitoring lt gt output Frequency y Gbvi9 gt Y 0 00 kz mm mE S ES lt P Motor Parameters lt P Motor Nom Volt vw Ge gt Y PIP20 gt V 400V 2 1 2 Value line editing erm Mode Edit Accept SEA change value value Motor Nom Volt A 400 V p v enter D WARNING Changing parameter settings during running may cause a hazardous situation Parameter settings must not be changed during running 26 83 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice A BAM Materials Handling Inc R amp M 4501 Gateway Boulevard MATRAS Springfield Ohio 45502 TANDHING P 937 328 5100 INC FAX 937 325 5319 2 2 Storing and restoring parameters 2 2 1 User parameters A File User parameters is stored in inverter s control unit User parameters are recommended to save after final set up The whole parameterset can be st
23. 1 1 5 Accel Time 1 1 5 Decel Time 1 1 5 Decel Time 1 1 5 Decel Time 1 1 5 Decel Time 1 1 5 r Parameters r Parameters r Parameters r Parameters Motor Nom Volt 460 Motor Nom Volt 460 Motor Nom Volt 460 Motor Nom Volt 460 Motor Nom Freq 120 Motor Nom Freq 120 Motor Nom Freq 120 Motor Nom Freq 120 Motor Nom Speed 3420 Motor Nom Speed 3370 Motor Nom Speed 3340 Motor Nom Speed 3440 Motor Nom Curr 4 9 Motor Nom Curr 9 3 Motor Nom Curr 11 Motor Nom Curr 19 Nom Flux Curr 32 Nom Flux Curr 6 2 Nom Flux Curr 6 3 Nom Flux Curr 12 Start Current 5 8 Start Current 10 Start Current Start Current 18 Current Limit Current Limit Current Limit 16 Current Limit 27 Min Freq S1 Min Freq S1 Min Freq S1 10 Min Freq S1 10 Min Freq S2 Min Freq S2 Min Freq S2 5 Min Freq S2 5 Max Freq S1 Max Freq S1 Max Freq S1 Max Freq S1 Max Freq S2 Max Freq S2 Max Freq S2 Max Freq S2 Max ESR Freq Max ESR Freq Max ESR Freq Max ESR Freq Drive Selection Drive Selection Drive Selection Drive Selection Pulse Number Pulse Number Pulse Number Pulse Number Zero Freq Volt Zero Freq Volt Zero Freq Volt Zero Freq Volt U f Mid Volt U f Mid Volt U f Mid Volt U
24. 240VAC 15mA EA and EB 0 24V 3kQ floating differential inputs Open loop vector control 0 250Hz Motor potentiometer or 2 4 step controller Slowdown and stop limit inputs for both directions Sn 100 Sn motor nominal slip 1 of nominal speed at speed range 10 100 1 3 of motor nominal slip at speed below 10 100 200 150 During acceleration and constant speed Thermistor based temperature measurement Fault is detected if the current momentarily exceeds 280 of rated current Fault is detected if DC voltage drops below 333V Fault is detected if DC voltage exceeds 911V Immediate fault stop Temperature sensor on the heat sink Circuit breaker Electronic supervision for the braking chopper and for the braking resistor Provided by electronic circuitry Independent measurement using sensor bearing pulse wheel or encoder 10 C 55 C 14 F 131 F for ED lt 60 40 C 60 C 31 F 140 F dry lt 95 RH no condensation Maximum 1000m at In Above 1000m In reduces 1 per each 100m Above 3000m consult factory Operation maximum displacement amplitude 3mm at 2 9Hz Maximum acceleration amplitude 0 5g 5m s at 9 200Hz Conforms to LV and EMC directives 055F 75 110 165 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice A BAM Materials Handling Inc R amp M 4501 Gateway Boulevard MATRAS Springfield Ohio 45502 NDLI
25. 3 S1 Freq 3 S1 20 Zero Flux Curr 80 Zero Flux Curr Zero Flux Curr Zero Flux Curr 80 Stray Flux Curr 40 Stray Flux Curr Stray Flux Curr Stray Flux Curr 40 Freq 2 S2 10 Freq 2 S2 Freq 2 S2 Freq 2 S2 10 Freq 3 S2 40 Freq 3 S2 Freq 3 S2 Freq 3 S2 40 Zero Speed Curr Zero Speed Curr Zero Speed Curr Zero Speed Curr Min Current Ref 90 Min Current Ref Min Current Ref Min Current Ref 90 Accel Comp TC 0 1 Accel Comp TC Accel Comp TC Accel Comp TC 0 1 Ref Angle S1 Ref Angle S1 Ref Angle S1 Ref Angle S1 Ref Angle S2 Ref Angle S2 Ref Angle S2 Ref Angle S2 Flux Curr Damp Flux Curr Damp Flux Curr Damp Flux Curr Damp Stop DC Freq Stop DC Freq Stop DC Freq Stop DC Freq Start Freq S1 Start Freq S1 Start Freq S1 Start Freq S1 Start Freq S2 Start Freq S2 Start Freq S2 Start Freq S2 Brake Stop Freq Brake Stop Freq Brake Stop Freq Brake Stop Freq ESR Point Freq ESR Point Freq ESR Point Freq ESR Point Freq ESR Point Volt ESR Point Volt ESR Point Volt ESR Point Volt IrAdd Motor IrAdd Motor IrAdd Motor IrAdd Motor IrAdd Generator IrAdd Generator IrAdd Generator IrAdd Generator Ramp Stretching Ramp Stretching Ramp Stretching Ramp Stretching Switching Freq Switching Freq
26. 325 5319 G4 7 Digital Input S1 V4 7 1 1 State of digital input S1 O OFF 1 ON S2 V4 7 1 2 State of digital input S2 O OFF 1 ON DIAS V4 7 1 3 State of digital input DIAS O OFF 1 ON DIA4 V4 7 1 4 State of digital input DIA4 O OFF 1 ON DIA5 V4 7 1 5 State of digital input DIA5 O OFF 1 ON OK V4 7 1 6 State of digital input OK O OFF 1 ON DID1 V4 7 1 7 State of digital input DID1 O OFF 1 ON DID2 V4 7 1 8 State of digital input DID2 0 0FF 1 ON DID3 V4 7 1 9 State of digital input DID3 O OFF 1 ON DID4 V4 7 1 10 State of digital input DID4 O OFF 1 ON DID5 V4 7 1 11 State of digital input DIDS O OFF 1 ON Basic Board V4 7 3 State of board A inputs 1 2 DIA3 DIA4 DIA5 O OFF 1 ON Corresponding X1 terminals 8 9 10 11 12 Extension Board V4 7 4 State of board D inputs DID1 DID2 DID3 DID4 DID5 02OFF 1 ON Corresponding X1 terminals 38 39 40 41 42 G4 8 SSU Overspd Lim 1 V4 8 1 Overspeed limit 1 level Percent of Max Freq S2 0 140 96 Overspd Lim 2 V4 8 2 Overspeed limit 2 ESR value Percent of Max Freq S2 0 140 G4 9 Service Phase U Curr V4 9 1 Phase U current of inverter output A Phase V Curr V4 9 2 Phase V current of inverter output A Phase W Curr V4 9 3 Phase W current of inverter output A Encoder Speed V4 9 4 Pulse frequency from pulse sensor Both A and B channel must be in Hz use He
27. 34 D 49 18 DIAS zu umi 45 KL Dad 1 X4 BAR O 4 Dag BEE 46 16 OK O ONE 35 15 gt OK xi KAE234 o 38 A515 CH l4 4 DID2 S11 4 39 520 4DID3 S21 4 40 53 xi 4 DID4 S12 LA 54 5 OLE DID5 S22 1 42 55 6 Gi 36 E 56 ONE m O we biz 8 8 oti ES ESA 37 A2 T DY 7 Xig8 28 153 154 SEET si X1 G19 7 49 163 164 69 83 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice A BAM Materials Handling Inc R amp M 4501 Gateway Boulevard EUER Springfield Ohio 45502 HANDLING EE P 937 328 5100 INC FAX 937 325 5319 D2FRO6F64R0S2 s Z1 A1 Z2 B 64 ohm B i20 ll EUR RA L20 O Li Q Z3 A O SN pe we iw 21 e F7 1 la j5 W 122 is i Io CM1 Z1 Z2 Z3 AND CM1 NOT Di Il fa Xt f 3 Era INCLUDED IN STANDARD OR 2 4 6 O IT MODELS SE 27 A 25 bi O 1 15 K7 2 j4 23 G A 26 K7 6 8 L1 L2 AC a 5 7 Ip 25 DC A27 G1 O E Dx X1 31A 5 32 POO i 11 S1 xi i EE 1 l 49 3 12 S2 1 E T 344 O l DIA 10 DUE 13 DIAS EIN LI S 45 40A en 14 DIA4 O 4 DIAS BEE 46 ok 166 ONE 35 115 gt O
28. 36 2 2 48 3 72 4 2 32 5 64 6 80 72 102 8 600 9 11000 10 1024 11 2000 12 2048 13 512 14 1200 Zero Freq Volt P2 2 15 Output voltage at zero frequency of motor nominal voltage 0 40 U f Mid Volt P2 2 16 Voltage in the selected middle point frequency of motor nominal 0 100 voltage U f Mid Freq P2 2 17 Middle point frequency 0 250 Hz Torque Boost P2 2 18 Torque maximization 0 2 Off 1 On RS Voltage Drop P2 2 19 Relative value of motor stator impedance voltage drop Value of this 0 512 parameter is calculated by formula given below Motor Nom Flux current x Measured motor resistance phase to phase x 2217 Motor nominal voltage Stop Function P2 2 20 Stopping mode selection 0 Brake Ramping When the drive command is switched off the motion is stopped 1 Ramping according to the set deceleration ramp Brake When the drive command is switched off the motor current is cut off and the motion is stopped by the mechanical brake G2 3 Expert Flux Current Kp P2 3 1 Gain for flux current control Too small or too large value results 0 32000 oscillation in the current control Must not be changed Flux Current Ti P2 3 2 The integration time of the flux current control Too small or too large 0 1000 ms value results oscillation in the current control Must not be changed S2 Flux Control P2 3 3 Increases or decreases the Flux Current controller values P2 3 1 amp 2 to 0 100 956 direction S2 Must n
29. CMT el 2 O e p E x8 SH o n x1 EIE Ee O A1 Ee d U p e Sie ut ul E E bioom des e ES 18mm 414 mm 16 30 in i eS Q De 0 71 in 450 mm 17 72 in Z1 CM1 z2 23 E J o x SES E IND E H UL 8 T ep E 7mm 453 5 mm 17 85 in E Eg 0 28 iny lt 467 5 mm 18 41 in 015F 018F 022F Weight 29 kg 64 Ibs Weight 31 kg 68 Ibs F7 K7 Gi O E Bo o obesos O 5 gne A is BOT ETSI E E EH F7 K7 Gi el S AM E EE x15 lolo 3 8 g UD e E M Booo ppoogiooooo EI o o 8 a 3 wo 8 E Al CM1 E Nj E Al E o 49 0 0 o o o o o b EE 2 S Zi E E ET 7mm 453 5 mm 17 85 in CM1 EIS L oS Pap 467 5 mm 18 41 in 5 xi oolololololog SE bola ek GEN L ge ojojojojo 72 Z Z1 ES 7mm 453 5 mm 17 85 in EI i ES 028 inf 467 5 mm 18 41 in 66 83 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M MATERIALS R amp M Materials Handling Inc 4501 Gateway Boulevard Springfield Ohio 45502 HANDLING INC P 937 328 5100 FAX 937 325 5319
30. Current Ref 90 Min Current Ref 90 Accel Comp TC 0 1 Accel Comp TC 0 1 Ref Angle S1 Ref Angle S1 Ref Angle S2 Ref Angle S2 Flux Curr Damp Flux Curr Damp Stop DC Freq Stop DC Freq Start Freq S1 Start Freq S1 Start Freq S2 Start Freq S2 Brake Stop Freq Brake Stop Freq ESR Point Freq ESR Point Freq ESR Point Volt ESR Point Volt IrAdd Motor IrAdd Motor IrAdd Generator IrAdd Generator Ramp Stretching Ramp Stretching Switching Freq Switching Freq DeadTime Comp DeadTime Comp DeadTimeCurrLim DeadTimeCurrLim 39 83 Brake Chopper Brake Chopper R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M MATERIALS HANDLING INC 2 4 Factory default parameters for 120Hz motors 002 Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 004 R amp M Materials Handling Inc 4501 Gateway Boulevard 005 007 T1 MF10MA200 460V 120Hz T2 MF10MB200 460V 120Hz T3 MF10MC200 460V 120Hz T4 MF11MA200 460V 120Hz Label Code Default Label Code Default Label Code Default Label Code Default G 2 1 General Parameters G 2 1 General Parameters G 2 1 General Parameters G 2 1 General Parameters Accel Time 1 1 5 Accel Time 1 1 5 Accel Time
31. Current Ref 90 Min Current Ref Min Current Ref 90 Accel Comp TC Accel Comp TC 0 1 Accel Comp TC Accel Comp TC 0 1 Ref Angle S1 Ref Angle S1 Ref Angle S1 Ref Angle S1 Ref Angle S2 Ref Angle S2 Ref Angle S2 Ref Angle S2 Flux Curr Damp Flux Curr Damp Flux Curr Damp Flux Curr Damp Stop DC Freq Stop DC Freq Stop DC Freq Stop DC Freq Start Freq S1 Start Freq S1 Start Freq S1 Start Freq S1 Start Freq S2 Start Freq S2 Start Freq S2 Start Freq S2 Brake Stop Freq Brake Stop Freq Brake Stop Freq Brake Stop Freq ESR Point Freq ESR Point Freq ESR Point Freq ESR Point Freq ESR Point Volt ESR Point Volt ESR Point Volt ESR Point Volt IrAdd Motor IrAdd Motor IrAdd Motor IrAdd Motor IrAdd Generator IrAdd Generator IrAdd Generator IrAdd Generator Ramp Stretching Ramp Stretching Ramp Stretching Ramp Stretching Switching Freq Switching Freq Switching Freq Switching Freq DeadTime Comp DeadTime Comp DeadTime Comp DeadTime Comp DeadTimeCurrLim DeadTimeCurrLim DeadTimeCurrLim DeadTimeCurrLim 36 83 Brake Chopper Brake Chopper R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice Brake Chopper Brake Chopper R amp M MATERIALS HANDLING INC
32. Gateway Boulevard MATRAS Springfield Ohio 45502 DLING NUI P 937 328 5100 INC FAX 937 325 5319 Current Limit P2 2 7 Defines the maximum motor current from the inverter If the output current exceeds the value set in parameter P2 2 7 the output frequency is lowered until the current drops below the current limit The rate of lowering the frequency depends on the current overshoot To avoid motor overloading set this parameter according to the rated current of the motor normally 1 5 2xI In multimotor drives nominal currents must be summarized Note The value must be limited to Drive maximum output current 1 minute value Min Freq S1 P2 2 8 Minimum frequency direction 1 0 Max Freq S2 Hz Hoisting application Smaller value than factory setting is not allowed to use Min Freq S2 P2 2 9 Minimum frequency direction 2 0 Max Freq S2 Hz Hoisting application Smaller value than factory setting is not allowed to use Max Freq S1 P2 2 10 Maximum frequency direction 1 0 250 Hz Max Freq S2 P2 2 11 Maximum frequency direction 2 0 250 Hz Max ESR freq P2 2 12 Maximum frequency when ESR activated 0 250 Hz Drive Selection P2 2 13 Application selection selection None causes F60 Parameter fault 0 2 None 1 2 Travel 2 Hoist Pulse Number P2 2 14 Pulse wheel pulse number 0 2 24 1 2
33. K7 6 8 SET 537 ile 0 3s 56 3 AC 4 5 7 E 5 S DC ped G1 E CH 6 7 D gt gt X1 31A 5 32 POO 11 S1 xi 33 E l e32 2 12 S2 id 344 A DIS RE 13 DIA3 cc Nero x 45 40A on 14 DIA4 O 4 DIAS BEE 46 gt 16 OK O ONE 35 15 gt OK xt KAE234 38 CY 51 EA O O 4 4 DID2 S11 4 39 52 4 ops S21 4 40 58 xi 4 DIDA S812 4 41 54 5 OLE me 4 DID5 S22 4 42 55 la 36 i ONE 360 7 4 ze uU ee X11 3 L4 2 gar SET 0 38 Le ES ESA 37 1 ZN ui X8 Ai C 18 48 BRT1 9 pp 7 F7 ec lt 48 O Oo d 158 154 8S X1 19 di 49 163 164 74 83 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice i R amp M Materials Handling Inc R amp M 4501 Gateway Boulevard MATRAS Springfield Ohio 45502 HANDLING E P 937 328 5100 INC FAX 937 325 5319 2 x D2FR18F21R3S2 PE 2 E Zi A1 Z2 B 210hm 2 11 ohm in B TR 120 fl EUR T 120 O L1 Q xi ekke Z3 A 130 98 U L2 0 922 3 U O uos 4 fp nies 2 SE UE UC ow 7 21 O F7 l1 3 5 w 122 is i i CM1 Z1 Z2 Z3 AND CM1 NOT al uH Xios OR
34. OUTI 4 Cl VT E i E T TIT A A A LU KaLa DC The main circuit diagram of D2V007 D2V055 BR B B oO A L1 O o U Ti i d o V T2 L3 1 0 WT3 5 1 BRKG BRK D DC 16 83 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice A BAM Materials Handling Inc R amp M 4501 Gateway Boulevard MATERIALS Springfield Ohio 45502 TANDLNG P 937 328 5100 INC FAX 937 325 5319 1 14 1 Power supply unit PSU Power supply unit PSU includes the main circuit components PSU has connectors for supply cables motor cables and braking resistor cables PSU also includes a D connector for CSU connection Main supply voltage terminals L1 Mains L1 L2 Mains L2 L3 Mains L3 PE Protective earth DC bus terminals B DC bus negative B DC bus positive Brake resistor positive R Brake resistor negative Motor output voltage terminals U T1 Motor U V T2 Motor V W T3 Motor W 1 14 2 Control unit CSU Control unit CSU includes a control board with five board slots for option boards and a control keypad for parameter adjustments CSU is connected to PSU through a D connector Yellow Red Sta
35. Point Volt ESR Point Volt ESR Point Volt ESR Point Volt IrAdd Motor IrAdd Motor IrAdd Motor IrAdd Motor IrAdd Generator IrAdd Generator IrAdd Generator IrAdd Generator Ramp Stretching Ramp Stretching Ramp Stretching Ramp Stretching Switching Freq Switching Freq Switching Freq Switching Freq DeadTime Comp DeadTime Comp DeadTime Comp DeadTime Comp DeadTimeCurrLim DeadTimeCurrLim DeadTimeCurrLim DeadTimeCurrLim 42 83 Brake Chopper Brake Chopper R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice Brake Chopper Brake Chopper R amp M MATERIALS HANDLING INC 045 4501 Gateway Boulevard Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 055 R amp M Materials Handling Inc 2 T8 MF13ZB200 460V 120Hz 2 T9 MF13ZC200 460V 120Hz Label Code Default Label Code Default G 2 1 General Parameters G 2 1 General Parameters P 2 1 10 Accel Time 1 1 5 Accel Time 1 1 5 Decel Time 1 1 5 Decel Time 1 1 5 r Parameters r Parameters Motor Nom Volt 460 Motor Nom Volt 460 Motor Nom Freq 120 Motor Nom Freq 120 Motor Nom Speed 3470 Motor Nom Speed 3470 Motor Nom Curr 88 Motor Nom Curr 112 Nom Flux Curr 34 Nom Flux
36. alarm A 83 Slack cable alarm 59 83 Possible cause Mathematical motor temperature model has detected motor overheating Motor is overloaded Analog input signal is out of selected range 1 9V or 2 10V control cable is broken signal source has failed Controller does not operate accurately Motor load is over adjusted value Motor load is under adjusted value R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice Checking Check motor load if no overload exists then check motor temperature model parameters Check reference cable reference source Check controller Check Overweight limit value Check Slack cable limit value R amp M Materials Handling Inc R amp M MATERIALS 4501 Gateway Boulevard Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC 9 TROUBLESHOOTING TABLE If inverter doesn t work but any fault doesn t found write down the following information before contacting to the supplier GENERAL INFORMATION WORK NUMBER CUSTOMER REFERENCE DATE PUT IN OPERATION DATE OF FAILURE SHORT DESCRIPTION OF FAILURE ERROR CODE INVERTER INFORMATION TYPE CODE ACCELERATION S TIME SERIALNUMBER DECELERATION S TIME CONTROL METHOD MIN FREQ Hz EP2 MAX FREQ Hz EP3 MS MO
37. amp M Materials Handling Inc 4501 Gateway Boulevard BEE Springfield Ohio 45502 HANDLING Oo P 937 328 5100 INC FAX 937 325 5319 MWh Counter T6 8 2 1 MWh counter can be reseted Clr MWh Counter P6 8 2 2 Clear MWh counter T6 8 2 1 Not reset Reset PwOn Day Counter T6 8 2 3 Number of power on days PwOn hour count T6 8 2 4 Number of power on hours Clr Optime cntr T6 8 2 5 Clear trip counters T6 8 2 1 T6 8 2 4 Software package 16 8 3 1 See software sticker under display IND3V114 NXP00002V182 SystemSw version 16 8 3 2 33 02 9431 Firmware interf 16 8 3 3 4 64 System load 16 8 3 4 Load of CPU Application id D6 8 4 1 1 See software sticker under display IND3V114 Industr3 Version D6 8 4 1 2 See software sticker under display IND3V114 11 40 Firmware interf D6 8 4 1 3 4 62 Power unit 16 8 5 1 Power unit id code Unit voltage 16 8 5 2 Nominal voltage of D2V 500V Brake chopper E6 8 5 3 There is brake chopper in D2V No Brake resistor E6 8 5 4 No braking resistor inside D2V No Serial number E6 8 5 5 Serial number of CSU State E6 8 6 1 1 State of board in slot A Run Program version E6 8 6 1 2 Program version of board in slot A 0 0 State E6 8 6 2 1 State of board in slot B Run Program version E6 8 6 2 2 Program version of board in slot B 10005 0 State E6 8 6 3 1 State of board in sl
38. ekke T Z3 A 130 88 8 U L2 0 92 U O uos 4 35 22 LI Ee Ri E ge E 21 e F7 M 3 5 F71 1 3 5 W 22 15 is jg is is hd CM1 Z1 Z2 Z3 AND CM1 NOT al 2 a mg X15 fi 1 23 EE INCLUDED IN STANDARD OR 2 j4 6 2 j4 6 O IT MODELS X1 20 i D e E 18 5 13 27 A25 DJ K71 O 1 l3 p24 6 4 K7 Tere 2 4 r O50 x1 210 23 Lag E a d K7 5 K7 6 8 Ch SET P7 0 3s sel a 4 ls 7 Ces 72 a O Is km 25 27 G1 DC 51 61 71 81 G ch 6 7 D CM OM Xi314 Jas OQ 11 S1 xi s eegene 32 E 12 S2 E 34 4 Daa 10 19 DIAS Os P 45 DIA oit 14 DIA4 O 4 DIAS L 46 ok 16 ONE 35 ME gt OK x KAE234 O38 3816 Lu 4 DID2 S11 4 39 52 4 om S21 4 40 86 xi L DID4 12 4 41 54 5 OLE g A DID5 S22 4 42 55 ls 3560 7 1c a A1 Al ES L Sei A2 A2 F11 BRT1 F71 F7 ics Es 33 34 33 34 3 F11 Xigyi9 lt 49 163 164 BRT1 KEEN 4 76 83 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice e R amp M Materials Handling Inc R amp M 4501 Gateway Boulevard MATERIALS Springfield Ohio 45502 G E P 937 328 5100 INC FAX 937 325 5319 4 4 Circuit diagrams for braking resistors D2FR06FR0S2 D2FH12FRH2S2 D2FH18FH3S2 D2FHRH24FH4S2 4 4 1 Internal wirings Other single B A wires D2FRO6FROS2 2 5 mm 1 5 mm 0 75 mm AWG 14 AWG6 AWG 20 D2FR12FR2S2 6 mm AWG 10 D2FR18FR3S2 6 mm AWG 10 D2FR
39. ends 360 grounding on inverter terminal the shield should be grounded always when going through terminals Some problems may occur when using shielded flat cable or in situations where the encoder cable has been placed too close 5cm to the motor cables and braking resistor cables 1 16 3 Proximity switch In modernisation cases there might be proximity switch as pulse sensor of motor 21 83 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice A BAM Materials Handling Inc R amp M 4501 Gateway Boulevard pner Springfield Ohio 45502 NDLING EE P 937 328 5100 INC FAX 937 325 5319 Inverter needs information about the motor rotation speed for stall speed difference and over speed supervision Type markings of the speed supervision sensors not needed in applications with bearing sensor or encoder and fixing distance from the pulse wheel air gap are shown in the table below Proximity switch air gap Honeywell 3GT101DC 0 5 1 0 mm Sch nbuch INSOR88 ICDM 8802 0 5 0 1 mm T Baumer IFRM08N1501 L 0 5 0 1 mm Te Note that the Honeywell sensor cable is lengthened and the wire colours are not equal to other sensors However colour markings corresponding to the other sensors have been added to wire ends not necessarily if cable has been shortened afterwards The connection of Honeywell sensor and the cable markings are shown in the
40. f Mid Volt U f Mid Freq U f Mid Freq U f Mid Freq U f Mid Freq Torque Boost Torque Boost Torque Boost Torque Boost Rs Voltage Drop Rs Voltage Drop Rs Voltage Drop Rs Voltage Drop Stop Function Stop Function Ramping Stop Function Stop Function rt rt rt rt Flux Current Kp Flux Current Kp 4000 Flux Current Kp Flux Current Kp Flux Current Ti Flux Current Ti 25 Flux Current Ti Flux Current Ti S2 Flux Control S2 Flux Control 100 S2 Flux Control S2 Flux Control Freq 0 Freq 0 1 Freq 0 Freq 0 Freq 1 Freq 1 3 Freq 1 Freq 1 Freq 2 S1 Freq 2 S1 10 Freq 2 S1 Freq 2 S1 Freq 3 S1 Freq 3 S1 20 Freq 3 S1 Freq 3 S1 Zero Flux Curr Zero Flux Curr 80 Zero Flux Curr Zero Flux Curr Stray Flux Curr Stray Flux Curr 40 Stray Flux Curr Stray Flux Curr Freq 2 S2 Freq 2 S2 10 Freq 2 S2 Freq 2 S2 Freq 3 S2 Freq 3 S2 20 Freq 3 S2 Freq 3 S2 Zero Speed Curr Zero Speed Curr Zero Speed Curr Zero Speed Curr Min Current Ref Min Current Ref 90 Min Current Ref Min Current Ref Accel Comp TC Accel Comp TC 0 1 Accel Comp TC Accel Comp TC Ref Angle S1 Ref Angle S1 Ref Angle S1 Ref Angle S1 Ref Angle S2 Ref Angle S2 Ref Angle S2 Ref Angle S2 Flux Cur
41. frequency range at normal speed Switch S2 4 selects the frequency range at ESR speed Extended Speed Range The exact tripping frequency level is selected with rotary switches Switch S1 sets the tripping level at normal speed value shown in V4 8 1 Switch S3 sets the tripping level at ESR speed value shown in V4 8 2 Overspeed tripping levels are shown at display as 96 of the nominal speed The overspeed setting should be 15 2596 above the full speed Switches S2 2 and S2 3 select range for overspeed detection level Range of detection level is the same for both normal and ESR Extended Speed range use Fine adjustment for normal use is done by rotary switch S1 and switch S2 1 Fine adjustment for ESR use is done by rotary switch S3 and switch S2 4 Overspeed detection levels are shown at display panel as of nominal speed Overspeed setting should be 15 25 above the full speed Adjusted overspeed detection level for normal use is shown in parameter V4 8 1 Adjusted overspeed detection level for ESR use is shown in parameter V4 8 2 Speed difference supervision F62 compares the motor actual speed pulse frequency with Drive frequency reference In practice this means that the motor slip is measured and if that exceeds a limit supervision stops the motion Stall supervision F63 stops the motion if there are no pulses coming from the sensor when the brake is open K7 energised SSU relay test F64 SSU Relay is tested i
42. is in ready state or only while running 0 Yes Ready Autotuning P2 3 31 Autotuning must not be done with ControlMaster Plus Hoisting 0 2 Not Done G2 4 Synchronization Not viewable witout OPT D1 option board Address P2 4 1 SystemBus node address Synchro is in use when the address is gt 0 the 0 4 OPT D1 option board is installed in the slot E and input DID1 is on Next Address P2 4 2 Next system bus node address 0 4 Last Address P2 4 3 Last system bus node address 0 4 Nominal Speed P2 4 4 Nominal speed of the hoist 0 00 300 00 m min Displacement Lim P2 4 5 Maximum displacement error between synchronized drives Only master 1 100 mm unit will use this parameter Gain P2 4 6 Correction signal gain Only master unit will use this parameter 0 10000 Sync Activation P2 4 7 Synchro activation state If During Run is selected activation of the unit O During Stop can be done while driving In this case all the units have to have During 4 During Run Run selected Default During Stop 30 83 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M R amp M Materials Handling Inc 4501 Gateway Boulevard MATRAS Springfield Ohio 45502 HANDLING P 937 328 5100 INC FAX 937 325 5319 Min Freq Offset P2 4 8 Parameter defines how much below minimum frequency can correction to
43. opened the brake contactor K7 connects two phases of mains voltage to terminals 1 2 and 3 which makes the device a full wave rectifier The full wave mode is used to get the brake open fast In addition the brake contactor shorts terminals 4 and 5 thus making the DC circuit K7 K7 After a time delay normally 0 3s the delayed contact of the brake contactor opens which disconnects the supply from terminal 3 and the rectifier changes to a half wave type Half wave operation prevents heating of the brake coil and is enough to keep the brake open To close the brake the brake contactor disconnects the supply to terminals 1 and 2 The released brake contactor also opens the brake coil DC circuit which speeds closing of the brake The purpose of the varistor there is overvoltage protection for K7 contacts and the brake coil 24 83 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice A BAM Materials Handling Inc R amp M 4501 Gateway Boulevard MATERIALS Springfield Ohio 45502 G HARDEN P 937 328 5100 INC FAX 937 325 5319 2 PARAMETER ADJUSTMENTS 2 1 The display panel 2002 rpm The display panel is used for Displaying the drive identification electrical values operating or fault parameters Altering the parameter settings Saving and restoring the parameter settings in the memory of the d
44. ov Common for encoder supply 27 DV Common for analog output 57 24V External supply for Control module 4 2 Layouts dimensions and weights 65 83 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice A BAM Materials Handling Inc R amp M 4501 Gateway Boulevard pner Springfield Ohio 45502 pU P 937 328 5100 ps FAX 937 325 5319 002F 005F 007F 011F Weight 12 kg 27 Ibs Weight 19 kg 42 Ibs T Ta o o Ka O O 3 D e o EE z O gs E JE sung 8 E K7 G1 A1 E F7 K7 Gi AR Zin
45. the run commands on display panel and correct the drum rotating direction The arrow rotates clockwise if S1 is applied and counter clockwise if S2 is applied Check the function of the speed sensor see chapter Speed sensors Check the function of the speed supervision circuit See chapter Functional test drive for SSU Drive direction S1 at minimum speed for 5 to 10 seconds Accelerate to full speed Run 5 to 10 seconds Stop Repeat the same in direction S2 Check the frequency display to make sure that the frequency changes through the whole operational frequency range from minimum to nominal speed 52 83 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice A BAM Materials Handling Inc R amp M 4501 Gateway Boulevard MATERIAS Springfield Ohio 45502 HANDLING TADRE P 937 328 5100 INC FAX 937 325 5319 Check motor operation acceleration deceleration and braking accelerate to full speed direction S1 change to full speed direction S2 and full speed direction S1 again and stop Check limit switch functions drive direction S1 slowly and check the limit switch operations Re check using full speed Hepeat the same check for direction S2 2 17 1 Functional test run for SSU m Note Test run for SSU must be made without load Disconnect the signal wire coming from the pulse sensor to terminal X1 51 All the SSU faults will be reseted automatically after o
46. 0 00 20 00 Hz frequency output of the drive be made SystemBus Speed P2 4 9 SystemBus communication speed Default 3 Mbit s 0 2 1 5 Mbit s 1 3 Mbit s 2 6 Mbit s 3 12 Mbit s Max Pos Error V2 4 10 1 Current position error of the hoist with the largest displacement to Mm synchronization reference position Only master unit displays this information Pos Error 1 4 V2 4 10 2 5 Unit 1 4 current position error to Synchro position Only master unit mm displays this information Peak Pos Error 1 4 V2 4 10 6 9 Unit 1 4 peak position error to Synchro position since last power off Only mm master unit displays this information Synchro Status V2 4 10 10 0 0 0 0 0 00000 11111 1 SystemBus address gt 0 Nominal speed gt 0 SSU board OK 1 SystemBus working properly 1 Unit is a Master 1 Unit is a Follower 1 Synchro is active in this station G4 Monitoring G4 1 Parameter backup Load Default Par B4 1 1 Restores Default Parameters to Active Parameters from the Control Unit memory Default Parameters are the parameters which have been saved in the factory Save User Par B4 1 2 Saves Active Parameters in the Control Unit as User Parameters Final parameters for the application must be saved as User Parameters after start up Load User Par B4 1 3 Restores User Parameters to Active Parameters from the control unit memory User Parameters are the
47. 1 D2V030NF1006 52571199 EMC level 0 1 D2V037NF1NO06 52571180 EMC level N S 1 D2V037NF1006 52571200 EMC level 0 1 D2V045NF1NO6 52571181 EMC level N S 1 D2V045NF1006 52571201 EMC level 0 1 D2V055NF1N06 52571182 EMC level N S 1 D2V055NF1006 52571202 EMC level 0 1 BOARDS INCLUDED IN INVERTER D2V Basic l O board NXOPTA6L 52335566 Slot A 1 1 1 1 1 1 1 1 1 Relay Thermistor NXOPTA3L 52335565 Slot B 1 1 1 1 1 1 n 1 1 1 n board UO Extension board NXOPTB9L 52335564 Slot D 1 1 1 1 1 1 1 1 1 m BOARDS NOT INCLUDED IN INVERTER D2V Speed supervision SSUL 52335567 Slot C 1 WoW Hn ft d td unit SystemBus board NXOPTD1L 52354858 Slot E 1 1 1 1 1 1 1 1 1 m BRAKE SUPPLY CIRCUIT BREAKER F7 Protective switch GV2 ME08 52297213 1 n 1 1 1 1 1 m Auxliary contact GV2 AN20 52275270 1 1 1 1 1 1 F71 Protective switch GV2 ME08 52297213 1 Auxliary contact GV2 AN20 52275270 1 BRAKE CONTACTOR K7 Contactor LC1 D09D7 52303564 42VAC 1 1 1 1 1 1 1 1 1 m C0O1E7 52296542 48VAC 1 1 1 1 1 1 1 1 1 H CO1F7 52296548 115VAC 1 1 1 1 1 1 1 1 1 36H LC1 D09P7 52296643 230VAC 1 1 1 1 1 1 1 1 1 m At K7 RC filter LA4 DA1E 52275256 42 48VAC 1 1 1 1 1 1 1 1 1 LA4 DA1U 52275257 115 230VAC 1 1 1 1 1 1 1 1 1 BRAKE CONTROL UNIT DC BRAKE G1 Brake control unit REC12 60010145 1 fi 1 1 1 62 83 R amp M Materials Handling Inc reserves the right to alter or amend the above information without not
48. 1 S3 value 2 steps smaller Drive with maximum speed The motion must stop after full speed is reached fault F64 Over speed is activated Set rotary switch S1 S3 back to original value 2 7 Settings for non standard cases Overspeed tripping frequency levels Area selection 300 3234 Hz 600 6467Hz 1200 12935Hz 9600 70722Hz 2 2 ON OFF OFF ON 2 3 OFF OFF ON ON Range selection Normal 2 1 OFF ON OFF ON OFF ON OFF ON 0 300 1027 600 2055 1200 4110 9600 32878 1 324 1109 647 2218 1295 4436 10359 35489 2 350 1195 700 2391 1400 4781 11196 38251 3 378 1291 756 2582 1511 5163 12092 41304 S1 Normal 4 408 1396 816 2793 1632 5585 13055 44684 5 441 1506 881 3012 1763 6024 14104 48188 45 83 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M MATERIALS HANDLING INC R amp M Materials Handling Inc 4501 Gateway Boulevard Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 Tripping level selection S3 ESR ESR Range selection 6 476 1625 951 3251 1902 6502 15217 52013 7 514 1755 1027 3511 2055 7022 16439 56174 8 555 1896 1109 3793 2218 7585 17744 60681 9 599 2048 1198 4096 2395 8192 19163 65536 A 647 2210 1296 4420 2587 8840 20696 70722 B 698 2381 1396 4763 2793 9526 22342 C 755 2586 1510 5163 3019 10326 24153 E D 815 2793 1630 5585 3259 11171 26075
49. 2 14 Pulse Number 32 48 64 80 Rotary switch S1 1 7 A D Switch S2 1 ON ON ON ON Switch S2 2 OFF OFF OFF OFF Switch S2 3 OFF OFF OFF OFF Switch S2 4 ON ON ON ON Rotary switch S3 1 7 A D 2 5 2 Settings for pulse wheel speed sensor or encoder 24 ppr The table below indicate the SSU settings for standard cases Motors with nominal frequency 50Hz or 60Hz are equipped with pulse wheel speed sensor or encoder After adjustment check that parameters V 4 8 1 Overspd Lim 1 and V 4 8 2 Overspd Lim 2 have value between 115 and 125 Check that parameters P 2 2 2 Motor Nom Freq and P 2 2 3 Motor Nom Speed have correct values from motor type plate Settings for pulse wheel sensor or encoder 24 ppr Power class 002 055 002 055 P 2 2 11 Max Freq S2 50 100 60 120 P 2 2 14 Pulse Number 24 24 Rotary switch S1 4 7 Switch S2 1 ON ON Switch S2 2 ON ON Switch S2 3 OFF OFF Switch S2 4 ON ON Rotary switch S3 4 7 2 6 Functional test run for SSU m Test run must be made without load Disconnect the signal wire coming from the pulse sensor to terminal X1 51 Drive with minimum speed The motion must stop within 1 s fault F63 stall supervision is activated Drive with maximum speed the motion must stop at once fault F62 Speed difference is activated Reconnect the disconnected signal wire to terminal X1 51 Set rotary switch S
50. 24FR4S2 10 mm AWG 8 77 83 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice A BAM Materials Handling Inc R amp M 4501 Gateway Boulevard MATERIALS Springfield Ohio 45502 G eee P 937 328 5100 INC FAX 937 325 5319 D2FRO6FROS2 32 ohm WIRING A 2 5 mm B 2 5 mm OTHERS 0 75 mm 32 ohm F11 X11 too Se Se X1 L 3 1A H Root xi 47 bs S Leu 5 T 6 O BLU BRN BLK M11 PE P xt 8 F11 BRT1 Q 33 34 9 Q 78 83 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice i R amp M Materials Handling Inc R amp M 4501 Gateway Boulevard MATERIALS Springfield Ohio 45502 G uaa P 937 328 5100 INC FAX 937 325 5319 D2FR12FR2S2 2x 45 ohm WIRING A 2 5 mm B 2 5 mm OTHERS 0 75 mm X1 ER 6 O BLU BRN jBLK M11 FE 3 X11 8 F11 BRT1 O 33 34 9 Q 79 83 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice A BAM Materials Handling Inc R amp M 4501 Gateway Boulevard EUER Springfield
51. 4 1 B Blue Yellow KAE234 1 Standard connection with sensor bearing KAE 234 D2L x1 V gt 6 3 red BROWN A 1 ae white WHITE B Z lue m G SI m A 2 7 ov O black GREEN Standard connection with sensor bearing Two channels connected for Synchro KAE2M D2L x E E red BROWN S 4 424V At o o 251 white WHITE EA Se 53 Z EB m s 52 3 A EA m 54 EB ov 25 e 56 black GREEN DV _ KAE 234 6 pu 1 4 B 5 O blue YELLOW 2 7 CM 20 83 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice e R amp M Materials Handling Inc R amp M 4501 Gateway Boulevard MATERIALS Springfield Ohio 45502 HANDLING SE P 937 328 5100 INC FAX 937 325 5319 M critical damage if The supply voltage is over 28V or a short circuit between the signal and the supply or induction heating or hammer mounting In case of sensor damage the whole motor has to be changed Buffer amplifier must be located as close to the sensor bearing as possible maximum distance 2 5m The cable between the buffer amplifier and inverter must be as far as possible from the cables of motor and braking resistor minimum distance gt 20cm ashielded and twisted cable grounded the shield at both ends 360
52. 5 Factory code example Factory D2L D2L 007 F V 52 A 0 N 1 L HS01 ELE83 ELE83 ELEO2 EN EL32 1 3 4 6 7 8 9 10 11 12 13 14 15 Pos Code Festure Feature Available properties code 1 8 D2L HS01 Device name D2L 4 6 007 ELE83 Power rating class 002 055 ELE83 values are composed of two features Power rating class and Supply voltage 7 F ELE83 Supply voltage F 380 500 VAC 50 60 Hz e g 007F ELE83 value ELEO2 value ELEO2 value 8 V ELEO2 Control voltage Y 42VAC 50 60 Hz T 115VAC 50 60 Hz 115 P 48VAC 50 60 Hz 48 V 230VAC 50 60 Hz 230 9 10 52 Revision code The latest revision may differ 11 A Braking resistor type A External resistor 12 0 Mounting 0 Standard ELE97 value EL32 value N ELE97 EMC level and S Standard without EMC filters grounded network NONEU GRD EL32 grounding N ENMQ Second environment grounded network EU GRD NONEU NONGRD 0 IT network non grounded network EU NONGRD 1 Standard with speed supervision 14 HS27 Boards 1 5 System bus with speed supervision 15 L Special L Varnished boards 1 6 Description of the control modes There are three different control methods command modes available 1 EP2 Electronic motor potentiometer function Stepless control using a 2 step controller 2 EPS Electronic motor potentiometer function Stepless contr
53. 502 P 937 328 5100 FAX 937 325 5319 3 3 2 Fault Counter HANDLING INC Fault counter value Counter value is shown in format Fault counter value Fault number E g 12 01 means that there has been 12 pieces overcurrent faults When counter value is blinking then you can monitor fault counter values by pressing up and down arrows Fault Counter Overcurrent fault counter Overvoltage fault counter Earth fault counter Saturation trip fault counter Undervoltage fault counter Input line supervision fault counter Output phase supervision fault counter Braking chopper supervision fault counter Inverter undertemperature fault counter Inverter overtemperature fault counter Microprocessor watchdog fault counter 3 4 IGBT temperature fault counter Profibus communication error fault counter Generator side current limit fault counter Thermistor fault counter Overspeed fault counter Speed difference fault counter Stall supervision fault counter Sum counter of following faults F4 F5 F8 F22 F23 F24 F26 F32 F33 F34 F35 F36 F37 F38 F39 F40 F48 F50 F54 F55 F60 F64 F65 F71 F72 V4 5 2 Total Faults Total number of all faults Inverter Alarm codes Alarm is a sign of an unusual operating condition Alarm remains in the display for about 30 seconds Alarm code A 16 Motor overtemperature A 50 Reference value alarm A 80 Multistep sequence alarm A 82 Overweight
54. 515 CH 4 4 DID2 S11 4 39 520 DID3 S21 4 40 53 xi 4 DIDA 12 A 54 5 OLE e o DID5 S22 1 42 55 3 36 m ONE 360 E E Lr niin WU Lay o 4 A47 ES ESA 37 A S ES A2 F Fi X11 8 gt E 18 48 BRT np F7 Xigd8 Y ij d 158 154 X16 19 a 485 163 164 71 83 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice A BAM Materials Handling Inc R amp M 4501 Gateway Boulevard MATERIALS Springfield Ohio 45502 G eee P 937 328 5100 INC FAX 937 325 5319 D2FR12F45R2S2 PE UL A i A1 Z2 B B 45 ohm F d PE o R mew Bl LI e o SC w O L1 Q L1 C ER ce Z3 A L3O U L2 0 92 U O y m DE von 4A WITH MULTICARE x4 oL V E I w 7 21 O F7 MH 8 5 W 22 is e i 9 CM1 Z1 Z2 Z3 AND CM1 NOT Ji E Xis f ds Ss INCLUDED IN STANDARD OR 2 4 e o l 323 IT MODELS O24 227 5 G 25 D 1 18 K7 2 4 23 G 2 K7 K7 16 18 SET 587 il 0 3s D 3 AC 4 5 7 5 DC A27 G1 S O 6 7 D j 57 at Xi315 32 ES ee ap 5 eta a GR ERE x1 81 2 11 S1 3 F eege
55. 52354911 1 gt 35mm gt 1 3 inch SYS 2M 52354876 2 gt 35mm gt 1 3 inch SYS 4M 52354912 4 35mm gt 1 3 inch H1 H2 H3 H4 1 15 Control voltage transformer Power of control voltage transformer has to be n 50VA 50VA min 250VA n number of inverters This power does not have to be added to otherwise needed transformer power 19 83 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice A BAM Materials Handling Inc R amp M 4501 Gateway Boulevard MATERIALS Springfield Ohio 45502 TANDING P 937 328 5100 INC FAX 937 325 5319 1 16 Speed sensors 1 16 1 Sensor bearing Inverter needs information about the motor rotation speed for stall speed difference and over speed supervision Bearing sensors are shown in the table below Motor type Motor code Pulses per revolution MF10MA200 T1 32 or 48 MF10MB200 T2 32 or 48 MF10MC200 T3 32 or 48 MF11MA200 T4 64 MF11MB200 T5 64 MF13Z 200 T6 80 MF13ZA200 T7 80 MF13ZB200 T8 80 MF13ZC200 T9 80 MF13X 200 TA 80 Sensor bearing requires KAE234 buffer amplifier If channel A is damaged channel B can be used instead in emergency situations With Synchro both channels must be connected Signal name Sensor bearing Wire colour between KAE234 Terminal number wire colour and motor plug 24V Red Brown KAE234 6 DV Black Green KAE234 2 A White White KAE23
56. 8 5100 INC FAX 937 325 5319 28 ROC1 EP ag Relay output 250V 8A normal open 29 ROC1 Relay contact ROC1 closes when inverter is powered and no faults occurs Relay contact ROC1 opens if the SSU has tripped in Overspeed Speed difference Zero speed Relay test fault Watch dog fault LED Blinking Status Red 1Hz OK Yellow 0 25Hz OK Yellow 4Hz Board internal fault or communication fault with control unit 1 14 6 I O Extension board Slot D NXOPTB9 I O Extension board ID 52305691 J p Terminal Signal name Description 1 DID1 Not used 2 DID2 42 240Vac 50 60Hz d 3 DID3 42 240Vac 50 60Hz Bva 4 DID4 42 240Vac 50 60Hz 5 DID5 42 240Vac 50 60Hz 6 COM Common for DID1 DID5 7 M dil o m 8 ROD1 3 The threshold voltage for digital inputs DID1 DID5 is 35VAC LED Blinking Status Yellow 0 25Hz OK Yellow 4Hz Board internal fault or communication fault with control unit 1 14 7 System bus board Slot E option NXOPTD1L System bus board ID 52354858 Terminal Signal name Description H1 RX1 SystemBus optical input 1 H2 RX2 SystemBus optical input 2 H3 RX3 SystemBus optical output 1 H4 RX4 SystemBus optical output 2 Optical cables Specification ID p Bend radius SYS 1M
57. Curr 44 Start Current 90 Start Current 110 Current Limit Current Limit 165 Min Freq S1 10 Min Freq S1 10 Min Freq S2 5 Min Freq S2 5 Max Freq S1 Max Freq S1 Max Freq S2 Max Freq S2 Max ESR Freq Max ESR Freq Drive Selection Drive Selection Pulse Number Pulse Number Zero Freq Volt Zero Freq Volt U f Mid Volt U f Mid Volt U f Mid Freq U f Mid Freq Torque Boost On Torque Boost On Rs Voltage Drop 100 Rs Voltage Drop 100 Stop Function Ramping Stop Function Ramping rt rt Flux Current Kp 4000 Flux Current Kp 4000 Flux Current Ti 25 Flux Current Ti 25 S2 Flux Control 100 S2 Flux Control 100 Freq 0 1 Freq 0 1 Freq 1 3 Freq 1 3 Freq 2 S1 10 Freq 2 S1 10 Freq 3 S1 20 Freq 3 S1 20 Zero Flux Curr 80 Zero Flux Curr 80 Stray Flux Curr 40 Stray Flux Curr 40 Freq 2 S2 10 Freq 2 S2 10 Freq 3 S2 40 Freq 3 S2 40 Zero Speed Curr Zero Speed Curr Min Current Ref 90 Min Current Ref 90 Accel Comp TC 0 1 Accel Comp TC 0 1 Ref Angle S1 Ref Angle S1 Ref Angle S2 Ref Angle S2 Flux Curr Damp Flux Curr Damp Stop DC Freq Stop DC Freq Start Freq S1 Start Freq S1 Start Freq S2
58. D1 29 Free NO contact of relay ROD1 8 K7 153 Free NO contact of K7 48 K7 154 Free NO contact of K7 9 K7 163 Free NO contact of K7 49 K7 164 Free NO contact of K1 20 K71 13 Free NO contact of K71 50 K71 14 Free NO contact of K71 21 PUR Not used 51 EA Encoder channel A 22 15V Not used 52 EA Encoder channel A 23 AIN1 Multicare speed reference input 0 10V 53 EB Encoder channel B 24 AIN2 Not used 54 EB Encoder channel B 25 AIN Common for analog inputs 55 24V 24V output for encoder 26 AOUT Multicare speed reference output 0 10V 56 DN Common for encoder supply 27 DV Common for analog output 57 24V External supply for Control module EE 64 83 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc R amp M MATERIALS 4501 Gateway Boulevard Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC 4 1 2 Power classes 015F 055F Name Description signal level Auxiliary power supply phase 1 Auxiliary power supply phase 2 91 L11 92 L12 93 L13 Auxiliary power supply phase 3 Nol Name Description signal level No Name Description signal level 1 BL1 AC brake supply phase 1 31 BD1 DC brake supply 1 2 BL2 AC brake supply phase 2 32 BD2 DC brake supp
59. E 880 3012 1760 6024 3521 12047 28167 F 951 3234 1902 6467 3804 12935 30435 2 4 S211 together with S1 are used for setting the tripping frequency level at normal speed S2 4 together with S3 are used for setting the tripping frequency level at ESR speed If ESR is not used set S2 4 S3 equal to S2 1 and S1 Pulse frequency can be calculated from formula Motor rpm x Pulses per rev 60 Example Normal use A 3000 rpm motor with 32 pulses per On the table the highest value under Check from V4 8 1 that the detection revolution has a full speed pulse 2000Hz is 1902Hz Suitable switch level is 1902Hz 1600Hz 118 9 of frequency of 1600 Hz settings are nominal speed Suitable maximum overspeed 2 2 OFF and S2 3 OFF detection level is 1600Hz 25 S2 1 OFF and S2 4 OFF 20002 S1 F and S3 F ESR use If ESR is applied for 150 of nominal S2 22OFF and S2 3 OFF are Check from V4 8 2 that the detection speed then the full ESR pulse frequency is 1 5 1600Hz 2400Hz Suitable maximum overspeed detection level is 2400Hz 25 3000Hz according to normal speed settings On the table the highest value under 3000Hz is 2793Hz Correct switch settings are S2 4 ON and S3 4 level is 2793Hz 2400Hz 116 4 of ESR speed Encoder with 600 ppr or over needs both encoder channels connected 46 83 R amp M Materials Handling Inc reserves the right to alter or amend the above information without n
60. E e INCLUDED IN STANDARD OR 2 j4 6 O g IT MODELS O24 27 AA G A 25 1 18 K7 2 j4 23 26 K7 9 c 5 K7 6 8 SET Za 0 3s 56 3 46 4 15 7 A 5 E E DC A 27 G1 3 O 6 7 D X1 31 4 Jas OQ 11 S1 xi F Bau 7 7 1 i 32 E 12 S2 enm E 34 4 Dag 10 m Q S5 e 45 a Hi E 14 DIA4 O 4 DIAS A112 465 116 OK ONE 35 15 gt OK xi KAE234 E ab l Q38 MSto Lu L DID2 S11 4 39 52 4 ops S21 4 40 53 x1 4 DID4 S12 4 41 54 5 OLE 4 ops S22 4 42 55 la 36 F ONE 560 7 KR ber r X11 3 Lu zi 4 O dy SET 0 88 Le ES ESA 37 A cu X1L 8 AM CU BRT1 F7 X1gy18 Bal 153 154 33 34 F11 Xigyi9 28 163 164 BRT1 EE a 75 83 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice A BAM Materials Handling Inc R amp M 4501 Gateway Boulevard EUER Springfield Ohio 45502 HANDLING EE P 937 328 5100 INC FAX 937 325 5319 2 x D2FR24F 16R4S2 PE L E A1 Z2 B 16 ohm 2 8 ohm B TR 120 EE 120 O L1 Q xi
61. English Original instructions SERVICE MANUAL FOR FREQUENCY CONTROL SYSTEM SUPDOC SM D2L016 0 ORD 25 8 2011 R amp M MATERIALS HANDLING INC C SM D2L0160100 0 PS05501 25 8 2011 R amp M Materials Handling Inc R amp M 4501 Gateway Boulevard EUER Springfield Ohio 45502 HANDLING P 937 328 5100 FAX 937 325 5319 INC Table of contents M GENERAL rms 6 USR eidele E E 6 1 27 BaSIC descriplioD sce IIR 7 1 8 Main components nnns nnn nnnnntrs aaaeaii de 7 E Eunctional description zoe nup DESEE ud 8 1 5 Factory code example Factory D3U nnn nnn nennen sss r einn 9 1 6 Description of the control modes eene nnnnemrn sse n nnn rennen asser nn nnn nns 9 1 6 1 ERZ COMTO 10 1 6 2 zuzegnsee 10 1 6 3 LEM 11 1 7 Mechanical brake contra 11 598 EMG ivi MEE d MM Md uu MEE 11 T INSTALLATION 13 WO GUBICIOS EE 13 1 10 Braking FeSISIOf cuarto c renes tete vet reset dd 13 1 11 Power Cabling tT 13 1 11 1 Shielded motor cable AAA 13 WTI reo Kos ET 13 IEEE 5 13 UP 5 Gable protect Pe 14 UP See e 14 UE 2 TOU E RE 14 1 12 S Itenripezsnp 15 1 12 1 Sh
62. F ambient temperature re cubicle heating F14 Inverter Temperature of heat sink is over acceptable Check X overtemperatur operating level ambient temperature e 90 194 inverter cooling fan operation Overtemperature warning is issued when the Cooling air flow through heat sink heat sink temperature exceeds 85 185 heat sink is not dusty F22 EEPROM Parameter save error After power off the inverter will automatically reset F23 checksum fault interference fault parameter settings The drive does not work properly nor component failure control unit enable driving after this fault Check all parameter settings 24V voltage output loading f the fault comes again contact authorized service center F 24 Changed data Changes may have occurred in the different No special actions required Take a critical attitude to the warning counter data due to mains interruption counter data F25 Microprocessor interference fault Reset switch power off and restart after the lamps of watchdog fault component failure control unit display are off If the fault comes again contact service F26 Power Unit Fault F31 IGBT Too high temperature in IGBT A hardware Reset switch power off and restart after the lamps of temperature temperature measurement has tripped keypad are off Check motor loading brake operation inverter heatsink inverter cooling fan operation environment temperature F32 F
63. Freq 0 1 Freq 0 1 Freq 0 1 Freq 0 1 Freq 1 3 Freq 1 3 Freq 1 3 Freq 1 3 Freq 2 S1 10 Freq 2 S1 10 Freq 2 S1 10 Freq 2 S1 10 Freq 3 S1 20 Freq 3 S1 20 Freq 3 S1 20 Freq 3 S1 20 Zero Flux Curr 80 Zero Flux Curr 80 Zero Flux Curr 80 Zero Flux Curr 80 Stray Flux Curr 40 Stray Flux Curr 40 Stray Flux Curr 40 Stray Flux Curr 40 Freq 2 S2 10 Freq 2 S2 10 Freq 2 S2 10 Freq 2 S2 10 Freq 3 S2 40 Freq 3 S2 30 Freq 3 S2 40 Freq 3 S2 40 Zero Speed Curr Zero Speed Curr Zero Speed Curr Zero Speed Curr Min Current Ref 90 Min Current Ref 90 Min Current Ref 90 Min Current Ref 90 Accel Comp TC 0 1 Accel Comp TC 0 1 Accel Comp TC 0 1 Accel Comp TC 0 1 Ref Angle S1 Ref Angle S1 Ref Angle S1 Ref Angle S1 Ref Angle S2 Ref Angle S2 Ref Angle S2 Ref Angle S2 Flux Curr Damp Flux Curr Damp Flux Curr Damp Flux Curr Damp Stop DC Freq Stop DC Freq Stop DC Freq Stop DC Freq Start Freq S1 Start Freq S1 Start Freq S1 Start Freq S1 Start Freq S2 Start Freq S2 Start Freq S2 Start Freq S2 Brake Stop Freq Brake Stop Freq Brake Stop Freq Brake Stop Freq ESR Point Freq ESR Point Freq ESR Point Freq ESR Point Freq ESR
64. K xt KAE234 E A a O88 isto la 4 DID2 S11 4 39 52 4 pips S21 4 40 58 xi 4 DIDA S12 A 41 54 5 OLE cO 4 DID5 S22 4 42 55 ls 36 F ONE 360 4 d Sieg Xi 3 Laun 4 La ES ES 37 Al A2 T F11 X11 8 A BRT1 19 Pn 7 F7 X1 918 A8 O ka ae ad 158 154 W I E xio ES 163 164 70 83 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice i R amp M Materials Handling Inc R amp M 4501 Gateway Boulevard MATRAS Springfield Ohio 45502 HANDLING E P 937 328 5100 INC FAX 937 325 5319 D2FR12F45R282 oo Zi A1 Z2 B 45 ohm za B 20 E L2 Q O L1 0 Z3 A AE T meme d we iw 7 21 e F7 1 3 5 W 22 gt e ls CM1 Z1 Z2 Z3 AND CM1 NOT Bt Xie l La eat INCLUDED IN STANDARD OR 2 Ja le o 23 IT MODELS 24 O 27 e p g E 1 18 K7 2 j4 23 G A 26 K7 l6 8 L1 L2 AC a 5 7 pb 25 s DC DES G1 D AL X 57 A EU ES Xam EIS TEE xi S1 8 11 S1 xi H 33 m l 52 3 12 S2 zm 3AL A pee RE 13 DIA3 EE S 45 DAS on 14 DIA4 O 4 DIAS A2 4860 R 186 ONE 35 115 gt OK KS Q38 A
65. NG E P 937 328 5100 INC FAX 937 325 5319 1 2 Basic description Inverter has many advantages and offers many new features when compared to other inverter based systems which might be used in crane applications Inverter The specific crane features for the inverter hardware and the special software are achieved by combining the experience and know how of crane applications with the latest technology Crane user interface Interface with pre designed locations for typical crane functions The main part of this interface is carried out by a terminal strip which has separated sections for signals with main control and electronics voltage levels Brake control Includes the brake contactor for disk brakes Includes also DC rectifier Electrical Braking Includes a braking transistor and a braking resistor Control methods Can be controlled by the electronic potentiometer control with 2 step or 3 step pushbuttons the multistep control with 2 4 step controllers Limit switch functions Built in slowdown S11 S21 and stop limit switch S12 S22 functions for both running directions Speed supervision Inverter includes a speed supervision unit SSU which is separate from the inverter and not dependent on Software This safety circuitry is used to monitor the speed of the motor In case of speed difference overspeed or stall the speed supervision unit stops the motion immediately Protections Includes a mot
66. Synchro application Major differences in brake operation braking times between drives can cause large displacement errors especially braking from full speed in fault case and could lead to hazardous situations d Multicare and Synchro functions must not be used together 47 83 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice A BAM Materials Handling Inc R amp M 4501 Gateway Boulevard pner Springfield Ohio 45502 NG E P 937 328 5100 INC FAX 937 325 5319 2 9 Start up Do normal start up according chapter Start up for each hoist If the crane has been ordered with the Synchro function it does not need any additional actions before use In case there is problems or synchronization is added afterwards do start up according the following list 1 Do normal start up routine for each hoist 2 For all drives check that the SystemBus Boards OPT D1 and optical cables are connected properly Checklist The unused fibre terminals are protected with rubber pins Optical cable clamp routing and minimum bending radius A Control units cover is closed and locked 3 Setthe parameters P2 42 Address one drive has to have address 1 this will function as master Every drive should have their own address P2 4 2 Next Address P2 4 3 Last Address P2444 Nominal Speed hoisting speed from hoist rating plate 4 Check from the panel th
67. TOR INFORMATION TYPE CODE NOMINAL VOLTAGE S SERIALNUMBER NOMINAL CURRENT S U F CURVE NOMINAL Travelling inverter FREQUENCY Zero freq volt NOMINAL SPEED U f Mid volt 96 POWER FACTOR U f Mid freq Hz PULSE SENSOR PULSE REV Hoisting inverter MEASURED VALUES INVERTER MOTOR VOLTAGE L1 L2 L1 L3 L2 L3 NOMINAL CURRENT U V V W W U PHASE TO PHASE VAC VAC VAC e Q VOLTAGE L1 L2 L3 PHASE TO GROUND VAC VAC VAC MEASURED CONTROL VOLTAGE V 60 83 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice A BAM Materials Handling Inc R amp M 4501 Gateway Boulevard MATERIAIS Springfield Ohio 45502 HANDLING E P 937 328 5100 INC FAX 937 325 5319 4 SERVICE The drive does not require regular maintenance However the following actions are recommended Check fault history Find out reasons of possible faults Clear the fault history Clean the heat sink Prevent the dust to spread inside cubicles Lock the fans before blowing compressed air Check that there are no abnormal noises coming from the cooling fan Tighten all screws and connectors Clean dust from PC boards Check the speed supervision circuit only in hoisting inverter See chapter Functional test run for SSU 61 83 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M MATERIALS HANDLING INC 4501 Gateway Boulevard Springfie
68. Terminals X1 21 27 and X1 51 57 are for electronics level signals Normally only shielded wires are connected to these terminals Check that no control or line voltage level wires are connected there 2 16 Checks before the first test run Check power supply voltage nominal voltage 10 Check control voltage nominal voltage 10 Make sure that run commands are off pushbuttons controller master switch at zero position Turn on power from main switch and control voltage switch Within about 1 second the control panel should display AC on and then in about 1 second the display changes to motor output frequency 0 00 and green READY status indicator turns on Ina fault situation the red FAULT status indicator blinks and the display shows a fault code instead of frequency Check that green RUN status indicator is off Check that external connections and selected control method are according to application Parameters are properly set after factory tests and no adjustments are needed except for the parameters that depend on application Write down on the parameter list all the values that have been changed and at the end save parameters to User parameters see chapter User parameters 2 17 Test run without load Make sure that movement will not cause any danger to the environment or to the crane itself Avoid driving close to the limit areas Check limit switches manually if possible Check
69. able Dimensioning of the fuses or MCCBs depends on the cable used and on the type of primary fuses or MCCBs If there are no other regulations the values given in this section can be used to dimension fuses three phase 400V supply The overload protection of inverter protects both the supply and the motor cables The fuses of the supply provide the short circuit protection 1 11 5 Cable length The maximum motor cable lengths in the preceding table are based on 150 of inverter rated current current during acceleration and a 2 5 voltage drop in the cable For longer cables the required conductor cross sectional area A mm2 is given by formula Ix 15x L A 2 43 p x U where is the cable length m k is the motor current A at shaft power Pe p is the allowed voltage drop in 96 U is the nominal motor voltage 1 11 6 Du dt filters If inverter is not mounted on the crane there has to be du dt filter at motor supply Also if total motor cable length sum of motor cables is over 100m with 002 005 or over 200m with 007 055 there has to be du dt filter at motor supply Power class Platthaus du dt filter Length mm Width mm Height mm Weight kg ID 002 003 ULC 910 920 100 110 180 1 2 52306553 004 005 ULC 914 931 125 110 200 3 52306554 007 018 ULC 918 951 155 125 225 7 52306555 022 045 ULC 923 927 190 135 260 12 52306556 055 ULC 942 1044 240 175 310 22 52306557
70. actory settings is not used Keypad set S6 4 4 Actual parameter values are compared to parameter file saved in Keypad Password S6 5 1 Password for group S6 5 Parameter lock P6 5 2 Not used Change Enable Startup wizard P6 5 3 Not used No Multimon Items P6 5 4 Enables or disables chancing of variables in multimonitor page ChangeEnable N4 23 1 ChangeDisable Default page P6 6 1 Default page to which the display automatically moves as the Timeout time has expired or as the power is switched on to the keypad If the Default Page value is 0 the function is not activated i e the last displayed page remains on the keypad display Default page OM P6 6 2 Timeout time P6 6 3 The time after which the keypad display returns to default page Contrast P6 6 4 Display contrast Backlight time P6 6 5 Determines how long the backlight stays before going out Value 0 0 65535 min means Forever InternBrake Res P6 7 1 Must not be changed Not conn Fan Control P6 7 2 Must not be changed First start HMI ACK timeout P6 7 3 Not used HMI retry P6 7 4 Not used MWh counter C6 8 1 1 MWh counter can not be reseted PwOn Day Counter C6 8 1 2 Total number of power on days PwOn hour count C6 8 1 3 Total number of power on hours 33 83 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M MATERIALS R
71. alter or amend the above information without notice R amp M MATERIALS HANDLING INC P 937 328 5100 FAX 937 325 5319 R amp M Materials Handling Inc 4501 Gateway Boulevard Springfield Ohio 45502 2 10 Optic cable connections Synchronization between 2 hoists Synchronization betw een 4 hoists Hoist A Hoist B Address Address P2 4 1 1 P2 4 1 2 Next Address Next Address P2 4 2 2 P2 4 2 1 Last Address Last Address P2 4 3 2 P2 4 3 2 Hoist A Address P2 4 1 1 Next Address P2 4 2 2 Last Address P2 4 3 4 Hoist B Address P2 4 1 2 Next Address P2 4 2 3 Last Address LI P I DL gp H1 H2 H3 H4 H1 H2 H1 H2 az H O P2 4 3 4 T Hoist C Hoist D Address Address P2 4 1 3 P2 4 1 4 Next Address Next Address P2 4 2 4 P2 4 2 1 Last Address Last Address P2 4 3 4 P2 4 3 4 H3 H 1E H4 H1 H2 H3 H4 d 2 11 Troubleshooting Should problems arise with the Synchro first check that all drives function correctly without synchronization being activated Problem Possible cause Checking
72. an cooling Cooling fan of the frequency converter do If the fault comes again contact authorized service fault not work when ON command has been given F35 Application Run time exception in the application Contact authorized service fault program F36 Control Unit Faulty Control Unit Contact authorized service F37 Device changed Option board changed Reset the fault X F38 Device added Option board added Reset the fault X F39 Device Option board removed Reset the fault X removed F40 Device Unknown option board or drive Check board and drive type unknown F41 IGBT Too high temperature in IGBT transistors Reset switch power off and restart after the lamps of tempetature long duration overload keypad are off Check lowered cooling motor parameters high environment temperature u f curve settings motor loading brake operation inverter heatsink inverter cooling fan operation environment temperature F43 Encoder failure Encoder failure Check 56 83 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M MATERIALS HANDLING INC R amp M Materials Handling Inc 4501 Gateway Boulevard Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 S3 Both EA and EB are missing Encoder type and pulse number S4 EA and EB are crossco
73. at for all drives the first and the second digit of the V2 4 10 10 Synchro Status are now 11xxx The first digit indicates that the Synchro is parameterized in use and the second digit indicates that the SystemBus is working properly Power off the drives if second digit is zero then power on and check again 5 Activate synchronization using digital input DID1 Check from the panel that for the master drive Address 1 the V2 4 10 10 Synchro Status is now 11101 and that for all the slave drives it is 11011 The third digit indicates that the drive is a master and the fourth digit indicates that the drive is a slave Fifth digit indicates that synchronization is activated from the digital input and there are totally at least two active drives in the SystemBus 6 For master drive check following synchronization control parameters P2 4 5 Displacement limit default 50 P2 4 6 Gain default 200 P2 4 7 Sync Activation default 0 During Stop P2 4 8 Min Freq Offset default 3Hz P2 4 9 System Bus Speed default 3Mbit s 7 Check that acceleration deceleration ramps are identical in each drive 8 Finally perform a test drive with no load on Check that There is no position difference between hooks with smooth driving or with lots of accelerations and decelerations V2 4 10 1 Max Pos Error in the master drive doesn t show any constant position error 48 83 R amp M Materials Handling Inc reserves the right to
74. atSinkTempMax V4 9 5 Recorded heatsink temperature highest peak value during run C HeatSinkTempMin V4 9 6 Recorded heatsink temperature lowest peak value when power is C connected to drive IGBT Temp Max V4 9 7 Recorded calculated IGBT temperature highest peak value C IGBT Temperature V4 9 8 Actual IGBT temperature C SlipAdjustChange V4 9 9 Slip adjust difference compared to Slip adjust parameter K G4 9 10 Max Current Max Current G4 9 10 1 Recorded maximum current A Max Current Freq G4 9 10 2 Frequency at recorded maximum current Hz Max Current Torq G4 9 10 3 Torque at recorded maximum current 96 G4 9 11 Encoder V4 9 11 1 Not used V4 9 11 2 Not used V4 9 11 3 Not used V4 9 11 4 Not used V4 9 11 5 Not used Freq Ref V4 11 Frequency reference Hz Speed Req V4 12 Not used Distance counter V4 13 Not used m DC Link Voltage V4 14 Actual value of measured DC link voltage V Heat Sink Temp V4 15 Temperature of heat sink C MotorTemperature V4 16 Calculated motor temperature in percent of maximum 96 Motor Power V4 17 Calculated actual power of nominal power of unit 96 Motor Voltage V4 18 Calculated motor voltage V Motor Torque V4 19 Calculated motor torque K motor nominal torque positive when motoring negative when generating Motor Current V4 20 Measured motor current A Motor speed V4 21 Calculated moto
75. ates a drive to synchronization Synchronization is active if at least two drives are active Synchronization is deactivated if only one drive is active When any drive connected to the system bus is active the current hook positions of drives are registered Hereafter the master controls all active drives so that the relative position between the hooks stays at this level Master gets the speed references and position information from the slave drives via SystemBus Smallest speed reference will be selected as Synchro speed reference and smallest position as Synchro position Master will then calculate the position differences for each drive and limit them if needed Then the master will calculate speed correction for each drive which is sent accordingly to each drive via SystemBus Only deceleration is allowed with correction If SystemBus option card is not installed DID1 functions as FWE activation input From the drives connected to the SystemBus the user must select one drive to function as a master Setting the parameter P2 4 1 Address to value 1 does this If one of the active drives has tripped to fault all drives will be stopped according the fault and only the tripped drive will show fault code Faults of passive drive won t affect the active drives If slow down limit of any active drive opens the limited speed will be used as a reference E 2 a3 Brake operation and maintenance should have extra attention with the
76. ble s must be shielded round cable s and grounded 360 at both ends D Note All shielded cables must be placed as far from the motor cables as possible gt 20cm Shielding must be continuous The pigtail the end to be connected of the shield should not be used instead 360 groundi ng should be used to minimize disturbances DD if control cable length is over 100m from transformer to inverter or inverter is not mounted on the crane make sure that Basic I O board Slot A is at least revision 271G and I O Extension board Slot D is at least revision 266H 1 13 EMC compatible grounding 1 13 1 Construction connections All metal construction parts of the cubicle must be electrically connected to each other using largest possible surface area Paint to paint connection must not be used 1 13 2 Cable connections Control cables and power cables should be separated and routed separately for eliminating noise coupling The distance between braking resistor cables and the other cables should be kept as long as possible The distance between the resistor cables should be kept as low as possible to prevent the antenna behavior Cable lengths should be kept as short as possible to minimize coupling capacitances and inductances 1 13 3 Shielded control cables Shielded control cables should be grounded in both ends The shield must be connected to the ground using the largest possible surface area Extra intermediary terminators cutting t
77. blems must be solved before continuing m Warning High voltages inside device Wait for at least five minutes after the supply voltage has been switched off before service actions Display in operating condition lights on indicates a dangerous voltage on the DC bus When display turns off the DC bus voltage is about 100V Note also that there is a dangerous voltage in the braking resistor always when the DC bus is charged m Do not connect any voltage to the output terminals U V W Otherwise the inverter will be damaged m The overload protection protects both the supply and the motor cables The fuses of the supply provide short circuit protection 2 15 Visual checks Check condition of cubicles Check that serial number of the drive is the same as in delivery documents Check the switch settings on SSU see Chapter Speed Supervision Settings If necessary open the control box cover and adjust the SSU settings Check the cabling to braking resistor Check the cabling to motor brake thermistors and speed sensor Check motor type Check the wire terminations in the motor connection box Check connections for motor thermistors brake wear and speed sensor circuits Disconnect motor U V W and brake cables to prevent damage of inverter Measure insulation resistance of brake coil and motor windings each phase to ground Re connect motor and brake cables Check braking resistor s
78. braking to ensure that the temperature of the resistors drops below 150 C 302 F Other features Slowdown limit switches S11 and S21 provide position dependent frequency limiting Any reason which opens contact RDY stops the operation of inverter In case of overload motor overheating etc the hoisting can be disabled by cutting the direction signal in terminal X1 8 Thermistor relay function which can be used when needed When the stop limit switch S12 or S22 opens K7 K71 in model 055F de energizes and the mechanical brake stops the motion Independent speed supervision unit SSU The speed measurement and supervision can be done either with encoder bearing sensor or proximity switch The measured signals are square wave pulses The frequency of the pulses is proportional to the speed of the motor and if the frequency is too high overspeed is detected If there are no pulses a stall situation is detected If the actual speed differs too much from the supply frequency of the motor the speed difference supervision stops the motion Proximity switch buffer amplifier A5 amplifies the sensor pulses and filters out disturbances The amplifier is located close to the sensor 8 83 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice i R amp M Materials Handling Inc R amp M 4501 Gateway Boulevard MATRAS Springfield Ohio 45502 TANDING P 937 328 5100 INC FAX 937 325 5319 1
79. d 055 1 x H15BD02 1 x1500 x 1000 Included 1 10 Braking resistor Inverter is delivered with external braking resistor Braking resistor types D2FR are equipped with cooling fans and thermistors Circuit diagrams are in appendix Power class Resistance ohm Type 002 005 90 D2HRO4F90R0S4 007 64 D2FRO6F64R0S2 011 015 45 D2FR12F45R2S2 018 022 21 D2FR18F21R3S2 030 16 D2FR24F16R4S2 037 045 11 2 x D2RF18F21R3S2 055 8 2 x D2FR24F16R4S2 In case of 2 resistor units power supply to transformers has to be taken from the same phases 1 11 Power cabling 1 11 1 Shielded motor cable In crane application inverter fulfils EN61800 3 A11 IEC 1800 3 second environment radiated emission requirements without shielded motor cable In the second environment shielded motor cable is recommended to use in fixed installations especially in buildings However motor cables in crane and festoon power supplies are normally not shielded due to the practical reasons 1 11 2 Double collectors If the power is supplied to the crane via conductor rails double collectors are needed This ensures a reliable contact with the rail in all circumstances Short interruptions and sparks between the conductor rail and the collector may cause nuisance tripping other undesired operations and in worst case even permanent damage to components 1 11 3 Cable selection Cabling for inverter can be done using n
80. delay to direction S1 0 Max Freq S2 Hz Start Freq S2 P2 3 20 Defines the output frequency during brake opening delay to direction S2 0 Max Freq S2 Hz Brake Stop Freq P2 3 21 When stopping the contact of the relay output ROB2 opens when the 0 Max Freq S2 Hz output frequency of drive goes below the value set in this parameter ESR Point Freq P2 3 22 Defines ESR field weakening point frequency in percents of motor 0 250 nominal frequency ESR Point Volt P2 3 23 Defines ESR field weakening point voltage in percents of motor nominal 0 250 96 voltage IrAdd Motor P2 3 24 With small speeds and heavy load the hoist movement does not have 0 200 enough voltage to produce sufficient torque Raising the value of this parameter increases the voltage Must not be changed IrAdd Generator P2 3 25 If motor voltage at generator area is too high reducing value of 0 200 parameter decreases the voltage Ramp Stretching P2 3 26 See Chapter Ramp Stretching Not used in hoisting 0 50 Switching Frequency P2 3 27 Must not be changed from factory setting 3 6 kHz DeadTime Comp P2 3 28 Dead time compensation time delay Parameter value does not tell the 0 10000 actual time used in compensation DeadTime CurrLim P2 3 29 Parameter that is used to control the current waveform in dead time 0 1000 compensation Brake Chopper P2 3 30 Defines when braking chopper is allowed to be activated 1 2 Yes Run Always while drive
81. drive has 0 5 seconds to respond and begin to accelerate at the same time once both brakes are opened Both drives end up running at the same reference speed after acceleration or deceleration EP hold situation speed correction is not possible at minimum speed or full speed The correction takes place whenever the two reference speed values deviate more than 1 96 or about 1 Hz One drive faulting out stops the other and the other drive will issue a multicare fault F70 When only one hoist is selected for operation the analog signal remains at zero volts and this disables the multicare mode in case of one hoist drive being faulty active fault is not cleared when a starting command is issued the analog signal would remain at 10 volts fault condition and both hoists would be inoperational The solution for allowing the operation of one hoist in single mode is to open up the analog connection between the two drives with the help of a small relay see picture below this relay must be capable of connecting DC current 2 12 Connections The analog output of one drive is connected to the analog input of the other drive and vice versa see below A shielded cable is used to establish the analog signal connection between two drives Both ends of the cable shield must be grounded using 360 degree grounding whenever possible 2 13 Setup pa a Verify the connection of analog inputs and outputs and cable shield grou
82. during run may cause an 55 83 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M MATERIALS HANDLING INC R amp M Materials Handling Inc 4501 Gateway Boulevard Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 undervoltage trip Subcodes e S1 EA is missing e S2 EB is missing Encoder cabling Brake opening Encoder mechanical assembly F10 Input line One input line phase is missing Check X supervision supply voltage mains connection F11 Output phase Current supervision has sensed that at least Check supervision one of the motor phases has no current motor cable connections measure motor phase currents and compare to display value F12 Braking Braking chopper or braking resistor circuit Reset switch power off and restart after the lamps of chopper has failed Test pulse measures transistor display are off supervision collector voltage Fault appears if Check braking resistor is broken braking resistor and insulation resistance braking chopper is broken e measure braking transistor IGBT and free wheeling braking resistor is not installed diodes f resistor is OK then the chopper is broken Contact authorized service F13 Inverter Temperature of heat sink is below Check X undertemperatu acceptable operating level 10C 14
83. ection Pulse Number Pulse Number Pulse Number Pulse Number Zero Freq Volt Zero Freq Volt Zero Freq Volt Zero Freq Volt U f Mid Volt U f Mid Volt U f Mid Volt U f Mid Volt U f Mid Freq U f Mid Freq U f Mid Freq U f Mid Freq Torque Boost Torque Boost Torque Boost Torque Boost On Rs Voltage Drop Rs Voltage Drop Rs Voltage Drop Rs Voltage Drop 130 Stop Function Stop Function Ramping Stop Function Stop Function Ramping rt rt rt rt Flux Current Kp Flux Current Kp 4000 Flux Current Kp Flux Current Kp 4000 Flux Current Ti Flux Current Ti 25 Flux Current Ti Flux Current Ti 25 S2 Flux Control S2 Flux Control 100 S2 Flux Control S2 Flux Control 100 Freq 0 Freq 0 1 Freq 0 Freq 0 1 Freq 1 Freq 1 3 Freq 1 Freq 1 3 Freq 2 S1 Freq 2 S1 10 Freq 2 S1 Freq 2 S1 10 Freq 3 S1 Freq 3 S1 20 Freq 3 S1 Freq 3 S1 20 Zero Flux Curr Zero Flux Curr 80 Zero Flux Curr Zero Flux Curr 80 Stray Flux Curr Stray Flux Curr 40 Stray Flux Curr Stray Flux Curr 40 Freq 2 S2 Freq 2 S2 10 Freq 2 S2 Freq 2 S2 10 Freq 3 S2 Freq 3 S2 20 Freq 3 S2 Freq 3 S2 40 Zero Speed Curr Zero Speed Curr Zero Speed Curr Zero Speed Curr Min Current Ref Min
84. efault Label Code Default G 2 1 General Parameters G 2 1 General Parameters G 2 1 General Parameters G 2 1 General Parameters Accel Time 1 1 5 Accel Time 1 1 5 Accel Time 1 1 5 Accel Time 1 1 5 Decel Time 1 1 5 Decel Time 1 1 5 Decel Time 1 1 5 Decel Time 1 1 5 r Parameters r Parameters r Parameters r Parameters Motor Nom Volt 400 Motor Nom Volt 400 Motor Nom Volt 400 Motor Nom Volt 400 Motor Nom Freq 100 Motor Nom Freq 100 Motor Nom Freq 100 Motor Nom Freq 100 Motor Nom Speed 2830 Motor Nom Speed 2790 Motor Nom Speed 2780 Motor Nom Speed 2860 Motor Nom Curr 4 8 Motor Nom Curr 9 4 Motor Nom Curr 10 7 Motor Nom Curr 18 Nom Flux Curr 3 2 Nom Flux Curr 6 2 Nom Flux Curr 6 3 Nom Flux Curr 12 Start Current 5 8 Start Current 10 Start Current 12 9 Start Current 18 Current Limit Current Limit Current Limit 16 Current Limit 27 Min Freq S1 Min Freq S1 Min Freq S1 10 Min Freq S1 10 Min Freq S2 Min Freq S2 Min Freq S2 5 Min Freq S2 5 Max Freq S1 Max Freq S1 Max Freq S1 Max Freq S1 Max Freq S2 Max Freq S2 Max Freq S2 Max Freq S2 Max ESR Freq Max ESR Freq Max ESR Freq Max ESR Freq Drive Selection Drive Selection Drive Selection Drive Sel
85. ent 74 Start Current 75 Current Limit 90 Current Limit Current Limit 93 Current Limit Min Freq S1 10 Min Freq S1 10 Min Freq S1 10 Min Freq S1 10 Min Freq S2 5 Min Freq S2 5 Min Freq S2 5 Min Freq S2 5 Max Freq S1 Max Freq S1 Max Freq S1 Max Freq S1 Max Freq S2 Max Freq S2 Max Freq S2 Max Freq S2 Max ESR Freq Max ESR Freq Max ESR Freq Max ESR Freq Drive Selection Drive Selection Drive Selection Drive Selection Pulse Number Pulse Number Pulse Number Pulse Number Zero Freq Volt Zero Freq Volt Zero Freq Volt Zero Freq Volt U f Mid Volt U f Mid Volt U f Mid Volt U f Mid Volt U f Mid Freq U f Mid Freq U f Mid Freq U f Mid Freq Torque Boost On Torque Boost On Torque Boost On Torque Boost On Rs Voltage Drop 100 Rs Voltage Drop 90 Rs Voltage Drop 180 Rs Voltage Drop 180 Stop Function Ramping Stop Function Ramping Stop Function Ramping Stop Function Ramping rt rt rt rt Flux Current Kp 4000 Flux Current Kp 4000 Flux Current Kp 4000 Flux Current Kp 4000 Flux Current Ti 25 Flux Current Ti 25 Flux Current Ti 25 Flux Current Ti 25 S2 Flux Control 100 S2 Flux Control 100 S2 Flux Control 100 S2 Flux Control 100
86. etwork 5 83 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M MATERIALS HANDLING INC 1 GENERAL 1 4 Technical data Power class Power kVA at 400V Output current In A Max current 1min A Overloadability Max output voltage Supply Supply voltage Allowable voltage fluctuation Nominal supply frequency Signal input levels Digital controls Encoder feedback Control features Control method Frequency control range Frequency command Limit switch functions Speed control range Speed accuracy Extended speed range Braking torque Protections Stall prevention Motor overload protection Overload protection Undervoltage blown fuse Overvoltage protection Momentary power loss Inverter overtemperature Mechanical brake Braking transistor Ground fault Overspeed stall Speed difference supervision Ambient conditions Ambient temperature Storage temperature Humidity Altitude Vibration 6 83 R amp M Materials Handling Inc 4501 Gateway Boulevard Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 002F O03F 004F 0O005F 007F 011F 015F O18F 022F 030F 037F 045F 4 5 5 5 7 9 13 17 22 29 33 40 50 60 6 5 8 10 13 18 24 32 42 48 60 75 90 10 12 15 20 27 36 48 63 72 90 113 135 1 5 xIn 1min 10min Equal to supply voltage 380 500VAC 10 50 60Hz 5 1 S2 DIA3 DIA4 DIAS DID1 DID2 DID3 DID4 DID5 42
87. grounding on inverter terminal the shield should be grounded always when going through terminals 1 16 2 Encoder Standard encoder has 24 pulses per revolution It is also allowed to use 600 1000 1024 2000 or 2048 ppr encoders but then there has to be both channels connected Order code for 24 ppr encoder is NM701NR28 Encoder connection examples are shown below All signal wires shall be included inside a single shielded cable Power supply to the encoder may also be included in the same cable terminal box D2L x1 AN 55 red 424V A 51 yellow EA Standard connection 53 Z EB m G 52 a Encoder 24 ppr EA f co D EB DN 56 blue ov terminal box D2L x1 V d 55 red 24V A d c 351 yelow EA Standard connection o 53 Z green EB m G O 52 J Encoder 600 ppr or more black EA fm e D white EB 0v O 56 blue OV In standard encoders there are also zero outputs Z Z which should be left disconnected If the encoder does not have negative channels A and B EA and EB must be connected to OV at motor terminal box alternative connection In order to avoid fault situations the cable between the encoder and inverter must be as far as possible from the cables of motor and braking resistor minimum distance gt 20cm a shielded and twisted cable grounded the shield at both
88. h Honeywell Colour if cable has been lengthened KAE 234 D2L xi V 6 o3 55 red brown 1 4 24V A S Oo 51 green green EA _ 3 2 G rae m kd iu 2 ot black white EN 83 83 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice
89. he shield are not allowed the shield should be as integrity as possible Spare conductors should be grounded in the both ends All shielded cable shields should be 360 grounded 15 83 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice A R amp M Materials Handling Inc R M 4501 Gateway Boulevard MATERIALS Springfield Ohio 45502 G HANDLIN P 937 328 5100 INC FAX 937 325 5319 2 COMPONENTS 1 14 Inverter Inverter D2V includes Power supply unit PSU and Control unit CSU which are separate parts PSU includes supply brake resistor and motor connections IGBTs are placed to PSU Microprocessors and ASIC are placed to CSU Same CSU can be used in every power class 1min Weight Weight D2V In Imax kg lbs D2V002NF1e000 6 5 10 6 13 D2V003NF1e000 8 12 6 13 D2V004NF1e000 10 15 6 13 D2V005NF1 96000 13 20 6 13 D2V007NF1 6000 18 27 10 22 D2V011NF1e000 24 36 10 22 D2V015NF1e000 32 48 20 44 D2V018NF1e000 42 63 20 44 D2V022NF1e000 48 72 20 44 D2V030NF1e000 60 90 37 82 D2V037NF1e000 75 113 37 82 D2V045NF1e000 90 135 37 82 D2V055NF1 6000 110 165 61 135 e defines emission level 0 EMC level 0 N EMC level N S The main circuit diagram of D2V002 D2V005 BR B B Q L1 AA A CIRCO CE Li 0A SE 4
90. ice R amp M Materials Handling Inc R amp M 4501 Gateway Boulevard MATRAS Springfield Ohio 45502 Boat P 937 328 5100 INC FAX 937 325 5319 ESD141 60003098 1 1 1 1 1 1 1 SECOND BRAKE CONTACTOR K71 Contactor LC1 D09D7 52303564 42VAC 1 CO1E7 52296542 48VAC 1 C0O1F7 52296548 115VAC 1 LC1 D09P7 52296643 230VAC 1 RC filter LA4 DA1E 52275256 42 48VAC 1 LA4 DA1U 52275257 115 280VAC 1 Auxliary contact LAD 8N20 52297562 1 LAD N04 52297548 1 COMPONENTS FOR EMC LEVEL N CM1 Y capacitor KC 307 00 52298693 42VAC 1 1 1 1 1 1 1 1 1 1 1 1 1 Z1 Ferrite RU2100 30 7 52299351 Emission level N 1 1 1 1 1 1 Z2 RH175285107 52297604 1 1 1 1 1 1 Z3 RH175285107 52297604 1 1 1 1 1 1 Z1 EF32010 52299352 2 2 2 Z2 W74270096 52299353 1 1 1 Z3 W7427015 52299354 2 2 2 Zi EF32010 52299352 2 2 2 Z2 W7427015 52299354 1 1 1 Z3 W742701111 52300355 7 7 T7 Z2 W7427015 52299354 3 Z3 W7427015 52299354 4 63 83 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice A BAM Materials Handling Inc R amp M 4501 Gateway Boulevard MATERIALS Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC 11 DRAWINGS 4 1 Description of terminals 4 1 1 Power classes 002F 011F No Name Description signal level
91. ielded signal cable AAA 15 112 2 Heference signals ne ree een e e e v de en ve en eR uda 15 um EE ege Ile er 15 CIZA Encoder iei eeeuteneiueutemeuiemte edidi 15 1 13 EMC compatible grounding doo e tin e e i eed erre e res 15 1 13 1 Construction CONNECTIONS ennemis nennen nnn net nsns redit rrr nnns sinn nnn 15 149 2 Gable connectors oen eee ene ect err ete eee cte ee vr ete eee e re ee ve eerie E e E 15 1 13 3 Shielded control cables 20 0 2 cece eee eee aera eee nnet nsns enden hne nnne nnne 15 2 MOI COIN zljp e H M 16 1 14 lcs ec meet 16 1 14 1 Power supply unit PSU 000 0 enhn nnnnmenn nnne nnn nnnnteti sanis s aaaee seen 17 1 14 2 Control unit CS 17 1 14 8 Basic I O board Slot Al 18 1 14 4 Relay Thermistor board Slot Bi 18 1 14 5 SSU Speed Supervision board Slot C A 18 1 14 6 UO Extension board Slot Di 19 1 14 7 System bus board Slot E option sssssssssssssssssseeeeeeeee nennen nnne nennen rsen nnn 19 1 15 Control voltage transtommer eene enne n sheet aaeee nsns en nenne nn nnne nnn 19 1 16 Speed K T aT 1o 6 00 2 cece cece ee eee eee eee ee eee eee 20 1 16 1 Sensor DEALING eee ee eee eee aaaeeeee eee 20 1 16 2 Emcoder cc eee aaa eee aaaeee eee 21 1 16 3 Proximity Switch 0 02 0 ee eee aaaeee nese 21 1 16 4 Buffer amplifier KAE234 000 0 eee ead eee eee nnn ner nsns nennt nnn nnns seen nnn 23 1 17 Brake controllers RM 23 inr NEL
92. in parallel with the brake via the brake contactor NC contacts The connection is partially ready in inverter Only the capacitors must be added outside inverter This connection can also be used to control 2 phase disk brakes or a separate KA372B brake control unit 1 8 EMC The abbreviated EMC stands for the Electromagnetic Compatibility According to the European EMC directive the apparatus shall be so constructed that e The electromagnetic disturbance it generates does not exceed a level allowing other apparatus to operate as intended 11 83 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice A BAM Materials Handling Inc R amp M 4501 Gateway Boulevard MATERIALS Springfield Ohio 45502 f G bip bed P 937 328 5100 INC FAX 937 325 5319 e The apparatus has an adequate level of intrinsic immunity of electromagnetic disturbance to enable it to operate as intended Declaration of conformity With the declaration of conformity the manufacturer informs that device is manufactured to fulfill required EMC standards CE mark The CE marking is a declaration by a manufacturer or importer located in the European Economic Area that a product complies with the safety and health requirements of the directive in question The manufacturer demonstrates for the authorities that the product complies with the safety requirements within the EU Environments Immunity and emissi
93. input 42 240Vac 50 60Hz 15 DIA5 Digital input 42 240Vac 50 60Hz Pests 16 OK Digital input 42 240Vac 50 60Hz OK signal OK input is connected straight to the ASIC Inverter is ready to operate when OK signal is active 1 17 COM Common for 42 240Vac 50 60Hz 18 COM Common for 42 240Vac 50 60Hz The threshold voltage for digital inputs S1 S2 DIA3 DIA4 DIA5 and OK is 35VAC 1 14 4 Relay Thermistor board Slot B NXOPTAS Relay Thermistor board ID 52305690 Terminal Signal name Description 21 ROB1 EE 4 22 ROB1 Relay output 250V 8A 23 ROB1 29 ROB2 SE Relay output 250V 8A normal open E 26 ROB2 28 T1 Thermistor input double isolated 29 T2 Rrrip 4 7kQ 1 14 5 SSU Speed Supervision board Slot C SSU is in CSU slot C see chapter Speed supervision settings SSU Speed supervision unit ID 52288044 Terminal Signal name Description 1 EA Threshold voltage 10VDC 2 EA Threshold voltage 10VDC 3 EB Threshold voltage 10VDC 4 EB Threshold voltage 10VDC 5 24V 24VDC short circuit protected 6 DV Common for encoder supply 18 83 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice A BAM Materials Handling Inc R amp M 4501 Gateway Boulevard MATERIALS Springfield Ohio 45502 G AEN P 937 32
94. isplay panel Meaning of the displays qm Motor is running blinks when ramping down Direction of motor rotation cm Motor is not running Power is on In case of a trip the symbol will not light up nm Drive is running outside of certain limit FAULT 9 Fault is on qu l O terminals are the selected control place Keypad is the selected control place The signalling LED s ready Power is on run Motor is running blinks when ramping down fault Fault trip Button description Reset active faults Switch between two latest displays Confirmation of selections eJ Fault history reset Browse the main menu and the pages of submenus e Edit values Move in menu C ER Move cursor Enter and exit edit mode Start button Ge Starts motor if the keypad is the active control place 25 83 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice A BAM Materials Handling Inc R amp M 4501 Gateway Boulevard MATERIALS Springfield Ohio 45502 ING RANDELIN P 937 328 5100 INC FAX 937 325 5319 Stop button Stops the motor if keypad is the active control place v WARNING Changing parameter settings during running may cause a hazardous situation Parameter settings must not be changed during running v WARNING Driving via display may cause a hazardous situation Panel control must
95. ld Ohio 45502 P 937 328 5100 FAX 937 325 5319 R amp M Materials Handling Inc 10 SPARE PARTS LIST FOR HOISTING INVERTER n Inverter D2V includes boards for slots A B and D but does not include SSU speed supervision unit for slot C POS DESCRIPTION NAME ID REMARKS eoe E lha the lone ree Soe ere oe UE aes oi SISISISISIS515 5 8 8 18 8S 8 INVERTER A1 Inverter D2V002NF1NO06 52571170 EMC level N S 1 D2V002NF1006 52571188 EMC level 0 1 D2V003NF1N06 52571171 EMC level N S 1 D2VOOS3NF1006 52571189 EMC level 0 1 D2VO04NF1NO6 52571172 EMC level N S 1 D2V004NF1006 52571190 EMC level 0 1 D2VOO5NF1NO6 52571173 EMC level N S 1 D2V005NF1006 52571192 EMC level 0 1 D2V007NF1NO06 52571174 EMC level N S 1 D2V007NF1006 52571193 EMC level 0 1 D2V011NF1NO06 52571175 EMC level N S 1 D2V011NF1006 52571194 EMC level 0 1 D2V015NF1NO06 52571176 EMC level N S 1 D2V015NF1006 52571195 EMC level 0 1 D2V018NF1NO06 52571177 EMC level N S 1 D2V018NF1006 52571196 EMC level 0 1 D2V022NF1NO6 52571178 EMC level N S 1 D2V022NF1006 52571197 EMC level 0 1 D2V030NF1NO06 52571179 EMC level N S
96. ly 2 3 BL3 AC brake supply phase 3 33 Ti Thermistor input 4 T12 Reserved for thermistors connections 34 T2 Thermistor input 5 OLE External control voltage 42 48 115 230Vac 35 ONE Neutral of external control voltage OLE 6 OLE External control voltage 42 48 115 230Vac 36 ONE Neutral of external control voltage OLE T RDY Stop with brake 37 ES External Stop 8 S1 Direction 1 run command 38 DID1 Free input 9 S2 Direction 2 run command 39 DID2 S11 Slowdown signal direction 1 0 DIA3 Accelerate speed 2 40 DID3 S21 Slowdown signal direction 2 1 DIA4 Not used hold speed 3 41 DID4 S12 Stop limit signal direction 1 2 DIA5 Not used speed 4 42 DID5 S22 Stop limit signal direction 2 3 43 4 44 5 K7 A1 Coil of brake contactor K7 45 ROB1 21 Not used 6 ROB1 22 Not used 46 ROB1 23 Not used 7 ROD1 28 Free NO contact of relay ROD1 47 ROD1 29 Free NO contact of relay ROD1 8 K7 153 Free NO contact of K7 48 K7 154 Free NO contact of K7 9 K7 163 Free NO contact of K7 49 K7 164 Free NO contact of K1 20 K71 13 Free NO contact of K71 50 K71 14 Free NO contact of K71 DSL Gr EE QUUM M rp 21 PUR Not used 51 EA Encoder channel A 22 15V Not used 52 EA Encoder channel A 23 AIN1 Multicare speed reference input 0 10V 53 EB Encoder channel B 24 AIN2 Not used 54 EB Encoder channel B 25 AIN Common for analog inputs 55 24V 24V output for encoder 26 AOUT Multicare speed reference output 0 10V 56
97. meters P2 2 8 and 2 2 9 After testing minimum frequencies should be changed back to their original values 2 20 After the test run Record all parameter value changes in the parameter list A Make sure all remarks and setting values are recorded tis recommended to store the parameter settings in file User parameters see chapter User parameters 53 83 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice A BAM Materials Handling Inc R amp M 4501 Gateway Boulevard MATERIALS Springfield Ohio 45502 NDLING RANDELIN P 937 328 5100 INC FAX 937 325 5319 3 TROUBLESHOOTING v Warning High voltages inside Frequency converter Wait for at least five minutes after the supply voltage has been switched off before service actions The display in the operating condition lights on indicates a dangerous voltage on the DC bus When display turns off the DC bus voltage is approximately 100V Note also that there is always a dangerous voltage in the braking resistor when the DC bus is charged 3 1 Field repair actions The purpose of troubleshooting and field repair actions is primarily to determine whether the drive or external devices in fact cause the problems After that the next step is to detect the possibly damaged components inside the drive If any damage inside the drive is caused by the environment motor failure brake failure power supply problems etc it i
98. motor cable insulation phase ground phase phase not symmetric load insulation failure in the motor or the cables F5 Charging Charging switch is open when START Check X switch command becomes active e control unit and power unit connections interference fault charging resistors component failure f the fault comes again change the control unit F6 External Stop Either the ES or RDY signal has been Check X tripped during run ES and RDY external connections Fault is not stored into fault history F7 Saturation trip Very high overload or defective component Reset switch power off and restart after the lamps of X display are off Check motor and motor cable insulation measure main circuit diodes and IGBT transistors f the fault comes again change the power unit F8 _ System fault System fault due to component failure or Reset switch power off and restart after the lamps of X faulty operation keypad are off Check read fault extension code and contact authorized service e If the fault comes again change the D2V F9 Undervoltage DC bus voltage has dropped below 333Vdc In case of temporary supply voltage break reset the X mains supply voltage interrupted fault and start again Check mains input inverter fault can also cause an If mains supply is correct an internal failure has occurred undervoltage trip Contact authorized service external fault
99. mple and only needed parameters are shown Letter front of the code number describes variable type A Application E Expander R Reference B Button G Group S System C Counter Info T Trip Counter D DynACode P Parameter V Value Label Code Function Description Adjustment range G2 1 General Parameters Password P2 1 1 Default 768 Service 2156 shows also group G2 3 Expert and G2 4 Synchronization Supply Voltage V2 1 2 Power unit nominal voltage F 380V 500V Device V2 1 3 Device Industrial Input Set P2 1 4 Input Set selection see chapter Control methods 12 IER 2 EP3 3 Multistep Analog Input Sel P2 1 5 Analog input selection 0 Not used 12 Multicare 2 Load 3 Multicare amp Load Slow speed freq P2 1 6 Speed when one of slow down limit switches S11 S21 is open 0 250 Hz Multistep 2 freq P2 1 7 om preset speed Multistep speed setting 0 250 Hz Multistep 3 freq P2 1 8 3 preset speed Multistep speed setting 0 250 Hz Multistep 4 freq P2 1 9 4 preset speed Multistep speed setting 0 250 Hz Accel Time 1 P2 1 10 Acceleration ramp is defined from zero to motor nominal frequency 1 300s P2 2 2 Shorter values than the factory setting must not be used Decel Time 1 P2 1 11 Deceleration ramp is defined from motor nominal frequency P2 2 2 to 1 300s zero Shorter values than
100. n every power up Driving is prevented if fault has been detected SSU Watchdog fault F65 Communication between SSU board and control board is tested once in 50ms Fault will be detected if there is communication error When a fault is detected the drive is stopped SSU Overspeed Limit F66 maximum setting of overspeed limit is 1 4xmaximum speed of direction S2 Fault will be detected if overspeed limit is set over that value When a fault is detected the drive is prevented 2 5 Standard settings 2 5 1 Settings for sensor bearing The table below indicate the SSU settings for standard cases Motors with nominal frequency 100Hz or 120Hz are equipped with bearing sensor After adjustment check that parameters V 4 8 1 Overspd Lim 1 and V 4 8 2 Overspd Lim 2 have value between 115 and 125 Max Freq S2 is normally set to 120Hz also when nominal frequency and Max freq S1 are 100Hz Check that parameters P 2 2 2 Motor Nom Freq and P 2 2 3 Motor Nom Speed have correct values from motor type plate Settings for sensor bearings Power class 002 005 002 005 007 011 015 055 44 83 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice A BAM Materials Handling Inc R amp M 4501 Gateway Boulevard MATRAS Springfield Ohio 45502 TAMIG P 937 328 5100 INC FAX 937 325 5319 P 2 2 11 Max Freq S2 120 120 120 120 P 2
101. nding both ends Enable the multicare function in both drives parameter Analog Input Sel P2 1 5 Multicare Verify parameters P2 1 6 P2 1 10 and P2 2 8 P2 2 12 are the same for both drives Activate pushbutton Test Voltage Max B2 1 12 2 On in both drives this produces a test voltage of 9 V analog output for calibrating the maximum value of speed correction A Read Ain Value V2 1 12 3 and use this value about 9 V for speed correction calibratation set Max Value Volt P2 1 12 5 both drives equal to received Ain Value this value is likely the same for both drives Activate pushbutton Test Voltage Min B2 1 12 1 On in both drives this produces a test voltage of 1 V analog output for calibrating the minimum value of speed correction Read Ain Value V2 1 12 3 again and use this value about 1V for speed correction calibration set Min Value Volt V2 1 12 4 both drives equal to received Ain Value this value again is likely the same for both drives Reset both programmable pushbuttons B2 1 12 1 Off and B2 1 12 2 Off both drives D 50 83 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice A BAM Materials Handling Inc R amp M 4501 Gateway Boulevard MATERIAS Springfield Ohio 45502 E P 937 328 5100 INC FAX 937 325 5319 Check Ain Value V2 1 12 3 is back at 0 V 2 14 Tes
102. ne second when the pulses from the pulse sensor are missing Drive with minimum speed The motion must stop within set time A fault F63 stall supervision is activated Drive with maximum speed the motion must stop at once A fault F62 Speed difference is activated Reconnect the disconnected signal wire to terminal X1 51 Setrotary switch S1 S3 value 2 steps smaller Drive with maximum speed The motion must stop after full speed is reached A fault F64 Over speed is activated Setrotary switch S1 S3 back to original value 2 18 Test run with load Note three loads are required Nominal load 10096 for normal operation Limited load for ESR optional An adequate extra load for dynamic overload testing and to test the ESR load limit Make sure that movement will not cause any danger to the environment or to the crane itself Ifthe optional extended speed range ESR is used check that the load limit is correctly set and hoisting with bigger loads is prevented Drive in both directions at minimum and maximum speeds Ifthe fan tube resistor unit is included check that fan s starts to blow when driving down with nominal load and continues to blow for about 4 5 minutes after stopping 2 19 Test run with overload If an overload test has to be performed during crane commissioning minimum frequencies should be raised for duration of the commissioning to 20Hz Minimum frequencies can be changed with para
103. nnected e S5 SSU board is missing or system load is too high F44 Device changed Option board or control unit has been Reset the fault Option board parameters or all parameters changed to different type or different power are set up to default values rating F45 Device added Option board of different type or drive of Reset the fault Option board parameters or all parameters different power rating added are set up to default values F50 Reference Analog input signal is out of selected range Check value fault 1 9V or 2 10V Reference cable Control cable is broken Reference source Signal source has failed F 51 Stop limit Stop limit has tripped Reset keep controller at zero 300ms Ensure that fault disappears after leaving the stop limit F55 Board Fault Some of following board is missing Reset switch power off and restart after the lamps of A Basic I O board keypad are off B Thermistor board Check D Expansion board board slots A B and D drive selection control mode F56 Generator side Too short deceleration time Reset has an additional 5 s time delay current limit generator side current limit Check deceleration time F57 Thermistor fault Thermistor input in relay thermistor board Check has detected motor overtemperature Fault e motor cooling and loading appears when thermistor input has been thermistor connection If expansion board thermistor open over 1s input is not used it should be sh
104. not stored faults F6 F70 repeated faults are stored only once F50 F51 F55 F60 F66 F71 F72 vs lt A Lei e 181 1 A Fault History lt P 57 Themistor lt P Operation days e HloHx gt YF T1235 Y 0 Fault Fault Possible cause Checking A B code F1 Overcurrent Inverter has measured too high current over Reset switch power off and restart after the lamps of X 4 In in the motor output display are off sudden heavy load increase Check short circuit in the motor or cable brake operation not suitable motor wrong motor parameters motor type and power rating parameters motor cable connection motor insulation motor loading F2 Overvoltage DC bus voltage has exceeded 13596 Reset has an additional 5s time delay X maximum level 911Vdc Check supply voltage raised gt 1 35 x Un high Adjust the deceleration time longer overvoltage spikes at mains or not measure main supply voltage level and wave form while sinusoidal wave form not driving Deceleration time is too short motor insulation motor cable insulation phase ground phase phase braking resistor cable braking resistor type and resistance braking chopper operation F3 Earth fault Current measurement has sensed Reset has an additional 5s time delay X unbalance in motor phase currents Check Supervision level is 5 of inverter nominal motor insulation current
105. nsor or encoder 24 pp 45 2 6 Functional test run for GG 45 2 7 Settings for Non standard cases nennen nennen nisse d nnn nn nnnnnn nisse nnns 45 b SYNCHRO FUNG TON S iini itta eomer enine RE FaXE RNFRLE Ri PIREULDI FABER PATE UR a pRUR e Ea Rin EXE Rin PUE 47 2 9 SUC OM eats veue reete nens EMI IMEEM IEEE I TEM 47 PASE C auo RRRRREEEMEEEEEEMMMMEMMMMMMM 48 2 10 Optic cable Connections nennen nnne nnn nn nn nnetr sisse ee ee creer 49 2 11 Troublesbootmg RR 49 7 MUETIGARE TUNG TION E 50 2 12 RRO S 50 2 13 gom 50 2 14 Test run without Joad nennen nnns ssh h nnt aaeee isis d nnn trn neris sse nennen nnns 51 8 START UP PROCEDURE P 52 2 15 IRo TE 52 2 16 Checks before the first test rum 52 2 17 Test run without Joad nennen nnnnmrn ns sn nnn nnn nnnnes isis d dn n nr nnnnr niis s nn nnt rnnt n nnns 52 2 17 1 Functional test run for GU 53 2 18 REPRINT 53 2 19 Test run with overload eee eeecceee eee e eee eeeaaaeee nese ceeeeeaaaaeeeeeeeeseeeaaaaeeeeeeeeseceaaaeeeeeeeeeseeencaaeeeeees 53 2 20 Atter thetest GUN e 53 S TROUBLESHOOTING i 54 3 1 ai lsBizerg teefm e 54 8 2 Typical functional tee E EE 54 8 3 Inverter fault COdGS m 54 3 3 1 Fault time Catal CONG uctor ttr eret nien idee itd er reta 58 3 3 2 a Eeviip
106. occur every now and then the reason may be one of following an incorrect air gap proximity switch the sensor is not properly on the top of the pulse wheel proximity switch disturbances are transferred to the sensor cable the pulse wheel is faulty Honeywell 3GT101DC Hall sensor requires tooth movement past the sensor A motionless tooth can not generate a pulse 22 83 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice A BAM Materials Handling Inc R amp M 4501 Gateway Boulevard MATERIAS Springfield Ohio 45502 HANDLING P 937 328 5100 INC FAX 937 325 5319 1 16 4 Buffer amplifier KAE234 The speed sensor proximity switch or sensor bearing is connected to inverter via KAE234 buffer amplifier KAE234 must be located near the sensor usually in the connection box of the hoist or the motor Without a buffer amplifier some faulty pulses could activate the speed supervision of inverter Typically the problem would be a momentary lack of pulses or oscillations at the sensor output Usually the noise sensitivity increases when the sensor temperature rises KAE234 connection with sensor bearing 69 xi 24V of AV Aen 09 55 N RED BROWN L d 24V an A E 1r LL QUT 4 S1 Je Cs WHITE WHITE x Oa z 4 XJ ov 2 li l ov 7 56 m BLACK GREEN ov 5 79 52 EA
107. ode Default Label Code Default Label Code Default Label Code Default G 2 1 General Parameters G 2 1 General Parameters G 2 1 General Parameters G 2 1 General Parameters P 2 1 10 Accel Time 1 1 5 Accel Time 1 1 5 Accel Time 1 1 5 P 2 1 10 Accel Time 1 1 5 Decel Time 1 1 5 Decel Time 1 1 5 Decel Time 1 1 5 Decel Time 1 1 5 r Parameters r Parameters r Parameters r Parameters Motor Nom Volt 460 Motor Nom Volt 460 Motor Nom Volt 460 Motor Nom Volt 460 Motor Nom Freq 120 Motor Nom Freq 120 Motor Nom Freq 120 Motor Nom Freq 120 Motor Nom Speed 3410 Motor Nom Speed 3500 Motor Nom Speed 3480 Motor Nom Speed 3470 Motor Nom Curr 22 Motor Nom Curr 31 Motor Nom Curr 37 Motor Nom Curr 44 Nom Flux Curr 12 Nom Flux Curr 15 Nom Flux Curr 15 Nom Flux Curr 17 Start Current 24 Start Current 32 Start Current 42 Start Current 48 Current Limit 31 Current Limit 46 Current Limit 54 Current Limit 63 Min Freq S1 10 Min Freq S1 10 Min Freq S1 10 Min Freq S1 10 Min Freq S2 5 Min Freq S2 5 Min Freq S2 5 Min Freq S2 5 Max Freq S1 Max Freq S1 Max Freq S1 Max Freq S1 Max Freq S2 Max Freq S2 Max Freq S2 Max Freq S2
108. ol using a 3 step controller 3 MS Multistep control 4 steps The control mode of inverter is selected by parameter P2 1 4 See chapter Control methods The parameters assigns digital inputs S1 S2 OK DIA3 DIA5 and DID1 DID5 It is not possible to chance the functions of the inputs separately The state of inputs can be checked from parameters V4 7 12 and V4 7 13 The input assignment according to the selected mode is explained in the following table Control mode EP EP3 MS Parameter P2 1 4 1 2 3 Signal Terminal S1 X1 8 S1 S1 S1 S2 X1 9 S2 S2 S2 OK X1 7 OK OK OK DIA3 X1 10 AP AP MS2 DIA4 X1 1 Not used HOLD MS3 DIA5 X1 12 Not used not used MS4 DID1 X1 38 FWE FWE FWE DID2 X1 39 S11 S11 S11 DID3 X1 40 S21 S21 S21 DID4 X1 41 S12 S12 S12 DID5 X1 42 S22 S22 S22 Desired speed levels for multi step control mode are selected with following parameters 9 83 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice A BAM Materials Handling Inc R amp M 4501 Gateway Boulevard MATERIALS Springfield Ohio 45502 G tip bd P 937 328 5100 INC FAX 937 325 5319 Speed Parameter Input Speed 1 P2 2 8 P2 2 9 1 S2 Speed 2 P2 1 7 MS 2 Speed 3 P2 1 8 MS 3 Speed 4 P2 1 9 MS 4 1 6 1 EP2 control gt gt RPE of c_coep2a eee A Pushb
109. on requirements are divided in two levels in the product standard according to the environments First environment means environment that includes domestic premises and also establishments directly connected to a low voltage power supply network T TTT Second environment means environment that includes all establishments other than those directly connected a low voltage power supply network PDS 2 Fulfilled EMC standards All products fulfil the immunity requirements defined in the EN 61800 3 Amendment 11 2000 for the second environment Nlevel products fulfil the emission requirements of the EN 61800 3 A11 2000 for the second environment 12 83 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice A BAM Materials Handling Inc R amp M 4501 Gateway Boulevard MATRAS Springfield Ohio 45502 HANDLING E P 937 328 5100 INC FAX 937 325 5319 1 INSTALLATION 1 9 Cubicles Inverter is delivered with external braking resistor Braking resistor types D2FR are installed in the same cubicle as the inverter itself Braking resistor D2HRO4F90RO0S4A for 002 005 is in own cubicle Power class Standard cubicle Cubicle size mm Braking resistor mm 002 005 EEO25 604 400 x 600 400 x 400 007 015 CC600E 600 x 1000 Included 018 030 KA220D2 1000 x 1000 Included 037 045 1 x KA220D2 1 x1000 x 1000 Include
110. onditions whenever the multicare mode is selected The table below shows the input receive and output send values during start acceleration stopping and in fault situation The multicare function is selected with an input parameter P2 1 5 In case of multicare fault a dedicated fault code F70 is issued If the operation of one drive is interrupted or the drive faults out for example upper limit fault the other drive will stop and show multicare fault F70 Programmable pushbuttons are used for multicare testing The multicare function is mainly designed for EP mode speed correction possible but it can also be used in MS multistep mode for run stop supervision without speed correction Ain1 value Input function Aout value Output function receive send 0 0 2V Single drive selected Multicare function not used DV Direction signals S1 and S2 not active in multicare mode 0 3 0 7 V Brake open acknowledged acceleration not 0 5 V Brake open acceleration not allowed allowed 0 8 1 0 V Acceleration allowed 1 0V Acceleration allowed 1 9V Speed correction range 1 9V Speed correction range 9v Acceleration acknowledged 9v Accelerating gt 9 5V Fault acknowledged Immediate brake stop F70 10V Fault Immediate brake stop fault code issued The multicare function controls and monitors the following situations in multicare mode A Both drives start nearly simultaneously the other
111. or thermal protection which is based on motor temperature measurement by Klixon placed in motor windings A great number of other protections included are shown in the technical data Tested parameters Inverter includes tested parameters with different motors for all power ratings This is a benefit which makes every inverter delivery a proven solution The tested and pre set motor parameters enable a quick start up in crane commissioning 1 3 Main components The main components are Power class A1 Inverter F7 Brake supply circuit breaker 007 055 K7 Brake contactor G1 Brake control unit REC12 002 011 G1 Brake control unit ESD141 015 055 F71 Circuit breaker for the second brake contactor 055 K71 Second brake contactor 055 The most important external components are R1 Braking resistor unit M1 Hoisting motor Y1 Mechanical brake A5 KAE234 Proximity switch buffer amplifier for speed sensor B5 Speed sensor B6 Thermal sensor for motor protection Overload protection device Control devices switches pushbuttons etc Limit switches Example layout 7 83 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M MATERIALS HANDLING INC R amp M Materials Handling Inc 4501 Gateway Boulevard Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 O
112. ored to User parameters with parameter B 4 1 2 Save User Par Enter lt press Enter Parameters can be restored from User parameters with parameter B 4 1 3 Load User Par Enter lt press Enter A After restoring always check the motor parameters Parameters in use can be compared to User parameters by parameter S 6 6 2 D Parameters restored from User parameters are reseted after power off unless they are not confirmed with Enter one by one Easiest way to restore User parameters permanently is to compare parameters to User parameters by parameter S 6 6 2 and adjust them to the same value 2 2 2 Default parameters File Default parameters is stored in inverter s control unit Default parameters are saved at the factory and they should not be changed In default parameters there are the same parameter values as shown in parameter list delivered with inverter Since serial number 03L50700 Parameters can be restored from Default parameters with parameter B 4 1 1 Load Default Par Enter press Enter A After restoring always check the motor parameters Parameters in use can be compared to Default parameters by parameter S 6 6 1 Value 0 at parameter S 6 6 1 means that parameters in use are identical to Default parameters D Parameters restored from Default parameters are reseted after power off unless they are not confirmed with Enter one by one Easiest way to restore Default
113. ormal crane cables All the cables must be dimensioned according to local regulations Ambient temperature cabling method size of bunches etc and allowable current for the cable in use must be taken into consideration If there are no other regulations following values can be used three phase 400V supply The table below is based on ED lt 60 and ambient temperature 40 104F A highe r ambient temperature may require increased cable sizes The input current does not exceed the continuous current Icont of inverter so it is selected to be the dimensioning current If the actual load current is below inverter continuous current then the fuses and the supply cable may be dimensioned according to the load current 13 83 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice A BAM Materials Handling Inc R amp M 4501 Gateway Boulevard Hi ES Springfield Ohio 45502 ING EE P 937 328 5100 INC FAX 937 325 5319 007 Continuous current Jour Fuse Max motor cable length 160 160 160 160 160 160 160 160 160 Motor cable oe F Continuous current Icont 7 oe Braking resistor cable wo Braking resistor cable 40 C 104 F Max motor cable length a a 104 F s ur 1 11 4 Cable protection To protect the supply cables against short circuit there must be fuses or motor circuit breakers MCCBs installed at the mains end of the supply c
114. orted motor parameters the brake operation F60 Parameter fault Inverter has lost parameters Drive selection Download parameters from keypad parameter has changed to 0 none F61 Overspeed Fault SSU has tripped to Overspeed hardware Reset switch power off and restart after the lamps of supervision Motor speed has increased keypad are off above overspeed detection level Check function and cabling maximum frequency setting parameters SSU settings F62 Speed Difference SSU has tripped to Speed Difference Reset switch power off and restart after the lamps of Fault keypad are off Check pulse sensor encoder function and cabling pulse sensor encoder pulse number speed difference supervision settings F63 Stall Supervision SSU has tripped to Stall Reset switch power off and restart after the lamps of Fault keypad are off Check brake operation pulse sensor encoder function and cabling stall supervision settings F64 SSU Relay Test Relay in SSU board is damaged or SSU Reset switch power off and restart after the lamps of Fault relay is bypassed keypad are off Check ES and RDY external connections OK input operation change SSU board F65 SSU Watchdog SSU internal fault Reset switch power off and restart after the lamps of interference fault between SSU board and display are off control board Check component failure control board or SSU ISSU status System menu System info Expander board boards C SSU status
115. ot B Run Program version E6 8 6 3 2 Program version of board in slot B 10503 14 State E6 8 6 4 1 State of board in slot B Run Program version E6 8 6 4 2 Program version of board in slot B 10501 4 Not used IU filtered V6 9 1 U phase current A IV filtered V6 9 2 V phase current A IW filtered V6 9 3 W phase current A U Temperature V6 9 4 Phase U temperature C V Temperature V6 9 5 Phase V temperature C W Temperature V6 9 6 Phase W temperature C Card Temperature V6 9 7 Card temperature C Power multimonitor V6 11 1 Output current values and power card temperature The memory of active faults can store the maximum of 10 faults in the 34 83 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc R amp M 4501 Gateway Boulevard MATRAS Springfield Ohio 45502 TANDING P 937 328 5100 INC FAX 937 325 5319 order of appearance By pushing the Q button you will enter the Fault time data record menu indicated by T 1 T 13 In this menu some selected important data valid at the time of the fault are recorded T 1 Counted operation days d T 2 Counted operation hours hh mm ss TA Output frequency Hz T 4 Motor current A T 5 Motor voltage V T 6 Motor power K T 7 Motor torque K T 8 DC voltage V T 9 Unit
116. ot be changed Used in hoisting application Freq 0 P2 3 4 Constant current mode frequency limit in percentage of nominal 0 100 frequency Between 0 Hz and Freq 0 current control keeps motor current in value of P2 3 12 Zero Speed Current 29 83 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M MATERIALS R amp M Materials Handling Inc 4501 Gateway Boulevard Springfield Ohio 45502 EE P 937 328 5100 INC FAX 937 325 5319 Freq 1 P2 3 5 Flux current mode frequency limit in percentage of nominal frequency 0 100 Between frequencies Freq 1 and Freq 2 drive is controlled with special flux current control method Freq 2 S1 P2 3 6 Mixed current voltage mode frequency limit in percentage of nominal 0 100 frequency in direction S1 Must not be changed Freq 3 S1 P2 3 7 U f control mode frequency limit in percentage of nominal frequency in 0 100 direction S1 Must not be changed Zero Flux Curr P2 3 8 Relative value of flux current of motor Typical value of this current control 0 100 96 method is 80 96 Parameter is not related to motor real physical values Must not be changed Stray Flux Curr P2 3 9 Relative value of stray flux current of motor Typical value of this current 0 100 96 control method is 40 96 Parameter is not related
117. otice A BAM Materials Handling Inc R amp M 4501 Gateway Boulevard MATRAS Springfield Ohio 45502 ANDLING eee P 937 328 5100 INC FAX 937 325 5319 6 SYNCHRO FUNCTION The Synchro function is designed for hoisting applications where up to four separate hoisting machineries can be driven in speed synchronization without external computing device This is a SystemBus based common hoist application The Synchro application has following major requirements Ew pee Two channel speed feedback from the motor to the drive Synchronization activation via digital input DID1 OY Gj SystemBus option boards and fibre optic cable s between the drives Software version Ind2V101 or newer di li Nee es eee er ql 1 ear xx ecce bequem ees tat eis eed puris xr enr l lk 2 8 Function In the Synchro function it is possible to connect up to four drives to common use Drives can be active or passive Active means that the drive will participate on the Synchronization and passive means that the drive will only echo the data forward For example three drives can be active and one passive Back up drive Master drive can also be passive In this case it will only handle the calculation of the correction for the other drives Digital input DID1 activ
118. parameters which have been saved after start up G4 1 4 Factory Default Save Default Par B4 1 4 1 Saves Active Parameters in the Control Unit as Default Parameters Default Parameters are the parameters which must be saved in the factory For factory use only G4 2 Analog I O Ain1 Value V4 2 1 Value of analog input Ain 0 10V Ain2 Value V4 2 2 Value of analog input Ain2 0 10V Aout1 Value V4 2 3 Value of analog output Aout1 0 20 mA Aout2 Value V4 2 4 Value of analog output Aout2 0 10V G4 3 Relay output ROB1 State V4 3 1 State of relay output ROB1 O OFF 1 ON ROB2 State K7 V4 3 2 State of relay output ROB2 K7 O OFF 1 ON ROC1 State V4 3 3 State of relay output ROC1 O OFF 1 ON ROD1 State V4 3 4 State of relay output ROD1 O OFF 1 ON ROE1 State V4 3 5 State of relay output ROE1 O OFF 1 ON ROE2 State V4 3 6 State of relay output ROE2 O OFF 1 ON ROES State V4 3 7 State of relay output ROE3 O OFF 1 ON G4 4 Operate counters Not used G4 5 Fault Counter Fault Counter V4 5 1 4 5 24 Fault counter value Other faults V4 5 25 Other faults Total Faults V4 5 26 31 83 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice A BAM Materials Handling Inc R amp M 4501 Gateway Boulevard MATERIALS Springfield Ohio 45502 LING aN P 937 328 5100 INC FAX 937
119. parameters permanently is to compare parameters to Default parameters by parameter S 6 6 1 and adjust them to the same value 2 2 3 Keypad settings A File Keypad settings is stored in keypad Default value for parameter P 6 5 4 is On This makes every change to be stored to file Keypad settings The whole parameterset can be stored to file Keypad setting with parameter S 6 5 1 Up to keypad Select gt press gt Al param blinks on display confirm with enter A Parameters can be restored from keypad s file Keypad settings with parameter S 6 5 2 Down from keypad Select gt press gt Al param blinks on display confirm with enter A After restoring always check the motor parameters 2 2 4 Factory settings A Factory settings are not used 27 83 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc R amp M MATERIALS 4501 Gateway Boulevard Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC 3 PARAMETER DESCRIPTIONS This manual describes parameters with software Ind2V081 Under control panel there is sticker for software version Parameters are assorted to Groups All Groups are not always listed in control panel Groups are shown in control panel according to password level and selected functions This feature makes visible parameter menu si
120. peed 2910 Motor Nom Speed 2890 Motor Nom Curr 55 Motor Nom Curr 64 Motor Nom Curr 62 Motor Nom Curr 72 Nom Flux Curr 22 Nom Flux Curr 26 Nom Flux Curr 30 Nom Flux Curr 30 Start Current 60 Start Current 75 Start Current 74 Start Current 75 Current Limit 90 Current Limit Current Limit 93 Current Limit Min Freq S1 10 Min Freq S1 10 Min Freq S1 10 Min Freq S1 10 Min Freq S2 5 Min Freq S2 5 Min Freq S2 5 Min Freq S2 5 Max Freq S1 Max Freq S1 Max Freq S1 Max Freq S1 Max Freq S2 Max Freq S2 Max Freq S2 Max Freq S2 Max ESR Freq Max ESR Freq Max ESR Freq Max ESR Freq Drive Selection Drive Selection Drive Selection Drive Selection Pulse Number Pulse Number Pulse Number Pulse Number Zero Freq Volt Zero Freq Volt Zero Freq Volt Zero Freq Volt U f Mid Volt U f Mid Volt U f Mid Volt U f Mid Volt U f Mid Freq U f Mid Freq U f Mid Freq U f Mid Freq Torque Boost On Torque Boost On Torque Boost On Torque Boost On Rs Voltage Drop 100 Rs Voltage Drop 90 Rs Voltage Drop 180 Rs Voltage Drop 180 Stop Function Ramping Stop Function Ramping Stop Function Ramping Stop Function Ramping rt rt rt rt Flux Current Kp 4000
121. r Damp Flux Curr Damp Flux Curr Damp Flux Curr Damp Stop DC Freq Stop DC Freq Stop DC Freq Stop DC Freq Start Freq S1 Start Freq S1 Start Freq S1 Start Freq S1 Start Freq S2 Start Freq S2 Start Freq S2 Start Freq S2 Brake Stop Freq Brake Stop Freq Brake Stop Freq Brake Stop Freq ESR Point Freq ESR Point Freq ESR Point Freq ESR Point Freq ESR Point Volt ESR Point Volt ESR Point Volt ESR Point Volt IrAdd Motor IrAdd Motor IrAdd Motor IrAdd Motor IrAdd Generator IrAdd Generator IrAdd Generator IrAdd Generator Ramp Stretching Ramp Stretching Ramp Stretching Ramp Stretching Switching Freq Switching Freq Switching Freq Switching Freq DeadTime Comp DeadTime Comp DeadTime Comp DeadTime Comp DeadTimeCurrLim DeadTimeCurrLim DeadTimeCurrLim DeadTimeCurrLim 40 83 Brake Chopper Brake Chopper R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice Brake Chopper Brake Chopper R amp M MATERIALS HANDLING INC 011 4501 Gateway Boulevard Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 015 R amp M Materials Handling Inc 018 022 T5 MF11MB200 460V 120Hz T6 MF13Z 200 460V 120Hz T7 MF13ZA200 460V 120Hz T8 MF13ZB200 460V 120Hz Label C
122. r speed Rpm Output frequency V4 22 Output frequency to the motor Hz 32 83 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc R amp M 4501 Gateway Boulevard MATERIALS Springfield Ohio 45502 TANDING P 937 328 5100 FAX 937 325 5319 INC Multimonitor N4 23 1 Multimonitor page shows motor current motor voltage and putput frequency in display in the same time Monitor variables can be changed if parameter P6 5 4 ChangeEnable Panel Control B5 1 Must not be used Off On Speed Reference R5 2 Speed reference for panel control Language S6 1 Keypad language English Application S6 2 Application Crane Parameter Sets 86 3 1 Not used see parameter group G4 1 Parameter backup Up to keypad 86 3 2 Save parameter settings up to keypad Down from keypad S6 3 3 Download parameter settings down from keypad Autom BackUp P6 3 4 Changes in parameters are automatically saved to Keypad settings Yes No Set 1 86 4 1 Actual parameter values are compared to Default parameters Value of Par No Default val parameters can also be changed in this display Actual value Set 2 86 4 2 Actual parameter values are compared to file User parameters Value Par No User val of parameters can also be changed in this display Actual value Factory settings S6 4 3 Parameter file F
123. re beginning of u f curve tuning Some parameters are not accessible or changing is not possible Check password that password has value 2156 Check that parameter value is inside the limits Parameter value can not be changed in RUN state Parameter value change must be confirmed with Enter button 3 3 Inverter fault codes If any of the following failures is found the inverter displays the fault code and closes the mechanical brake causing the movement to stop If several faults occur one after another the latest one is displayed the others are stored to fault history page When inverter fault supervision trips the FAULT indicator turns on and the blinking fault code F xx xx fault number appears on the display 54 83 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice A BAM Materials Handling Inc R amp M 4501 Gateway Boulevard MATRAS Springfield Ohio 45502 HANDLING TEAREN P 937 328 5100 INC FAX 937 325 5319 The drive includes an automatic fault reset operation the fault code stays on the display until the fault is removed and the controller released back to 0 position Some of the fault codes require to switch the power off before run is possible The faults are stored to the fault history from there they can be seen if necessary The fault history can store last 30 fault codes Following exceptions exist when storing faults to the fault history
124. req 3 S2 Freq 3 S2 Freq 3 S2 40 Zero Speed Curr Zero Speed Curr Zero Speed Curr Zero Speed Curr Min Current Ref 90 Min Current Ref Min Current Ref Min Current Ref 90 Accel Comp TC 0 1 Accel Comp TC Accel Comp TC Accel Comp TC 0 1 Ref Angle S1 Ref Angle S1 Ref Angle S1 Ref Angle S1 Ref Angle S2 Ref Angle S2 Ref Angle S2 Ref Angle S2 Flux Curr Damp Flux Curr Damp Flux Curr Damp Flux Curr Damp Stop DC Freq Stop DC Freq Stop DC Freq Stop DC Freq Start Freq S1 Start Freq S1 Start Freq S1 Start Freq S1 Start Freq S2 Start Freq S2 Start Freq S2 Start Freq S2 Brake Stop Freq Brake Stop Freq Brake Stop Freq Brake Stop Freq ESR Point Freq ESR Point Freq ESR Point Freq ESR Point Freq ESR Point Volt ESR Point Volt ESR Point Volt ESR Point Volt IrAdd Motor IrAdd Motor IrAdd Motor IrAdd Motor IrAdd Generator IrAdd Generator IrAdd Generator IrAdd Generator Ramp Stretching Ramp Stretching Ramp Stretching Ramp Stretching Switching Freq Switching Freq Switching Freq Switching Freq DeadTime Comp DeadTime Comp DeadTime Comp DeadTime Comp DeadTimeCurrLim DeadTimeCurrLim DeadTimeCurrLim DeadTimeCurrLim 41 83 Brake Chopper Brake Chopper R amp M Materials Handling Inc reserves the righ
125. rt Freq S1 Start Freq S1 Start Freq S1 Start Freq S1 Start Freq S2 Start Freq S2 Start Freq S2 Start Freq S2 Brake Stop Freq Brake Stop Freq Brake Stop Freq Brake Stop Freq ESR Point Freq ESR Point Freq ESR Point Freq ESR Point Freq ESR Point Volt ESR Point Volt ESR Point Volt ESR Point Volt IrAdd Motor IrAdd Motor IrAdd Motor IrAdd Motor IrAdd Generator IrAdd Generator IrAdd Generator IrAdd Generator Ramp Stretching Ramp Stretching Ramp Stretching Ramp Stretching Switching Freq Switching Freq Switching Freq Switching Freq DeadTime Comp DeadTime Comp DeadTime Comp DeadTime Comp DeadTimeCurrLim DeadTimeCurrLim DeadTimeCurrLim DeadTimeCurrLim 38 83 Brake Chopper Brake Chopper R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice Brake Chopper Brake Chopper R amp M MATERIALS HANDLING INC 045 4501 Gateway Boulevard Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 055 R amp M Materials Handling Inc 2 T8 MF13ZB200 400V 100Hz 2 T9 MF13ZC200 400V 100Hz Label Code Default Label Code Default G 2 1 General Parameters G 2 1 General Parameters P 2 1 10 Accel Time 1 1 5 Accel Time 1 1 5 Decel Time 1 1 5 Decel Time 1
126. s very important to repair change faulty items to prevent reoccurring problems The best way to repair a faulty inverter is to replace it with a new one If the fault can be located it is also possible to replace some of the components When replacing an inverter or a Control unit with a new one the parameter list of the existing drive is needed so that the parameter settings can be copied to the new one If parameters have been copied to the keypad before damage it may be used for uploading the parameters to the spare part inverter requires same software versions 3 2 Typical functional problems Inverter does not start when mains is connected Check mains voltage between terminal L1 L2 and L3 Indicator Ready is on and Indicator Fault is off but motor does not run Check control mode selection Check voltage at run command terminals X1 8 and X1 9 Check state of digital inputs from parameter V4 7 12 Motor runs poorly Check that load is not over nominal Check that all cables are connected correctly and the junctions are reliable Check that all motor dependant parameters are correct Check the voltage of the slowdown limit switch input Check state of digital inputs from parameter V4 7 13 Check that motor s brake opens completely Check that minimum speed parameters do not have too small values Check u f curve tuning If the main girder is new it might be necessary to drive trolley several times with no load from end to end befo
127. t run without load Display monitoring parameter Frequency reference V4 9 on both drives In EP mode accelerate the hoist up and down to any speed between the minimum speed and maximum speed and verify both drives display the same frequency reference 0 25 Hz when constant speed is reached Lower the frequency value of Max Freq S1 P2 2 10 of one drive temporarily about 20 Hz run in up direction and verify the faster hoist will slow down after accelerating Again check that both drives display the same frequency reference Return Max Freq S1 back to its original value Run both hoists up in tandem mode and stop one hoist by disconnecting the voltage from its upper stop limit terminal X1 41 the other hoist must stop and display Multicare Fault F70 Reconnect the voltage back to terminal X1 41 A Repeat the same test with the other hoist Check both hoists operate normally in tandem mode and single mode when reaching the slow down and end stop limit in both directions 51 83 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice A BAM Materials Handling Inc R amp M 4501 Gateway Boulevard MATERIALS Springfield Ohio 45502 LING RANDELIN P 937 328 5100 INC FAX 937 325 5319 8 START UP PROCEDURE If any problems or malfunctions occur during the start up refer to Chapter Troubleshooting to find out the reason All pro
128. t to alter or amend the above information without notice Brake Chopper Brake Chopper R amp M MATERIALS HANDLING INC 030 037 R amp M Materials Handling Inc 4501 Gateway Boulevard Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 037 037 T9 MF13ZC200 460V 120Hz TA MF13X 200 460V 120Hz 2 T6 2 MF13Z 200 460V 120Hz 2 T7 2 MF13ZA200 460V 120Hz Label Code Default Label Code Default Label Code Default Label Code Default G 2 1 General Parameters G 2 1 General Parameters G 2 1 General Parameters G 2 1 General Parameters Accel Time 1 1 5 Accel Time 1 1 5 Accel Time 1 1 5 Accel Time 1 1 5 Decel Time 1 1 5 Decel Time 1 1 5 Decel Time 1 1 5 Decel Time 1 1 5 r Parameters r Parameters r Parameters r Parameters Motor Nom Volt 460 Motor Nom Volt 460 Motor Nom Volt 460 Motor Nom Volt 460 Motor Nom Freq 120 Motor Nom Freq 120 Motor Nom Freq 120 Motor Nom Freq 100 Motor Nom Speed 3470 Motor Nom Speed 3470 Motor Nom Speed 3500 Motor Nom Speed 3480 Motor Nom Curr 56 Motor Nom Curr 65 Motor Nom Curr 62 Motor Nom Curr 74 Nom Flux Curr 22 Nom Flux Curr 26 Nom Flux Curr 30 Nom Flux Curr 30 Start Current 60 Start Current 75 Start Curr
129. table below Signal name Sensor Cable Colour marking Terminal number 212 24V Red Brown Brown KAE234 6 29 Honeywell 3GT101DC PULSE Green Green Black KAE234 1 OV Black White Blue KAE234 2 2 Sch nbuch INSOR ICDM 8802 Red Brown 6 z ER EL Ee Eescht OU m lea I ITI JJ H3 H3ANI Baumer IFRM08N1501 L Note the following details buffer amplifier must be located as close the proximity switch as possible maximum distance 3m sensor cable must be located as far from the motor cables and braking resistor cable as possible minimum distance gt 20cm In order to avoid fault situations the cable between the encoder and inverter must be as far as possible from the cables of motor and braking resistor minimum distance gt 20cm J a Shielded and twisted cable grounded the shield at both ends 360 grounding on inverter terminal the shield should be grounded always when going through terminals Some problems may occur when using shielded flat cable or in situations where the encoder cable has been placed too close 5cm to the motor cables and braking resistor cables Cabling methods and distances determine the best way to ground the shielded cable at both ends or only at one end Buffer amplifier pulse output can be measured during driving If the pulse sequence is not uniform and for instance longer pulses
130. temperature C T 10 Ready 0 Not Ready 1 Ready Run OzNot Running 1 Run T 11 Direction 0 Off 1 On Fault O No 1 Yes T 12 Warning O No 1 Yes At reference O No 1 Yes T 18 0 speed 0 Not Zero Speed 1 Zero Speed M8 Fault history The fault memory can store a maximum of 30 faults in the order of appearance The number of faults currently in the fault history is shown on the value line of the main page The order of the faults is indicated by the location indication in the upper left corner of the display The latest fault carries the indication F8 1 the second latest F8 2 etc The Fault time data record pages are accessible at each fault If there are 30 uncleared faults in the memory the next occurring fault will erase the oldest from the memory Pressing the Enter button for about 2 to 3 seconds resets the whole fault history 35 83 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M MATERIALS HANDLING INC R amp M Materials Handling 4501 Gateway Boulevard Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 Inc 4 FACTORY DEFAULT PARAMETERS 2 3 Factory default parameters for 100Hz motors 002 004 005 007 T1 MF10MA200 400V 100Hz T2 MF10M B200 400V 100Hz T3 MF10MC200 400V 100Hz T4 MF11MA200 400V 100Hz Label Code Default Label Code Default Label Code D
131. the factory setting must not be used G2 1 12 Multicare Test Voltage Min B2 1 12 1 1 00V is given to Analog output Aout2 by this button Off On Test Voltage Max B2 1 12 2 9 00V is given to Analog output Aout2 by this button Off On Ain 1 Value V2 1 12 3 Value of analog input Ain1 voltage V Min Value Volt 1 P2 1 12 4 Ain1 value when test voltage min has been selected in the other drive 0 10V Max Value Volt 1 P2 1 12 5 Ain value when test voltage max has been selected in the other drive 0 10 V G2 2 Motor Parameters Motor Nom Volt P2 2 1 Nominal motor voltage Un from motor rating plate 0 750 V Motor Nom freq P2 2 2 Nominal motor frequency fn from motor rating plate 0 250 Hz Motor Nom Speed P2 2 3 Nominal motor speed n from motor rating plate 0 6000 rpm Motor Nom Curr P2 2 4 Nominal motor current In from motor rating plate In multimotor drives nominal currents must be summarized Nom Flux Curr P2 2 5 Motor nominal flux current lo same as no load current or magnetizing current from motor rating plate In multimotor drives nominal flux currents must be summarized Start Current P2 2 6 Start current Current level which is used in motor starting situation Hoisting application default value is motor s nominal current but not over nominal current of the inverter 28 83 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice A BAM Materials Handling Inc R amp M 4501
132. tion Displacement limit has been exceeded Check Displacement Difference in acceleration deceleration or That ramp times are similar in each drive braking times between the drives Value of parameter P2 4 5 Displacement Lim in master drive Speed feedback operation Mechanical brake operation and adjustments F93 SystemBus Synchro activation is not done in correct Stop driving before the Synchro is activated or Activation operation state deactivated A Can be done by the user B Can be done only by manufacturer authorized personnel 3 3 1 Fault time data record When a fault occurs the fault number is displayed By pushing the menu button right here you will enter the Fault time data record menu indicated by T 1 T 13 In this menu some selected important data valid at the time of the fault are recorded The data available are Counted operation days Counted operation hours Output frequency Motor current Motor voltage Motor power Motor torque DC voltage Unit temperature hh mm ss Ready Run Direction Fault Warning At reference 0 speed OzNot Ready 0 Not Running 0 Off 1 On 0 No 1 Yes 0 No 1 Yes 0 No 1 Yes 0 Not Zero Speed 1 Zero Speed 1 Ready 1 Run 58 83 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc R amp M MATERIALS 4501 Gateway Boulevard Springfield Ohio 45
133. to motor real physical values Must not be changed Freq 2 S2 P2 3 10 Mixed current voltage mode frequency limit in percentage of nominal 0 100 925 frequency in direction S2 Must not be changed Freq 3 S2 P2 3 11 U f control mode frequency limit in percentage of nominal frequency in 0 100 direction S2 Must not be changed Zero Speed Curr P2 3 12 Relative value of motor current used in small frequencies of motor 0 250 96 nominal current Must not be changed Min Current Ref P2 3 13 Minimum value of motor current used in current control area of motor 0 100 nominal current Must not be changed Accel Comp TC P2 3 14 Acceleration compensation time constant which describes rotating 0 300s masses of drive system Physical description of this parameter is a time which is needed to accelerate rotating masses from zero to nominal frequency with motor nominal torque Must not be changed Ref Angle S1 P2 3 15 Voltage current angle difference S1 1536 equals 90 angle Used in 0 3000 direction changes Must not be changed Ref Angle S2 P2 3 16 Voltage current angle difference S2 1536 equals 90 angle Used in 0 3000 direction changes Must not be changed Flux Curr Damp P2 3 17 Flux Current Ctrl stabilator time constant in milliseconds Must not be 0 400 ms changed Stop DC Freq P2 3 18 Defines the frequency at witch DC braking starts 0 250 Hz Start Freq S1 P2 3 19 Defines the output frequency during brake opening
134. tus wees GREEN blinking blinking Everything is OK 0 5Hz 0 5Hz IEC Application Scheduler is running and Application is running blinking blinking IEC Application Scheduler is running 0 25Hz 0 5Hz and Application is NOT running OFF blinking IEC Application Scheduler and 0 5Hz Application are NOT running YELLOW RED D BH Green Status ON PSU ready OFF PSU not ready A B C D E 17 83 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M MATERIALS R amp M Materials Handling Inc 4501 Gateway Boulevard Springfield Ohio 45502 HANDLING INC P 937 328 5100 FAX 937 325 5319 1 14 3 Basic I O board Slot A Basic l O Board is in CSU slot A It has two board levels one for electronics level signals terminals 1 10 and one for control voltage signals 42 240Vac NXOPT A6 Basic I O board ID 52288046 Terminal Signal name Description 1 PUR Not used 2 415V Not used 3 AIN1 Analog input 1 0 10V 4 AIN2 Not used 5 AIN Common for analog input and output signals 6 AOUT1 Not used 7 AOUT2 Analog output 2 0 10V 8 DOA1 Not used 9 DV I O ground terminal 10 24V Not used N 11 S1 Digital input 42 240Vac 50 60Hz Direction S1 12 2 Digital input 42 240Vac 50 60Hz Direction S2 13 DIA3 Digital input 42 240Vac 50 60Hz 14 DIA4 Digital
135. ue and after that the brake is opened The same applies for stopping while the brake is being closed the motor still generates torque During a direction change the brake is kept open all the time Inverter decelerates the motor to a stop according to the set deceleration time when the run command is switched off so the brake is used only as a holding brake This way brake wear is minimized Only if a failure occurs or the emergency stop button is pushed the brake closes immediately stopping the motor and the load Models 002F 011F have a built in REC12 brake control unit which is a line voltage half wave rectifier The half wave type rectifier reduces losses and is enough to open the brake There is a contactor to switch the line voltage on and off Models 015F 055F have a built in ESD141 brake control unit which is a line voltage full half wave rectifier Full wave rectification is used to open the brake quickly Then the rectifier changes to a half wave type which reduces losses but is enough to keep the brake open There is a contactor to switch the line voltage on and off The same contactor also disconnects the DC voltage directly from the brake coil which guarantees that the brake closes fast Model 055F includes a 3 phase AC supply for the brake control Inverter controls this line and it is protected by an adjustable circuit breaker max 4 0A When a shoe brake is used brake closing is speeded up by capacitors They are connected
136. utton controller position B Speed 0 decelerate to zero 1 while starting drive minimum speed while running hold speed 2 while running accelerate while running at maximum speed hold speed 1 6 2 EP3 control gt gt VV A C coep3a eee age A Pushbutton controller position B Speed decelerate to zero step 1 drive minimum speed step 2 hold speed step 3 while running accelerate while running at maximum speed hold speed XI SS 10 83 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice A BAM Materials Handling Inc R amp M 4501 Gateway Boulevard MATERIAS Springfield Ohio 45502 HANDLING Mutui P 937 328 5100 INC FAX 937 325 5319 1 6 3 MS4 control EE Aj c coms4b eee A Controller position B Speed decelerate to zero step 1 drive minimum speed step 2 drive speed2 step 3 drive speed3 step 4 drive maximum speed ee o o o BONZO 1 7 Mechanical brake control Inverter has a brake contactor to control electromechanical disk brake of hoisting motor The disk brake is opened and kept open during run by DC voltage When there is no voltage present the brake is closed and also kept closed by spring force The brake is controlled so that during starting the motor first generates torq
137. y Verify all of the connections are in accordance to the drawings Verify the motor supply is connected correctly faulty connection will destroy the inverter Check the device cover is properly installed High voltages are present in this device Switch the power off and after the display turns off wait 5 minutes before opening the cover Insulation resistance test with a megger multimeter requires special precautions Do not make any measurements inside the device when it is connected to the main supply Do not touch the components on the circuit boards Electrostatic discharge may cause damage or destroy the IC circuits Check all ventilation holes are clear and unobstructed Check that hot air coming from the brake resistors does not cause any danger Do not make any inspections unless the supply has been disconnected by the main switch It is forbidden to use radiophones or portable phones near this device with the doors open All the doors and covers must be closed during crane operation R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice e R amp M Materials Handling Inc R amp M 4501 Gateway Boulevard MATERIALS Springfield Ohio 45502 NDLING PALE P 937 328 5100 INC FAX 937 325 5319 v Drive is not intended to be used in a low voltage public network which supplies domestic premises Radio frequency interference is expected if used in such a n

SERVICE MANUAL FOR FREQUENCY CONTROL SYSTEM

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