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- R&M Materials Handling equipment

1. ccccccssseeccccceeseeceeecsesseceessaasseeeeeesaaeeeeesseaaeeeesseaeeeeeesaageeeeseaas 17 6 2 Main OETA OG US cessere r ERE RERE EER AA E EE RE ET Er RS 18 621 Contolpanei sesira E e a E a E 19 6 2 2 Terminal for program Connection Tool for TDN ccccceecceceseeeeeeeeeeeeeeeeseeeseeeeeesseeeeeeseeeeessaaeeeesseeenens 19 623 TRCN Soe cece nccszsaneateaseeactcecueeddanedsustteede caecuaepeuteaosdahdaseusabeaeaqcatdaneseanth ened cicateceaeadeodceb se sdeeeusenesdancauaiteaces 20 6 2 4 Braking resistor cccccsscccccssececceesceccsesececcauseeeseuseeecsageeessaueeeeseuseeessageeessaeeesseuseeessageeessauseessegeeeessageeenes 25 029 EMO FIO ees gst cats chee scepasea nats sbinwoss antd enc EO AEE eE EAE E E EE EE TEENE T AEA 26 PREPARING THE PRODUCT FOR USE creerii EE 29 7 1 Transport and SUN A Ca oacrirccisciccctscieiecianatiasecete eteatlsethert ced cad snievinacihccinye cea anastdstmindicln stinsptnwddlencannehsindeaenideindeedsteueentanentce 29 7 2 Safety precautions before installation ccceeeecceccceeeeeeeeecaeeeeeeeeseeesceeeesaeeseeeessaaseeeeessseeeeeessaaeeeesessaaeeeees 29 7 3 POU UN eee E E idaren an E EEEE E E E EEES 30 Fol DIMENS ONG sosis a e a a a a a e e a a a a R 30 Lae MOUM esne re E e EAE EE AEE A R E EAA A EAE A EAE E ERR EEEE RRE 31 8 USER INIERFA OE aE E E EE A EEE EE 33 8 1 TPS LAY ANS lease A sincicep cic ete cted ete cse A E E og eeceetetenoes 33 8 2 PIG OIAY ODOM S wat ecesiececcnanustt os
2. INC 9 PARAMETERS The listed parameters can be read from the display of the frequency converter Changing parameter settings during running may cause a hazardous situation Parameter settings must not be changed during running Incorrect parameter settings can lead to equipment malfunction or personal injuries 36 68 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 enicha Springfield Ohio 45502 TENTARE P 937 328 5100 FAX 937 325 5319 INC 9 1 General Parameter Description Parameters are assorted to Groups as shown in the parameter tree G00 Monitoring values gg pp 00 01 Brake relay state 00 02 MI port status 00 03 Motor current 00 04 Motor voltage 00 05 IGBT temperature 00 06 DC link voltage 00 07 Frequency reference 00 08 Output frequency 00 09 Parameterlock IN G01 General Parameters Cne ec 01 01 Accel time 01 02 Decel time 01 03 MinFrequency 01 04 MaxFrequency 01 05 Slowdown frequency 01 06 InputSet Go left i TS Goright Store parametervalue G02 Motor Parameters 02 01 Motor Nominal Voltage 02 02 Motor Nominal Frequency 02 03 Motor nominal current 02 04 No oad current 02 05 Current Limit 02 06 DC Brake Current level 02 07 Motor Cos Phi 02 08 Auto tuning 02 09 Motor Stator Rs 02 10 Motor Type IN G03 U f settings 03 01 Zero freque
3. Overvoltage at Too high DC link voltage at start Check the mains supply voltage and Xx start wave form INC External Communication error to an external Check the connection communication device Xx error FA 73 Signals S1 and S2 have been Check the digital I O cabling I O fault simultaneously on for over 500 ms Xx Short circuit in pendant cable FA 80 CAN fault Both driving commands from CAN Check CAN master are simultaneously on for over 500 X ms CAN CAN communication does not work Check CAN bus communication when CAN control mode is selected Check the correct input set selection X P01 06 FA83 CAN bus fault CAN bus is not detected Check CAN bus a ae ae 45 68 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 imicin emt Springfield Ohio 45502 HANDLING P 937 328 5100 FAX 937 325 5319 INC 10 COMMISSIONING If any problems or malfunctions occur during the commissioning refer to chapter Troubleshooting to find out the reason The source of any problems with the product must be solved before continuing with the commissioning procedure To avoid electrical shock ensure that the main isolation switch is turned to the off position before connecting the frequency converter to the mains supply To avoid damage to the equipment or persons ensure the proper mount
4. 164 PTO HN e E E E EE E ead 61 169 IVAN eessen e a a E a a i E E 61 16 6 Test run without load oo ccccecccecceccceseeceeeseeceeeeeeceeeueueeauueaueuuueaueaueeaueaueeeeuuueeeuuueeeauueueeeueeeusauueeeeueueess 62 167 SST VTE OAS enerne EA RA EE EAEE EREA 63 16 8 Alter the test fU eisenai rnn aE en EEA A ee nee ae Aaaa 63 17 APPENDIX ELECTRICAL CONNECTIONS 1 00 occ cececeeeeceseeeeeeseeeeseeeeeeseeeeeeseeeeeereeeeneneneens 64 18 APPENDIX DEFAULT PARAMETERS WITH COMPACT BRAKE MOTORS naan 68 3 68 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 femenicintsctnsens Springfield Ohio 45502 ncaa P 937 328 5100 FAX 937 325 5319 INC 1 UPDATE HISTORY Section Descriptor SSS lt sS S S SSSC i ate Handedty Whole document Figure improvements textual improvements and updates 11 2013 XJAASKPA 4 68 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 jennie Springfield Ohio 45502 tench P 937 328 5100 FAX 937 325 5319 INC 2 GENERAL INTRODUCTION 2 1 Foreword About this manual This manual offers guidance to enable safe and efficient service Taking the time to read this manual will help you to prevent damage to the product and most importantly pe
5. 181 8 8 0 55 _ om m m ma wi w2 ws wa bi o2 288 0 197 0 246 5 260 0 163 0 149 0 1160 130 0 2084 6 55 H1 H2 H3 H4 wi w2 w3 w4 D1 D2 353 0 166 0 290 310 243 0 111 0 180 200 0 2335 6 9 30 68 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 anean Springfield Ohio 45502 aiaiai P 937 328 5100 FAX 937 325 5319 7 3 2 Mounting There are two possible ways to mount a frequency converter to the panel wall mounting or through panel mounting INC The frequency converter has a forced airflow cooling thus the device can be mounted at any angle without affecting its operation Wall mounting frames A and B Initially tighten the screws so that they can be fitted into the holes at the upper part of the frequency converter Use screw locking liquid Once the device is held up by the screws tighten the upper screws and then secure the lower part with screws Wall mounting frames C and D If wall mounting is used it is recommended to use rising frames designed for this purpose Fix the frequency converter to the rising frame with screws Fit the rising frames on the mounting panel and fix with screws Use screw locking liquid Once the device is fitted tighten the screws Through panel mounting
6. voltage must be 42 240 VAC CD005388_1 After the start up if DIR1 indicator is lit the frequency converter accepts the driving commands CD005425 1 If a fault is indicated the frequency converter does not accept drive commands until the cause of the fault is eliminated CD005399 1 10 3 Test run without load If traveling motors are supplied with a disc brake perform auto tuning See chapter Auto tuning Ensure that movement of the equipment does not cause any danger to the environment or to the crane itself Avoid driving close to the limit areas Check the travel limit switch functionality manually if possible by measuring their state when they are turned into different positions After the check turn the limit switches back to neutral position 49 68 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 femenicintsctnsens Springfield Ohio 45502 ncaa P 937 328 5100 FAX 937 325 5319 IC Check the limit switch functions 1 Drive slowly in one direction and check that the limit switch operates properly 2 Recheck by driving at full speed 3 Repeat the steps to the opposite direction Note The one step slowdown limit switch does not stop the motion IN Ensure that the motor operates properly 1 Drive in one direction at minimum speed for 5 10
7. Fit the device into the opening in the panel Use screw size M5 with screw locking liquid Once the device is fitted tighten the screws 31 68 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 hamniamini Springfield Ohio 45502 irienna P 937 328 5100 FAX 937 325 5319 INC Du dt filters 004 011 Du dt filter at motor supply is needed if e Motors are not made for inverter use e Inverter is not mounted on the crane e Number of motors is greater than 2 e Total motor cable length is over 100 m 330 ft 020 034 Du dt filter at motor supply is needed if e Motors are not made for inverter use e Inverter is not mounted on the crane e Number of motors is greater than 4 e Total motor cable length is over 200 m 660 ft Examples of possible du dt filters Platthaus du dt Length mm Width mm Height mm Weight kg filter 004 007 ULC 910 920 52306553 ULC 914 931 200 52306554 020 034 ULC 918 951 225 52306555 32 68 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice j R amp M Materials Handling Inc R amp M 4501 Gateway Boulevard jennie Springfield Ohio 45502 senceinasoie P 937 328 5100 FAX 937 325 5319 INC 8 USER INTERFACE 8 1 The display panel The display panel is used for
8. MCCBs If there are no other regulations the values given in this section can be used to dimension fuses three phase 400V supply Overload protection protects both the supply and the motor cables Fuses of the supply provide protection against short circuit 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 mmz is given by formula x 15 x lp p x A 243 x where is the cable length m is the motor current A at shaft power P is the allowed voltage drop in is the nominal motor voltage lt i ai 59 68 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 finns Springfield Ohio 45502 neil P 937 328 5100 FAX 937 325 5319 INC 16 QUICK GUIDE If any problems or malfunctions occur during the start up refer to Chapter Troubleshooting to find out the reason All problems must be solved before continuing the operations 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 100 V Note also that
9. any and all claims demands AND damages regardless of their nature or type losses and expenses whether Known or unknown present or future any and all liability of and from any and all manner of actions cause s of actions all suits in law in equity or under statute State or Federal of whatever kind or nature third party actions including suits for contribution and or indemnity on account of or in any way arising out of acts or omissions of the Owner or READER and relating in any way to this MANUAL or THE PRODUCTS referenced herein including but not limited to the Owner s or READER S use thereof or any other cause identified herein or that may be reasonably inferred HEREFROM 6 68 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 2 6 Terminology The following terms and definitions may have been used in this manual Authorized personnel Bridge CE marking Check Compact brake motor Controller Current rating EMC Filter Flux braking Hoist Main girder Main isolation switch Power supply Qualified personnel Resistor braking Slowdown limit Stop limit Travel Trolley hoisting unit 7 68 Persons who are authorized by the owner and who have the necessary training to carry out opera
10. e Displaying the status electrical values operating or fault parameters e Altering the parameter settings D Fyre M STOP Omm Re DIR2 ol em 52 Be aje To TO 1 Display 2 UP and DOWN button 3 LEFT button 4 OK button 5 STOP button 7 8 2 Display options 8 2 1 Drive status Drive status Is indicated with an LED light The state is active when the LED next to the corresponding text is lit For example when the drive is running LED next to the text RUN is lit RUN state indicates that the drive is running STOP state indicates that the drive is not running DIR1 state indicates that the direction S1 forward is active DIR2 state indicates that the direction S2 reverse is active 8 2 2 Display messages Description Frequency converter output frequency ma a m Ww i L Frequency converter output current 33 68 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 fasniintacen Springfield Ohio 45502 nein P 937 328 5100 FAX 937 325 5319 INC Motor voltage CO005392_ 1 Parameter Example 02 03 CD005395_1 Fault Example FA06 CD005399_1 8 3 Navigation on the control keypad The frequency converter is monitored and controlled with parameter groups The parameters are identified with gg pp where gg deno
11. motor current from the display The motor current should be an average of lo and sum of motor nominal currents To increase or decrease current increase or decrease parameter 03 01 Zero frequency voltage value Set parameter 01 03 MinFrequency back to the original designed value 16 6 Test run without load e Make sure that the movement does not cause any danger to the environment or to the crane itself Avoid driving close to the limit areas Check the limit switches manually if possible Check the run commands on the display panel and correct the traveling direction e Drive direction S1 at minimum speed for 5 10 seconds Accelerate to the full soeed Run for 5 10 seconds Stop Repeat the same in direction S2 Check on the frequency display to ensure that the frequency changes through the whole operational frequency range from minimum to the nominal speed e Check the motor operation acceleration deceleration and braking accelerate to the full speed in direction S1 change to direction S2 at full soeed and again to direction S1 at full soeed and then stop e Check the limit switch functions drive in direction S1 slowly and check the limit switch operations Recheck the limit switch operations when driving at full soeed Repeat the same checks for direction S2 62 68 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
12. reset the fault and check the mains supply If the mains supply is correct an internal fault has occurred Contact an authorized service center Check the following e Supply cable connections e Supply voltage Check the following e Operating environment temperature e Cubicle heating Check the following Operating environment temperature Frequency converter cooling fan operation Air flow through heat sink Heat sink cleanliness Switch off power and back on The parameter settings are automatically reset If the problem persists contact an authorized service center Switch off power and turn back on after the display lights go out If the problem persists contact an authorized service center The device is not parameterized for the application Check all parameters 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 HANDLING on tarnot P 937 328 5100 FAX 937 325 5319 Stop limit Signal S12 or S22 is inactive Reset by keeping the controller at 0 for over 500 ms Reset time is adjustable with parameter 05 06 FA54 Reset Time x Check the following e InputSet selection P01 06 e State of inputs DID4 and DIDS P00 02 Deceleration The defined deceleration ramp Check the deceleration ramp time X distance cannot be followed parameter 01 02
13. second environment e Emissions N level products fulfil the emission requirements lower than specification of the EN 61800 3 A11 2004 for the second environment O level products fulfil the emission requirements they might exceed the limit of N level products of the EN 61800 3 A11 2004 for the second environment Note The involved products are designed for Second Environment Industrial Environment only The disturbances emitting from the basic products are not filtered to the required level of residential commercial and light industrial e g offices gasoline station retailer shops etc environment First Environment In this sense these products should not be used in First environments If you still want to use them in First environments additional requirements are needed please contact product supplier 058905_1 Note EMC filters in N level products might cause disturbances on residual current device RCD 058905_4 9 68 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 hamniamini Springfield Ohio 45502 irienna P 937 328 5100 FAX 937 325 5319 INC 3 SAFETY FIRST Safety requirements must be understood and followed 3 1 Personal protective equipment PPE For safety the service personnel or others in close proximity to the product may be required to wear Personal Prot
14. seconds 2 Accelerate to the full speed 3 Run with full speed for 5 10 seconds 4 Stop 5 Repeat the task for the opposite direction If there are problems in the operation or a fault situation occurs in the frequency converter see chapter Troubleshooting Ensure that the motor acceleration deceleration and braking operations work properly Check the motor operation 1 Accelerate to the full speed in one direction 2 Change to the opposite direction at full speed 3 Again change to the opposite direction at full speed 4 Stop If there are problems in the operation or a fault situation occurs in the frequency converter see chapter Troubleshooting 10 4 Test run with load Ensure that crane movements do not cause any danger to the environment or to the crane itself Drive the movements in both directions at minimum and maximum speeds Check that the crane moves at minimum and maximum speeds Drive runway length with full load 50 68 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice j R amp M Materials Handling Inc R amp M 4501 Gateway Boulevard iosenitnhmacanisont Springfield Ohio 45502 serio P 937 328 5100 FAX 937 325 5319 INC Check the deceleration ramp time If the movement stops suddenly during the deceleration check the frequency converter fault code See chapter Troubleshooting Check that the limit switc
15. that Underwriters Laboratories UL has tested representative samples of the product and determined that they meet UL s requirements These requirements are based primarily on UL s published and nationally recognized Standards for Safety The China Compulsory Certificate mark commonly known as the CCC Mark is a compulsory safety mark for a variety of products sold on the Chinese market The CCC mark is required for both domestically manufactured products and products imported into China The RoHS marking means that a product complies with the directive for the restriction of the use of certain hazardous substances in electrical and electronic equipment The WEEE indicates that the product should be disposed of according to the WEEE directive regulations The frequency converters carry the CE label as a proof of compliance with the Low Voltage Directive LVD and the Electro Magnetic Compatibility EMC 8 68 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 jennie Springfield Ohio 45502 senceinasoie P 937 328 5100 FAX 937 325 5319 INC 2 2 EMC The abbreviation EMC stands for 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
16. there is a dangerous voltage always in the braking resistor when the DC bus is charged Do not connect any voltage to the output terminals U T1 V T2 W T3 The frequency converter will be damaged The overload protection of TDN protects both the supply and the motor cables The supply fuses provide short circuit protection 058905_1 16 1 Visual checks Check the condition of cubicles Check that the serial number of the drive is the same as in the delivery documents Check the cabling to the braking resistor Check the cabling to the motor brake and thermistors Check the motor type Check the wire terminations in the motor connection box Check the connections to the motor thermistors thermostat and the brake wear Disconnect the motor U V W and brake cables to prevent damages to the frequency converter measure the insulation resistance of the brake coil and the motor windings each phase to ground e Reconnect the motor and brake cables 16 2 Checks before the first test run Check the power supply voltage Check the control voltage Make sure that the run commands are off push buttons controller Zero position Turn on power from the main switch The control panel display is lit within about 1 second In a fault situation the FAULT status indicator blinks and the display shows a fault code instead of frequency Check that RUN status indicator is off Check that the external connections and the s
17. to view select and change the wanted items CD005302_ 1 1 Display 2 UP and DOWN button 3 LEFT button 4 OK button 5 STOP button see chapter User interface for more detailed information of display options and navigating in the menu 6 2 2 Terminal for program Connection Tool for TDN More information of Connection Tool for TDN can be found in Owner s Manual Connection Tool for TDN 19 68 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 HANDLING P 937 328 5100 FAX 937 325 5319 ING 6 2 3 Terminals TO AVOID AN ELECTRICAL SHOCK DISCONNECT THE MAINS SUPPLY A DANGER BEFORE WORKING ON THE TERMINALS OF FREQUENCY CONVERTER WAIT AT LEAST 5 MINUTES AFTER THE COOLING FAN HAS STOPPED AND INDICATORS HAVE SWITCHED OFF The frequency converter power module has terminals for 3 phase power supply for 3 phase motor output and external braking resistors The frequency converters of higher current ratings also have a terminal for DC bus which must not be connected CDOOXXXX_1 CD006133_1 CD006132_1 Frame C power supply terminals Frame D power supply and braking resistor terminals 20 68 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Mat
18. tools Hand lines securely attached to the building structure should be used for lifting or lowering materials and tools Use proper safety equipment to prevent objects from falling when working in high places Safety devices must be restored to operational status Ensure that any safety devices which have been bypassed for testing purposes have been restored to full operational status before allowing the product to be used for normal operation Minimize the risks of moving machinery Secure the area so that personnel are not at risk from the movements of machines automatic doors or adjacent cranes at the installation site Ensure that machinery and equipment cannot start up accidentally and cannot move during installation and servicing Be prepared in case equipment moves in the wrong direction during testing Perform regular inspections and preventive maintenance To ensure ongoing safe and efficient operation of the product carry out regular inspections and preventive maintenance in compliance with the instructions Keep a record of all inspections and servicing If in doubt contact the supplier of the product 12 68 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 HANDLING Minani rae ia P 937 328 5100 FAX 937 325 5319 INC 4 IDENTIFICATION 4 1 Man
19. values group 00 The first parameter group which is identified with a group number 00 contains monitoring values Monitoring values show information about the current state of the frequency converter Monitoring values differ from the parameters the monitoring values can only be browsed with the keypad not changed The monitoring values available are as follows cove _ Porantrmanw Unt rane owt owen Brake relay state 0 or 1 Output relay status Contact between RA and RC 0 Contact is open 1 Contact is closed MI port status Multifunction Input Terminal status Leftmost bit corresponds to DI1 state and the rightmost bit corresponds to DI6 state When the digital input is ON the upper vertical bar of the bit is lit When the digital input is OFF the lower vertical bar is lit I BA mA Example value of parameter DI status DI1 ON DI2 OFF DI3 ON DI4 OFF DI5 ON DI6 ON Note Value 1 in parameters 05 01 DI4 05 02 DI5 and 05 03 DI6 sets the status of DI ON even when there is no voltage in the input The status indicator of digital inputs bit 0 DI1 status bit 1 Dl2 status bit 2 DIS status bit 3 D14 status bit 4 DI5 status bit 5 DI6 status current Ao ae Motor current as a percentage of the motor nominal current EC O e S poas iesroroeae freumes cae spoarTarssoronoeaue poas foomo fv reoeo oo C He ___ Atenreieosn ae ranp apr 38 68 R amp M Materials Handling Inc
20. 07 011 02 4 004 ELE85 ee a ELE85 Bridge travel inverter power rating Values are composed of two features Supply voltage E 380 480 VAC 50 60 Hz Power rating class and Supply voltage e g 004E ELE84 ELE85 value 23 1 ELEO2 Control voltage 1 48 230 VAC 50 60 Hz ELE02 Control voltage for digital input 24 25 1 Revision code The latest revision may differ 26 Braking resistor type 0 External resistor 2 Mounting W Wall mounting 1 Through Flange mounting 8 2 me ve ang M Modifiable grounded gt non grounded not vice versa grounding 29 Option board O0 Standard includes 48 230 VAC digital input option card 15 68 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 5 TECHNICAL DATA Mains connection Supply voltage Uin Supply voltage frequency Connection to mains Motor connection Output voltage Nominal output current Continuous output current Starting current Output frequency Digital inputs Control voltage 48 240 Vac 50 60 Hz Control features Control method Switching frequency Acceleration time Deceleration time Ambient conditions Storage temperature Relative humidity Air quality Chemical vapors Mechanical particles Altitude Vibration EN50178 EN
21. 20 4 2 kg 034 7 5 kg 61800 5 1 2007 EN60204 1 2009 CE UL cUL FI IEC see the unit main sticker for more detailed approvals 820 Voc trip level 333 Voc trip level Safety Protections Over voltage protection Under voltage protection Earth fault protection lutlv lw gt 0 05In IGBT gt 100 C IGBT lt 20 C Unit over temperature Unit under temperature Overcurrent protection Yes Motor overtemperature supervision Yes 16 68 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 jennie Springfield Ohio 45502 senceinasoie P 937 328 5100 FAX 937 325 5319 INC 6 CONSTRUCTION 6 1 Intended use of the frequency converter These frequency converters are designed for industrial crane usage to control the speed of the trolley and bridge movements Possible motor control methods to be used are MS and EP More information of the control methods can be found in chapter Control methods It is possible to use these frequency converters also with the CAN bus The frequency converter shall be used only in crane applications Only the product manufacturer shall perform any voltage withstand tests 0589051 058905_1 Any alterations and or modifications to the product not authorized by the manufacturer are strictly prohibited Opening the product cover voids its warrant
22. 22 Stoplimitreverse o O ES Motor temperature protection External stop o O 23 68 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 HANDLING INC P 937 328 5100 FAX 937 325 5319 Digital inputs and the control method EP slow and stop P01 06 0 S1 EP slow MS slow and stop MS slow CAN slow and CAN slow stop P01 06 1 P01 06 2 P01 06 3 P01 06 4 P01 06 5 S1 S1 a a E a E ME sss se pos sese ser es san s sen The screw tightening torqu es of the power module terminals Tightening torques for control input terminals Frame A B C A DANGER 24 68 THE MOTOR TERMINALS U V1 V V2 W T3 AND BRAKING RESISTOR TERMINALS B1 AND B2 WHEN APPLICABLE ARE LIVE WHEN THE FREQUENCY CONVERTER IS CONNECTED TO A MAINS SUPPLY EVEN WHEN THE MOTOR IS NOT RUNNING THE CONTROL BOARD S RELAY OUTPUT TERMINALS WHEN APPLICABLE MAY HAVE A DANGEROUS CONTROL VOLTAGE EVEN WHEN THE FREQUENCY CONVERTER IS DISCONNECTED FROM THE MAINS SUPPLY THESE CONDITIONS MAKE A RISK OF ELECTRICAL SHOCK POSSIBLE The RCD current from the frequency converter can exceed 3 5 mA AC According to standard EN61800 5 1 a reinforced protective ground connection shall be ensured to reduce the risk of an electrical shock Loosen terminal screws with caution Dropp
23. 60068 2 6 Ambient operating temperature 380 480 V 10 10 3 phase 45 66 Hz Once per minute or less normal case O Un 004 In 3 4A max 5 1A 007 In 6 8A max 10 2A 011 In 10 4A max 15 6A 020 In 19 2A max 28 8A 034 In 33 8A max 50 7A Rated current at ambient temperature max 50 C overload 1 5 x In max 1 min 1Omin 2 x In for 2 sec every 20 sec 0 250 Hz Frequency Control U f 3 6 kHz 0 20s 0 1s steps 0 20s 0 1s steps 10 C no frost 50 C outside the cubicle 40 C max ED 40 20 C 60 C 0 95 RH non condensing non corrosive no dripping water IEC 721 3 3 unit in operation class 3C2 IEC 721 3 3 unit in operation class 3S2 100 load capacity no derating up to 1000 m 1 derating for each 100 m above 1000 m max 2000 m Amplitude acceleration e 10 HzSf 57 Hz Fix Amplitude 0 075mm e 57 HzSf 150 Hz Fix Acceleration 1G e Sweep rate 1 octave min Duration 10 cycles per axis on each of three mutually perpendicular axes e Waveform Half sine e Operating three shock pulses of 15G peak acceleration for 11 1 ms Shock duration in each direction of three mutually perpendicular EN50178 IEC 68 2 27 e Non operating three shock pulses of 30G peak acceleration for 11 1 ms duration in each direction of three mutually perpendicular Package drop test ISTA Procedure 1A Enclosure class IP20 Weight 004 1 2 kg 007 1 9 kg 011 4 2 kg 0
24. 8 ee EI o gee somee se ceneeea somes ese scene cee psees sau A EE EE soece senctantcecsvncs seuaneee cee ryseu Geeuteoeseeees 9 A Ed PU drapes rsetleaecreste tee arn tac cpstniia cen negates tenance nen teleost eases inate et gon aed aneeenanateeiaeaieetoren 10 3 1 Personal protective equipment PPE cccccccssseeecceeseeccseseeccceseeeseaseeecsaseeseeaseeessaueeessaneeessegseesseaseeeses 10 td WN POLS MON arecrtsic etna eaters eres ten ath EE E E E E E E E E 10 3 2 Re 1 been ea em eee nee eee een A 11 3 3 M in WS ONION ISS WN CM eee sciatienmanercocntsscxieadaneneniancesimaaends aE aE EREE Er EAr RA Ene REKAO AEA EnaA TLK REA RAin 11 3 4 Safety during maintenance ccceeecccccseeseceecceeseececccaeueeeeecauaeeeeesauseeeessaaseceeeseeaseeeeesseaseceeessaasesessssaaseeees 11 A IDENTIFICATION iirc AE E E E E 13 4 1 NAMI AC HELGE E E ET A E OET EE EE EE E EE EE EE ET EE E E E EE E N E 13 AL SUO G eaea e E EE E EEE E E EEEE 13 4 2 Factory code example Factory TDN ccccccssssseceeceeseceeeceeeeeceeecaeaeeceeeseeaseceeeseaaeeesssuaaeeeesssaageseeeesaaass 14 4 3 R amp M code example R amp M ControlMaster LDR Factory TDN cccccccceseeeeeeeeeeeeeeeeeeeeeeeeeeeseaaeeeees 15 5 TEGH HNIGAL DAI Aicaptictnteietescuacestcenncsntacapedeaaaeetenedodedanscenndsheanapdsusdecntebecndacauadansiahesateisuadcuatasedeenaenaaat 16 o CONAC TON E EEE EE E EEA E A A EA E E E AS 17 6 1 Intended use of the frequency converter
25. Boulevard feamainna Springfield Ohio 45502 senceinasoie P 937 328 5100 FAX 937 325 5319 16 7 Test run with load Make sure that the movement does not cause any danger to the environment or to the crane itself e Drive in both directions at minimum and maximum speeds 16 8 After the test run e Record all parameter value changes in the parameter list e Make sure that all remarks and setting values are recorded INC 63 68 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 ninth Springfield Ohio 45502 nein P 937 328 5100 FAX 937 325 5319 INC 17 APPENDIX ELECTRICAL CONNECTIONS A sample electrical drawing for the limit switch connections and the brake control CD006092 1 Parameter 01 06 InputSet 0 EP slow and stop b e D Te A O Parameter 01 06 InputSet 1 64 68 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice j R amp M Materials Handling Inc R amp M 4501 Gateway Boulevard iosnniinhmacanison Springfield Ohio 45502 inrntii P 937 328 5100 FAX 937 325 5319 INC CD006094 1 Parameter 01 06 InputSet 2 MS slow and stop CD006095 1 Parameter 01 06 InputSet 3 65 68 R amp M Materials Handling Inc reserves the right to alter or amend the above infor
26. DI3 DI6 vary depending on the parameter settings CD005396_1 CD005388_1 Digital input terminals 22 68 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 anean Springfield Ohio 45502 raaire P 937 328 5100 FAX 937 325 5319 INC Terminals S L2 3 phase input T L3 U T1 Power module MAE Motor output WIT3 TDN004 B1 B2 Braking resistor TDNOO07 020 B1 B2 Braking resistor TDNO007 020 po NOT to be connected Connecting cables to this terminal may damage the device seriously TDN034 B1 B2 Braking resistor TDN034 TDN034 a NOT to be connected Connecting cables to this terminal may damage the device seriously TDN007 020 Protective earth a ave command forward aed Ci 82 eve command reverse 2 pn ____Fumetion depends on parameter settings 4 be Funoton depends on parameter settings Ps ps Funoton depends on parameter settings a C common for relay contact RA RC for brake control NO normally open for relay contact RA RC RC for brake control O w am o O O E O n oso o O n f own O O Oo oooO OYO O w omne o oea O O Control signals Drive command forward Drive command reverse MS2_ Mulltistep second step Acceleration command OoOo M Slowdown limit forward a O Stop limit forward S21 Slowdown limit reverse o O
27. E AOO E auto stost east mearectanaeeest 53 11 4 Determining MOVEMENT CITE CON i escectessecccsceacncencesasecareaceinsaecscdateaweteeeeswaqecveadeniaisecsgideeueteawseupanceaeumeieseces 53 12 MAINTENANCE eeri ee ee a eee E 55 121 Replacing the lanseeraus EE E a e aE a aara ERA E EE A RESER EES 55 22 SPED aer E E E E eee E AEE E EEEE 55 13 TROUBLESHOOTING G erisera nonan EEE A EE EEO 56 1831 Problems and SOMOS aecncecsaccccensccntccesaccsmcpeateedased duce aAA AAAA RANAR AAPA APREA AREE NATER RENATE 56 Te PFU OOC oeenn eee eee 57 14 TAKING PRODUCT OUT OF OPERATION ccc cc cc cecececeececeeeeseceeeeeeeeeeeceeeeeeseeeeeeseeeeeereeeeneneneees 58 14 1 Disp salo waste NIAC TAINS suseisancecacsmrasavacsnmuasnendenannanatcenesceies quncunintragnnnr ena meattausyeaeneuaduamiaieanamensmmciainenaneds 58 15 CABLES AND FUSES io neers darn seers tecie EE E E eta aie E EEE EEEE 59 16 COTS GID ere E A E E A E E 60 10r Veulen K eE E E EAE EEE EEE EEE EAEN 60 16 2 Checks before the first TESTU siessccccctccsannciscnciecuacuinads aecunsabaceanadinepabaeuacsdnads davunastacsanedtacnsbeeeans tends etseeempoeseiane 60 16 3 Check motor parameters cericcaceccstssacendssocdacteatorausatocensamadansetdeadennt2ed puns aadenen ted eenaeiesdoned hiaxactabadasentedexnaitedeue 61 16 3 1 Compact brake motors MFO6MA MFOGLA cccccceccceeeceseeeeeeceeeseeeeeseeaseeessseaeseeeseseaeeeesesaeeeees 61 16 3 2 TOR MNCL OS eera enn cenctasnsenecsemesnecs EA EE E dean E E E 61
28. English Original instructions SERVICE MANUAL FOR FREQUENCY CONTROL SYSTEM ControlMaster LDR 159852 12 2013 SUPDOC_SM_TDNO30 0 ORD 20 12 2013 M MATERIALS HANDLING INC gt DOC_SM_TDNO0300100 0 PS18733 11 13 2029 R amp M Materials Handling Inc R amp M 4501 Gateway Boulevard hamniamini Springfield Ohio 45502 irienna P 937 328 5100 FAX 937 325 5319 INC Table of contents T UFDATE RIS TOR crre E 4 2 CQENERALINTRODUGTON rirse EE A EEA 5 2 1 Foreword About this FANN Alors cose sainatetsamceisacamaisrementuacseacanceacedecenteciamentandssictsaeaialesiseousarcincadiannaeatuneniewnsneeasebeaecteoss 5 2 2 Symbols Used in this Manual cccccceeeececeeeeeeeeeeeceeeeeeeeeeeeeeeeeeeeeeeseeeeeseeaeeeeeseeeeeeeeessaeseeeeessaaeeeeeessegeeeeeesas 5 2 3 Safety Alert Symbols and Signal WordS cccccccccseeeeeeeeceeeeeeeeeeeeeeeeeeseeeseeeessaeeeeeeeeeaeeeceeesaeaeeeeeessegeeeeeeeas 5 2 4 QUESTIONS ANd COMMENMS cceeeccccccseeeeeeeeeeeeeeeeeeeaeeeeeeeeeeeeeeeeeeeeeeeeeeesseeseeeeesseaeeeeeesseaeceeessaaeeeeeessageeeeeenas 6 2 5 IVAN NSS A E E A 2c ong E N E E E E EN PE A E E E 6 2 6 TERN ON OY soreness e REE REE E REA a AEE a eR E 7 2 7 Directives and SIEAMGARGS sasctecsceceseaeceasaeed caustncacenedesedcstsseanseseeenacgeccuendehameseGaesanes destavaaed sedecxdesacesesausiecdexsaesdaaetse 8 ae a an Oe V6 G GG eee mene nee keene nee ee Roe ene ee ee ee ee ee ee eee eee ee eee eee
29. ONODI winacranietentenaienestarenccaneraeaavanncenstactuvnsaesuuaeaihensua eanaues hep tantesesesonadsshaecseuuchesagienpeleeneaesuinmmunssuaouenaias 42 9 2 8 Diagnostics and drive iNfOrMatiOn ccccccssssecceecseeeeeeeeeeeeeeeeescaeeeeeeesseeeceeeeseeeeeeesseaeeeeeessaageeeeessaeeeees 42 2 Mca 1A 6 lt gt anne ee SE APE eee ae ee 43 10 COMMISSIONING lt ssrrinrsisarnrn ennn AEDA ES E abil DaN Rn NERE ERa FAE ees 46 IO VENCO ae aa E E E EE A EE E E 46 10 2 CHECKS before the first HUA sescicneciicscnccansioseacsevencatisbeneeh nsdenscanslexiessnevendaatdsenesbneencabdlesesaviyenteatdsdeesbvolenmabiiencce 47 10 2 1 PowerUp OCS IS seisicsssiricoresuiirorers inmeden erasanda daea ii aea iiaeia a annida iiaii aeii 47 10 3 Test run without load sii caves cctscdenacencttennes asd esetcavecnectnsescus eovencea Sandneat davesnasteatesestnotenece tone eunie iewsas nctenene vavenneeandeaus 49 104 Testun wiih IO AC se oes estes cetateea concedes aelavoeccutaqncentee grade ad teyoas bevenaceetaeedeetaeaes lt densuudes eltebicdateenaendseeuncseseupecediece 50 10 5 After the test run sae ce target tet de quate actesedecenteaneaceacodeeay aadeeceGnane sien Seeeaacegeodencstedacactecadaiactentaceusoedeneeyacenadeeacsiee 51 11 OPERATING INSTRUCTIONS wrctcccucccccdsccccusascnienedeasdsascgeaddentatniaacescatdandnsadabseiupdeeedsaatsbbedeeiatideuads 52 l CONTO TAS IOS organine a E a E E E phos seeanaauuniunnatuseasaceaicnnes 52 IIe oWO aenea E EE E EE 53
30. TERIALS HANDLING INC FA 08 Undervoltage DC link voltage below 333 Vdc with input voltage gt 380 V Mains supply voltage interrupted Frequency converter fault External fault during operation Phase lost One or more input phases are lost Under temperature Frequency converter IGBT temperature below 10 C Overtemperature Frequency converter IGBT temperature over 100 C EEPROM programming error Parameters not saved correctly Communication error between IO and control board Inner communication error Parameter fault Motor Nominal Current has value 0 44 68 Reset automatically after both direction commands have been switched off for 500 ms Check the following Deceleration time Main supply voltage and wave form Braking resistor cable Braking resistor type and resistance Braking chopper operation Switch off power and turn back on Check the following e Motor insulation e Cable insulation phase ground phase phase Check the following e ES external connections e Control mode selection e DI6 input state e Motor temperature the thermal protection of the motor normally connected to ES signal The fault is reset automatically after DI6 is switched back to 1 and both direction commands have been switched off for 500 ms Switch off power and turn back on If problem persists contact an authorized service center If the voltage brake has been temporary
31. as intended 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 a device is manufactured to fulfil required EMC standards Environments Immunity and emission requirements are divided in two levels in the product standard according to the environments First environment is an environment that includes domestic premises and other establishments directly connected to a low voltage power supply network Second environment is an environment that includes all the establishments other than those directly connected a low voltage power supply network y ON EMC levels There are three EMC levels S N and 0 e S level No manufacturer s EMC solution is adopted and products will be used in other market areas than European Union EU when local power supply system is the grounded network e N level Manufacturer s EMC solution is adopted to fit for Second Environment and products will be used in EU when local power supply system is the grounded network e 0Q level No manufacturers EMC solution is adopted products can be used in either EU or other market areas when local power supply system is the non grounded network Fulfilled EMC standards e Immunity All products fulfil the immunity requirements defined in the EN61000 6 2 2005 and the EN 61800 3 Amendment 11 2004 for the
32. aults while others may require the frequency converter to be powered down The causes of the fault s must be resolved and both drive commands have to be at the OFF position for 0 5s before the motor can be started again In a case of an overcurrent fault the supply voltage must be switched off and back on before it is possible to resume the operation 57 68 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 hamniamini Springfield Ohio 45502 irienna P 937 328 5100 FAX 937 325 5319 INC 14 TAKING PRODUCT OUT OF OPERATION 14 1 Disposal of waste materials Waste material from installation maintenance or dismantling shall be disposed of according to local regulations If the product is taken out of use the metal and electrical parts should be recycled In addition to local regulations liquids like oil grease and other chemicals shall never be spilled onto the ground or soil Used oil and grease shall be stored in containers indicated for the purpose 58 68 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 senate P 937 328 5100 FAX 937 325 5319 INC 15 CABLES AND FUSES Cabling can be done using cables recommended for cra
33. auses the problems It is also possible that a faulty external device has damaged the frequency converter In that case it is important to repair or change any faulty devices to prevent the problems from recurring When replacing a frequency converter with a new one the parameter list of the old frequency converter is needed for copying parameter settings to the new frequency converter Reducing the ramp time value from the value of the original delivery is not allowed 13 1 Problems and solutions The frequency converter does not Check the main voltage between terminals L1 L2 and L3 start up DIR1 indicator stays unlit Check that there are no devices causing disturbances connected in the same voltage supply when it is started as the crane Such are for example devices that require large currents large motors welding devices and so on NOTE When the EMC filter wire is connected the frequency converter has RC filters connected to the power supply side to reduce disturbances to the network The DIR1 indicator is lit after a Check the motor cable connection previous fault and there is no fault Check the limit switches code that is displayed but motor does ori Check the voltage in direction command terminal 1 DI1 and terminal 2 DI2 Check also the common terminal 7 The motor runs poorly the Check that the crane is not overloaded trolley bridge does not move as it Check that all the cables are correctly conne
34. cted and not loose supposed to move Check that all the motor parameters are set according to the motor nominal values See chapter Motor Parameters Check that the U f curve parameters are set according to the table chapter Default Parameters with Compact Brake Motors for compact brake motors For disk brake motors perform the auto tuning Check the input set selection from parameter 01 06 Check the status of inputs from parameter 00 02 Check the digital input deactivation from parameter 05 01 05 02 and 05 03 Check the voltage between the digital input and the common from terminals Check that the motor brake opens completely Check that the minimum speed parameter value has not been set too low Drive with the device along the trolley crane runway from end to end for a couple of times in order to smooth out the runway Check the parameter settings for current limit Driving to a stop limit immediately cuts off power to the motor 058905_1 56 68 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 jennie Springfield Ohio 45502 sinceinaso P 937 328 5100 FAX 937 325 5319 INC 13 2 Fault codes When the frequency converter detects an unacceptable situation it stops the current movement and indicates a warning or fault code Software resets automatically some of the f
35. ds Automatic reset The fault is reset automatically after both direction commands have been switched off DI1 0 and DI2 0 or if CAN control mode is used DIR1CAN 0 and DIR2CAN 0 for 500 ms Power off reset The fault is reset by removing the AC input voltage of the frequency converter The external voltage of 24 V does not need to be removed for the power off reset The resetting method depends on the type of the fault Resetting method Possible cause s Solution s and check s Overcurrent A too high current in motor output Switch off power and turn back on due to for example after the display lights go out e Sudden increase in heavy load Check the following Motor or cable short circuit Brake operation Unsuitable motor Motor type and power rating x Incorrect motor parameter Parameters uf parameters Auto settings tuning Motor cable connection Motor insulation Motor load 43 68 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 Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 Overvoltage DC link voltage is above 820 V with input voltage 440 V Ground fault Unbalanced motor phase currents Asymmetric load Insulation failure in motor or cable External Stop DI6 is zero or STOP button of the keypad is pressed Hardware error Component failure Faulty operation R amp M MA
36. e 8 MFOo6LA200 400V_ 1x 2x 4x 02 06 DC Brake Current Level 3 6 12 03 01 Zero Frequency Voltage 8 8 8 MFo6mA200 400V 1x 2x 4x 02 06 DC Brake Current Level 3 6 12 68 68 MFo6LA100 400V _ 1x 2x 4x 02 02 Motor Nominal Frequency 80 80 80 02 06 DC Brake Current Level 3 6 12 03 01 Zero Frequency Voltage 6 6 6 03 03 Mid Point Frequency 8 8 8 MFo6LA200 460V 1x 2x 4x 02 06 DC Brake Current Level 3 6 12 MFo6ma200 460V 1x 2x 4x 02 06 DC Brake CurrentLevel 3 6 12 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice
37. e changed to 0 by disconnecting the EMC filter connection to the ground TO AVOID AN ELECTRICAL SHOCK DISCONNECT THE MAINS SUPPLY A DANGER BEFORE CUTTING REMOVING EMC FILTER CONNECTION WAIT AT LEAST 5 MINUTES AFTER THE COOLING FAN HAS STOPPED AND INDICATORS HAVE SWITCHED OFF If the frequency converter is connected to an IT network before the EMC filter connection wire is cut removed the converter will be irreparably damaged The filter connection wire cannot be reconnected after it has been cut CD003493 1 CD006137_1 Frame A EMC filter wire Frame B EMC filter wire 26 68 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 lassectie Springfield Ohio 45502 HANDLING minieren P 937 328 5100 FAX 937 325 5319 ING CD003494 1 _ CD006138_1 qa Frame C EMC filter wire Frame D EMC filter wire Frame A B C Disassembling EMC filter connection CDO0G182_1 Ie We S TS the gt a j BVK ii KL Fri CD006084_1 CD006085_1 Open the lid unmount the screw that holds the EMC filter Pull out the EMC filter connection wire from its slot connection wire When the EMC filter wire is connected the frequency converter has RC filters connected to the power supply side to reduce disturbances to the network The capacitors of these filters
38. ective Equipment PPE Various types of PPE are available and must be selected according to the requirements of the working environment Note Follow the local regulations and requirements of the working environment 058905_1 3 1 1 Fall Protection While personnel are performing inspection or maintenance work at heights they must follow fall protection procedures as required by local regulations Fall prevention practices and fall protection equipment aim to protect personnel working on or around the equipment from exposure to falls If the equipment does not have a service platform or handrail personnel must use a properly fitted safety harness that is attached to the dedicated fixing points on the building or equipment in order to prevent falls If the product does not have dedicated fixing points for fall protection it is the owner s responsibility to make sure that there are suitable fixing points in the building structure If ladders must be used personnel must practice setting and securing the ladders before using them for actual work A typical fall protection program may include e Documented and established site policies and procedures Conducting site assessments for fall hazards Selection of the proper fall protection system and equipment Training on fall protection procedures and the proper use of fall protection systems Inspection and proper maintenance of fall protection equipment Measures to prevent falli
39. elected control parameters are in accordance with the application 60 68 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 senate P 937 328 5100 FAX 937 325 5319 16 3 Check motor parameters In most cases the parameters are properly set after factory tests and no adjustments are needed except for the application specific parameters INC If the factory has not had information about the motors adjust the motor related parameters with the steps described in this section Write down all the parameter values that have been changed and in the end save the set parameter values to file User parameters see Chapter Parameters 16 3 1 Compact brake motors MFO6MA MFO6LA Enter the motor parameter values according to the table in appendix Default parameters with compact brake motors 16 3 2 Other motors e Enter the motor nominal voltage into parameter 02 01 Motor Nominal Voltage e Enter the motor nominal values into parameters 02 02 Motor Nominal Frequency and 02 03 Motor nominal current e Perform the auto tuning See chapter Auto tuning 16 4 Auto tuning Before the auto tuning e Check the motor connections e Check that the parameters from 02 01 to 02 08 and 02 10 are set according to the delivery documentation and the instructions in cha
40. eration 1 input is inactive DI5 always on Specifies digital input 6 state 0 input is active normal operation 1 input is inactive DI6 always on 41 68 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 fitness Springfield Ohio 45502 HANDLING inmost P 937 328 5100 FAX 937 325 5319 SlowdownMode Specifies slowdown limit function 11 S21 at limit activation 0 Slow allows only slow speed to the opposite direction 1 Fast allows fast speed to the opposite direction Electrical braking method TDNOO4 Sets electrical braking method 1 flux 0 Resistor braking braking 1 Flux braking 2 Resistor and flux braking TDNOO7 Set TDNO11 TDNO20 TDNOO4 TDNO34 1 flux braking 0 resistor TON007 TNDO11 TDNO20 TDNO34 braking 0 resistor braking 05 06 FA54 Reset Time 0 0 5 0 oO Resetting time for fault F54 Stop limit INC 9 2 7 CANopen Code Parametername name Parametername Unit Range Range Default Description e address 1 254 0 disable Communication address 0 disable CANbus baud rate 1 500K CANbus baud rate 0 1M 1 500 K 2 250 K 3 125 K 4 100 K Gain of CANbus 0 00 2 00 1 00 The gain of CANbus frequency frequency CANbus warning Read only parameter Guarding Time out Heartbeat Time out SYNC Time out SDO Time ou
41. erials Handling Inc R amp M 4501 Gateway Boulevard eictahseananaon Springfield Ohio 45502 HANDLING limeenea P 937 328 5100 FAX 937 325 5319 ING ld A Ca p A CD006134_1 CD006135_1 Frame C motor output and braking resistor terminals Frame D motor output terminals 21 68 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 itn Springfield Ohio 45502 HANDLING __ _ P 937 328 5100 FAX 937 325 5319 Frame D installing the I O card earthing cable INC CD006079 1 f re gt a Oo Open the lid unmount the screw in the leftmost slot and insert After inserting the cable head inside fasten it with the screw the earthing cable head inside via the opening at the bottom of the slot The control voltage for digital inputs can be 48 240 VAC 50 60 Hz All digital inputs must be connected to the same control voltage transformer The transformer must have galvanically separated windings and the neutral phase of the secondary circuit must be connected to the protective earth The frequency converter has protection against earth faults in the motor or in the motor cables The function of inputs DI1 and DI2 are always direction commands S1 and S2 The functions of inputs
42. ernal connections and the project specific parameters are set according to the electrical drawings Make sure that the main power isolation switch is ON The product becomes operational energized only after the necessary steps have been followed to establish the communication between the product and the controller If applicable use the key switch to turn on the controller 1 16da 47 68 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 ninth Springfield Ohio 45502 nein P 937 328 5100 FAX 937 325 5319 To prepare the controller for operation release the emergency stop button 1 06284 1 Energize the product by pressing the start pushbutton O62ea0_1 The frequency converter goes into a ready to run state after the power supply is connected The frequency converter verifies that both direction signals are switched off 7 Measure the power supply voltage The main voltage must be between 380 480VAC 48 68 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice A a 5 i CD00S41T1_1 i R amp M Materials Handling Inc R amp M 4501 Gateway Boulevard iosenitnhmacanisont Springfield Ohio 45502 serene P 937 328 5100 FAX 937 325 5319 Measure the control voltage at the transformer The control
43. f the load is dissipated as thermal energy in the braking resistors while lowering Slowdown limit reduces the speed of the crane or trolley before the end of the runway Stop limit stops the crane or trolley at the end of the runway Drive mechanism for moving the trolley or main girder along the runway The trolley hoisting unit moves along the main girder 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 2 Directives and standards 2 7 1 CE CSA UL CCC This product complies with one or more of the following requirements and directives described in this section For more detailed information about which requirements the product meets see the main sticker attached to the device CE CSA UL CCC RoHS WEEE The CE marking certifies that a product has met EU health safety and environmental requirements which ensure consumer safety The CSA marking means that a product has been tested and meets applicable standards for safety and or performance including the applicable standards written or administered by the American National Standards Institute ANSI Underwriters Laboratories UL Canadian Standards Association CSA National Sanitation Foundation NSF and others The UL marking means
44. from the motor type plate Motor Nominal Frequency 10 0 600 0 From motor The nominal frequency of a motor type plate Set from the motor type plate Motor nominal current A 0 0 2x Number of The sum of the nominal currents of the motors nominal motors x Set the number of motors x the nominal current of one current of nominal motor TDN current of one motor o Current Limit 0 0 2x 1 5 x nominal The maximum output current nominal current of current of TDN TDN INC TDN load current motor No load current 0 0 nominal Number of The current of a motor without load current of motors x No Set the number of motors x the no load current of one of one motor Hz If there is no lo in the name plate set value to 0 A 39 68 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 hamniamini Springfield Ohio 45502 nein P 937 328 5100 FAX 937 325 5319 DC_Brake Current level 0 0 nominal i i ing current of Disc brake motors 80 of the sum of the motor nominal currents Compact brake motors the number of motors x 3A Max 1 5 x the nominal current of TDN 02 07 Motor Cos Phi 02 08 Auto tuning 0 Auto tuning not done 1 Start auto tuning 3 Auto tuning completed successfully 4 Auto tuning has failed 6 U f parameters and Motor Stator Rs are modified after successfu
45. h functions with full load If the slowdown limit is used 1 Drive slowly in one direction and check that the slowdown limit operates properly 2 Repeat the task for the opposite direction If the stop limit is used 1 Drive in one direction at full soeed and check that the stop limit operates properly 2 Repeat the task for the opposite direction The one step slowdown limit switch does not stop the motion 0589051 10 5 After the test run Record the parameter value changes to a parameter list The history of the changed values is needed in case the frequency converter is replaced with a new one 51 68 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 airin tanaan Springfield Ohio 45502 iraniane P 937 328 5100 FAX 937 325 5319 INC 11 OPERATING INSTRUCTIONS 11 1 Control methods EP Electronic Potentiometer push button control Released stop The device does not move or if it is already moving it decelerates to a complete stop Step 1 slow hold If push button is half pressed step 1 the device accelerates until it reaches the preset slow speed If push button is half pressed step 1 when the device is moving above the preset slow speed the current speed is held without accelerating or decelerating Step 2 accelerate The device accelerates continuous
46. id mid point frequency parameter 03 03 Mid point freq Measure the motor stator resistance e Switch off the power and disconnect the motor cables from the motor output terminals e Measure the motor stator phase impedance Rs of a cold motor on the disconnected cable ends If there are several motors that are connected in parallel the correct value is approximately the stator impedance of one motor that is divided by the number of motors Reconnect the motor s and switch on the power Set value to parameter 02 09 Motor Stator Rs Measure no load current e Check that there is no load on the hoist e Drive at full soeed and check motor current lo from the display e Set value to parameter 02 04 No load current Calculate starting values Calculate the values from where to start the tuning e Uo Rs lo Un e Umid 1 4 Uo e fmid Uo fn Set values to parameters Uo to parameter 03 01 Zero frequency voltage Umid to parameter 03 02 Mid point volt fmid to parameter 03 03 Mid point freq Adjust Umid Set value fmid to parameter 01 03 MinFrequency Drive at minimum speed fmid Check motor current from the display The motor current should be an average of lo and sum of motor nominal currents e Increase or decrease the value of parameter 03 02 Mid point volt to increase or decrease current Adjust Uo e Set value fmid 2 to parameter 01 03 MinFrequency e Drive at minimum speed fmid 2 e Check
47. ing of the motor before starting Also make sure that the machinery connected to the motor allows the motor to run 10 1 Visual checks Check that the main power is switched off Check that the serial number of the drive is the same as in the delivery documents Check the connections and the condition of the cabling to the motor the braking resistor the grounding and the thermistors Check that the motor type the nominal voltage the nominal current and the nominal frequency are same as the parameterized values in the electrical drawings 46 68 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 ee Springfield Ohio 45502 HANDLING a P 937 328 5100 FAX 937 325 5319 INC 10 2 Checks before the first run Check that the main power is switched off When installing a new unit disconnect the motor U T1 V T2 W T3 cables to prevent damage to the frequency converter Measure the insulation resistance of the motor windings each phase to ground The insulation resistance requirement for new motor Cold motor 10 40 C 2 5 MQ Warm motor 40 C or more 2 1 MQ If the insulation resistance is less than the requirement the motor must be dried Cd00S54T1_1 Reconnect the motor cables and check the tightness of the other cables 8 o Check that the ext
48. ing terminal screws inside the equipment when unfitting them may cause serious damage to the equipment R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice j R amp M Materials Handling Inc R amp M 4501 Gateway Boulevard lomnica Springfield Ohio 45502 sini P 937 328 5100 FAX 937 325 5319 INC 6 2 4 Braking resistor TDNO004 TDNO07 TDNO11 TDNO20 TDN034 Minimum resistance ohm 25 wo e z2 Typicalresistor OOO S S S y S Resistanceohm mw s s Resistor RK02 can be installed into a resistor cubicle of its own or at the back side of the frequency converter assembly plate In case of 2 RKO2 two RKO2 resistors are connected in parallel See the following figures CD006257_1 CD006184_1 RK02 in its own cubicle R box 2 RKO2 at the back side of the frequency converter assembly plate 25 68 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 farina h Springfield Ohio 45502 TRAILS P 937 328 5100 FAX 937 325 5319 INC 6 2 5 EMC Filter The frequency converter has an internal EMC filter in the power supply By default the EMC level of the frequency converter is set to N by the manufacturer If the mains network is non grounded IT network the EMC level of the frequency converter must b
49. isplay notices Ensure that the secured area is spacious enough to prevent injuries which could occur as a result of falling components or tools Inform that equipment will be undergoing maintenance Before starting maintenance people must be properly informed that the equipment is being removed from operation Ensure that there is no load on the lifting device Before starting maintenance there should be no load on the hook or lifting device Park the hook on the ground if there is any chance that the hoisting brake will be opened during maintenance A raised empty hook will fall to the ground if the hoisting brake is opened 11 68 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 hammma inama Springfield Ohio 45502 nesta P 937 328 5100 FAX 937 325 5319 Turn all controllers and main switches off All controllers and main isolation switches must be placed in the off position before starting maintenance Lockout Tagout The product power source must be locked out and tagged out when necessary in accordance with local regulations See chapter Lockout Tagout Procedure Verify that power is completely disconnected Measure between the phases and between each phase to ground to ensure that power is completely disconnected from the product Use hand lines for lifting and lowering
50. l auto tuning When value 1 is set the auto tuning starts the brake is not opened and the motor will not run Motor Stator Rs The phase to phase resistance ohms of a motor The value is automatically set during auto tuning For compact brake motors check the value from appendix Default parameters with compact brake motors Motor Type 0 Normal DC brake 1 Compact brake INC With value 1 compact brake motors the auto tuning does not change u f parameters or Motor Stator Rs check the values from the motor parameter table 9 2 4 U f settings LT tid Woli Zoro Freq Wolt Lu Mid Freg U f Mid Volt Output voltage in per cents of the motor nominal voltage at mid point frequency U f Mid Freq Hz U f curve mid point frequency Zero Freq Volt Output voltage in per cents of the motor nominal voltage at zero frequency 40 68 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 0 0 120 0 HANDLING INC Mid point voltage 0 00 100 0 Mid point frequency peta pemen Compact brake motors check from the table Normal motors perform auto tuning Compact brake motors check from the table Normal motors perform auto tuning Compact brake motors check from the table Normal motors perf
51. ls Handling Inc R amp M 4501 Gateway Boulevard femenicintsctnsens Springfield Ohio 45502 ncaa P 937 328 5100 FAX 937 325 5319 If the slowdown limit signal is deactivated when the motor is not running the frequency converter cannot determine which direction is safe Therefore the maximum speed is limited in both directions until the slowdown limit signal is activated Same applies if the slowdown limit signal is deactivated during a power shortage INC If the stop limit signal is deactivated when the motor is not running the frequency converter cannot determine which direction is blocked In this situation it is possible to run in both directions with minimum speed The normal operating speeds are restored when the stop limit signal is activated 54 68 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 jennie Springfield Ohio 45502 tench P 937 328 5100 FAX 937 325 5319 INC 12 MAINTENANCE Note Mechanical and electrical maintenance work requires special skills and tools to ensure safe and reliable operation of the product Maintenance work shall be carried out only by authorized service personnel or an experienced service technician authorized by the product s manufacturer or manufacturer s representative 058905 4 Ensure proper air flow and cooling of the frequency converte
52. ly until the push button is released or the maximum speed is reached b a 5e Push button released the motor does not turn Push button step 1 pressed the motor accelerates until it reaches the preset slow speed Push button step 1 pressed the current speed is held 3 2 3 Push button step 2 pressed the motor accelerates towards maximum speed 4 5 Push button step 2 pressed the motor accelerates until it reaches maximum speed 6 Push button step 1 pressed the current maximum speed is held 7 Push button released the motor decelerates 8 Push button step 1 pressed the current speed is held 9 Push button released the motor decelerates to a complete stop 52 68 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 armeani Springfield Ohio 45502 aeiaai P 937 328 5100 FAX 937 325 5319 INC When a push button is pressed or released the movement accelerates or decelerates smoothly The operator SHALL account for the starting and stopping distances before making crane movements MS2 Multistep 2 pushbutton control 1 062da The motor moves at a speed corresponding to the pushed step of the pushbutton The motor moves at its slowest speed when the pushbutton is partially pushed and at its maximum speed when the pushbutton is fully pushed The motor stops moving after ramp time when the pushbut
53. mation without notice R amp M Materials Handling Inc R amp M 4501 Gateway Boulevard niin Springfield Ohio 45502 ninantan P 937 328 5100 FAX 937 325 5319 INC 30 480 W su 4 SLOW F C Fi MOTOR STOP Eirin maeh L J MOTOR or La i oO 1 Options components inside dotted lines are options according to the application 2 An alternative connection for stop limits 12 S22 An example of TDN using a brake contactor 66 68 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 joseniinhmacanison Springfield Ohio 45502 rieni rentia P 937 328 5100 FAX 937 325 5319 INC cD006096_1 BRAKE Guidelines for an external brake contactor connection 67 68 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 18 APPENDIX DEFAULT PARAMETERS WITH COMPACT BRAKE MOTORS 02 06 DC Brake Current Level the maximum current of TDN can limit this value MFo6MmA100 400V 1x 2x 4x 02 02 _ Motor Nominal Frequency 80 80 80 03 01 Zero Frequency Voltage 9 9 9 03 03 Mid Point Frequency 8 8
54. may cause the RCD Residual Current Device to trip Therefore the use of RCD with the frequency converter controlled cranes is not recommended 27 68 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 haamini namia Springfield Ohio 45502 ninenin P 937 328 5100 FAX 937 325 5319 INC Use of RCD with the frequency converter controlled cranes is not recommended 28 68 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 anean Springfield Ohio 45502 senate P 937 328 5100 FAX 937 325 5319 INC 7 PREPARING THE PRODUCT FOR USE 7 1 Transport and storage The product must be stored in an environment meeting the following conditions e Storage temperature between 20 C and 60 C e Relative humidity below 90 no condensation e Installation site altitude below 1000 meters After unpacking the component ensure that there are no visible signs of transport damage Make sure that the type code indicated on the main sticker corresponds with the type code of your order Frequency converter DC link capacitors should be reformed by powering up the frequency converter once a year for one hour 7 2 Safety precautions before installation Before installing check tha
55. ncy voltage 03 02 Mid point volt 03 03 Mid point freq G04 Brake control 04 01 Brake Opening Delay 04 02 Stop DC frequency 04 03 Start DC frequency 04 04 DC Brake Time During Stopping 04 05 Brake Close Frequency Ul G05 Protection 05 01 DIl4 Deactivation 05 02 DI5 Deactivation 05 03 DI6 Deactivation 05 04 SlowdownMode 05 05 Electrical braking method 05 06 FA54 Reset Time I G06 CANopen parameters 06 01 Communication address 06 02 CANbus baud rate 06 03 Gain of CANbus frequency 06 04 CANbus warning ll G07 Diagnostics and drive information 07 01 Motor runtime 07 02 Motor run time 07 03 1st fault record 07 04 2nd fault record 07 05 3rd fault record 07 06 4th fault record 07 07 5th fault record 07 08 Identity code 07 09 Rated current 07 10 Power SW Ver 07 11 Control SW Ver 07 12 DriveDIR Di4 not used 07 13 DriveDIR DI5 not used 37 68 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 finns Springfield Ohio 45502 nein P 937 328 5100 FAX 937 325 5319 9 2 PARAMETER DESCRIPTIONS Initially the display shows the monitoring value Output frequency F INC Pressing the EA DOWN button on the keypad shows the next monitoring value Output voltage U and Output current I Pressing the Z3 UP button shows the previous monitoring value 9 2 1 Monitoring
56. ne installations All cables must be dimensioned according to local regulations Ambient temperature cabling method size of bundles and so on and allowable current for the cable must be taken into consideration If there are no other regulations the values in table below can be used three phase 400V supply The table below is based on ED lt 60 and ambient temperature 40 C 104 F A higher ambient temperature may require increased cable sizes The braking resistor cable is selected according to braking resistor current lres for the resistors mentioned in document Cables smaller than specified must not be used The braking resistor current should be used only to select a thicker cable for higher ambient temperatures Powercass nn ooe O ooe j oe O oe O E Continuous current 10 4A 19 2A 33 8A Fuse 20A 35A Motor cable default length 50m 50m 50m 50m 50m Motor cable of default length at 40 C 1 5mm 1 5mm 2 5mm 4mm 10mm AWG 14 AWG 14 AWG 14 AWG 12 AWG 8 Braking resistor current 11 2A Braking resistor cable 40 C 2 5mm 2 5mm 2 5mm 2 5mm 2 5mm AWG 14 AWG 14 AWG 14 AWG 14 AWG 14 Note An ambient temperature higher than 40 C may require increased cable sizes 0589051 l 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 cable Dimensioning of the fuses or MCCBs depends on the cable used and on the type of primary fuses or
57. ng objects Rescue Plans If necessary contact your supplier or service organization for assistance with designing your fall protection program 10 68 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 oenicncctamnsh Springfield Ohio 45502 Minnini P 937 328 5100 FAX 937 325 5319 3 2 Fire Safety In the event of a fire only attempt to fight it if you can do so without putting yourself in danger Turn the power off if it is possible to do so Evacuate the area Notify other people about the potential danger and call for help Never use a powder type fire extinguisher on high voltage INC 3 3 Main isolation switch Service personnel shall be aware of main isolation switch functionality Eventhough one switch is turned off there may still be voltage in some parts of the product This may result in exposure to electric shocks 3 4 Safety during maintenance Before and during product maintenance the following precautions should be taken by maintenance personnel Choose a safe working location The product should be moved to a location where it will cause the least disturbance and where it can be accessed easily Prevent unauthorized access to the site Prevent unauthorized persons and bystanders from walking on or below the work site For example you can lock doors install barriers and d
58. of trolley travel control Device name TDN BT01 BT01 Type of bridge travel control ELE84 ELE84 Trolley travel inverter power rating P rating class 004 007 011 020 034 j ELE85 Se ae ELE85 Bridge travel inverter power rating Values are composed of two features Supply voltage E 380 480 VAC 50 60 Hz Power rating class and Supply voltage e g 004E ELE84 ELE85 value Control voltage 1 48 230 VAC 50 60 Hz ELE02 Control voltage for digital input Revision code The latest revision may differ Braking resistor type O External resistor Mounting W Wall mounting 1 Through Flange mounting me ie ana M Modifiable grounded gt non grounded not vice versa grounding Option board O0 Standard includes 48 230 VAC digital input option card 14 68 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 senate P 937 328 5100 FAX 937 325 5319 INC 4 3 R amp M code example R amp M ControlMaster LDR Factory TDN ControlMaster LDR 004 TRO1 BTO1 ELE84 ELE85 ELE97 EL32 1 18 19 21 28 Code Peale Feature Available properties code TRO1 R BT01 value TR01 Type of trolley travel control D ControlMaster LDR gro Device name ControlMaster LDR TDN BT01 Type of bridge travel control ELE84 ELE84 Trolley travel inverter power rating P 4 0
59. orm auto tuning Output voltage in per cents of the motor nominal voltage at zero frequency Set Normal motors Do the auto tuning Compact brake motors Check value from appendix Default parameters with compact brake motors Output voltage in per cents of the motor nominal voltage at mid point frequency Set Normal motors Do the auto tuning Compact brake motors Check value from appendix Default parameters with compact brake motors Note The value is automatically set upon auto tuning U f curve mid point frequency Set Normal motors Do the auto tuning Compact brake motors Check value from appendix Default parameters with compact brake motors P 937 328 5100 FAX 937 325 5319 Brake Opening Delay 0 00 10 00 0 05 A delay after brake relay closing before the frequency starts to increase Stop DC frequency Hz 0 0 250 0 5 The frequency when Stop DC braking begins during stopping Start DC frequency 0 0 250 0 The frequency when Start DC braking ends during starting DC Brake Time During 0 00 a 00 braking time during stopping Stopping Brake Close Frequency 0 0 iall P frequency when the brake relay RA opens during Frequency stopping 9 2 6 Protection cose Pomme ont Roe os Bion 1 Specifies digital input 4 state 0 input is active normal operation 1 input is inactive DI4 always on Specifies digital input 5 state 0 input is active normal op
60. pter Parameters Note that parameter 02 09 Motor Stator Rs is set by the auto tuning functionality e Set parameter 02 08 Auto tuning value to 1 and the auto tuning function starts If the parameter value changes to e 3 Auto tuning was done successfully e 4 Auto tuning failed Try again start from checking the motor connections Auto tuning does not rotate the motor or close the brake relay that is it does not open the brake 0589051 The auto tuning process determines the following U f parameters 02 09 Motor Stator Rs 03 01 Zero frequency voltage 03 02 Mid point volt 03 03 Mid point freq 16 5 Manual tuning Before the manual tuning e Check motor connections e Check that parameters from 02 01 to 02 08 and 02 10 are set according to the delivery documentation and the instructions in chapter Parameters Rs stator resistance parameter 02 09 Motor Stator Rs lo no load current parameter 02 04 No load current Uo zero frequency voltage of motor nominal voltage parameter 03 01 Zero frequency voltage 61 68 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 femenicintsctnsens Springfield Ohio 45502 iiaeiai P 937 328 5100 FAX 937 325 5319 Umid voltage at midpoint frequency of motor nominal voltage parameter 03 02 Mid point volt INC Fm
61. r Remove dust from cubicle and frequency converter during regular maintenance Do not use aerosol dust remover Compressed air may damage the fan of the NOTICE frequency converter Inspect the frequency converter and it s environment during regular maintenance of application e Check fault codes Check fastening of frequency converter Check condition of wiring and terminal connections Check condition of cable bushings and door sealings on cubicle Check operation and cleanliness of cooling fan of frequency converter Check operation and cleanliness of cooling fan and filters of cubicle Any defects or abnormalities which are detected during the inspections must be investigated and corrected in accordance with the instructions relevant to component in question 12 1 Replacing the fan Push locking parts on the side of the fan gently and pull out the fan Unplug the wire Connect the new fan and adjust it into the place fas Yy ia So Ss a O 12 2 Spare parts TE a Display TDNKPEKC1 52487204 55 68 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 neil P 937 328 5100 FAX 937 325 5319 INC 13 TROUBLESHOOTING The purpose of troubleshooting is primarily to determine whether the frequency converter itself or any external device c
62. 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 HANDLING minana ranere P 937 328 5100 FAX 937 325 5319 00 08 Output frequency a ee Output frequency to the motor Parameter lock 1 disabled Parameter modification with the keypad 0 enabled 1 disabled 9 2 2 General Code Parameter name unit Range Defaut Description Accel time S 0 1 30 0 4 5 Acceleration time from zero to the nominal frequency of the motor Set according to the application Decel time S 0 1 30 0 4 5 Deceleration time from the nominal frequency of the motor to zero Set according to the application MinFrequency Hz 0 0 Max 10 Minimum driving frequency Frequency Set according to the application MaxFrequency Hz MinFrequency From motor Maximum driving frequency Motor type plate Set according to the application nominal frequency Slowdown frequency Hz 0 0 Max 15 Maximum driving frequency in slowdown area Frequency Set according to the application InputSet 0 5 The selection of the digital input function 0 EP slow amp stop 1 EP slow 2 MS slow amp stop 3 MS slow 4 CAN slow amp stop 5 CAN slow Set according to the application 9 2 3 Motor cose Parameter ame Unt pange poun Beeston Motor Nominal Voltage V 50 500 From motor The nominal voltage of a motor type plate Set
63. rsonnel situated close to it The product is designed to be safe when used correctly However there are many potential hazards associated with incorrect operation and these can be avoided when you know how to recognize and anticipate them This manual is not intended as a substitute for proper training but provides recommendations and methods for safe and efficient service 2 2 Symbols Used in this Manual Readers should familiarize themselves with the following symbols which are used in this manual 1 Indicates that the product is slowing down or is moving at its slowest speed 062P07 Indicates that the product is accelerating or moving at its highest speed NOTE Indicates items which require special attention by the reader There is no obvious risk of injury associated with notes 2 3 Safety Alert Symbols and Signal Words The following symbols are used in this manual to indicate potential safety hazards Obey all safety messages that follow this symbol to avoid possible injury or death Indicates a potentially hazardous situation which if not avoided MAY result in minor or moderate injury It may also be used to alert against unsafe practices Indicates a potentially hazardous situation which if not avoided COULD result in death or serious injury DANGER INDICATES AN IMMINENTLY HAZARDOUS SITUATION WHICH IF NOT AVOIDED WILL RESULT IN DEATH OR SERIOUS INJURY 5 68 R amp M Materials Handling Inc reserves the righ
64. t SDO buffer overflow CANbus Off Error protocol of CANopen CANopen boot up fault 07 01 Shows the accumulative motor operation time Shows the accumulative motor operation time 07 03 1 fault record m See table in i Shows the current fault record 7 chapter 07 04 2 fault record z Fault record 4 Shows the second most recent fault record aligns 07 05 3 fault record i Gene nmons Shows the third most recent fault record 07 06 4 fault record i 4 Shows the fourth most recent fault record 07 07 5 fault record a 4 Shows the fifth most recent fault record 42 68 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 HANDLING ovina P 937 328 5100 FAX 937 325 5319 07 08 Identity code The identity code of TDN TDNOO4 7 TDNOO7 11 TDNO11 13 TDNO20 17 TDNO34 23 INC 9 2 9 Fault codes If a fault situation occurs the frequency converter display shows a fault code The fault indicator turns on and the fault code starts to blink in the display Example Fault code FA06 on display CD005399 1 Fault handling In all fault situations a fast stop is activated the modulation of the drive is stopped and the brake relay is opened brake closes Restarting is disabled until the fault is reset by one of the following resetting metho
65. t A EE E EEE aud 33 3 22 Dive SIUS ee en a ea ee ns ee ae ee en 33 922 WISDIAY MSS a aese E A E EE EEE EE E OEE EAE 33 8 3 Navigation on the control keypad wetsvnmisnexderiancedsndnenddaatneassiamiancnsnniunasdundsundseatnnaniamaneaiincasmsatued seediantunesinwinnindss 34 031 Panel pulono sieren a a eee E 34 8 4 Seting paramet essen naei E Ea EEEE a EAE EEEE 35 8 4 1 Changing a parameter VAIUG veces cicansgesercaessccventavenussaansdenleiiadabieosdadyleusevesensanbedeaniiusduceced cienseuasectoabaliamaveneess 35 I PARAMETER reni aen dunn ecatoamnssadonmeiieeatcassedenampsenssansenuaneosennenaeceuas 36 9 1 General Parameter DesScripti N wiicctiacdoccncoccestunescmsaetenenedudsdanaavecansadenecereaaeaneadenaganceedssancdeteditandansecteaeaeneas dees 37 2 68 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 anean Springfield Ohio 45502 arenas P 937 328 5100 cian FAX 937 325 5319 9 2 PARAMETER DESCRIPTIONS cccececiar tec eascacunessetanequsonncarscdarcousencueeunedteouheoctsen der uecaquseauczenaedaeaousenicanseriaenent 38 Srl M mtonng valss TOU Q issnin E E 38 De GON a E A E an ee e ee nee 39 D2 a MOO e A A E E 39 AS eres A E O E A INE A E E E A IN A E T O T A E E A E 40 925 Brake 8 6 eae ee eE EAEE Aaaa AARAA EES 41 920 acl 811 2 6 8 eea E ET ae am A a EAEE ae AAEE A AAEE ee ee ee 41 Died
66. t there are no signs of damage on the frequency converter THE ELECTRICAL INSTALLATION SHALL BE PERFORMED ONLY BY A DANGER PERSONNEL AUTHORIZED BY THE MANUFACTURER IT IS POSSIBLE THAT INSTALLATIONS MADE BY UNAUTHORISED PERSONNEL ARE INCORRECT AND CARRY AN INCREASED RISK OF AN ELECTRICAL SHOCK DANGER CONVERTER SHALL ALWAYS BE GROUNDED WITH A GROUNDING TO REDUCE THE RISK OF ELECTRICAL SHOCK THE FREQUENCY CONDUCTOR CONNECTED TO THE GROUNDING TERMINAL THE FREQUENCY CONVERTER S POWER UNIT COMPONENTS ARE LIVE A DANGER WHEN THE CONVERTER IS CONNECTED TO MAINS THE VOLTAGE IS DANGEROUS AND DIRECT CONTACT WITH IT MAY CAUSE DEATH OR SERIOUS INJURY The frequency converter remains live while running a motor energized by a process The motor acts as a generator that feeds energy to the frequency converter creating a risk of an electrical shock The cover of the frequency converter shall not be opened The converter components may be damaged by a static voltage discharge from for example fingers 29 68 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 jeicnnctnicom Springfield Ohio 45502 HANDLING P 937 328 5100 FAX 937 325 5319 INC 7 3 Mounting 7 3 1 Dimensions The main dimensions of the four frame sizes are described in the following illustrations 174 0 162 0 100 0 89 0
67. t to alter or amend the above information without notice R amp M Materials Handling Inc R amp M 4501 Gateway Boulevard fone inanam Springfield Ohio 45502 etn hat P 937 328 5100 FAX 937 325 5319 NOTICE Addresses situations not related to personal injury such as likely or possible damage to equipment Indicates that a rule is mandatory and must be followed INC Indicates that a rule is a recommendation the advisability of which depends on the facts in each situation 2 4 Questions and Comments Any questions or comments relating to the content of this manual and or the operation maintenance and or service of manufacturer products should be directed to www rmhoist com 2 5 Manual Use Every person exposed to the manufacturer s equipment must prior to SERVICING AND OR MAINTAINING SUCH PRODUCTS read and understand the contents of this manual and strictly adhere AND CONFORM THEIR CONDUCT WITH AND TO THE INFORMATION RECOMMENDATIONS AND warnings provided herein Note Keep these instructions in a safe accessible location for future reference by personnel operating the equipment or exposed to the equipment s operation 0589051 Read and understand the contents of this manual prior to operating servicing and or maintaining the equipment Failure to do so can result in serious injury or death Manufacturer shall not be liable for and owner and READER shall release and hold manufacturer harmless from
68. tes a parameter group and pp a parameter within that group The parameter group numbers start from zero and parameter numbers from one CD005395 1 Example Parameter 02 03 8 3 1 Panel buttons Up Down Left Right OK Stop Fu BA En OK 34 68 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 jennie Springfield Ohio 45502 sinceinaso P 937 328 5100 FAX 937 325 5319 INC 8 4 Setting parameters Parameters are used for controlling and adjusting the functions of the frequency converter Parameter values can only be changed when the motor is not running 8 4 1 Changing a parameter value Press Left repeatedly until one of the output values F frequency U voltage or current is shown Press UP or DOWN button repeatedly until the correct parameter group gg is shown Press UP or DOWN button repeatedly until the correct parameter pp is shown Press UP or DOWN button repeatedly until the correct parameter value is shown 8 Press OK The value is stored and applied 35 68 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 hamsii snaaien Springfield Ohio 45502 arent P 937 328 5100 FAX 937 325 5319
69. tion or service actions The bridge main girder moves along the runway The CE marking of the product indicates that the product complies with the appropriate CE regulations A visual and functional assessment not a test of the product without dismantling A motor with an internal brake The brake is opened with motor current External brake control circuit is not needed The pendant or other type of controller is used by the operator to give commands to the crane The nominal current of the frequency converter The frequency converter has an internal EMC filter in the power supply Deceleration energy is dissipated as thermal energy in the motor s Drive mechanism for lifting and lowering the load The main girder bridge is connected to the bridge end carriages The main isolation switch is the power switch which the operator should normally use to turn off the power Power is supplied to the components via the power supply One with necessary qualification based on theoretical and practical knowledge of hoists or and cranes The person must be in a position to assess the safety of the installation in conjunction with the application Persons with the authority to undertake certain maintenance work on products of manufacturers include manufacturers service engineers and trained fitters with corresponding certification Deceleration energy is dissipated as thermal energy in the braking resistor In hoist movement potential energy o
70. ton is released When a pushbutton is pressed or released the movement will accelerate or NOTICE decelerate smoothly The operator SHALL account for the starting and stopping distances before making crane movements 11 2 Slowdown limit The slowdown limit reduces the speed of the crane or trolley before the ends of the runway In a normal state the limit switch contact is closed and the control voltage is connected to the input When the limit switch contact is opened the slowdown function activates The slowdown function limits the output frequency If the driving frequency is higher than the set slowdown frequency the frequency converter decelerates to the slowdown frequency In EP use the speed between the minimum speed and the slowdown speed can still be used The movement speed is reduced in the running direction or both directions depending on the settings 11 3 Stop limit The stop limit stops the crane or trolley at the ends of the runway In a normal state the limit switch contact is closed When the limit switch contact is opened the motion stops 11 4 Determining movement direction The frequency converter has to be aware in which direction the motor is running in order to execute the limit functions properly It has only one input for the slowdown limit and one input for the stop limit 53 68 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice i R amp M Materia
71. ufacturer Manufacturer R amp M Materials Handling Inc Address 4501 Gateway Boulevard 45502 SPRINGFIELD OH USA Note For further information about the product operational training or servicing please contact the manufacturer or manufacturer s representative 0589051 l 4 1 1 Main sticker The main sticker shows for example the model and serial number of the frequency converter as well as the rated voltage Barcode sticker location TDNXXXXXXXXXXXXX INPUT XX XXX XX XXX XXX XXX OUTPUT XXX XX XXX XXX XXX FREQUENCY RANGE XXX XXX Version XXX XXX O EMC level modified C IND C 055E43K0T0510001 ON T EQ 1211XX 1 440XX55 441100 Frequency range Indicates the frequency of control signals that the product can be connected to Version Indicates the software version EMC level modified Indicates whether the EMC level has been changed from the default level By default the EMC level is set as N See chapter EMC for more information of EMC levels 13 68 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 ornare P 937 328 5100 FAX 937 325 5319 INC 4 2 Factory code example Factory TDN TDN 004 E M TRO1 BTO1 ELE84 ELE85 ELE84 ELE85 ELE97 EL32 1 3 4 6 7 13 peace Feature Available properties code TRO1 TRO1 Type
72. y 17 68 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 netstat P 937 328 5100 FAX 937 325 5319 INC 6 2 Main components Frame A Frame B Model 004 Model 007 CD005306_1 CDO005307_ 1 Frame C Frame D Models 011 and 020 Model 034 oe T i CD005303 1 CD005304_1 Pos Pat Description 4 Display o Display and navigation buttons 2 Digital input terminals Digital input terminals 3 Terminais 3 phase power supply and motor supply terminals 4 EMC filter connection EMC level of the frequency converter can be modified by cutting the EMC connection 5 Fan Fan for cooling the frequency converter 6 Main sticker identification data 7 Terminal for the A terminal for the connection to the Connection Tool for TDN program running in a separate PC Connection Tool for TDN 18 68 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice j R amp M Materials Handling Inc R amp M 4501 Gateway Boulevard jennie Springfield Ohio 45502 HANDLING P 937 328 5100 FAX 937 325 5319 INC 6 2 1 Control panel The control panel contains e Display 1 indicating status electrical values operating or fault parameters e Navigation buttons 2 5

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