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SERVICE MANUAL FOR FREQUENCY CONTROL SYSTEM

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1. POS DESCRIPTION NAME ID REMARKS x n 8 8 8 8 8 5 5 5 8 8 81 8 8 INVERTER A1 Inverter D2V002NF1NO3 52318240 EMC level N S 1 D2V002NF1003 52318207 EMC level 0 1 D2V003NF1N03 52318239 EMC level N S 1 D2V003NF1003 52318208 EMC level 0 1 D2V004NF1NO3 52318238 level N S 1 D2V004NF1003 52318209 EMC level 0 1 D2V005NF1N03 52318237 level N S 1 D2V005NF1003 52318210 level 0 1 D2V007NF1NO3 52318236 level N S 1 D2V007NF1003 52318211 level 0 1 2 011 1 03 52318235 level N S 1 D2V011NF1003 52318212 EMC level 0 1 D2V015NF1NO3 52318234 level N S 1 D2V015NF1003 52318213 level 0 1 D2V018NF1N03 52318233 EMC level N S 1 D2V018NF1003 52318214 level 0 1 D2V022NF1N03 52318232 level N S 1 D2V022NF1003 52318215 EMC level 0 1 D2VO30NF1NO3 52318231 level N S 1 2 030 1003 52318216 EMC level 0 1 D2V037NF1NO3 52318230 level N S 1 D2V037NF1003 52318217 EMC level 0 1 D2V045NF1NO3 52318229 level N S 1 D2V045NF1003 52318218 level 0 1 D2V055NF1NO3 52318228 EMC level N S 1 D2V055NF1003 52318219 EMC level 0 1 BOARDS INCLUDED IN INVERTER D2V Basic l O board 6 52288046 SIot A 1 1 1 1 1 1 1 1 1 1 1 1 1 Relay Thermistor 52305690 Slot B 1 1 1 1
2. 34 83 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R M MATERIALS HANDLING INC R amp M Materials Handling Inc 4501 Gateway Boulevard Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice Flux Curr Damp P2 3 17 Flux Current Ctrl stabilator time constant in milliseconds Must not be 0 400 ms changed Not used in traveling application D2T Stop DC Freq P2 3 18 Defines the frequency at witch DC braking starts 0 250 Hz Start Freq S1 P2 3 19 Defines the output frequency during brake opening delay to direction 0 Freq 52 Hz S1 Start Freq S2 P2 3 20 Defines the output frequency during brake opening delay to direction 0 Max Freq S2 Hz S2 Brake Stop Freq P2 3 21 When stopping the contact of the relay output ROB2 opens when the 0 Max Freq S2 Hz output frequency of drive goes below the value set in this parameter ESR Point Freq P2 3 22 Defines ESR field weakening point frequency in percents of motor 0 250 nominal frequency ESR Point Volt P2 3 23 Defines ESR field weakening point voltage in percents of motor 0 250 no
3. Standard connection with sensor bearing KAE 234 D2L E V 5 o3 red BROWN 4 At white WHITE B z lt lue m a a 2 7 ov black GREEN Standard connection with encoder 24 ppr terminal box D2L x1 __ 55 red 24V 51 yellow 53 2 m 52 a EA 2 0 154 EB ov 56 blue ov Standard connection with encoder 600 ppr or more terminal box D2L xo __ V 55 red 24V 51 yellow B 53 2 G 52 4 black EA 2 B 54 white EB ov 56 blue ov Standard connection with proximity switch Baumer Sch nbuch KAE 234 D2L V 6 3 brown At O black EN 2 lt m a a 2 7 ov blue 82 83 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc Inv 4501 Gateway Boulevard Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 MATERIALS HANDLING INC Standard connection with proximity switch Honeywell Colour if cable has been 234 D2L 1 155 lengthened red brown Ay nd 24V 51 green green _ 53 2 EB m G 52 a EA 0 54 ov 2 56 white ov 83 83 R amp M Materials Handling Inc reserves the rig
4. 49 8 1 Connections 0 49 8 2 Set p ccce RIDERE Oe es 50 8 3 Test run without 50 9 START UP PROCEDURE 51 9 1 Visual 51 9 2 Checks before the first test run 51 9 3 Test run without load 51 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 R M MATERIALS HANDLING i mv 937 325 5319 9 3 1 Functional test run for 50 52 9 4 Test run with load 52 9 5 Test run with overload 52 9 6 After the 52 10 TROUBLESHOOTING 53 10 1 Field repair actions 53 10 2 Typical functional problems 53 10 3 Inverter fault codes 54 10 3 1 Fault time data 57 10 3 27 Fault Counter teen 58 10 4 Inverter Alarm codes 59 11 INVERTER TROUBLESHOOTING TABLE 60 12 SERVICE ra eere e 61 3 83 13 SPARE PARTS LIST F
5. 25 ROB2 Pd Relay output 250V 8A normal open 26 ROB2 um 28 T1 Thermistor input double isolated 29 T2 Rtrip 4 7kQ Es 3 1 5 SSU Speed Supervision board Slot C SSU is in CSU slot C see chapter Speed supervision settings 20 83 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc Inv 4501 Gateway Boulevard UTE Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC SSU Speed supervision unit ID 52288044 Terminal Signal name Description 1 EA Threshold voltage 10VDC 2 EA Threshold voltage 10VDC 3 Threshold voltage 10VDC 4 EB Threshold voltage 10VDC 5 24V 24VDC short circuit protected 6 OV Common for encoder supply E YELLOW 28 ROC1 Relay output 250 8A normal open 29 ROC1 J Relay contact ROC1 closes when inverter is powered and no faults occurs Relay contact ROC1 opens if the SSU has tripped in Overspeed Speed difference Zero speed Relay test fault Watch dog fault LED Blinking Status Red 1Hz OK Yellow 0 25Hz OK Yellow 4Hz Board internal fault or communication fault with control unit 3 1 6 I O Extension board Slot D NXOPTB9 I O Extension board ID 52305691 Ter
6. 5 7 pc 125 G1 Oi l D go Be SS 11 S1 452 OF 12 82 1 DIA3 25 13 DA QE 14 DIA4 4 DIAS ONE C gt OK KAE234 4 002 11 Dips 521 DIDA 12 15 OLE cs 0105 822 ONE X11 3 4 ES ES f rs 2 11 X11 8 BRT1 19 RDY Xt 18 48 153 154 1 719 49 163 164 70 83 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice MATERIALS HANDLING 4501 Gateway Boulevard Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 R amp M Materials Handling Inc D2L 011F L3 L2 110 F7 1 3 5 tome J d iH 246 D gt 1 3 K7 2 4 6 8 1112 15 7 DC G1 v D 4 32 51 52 DIA3 4 DA 4 DIAS DID2 DID3 1 4 0104 5 A OLE Pe DIDS ES 11 BRT1 WITH 1 27 123 2125 iy nS ee A 11 51 12 52 13 DIA3 14 DIA4 ONE 511 521 512 522 X11 3 4 5 X11 8 9 RDY 7 D2FR12F45R282 Z1 Z2 Z3 AND CM1 NOT INCLUDED IN STANDARD OR IT MODELS OK KAE234 4 3 A1 K7 A2 1 18 48 153 154 X1 19 49 163 164 71 83 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R M MATERIALS
7. 2 3 11 Freq 3 52 Freq 3 52 Freq 3 52 40 2 3 12 Zero Speed Curr Zero Speed Curr Zero Speed Curr P 2 3 13 Min Current Ref Min Current Ref Min Current Ref 90 P 2 3 14 Accel Comp TC Accel Comp TC Accel Comp TC 0 1 2 3 15 Ref Angle S1 Ref Angle S1 Ref Angle S1 2 3 16 Ref Angle S2 Ref Angle S2 Ref Angle S2 2 3 17 Flux Curr Damp Flux Curr Damp Flux Curr Damp 2 3 18 Stop DC Freq Stop DC Freq Stop DC Freq P 2 3 19 Start Freq 51 Start Freq 51 Start Freq S1 P 2 3 20 Start Freq 52 Start Freq S2 Start Freq S2 P 2 3 21 Brake Stop Freq Brake Stop Freq Brake Stop Freq P 2 3 22 ESR Point Freq ESR Point Freq ESR Point Freq 2 3 23 ESR Point Volt ESR Point Volt ESR Point Volt P 2 3 24 IrAdd Motor IrAdd Motor IrAdd Motor 2 3 25 IrAdd Generator IrAdd Generator IrAdd Generator P 2 3 26 Ramp Stretching Ramp Stretching Ramp Stretching 2 3 27 Switching Freq Switching Freq Switching Freq P 2 3 28 DeadTime Comp DeadTime Comp DeadTime Comp P 2 3 29 DeadTimeCurrLim DeadTimeCurrLim DeadTimeCurrLim P 2 3 30 Brake Chopper Brake Chopper Brake Chopper P 2 3 31 Autotuning 44 83 Autotuni
8. 250 Hz Torque Boost P2 2 18 Torque maximization Off RS Voltage Drop P2 2 19 Relative value of motor stator impedance voltage drop Value of this 0 512 parameter is calculated by formula given below Motor Nom Flux current x Measured motor resistance phase to phase x 2217 Motor nominal voltage 33 83 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc Inv 4501 Gateway Boulevard ew Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC Stop Function P2 2 20 Stopping mode selection 0 Brake Ramping When the drive command is switched off the motion is stopped according to the set deceleration ramp Brake When the drive command is switched off the motor current is 1 Ramping cut off and the motion is stopped by the mechanical brake G2 3 Expert Flux Current Kp P2 3 1 Gain for flux current control Too small or too large value results 0 32000 oscillation in the current control Must not be changed Not used in traveling application D2T Flux Current Ti 2 3 2 The integration time of the flux current control Too small or too large 0 1000 ms value results oscillation in the current control Must not be changed Not used in traveling application D2T S2 Flux Control P2 3 3 Increases or decreases the Flux Current controller values P2 3 1
9. DIDS 71 1 WITH MULTICARE X1 126 227 123 125 11 51 12 52 13 DIA3 14 DIA4 ONE CX S11 S21 S12 S22 F7 33 34 D2FR18F21R3S2 21 ohm 21 22 23 1 INCLUDED IN STANDARD OR IT MODELS gt OK KAE234 SET 0 35 Al 2 X1 18 48 7745340 154 X1 219 49 163 164 73 83 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling 4501 Gateway Boulevard Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 MATERIALS Inc D2L 030F X1 31 2532 X1 5 OLE WITH MULTICARE N 1 21 123 1 25 21 11 51 52 12 52 D 13 DIA3 DIA 14 DIA4 DIAS ONE DID2 511 DID3 521 DID4 12 DIDS 22 F7 33 34 D2FR24F 16R4S2 Z1 Z2 Z3 AND CM1 NOT INCLUDED IN STANDARD OR IT MODELS gt OK KAE234 SET 0 35 Al 2 X1 18 48 7745340 154 X1 219 49 163 164 74183 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R M MATERIALS HANDLING INC R amp M Materials Handling Inc 4501 Gateway Boulevard Springfield Ohio 45502 P 937 328 5100
10. HANDLING INC R amp M Materials Handling Inc 4501 Gateway Boulevard Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 L3 12 110 xt 130 93 120 np AND 00000000007 tute amos WITH MULTICARE 1 421 F7 135 h 25502 ej gt 1 gt ai 1 T 24 6 23 1124 et 1 25 1 3 K7 2 4 23 1 26 K7 K7 6 8 55 1 1 0 35 56 3 4 15 7 E 1 27 G4 Pe D 57 X131 Oe OR A ad 1 Si o8 1151 452 z9 12 82 DIAS 209 3S IA DIA i d DIR DIAS 12 Ok ONEC 235 138 4 0102 511 39 4 DID3 521 40 xi 4 004 22 1 5 DIDS 622 542 136 ONE 1 147 14 147 5 327 or 11 BRT1 9 Rov 7 D2FR12F45R282 Z1 Z2 Z3 AND CM1 NOT INCLUDED IN STANDARD OR IT MODELS OK KAE234 4 3 27 SET 0 38 A1 A2 X1 18 48 153 154 X1 19 49 163 164 72 83 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice 4501 Gateway Boulevard Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 MATERIALS HANDLING INC R amp M Materials Handling Inc D2L 018F 022F X1 31 2532 X1 5 OLE 51 52 DIA3 DIA4 DIAS DID2 DID3 DID4
11. FAX 937 325 5319 2x D2FR18F21R3S2 A 21 ohm 2 11 ohm B TS ER O E TP V O F7 1 3 5 tE el 5 Z1 Z2 Z3 AND CM1 NOT 1 INCLUDED IN STANDARD OR 246 IT MODELS 4 227 D Y 1 3 K7 2 4 23 55 6 8 SET 12 0 3s 74 56 3 AC 4 5 7 2 5 DC 61 M 6 7 592220002 ST 11 S1 52 12 S2 DIA3 gt 13 DIA3 DIA4 14 DIA4 4 DIAS gt OK KAE234 4 DID2 511 DID3 S21 xi DID4 512 5 i OLE 0105 522 6 3 ONE gt 7 X11 3 14 SET 0 35 ES ES xi ur Z1 FM X11 8 d BRT1 29 RDY F7 Kloe 48 O 2 i ia 7 153 154 11 X11 8 X119 49 d 163 164 BRT1 75 83 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc 4501 Gateway Boulevard Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 R M MATERIALS HANDLING INC 2x D2FR24F 16R4S2 PE 1 16 ohm 2 8 ohm B ria aM 12 110 1 3 93 L3 U 12092 A O 2252 ow A O F7 1 35 71 135 I 71 Z2 Z3 AND CM1 d 1 b INCLUDED IN STANDARD OR 2 E IT MODELS i 127 be D A 2
12. ROD1 x1 1 4 47 C 2 5 6 7 X11 18 33 F11 C12 BLU BRN BLK gt 4 M12 BRT1 34 C11 BLU BRN BLK 11 3 BRT2 EN 80 83 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R M MATERIALS HANDLING INC R amp M Materials Handling Inc 4501 Gateway Boulevard Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 D2FR24FR4S2 X11 B m2 g 4x 32 ohm R1 4 R2 4 4x 32 ohm WIRING A 10 mm B 2 5 mm OTHERS 0 75 01230 230 11 21 2 1 1 3 4 64 17 E ROD1 x1 1 4 47 C 2 5 6 7 11 18 33 C12 BLU BRN BLK gt 4 M12 PE 11 BRT1 34 C11 BLU BRN BLK Mii 6 3 BRT2 EN 81 83 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc Inv 4501 Gateway Boulevard Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 MATERIALS HANDLING INC 14 5 Standard connections for pulse sensors
13. Stop Function Stop Function Ramping Stop Function G 2 3 Expei rt rt rt rt P 2 3 1 Flux Current Kp Flux Current Kp Flux Current Kp 4000 Flux Current Kp P 2 3 2 Flux Current Ti Flux Current Ti Flux Current Ti 25 Flux Current Ti P 2 3 3 52 Flux Control 52 Flux Control 52 Flux Control 100 52 Flux Control P 2 3 4 Freq 0 Freq 0 Freq 0 1 Freq 0 P 2 3 5 Freq 1 Freq 1 Freq 1 3 Freq 1 P 2 3 6 Freq 2 51 Freq 2 51 Freq 2 81 10 Freq 251 2 3 7 Freq 3 S1 Freq 3 51 Freq 3 81 30 Freq 3 51 P 2 3 8 Zero Flux Curr Zero Flux Curr Zero Flux Curr 80 Zero Flux Curr P 2 3 9 Stray Flux Curr Stray Flux Curr Stray Flux Curr 40 Stray Flux Curr P 2 3 10 Freq 252 Freq 2 52 Freq2 52 10 Freq 2 52 2 3 11 Freq 3 52 Freq 3 52 Freq 3 52 20 Freq 3 52 P 2 3 12 Zero Speed Curr Zero Speed Curr Zero Speed Curr Zero Speed Curr P 2 3 13 Min Current Ref Min Current Ref Min Current Ref 90 Min Current Ref P 2 3 14 Accel Comp TC Accel Comp TC Accel Comp TC 0 1 Accel Comp TC P 2 3 15 Ref Angle 51 Ref Angle 51 Ref Angle 51 Ref Angle 51 P 2 3 16 Ref Angle S2 Ref Angle S2 Ref Angle S2 Ref Angle S2 P
14. The overspeed setting should be 15 25 above the full speed Switches 52 2 52 3 select range for overspeed detection level Range of detection level is the same for both normal and ESR Extended Speed range use Fine adjustment for normal use is done by rotary switch S1 and switch S2 1 Fine adjustment for ESR use is done by rotary switch S3 and switch S2 4 Overspeed detection levels are shown at display panel as of nominal speed Overspeed setting should be 15 25 above the full speed Adjusted overspeed detection level for normal use is shown in parameter V4 8 1 Adjusted overspeed detection level for ESR use is shown in parameter 4 8 2 Speed difference supervision F62 compares the motor actual speed pulse frequency with Drive frequency reference In practice this means that the motor slip is measured and if that exceeds a limit supervision stops the motion Stall supervision F63 stops the motion if there are no pulses coming from the sensor when the brake is open K7 energised SSU relay test F64 SSU Relay is tested in every power up Driving is prevented if fault has been detected SSU Watchdog fault F65 Communication between SSU board and control board is tested once in 50ms Fault will be detected if there is communication error When a fault is detected the drive is stopped SSU Overspeed Limit F66 maximum setting of overspeed limit is 1 4xmaximum speed of direction S2 Fault will be detected if o
15. confirm with enter After restoring always check the motor parameters 4 2 4 Factory settings Factory settings are not used 31 83 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc 4501 Gateway Boulevard Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 R M MATERIALS HANDLING INC 5 PARAMETER DESCRIPTIONS This manual describes parameters with software Ind2V070 Under control panel there is sticker for software version Parameters are assorted to Groups All Groups not always listed in control panel Groups are shown in control panel according to password level and selected functions This feature makes visible parameter menu simple and only needed parameters are shown Letter front of the code number describes variable type A 7 Application E Expander R Reference B Button S System C Counter Info T Trip Counter D DynACode P Parameter V Value Label Code Function Description Adjustment range G2 1 General Parameters Password P2 1 1 Default 768 Service 2156 shows also group G2 3 Expert Supply Voltage V2 1 2 Power unit nominal voltage F 380V 500V Device V2 1 3 Device Industrial Input Set P2 1 4 Input Set selection see chapter Contro
16. mm 32 ohm OL230 ON230 X11 PE 21 2 ewe 1 x1 o 1 3 1 17 Q E ROD1 x1 1 4 47 O C 5 6 X11 18 33 C11 BLU BRN BLK M1 34 F11 BRT1 34 78 83 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc Inv 4501 Gateway Boulevard TUTUP Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC D2FR12FR2S2 2x 45 ohm WIRING A 2 5 mm B 2 5 OTHERS 0 75 mm OL230 ON230 PE 21 2 it x1 o 1 3 _1 17 Q F ROD1 x1 1 4 147 lt C11 5 6 BLU BRN BLK M1 9 9 X11 18 F11 BRT1 33 34 79 83 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R M MATERIALS HANDLING INC R amp M Materials Handling Inc 4501 Gateway Boulevard Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 D2FR18FR3S2 3x 32 ohm WIRING A 6 B 2 5 OTHERS 0 75 OL230 ON230 PE 21 2 1 1 3 4 64 17 E
17. 2 10 Max Freq S1 Max Freq 51 Max Freq S1 2 2 11 Max Freq 52 Max Freq 52 Max Freq 52 2 2 12 Max ESR Freq Max ESR Freq Max ESR Freq P 2 2 13 Drive Selection Drive Selection Drive Selection P 2 2 14 Pulse Number Pulse Number Pulse Number P 2 2 15 Zero Freq Volt Zero Freq Volt Zero Freq Volt 2 2 16 U f Mid Volt U f Mid Volt U f Mid Volt P 2 2 17 U f Mid Freq U f Mid Freq U f Mid Freq P 2 2 18 Torque Boost Torque Boost Torque Boost P 2 2 19 Rs Voltage Drop Rs Voltage Drop Rs Voltage Drop 180 P 2 2 20 Stop Function Stop Function Stop Function Ramping G 2 3 Expei rt rt rt P 2 3 1 Flux Current Kp Flux Current Kp Flux Current Kp 4000 P 2 3 2 Flux Current Ti Flux Current Ti Flux Current Ti 25 P 2 3 3 52 Flux Control 52 Flux Control 52 Flux Control 100 P 2 3 4 Freq 0 Freq 0 Freq 0 1 P 2 3 5 Freq 1 Freq 1 Freq 1 3 P 2 3 6 Freq 2 51 Freq 2 51 Freq 2 51 10 P 2 3 7 Freq 3 S1 Freq 3 51 Freq 3 51 20 2 3 8 Zero Flux Curr Zero Flux Curr Zero Flux Curr 80 P 2 3 9 Stray Flux Curr Stray Flux Curr Stray Flux Curr 40 P 2 3 10 Freq 252 Freq 2 52 Freq2 82 10
18. 2 3 17 Flux Curr Damp Flux Curr Damp Flux Curr Damp Flux Curr Damp P 2 3 18 Stop DC Freq Stop DC Freq Stop DC Freq Stop DC Freq P 2 3 19 Start Freq S1 Start Freq S1 Start Freq S1 Start Freq S1 P 2 3 20 Start Freq S2 Start Freq S2 Start Freq S2 Start Freq S2 P 2 3 21 Brake Stop Freq Brake Stop Freq Brake Stop Freq Brake Stop Freq P 2 3 22 ESR Point Freq ESR Point Freq ESR Point Freq ESR Point Freq P 2 3 23 ESR Point Volt ESR Point Volt ESR Point Volt ESR Point Volt P 2 3 24 IrAdd Motor IrAdd Motor IrAdd Motor IrAdd Motor P 2 3 25 IrAdd Generator IrAdd Generator IrAdd Generator IrAdd Generator P 2 3 26 Ramp Stretching Ramp Stretching Ramp Stretching Ramp Stretching 2 3 27 Switching Freq Switching Freq Switching Freq Switching Freq P 2 3 28 DeadTime Comp DeadTime Comp DeadTime Comp DeadTime Comp P 2 3 29 DeadTimeCurrLim DeadTimeCurrLim DeadTimeCurrLim DeadTimeCurrLim P 2 3 30 Brake Chopper Brake Chopper Brake Chopper Brake Chopper P 2 3 31 43 83 Autotuning Autotuning R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice Autotuning Autotuning R amp M Materials Handling In
19. 2 5 Nom Flux Curr 32 Nom Flux Curr 6 2 Nom Flux Curr 6 3 Nom Flux Curr 12 P 2 2 6 Start Current 5 8 Start Current 10 Start Current 12 9 Start Current 18 P 2 2 7 Current Limit 10 Current Limit 15 Current Limit 16 Current Limit 27 P 2 2 8 Min Freq 51 10 Min Freq S1 10 Min Freq S1 10 Min Freq S1 10 P 2 2 9 Min Freq 52 5 Min Freq S2 5 Min Freq 52 5 Min Freq S2 5 P 2 2 10 Max Freq S1 Max Freq 51 Max Freq S1 Max Freq 51 2 2 11 Max Freq 52 Max Freq 82 Max Freq 52 Max Freq 52 2 2 12 Max ESR Freq Max ESR Freq Max ESR Freq Max ESR Freq P 2 2 13 Drive Selection Drive Selection Drive Selection Drive Selection 2 2 14 Pulse Number Pulse Number Pulse Number Pulse Number P 2 2 15 Zero Freq Volt Zero Freq Volt Zero Freq Volt Zero Freq Volt 2 2 16 U f Mid Volt U f Mid Volt U f Mid Volt U f Mid Volt P 2 2 17 U f Mid Freq U f Mid Freq U f Mid Freq U f Mid Freq P 2 2 18 Torque Boost Torque Boost Torque Boost Torque Boost 2 2 19 Rs Voltage Drop Rs Voltage Drop Rs Voltage Drop 190 Rs Voltage Drop 130 P 2 2 20 Stop Function Stop Function Stop Function Ramping Stop Function Ramping G
20. 72 23 Ay K7 55 SET 115 035 56 3 224 517 52 62 72 82 le kn os 4 DC 51 61 71 81 i G1 Q 6 7 XIA ASR a ST 11 51 52 12 52 DIA3 P C 13 DIA3 DIA4 14 DIA4 DIAS ONE gt 234 4 DID2 511 DID3 521 m DID4 12 5 OLE DIDS 22 6 3 ONE gt 7 X11 3 214 N Ait ES 71 11 S EN BRT1 19 RDY E74 F7 X1 18 48 255402 153 154 11 X11 8 1 19 49 n 463 104 BRT1 76 83 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc Inv 4501 Gateway Boulevard TUTUP Springfield Ohio 45502 P 937 328 5100 HANDLING i mv 937 325 5319 14 4 Circuit diagrams for braking resistors D2FROGFRO0S2 D2FR12FR2S2 D2FR18FR3S2 D2FR24FR4S2 14 4 1 Internal wirings Other single B wires D2FRO6FROS2 2 5 mm 1 5 mm 0 75 mm AWG 14 AWG 6 AWG 20 D2FR12FR2S2 6 mm AWG 10 D2FR18FR3S2 6 mm AWG 10 D2FR24FR4S2 10 mm AWG 8 77 83 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R M MATERIALS HANDLING INC R amp M Materials Handling Inc 4501 Gateway Boulevard Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 D2FROGFROS2 32 ohm WIRING A 2 5 B 2 5 OTHERS 0 75
21. Inv 4501 Gateway Boulevard Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC Serial number E6 8 5 5 Serial number of CSU State E6 8 6 1 1 State of board in slot A Run Program version E6 8 6 1 2 Program version of board in slot A 0 0 State E6 8 6 2 1 State of board in slot B Run Program version E6 8 6 2 2 Program version of board in slot B 10005 0 State E6 8 6 3 1 State of board in slot B Run Program version E6 8 6 3 2 Program version of board in slot B 10503 14 State E6 8 6 4 1 State of board in slot B Run Program version E6 8 6 4 2 Program version of board in slot B 10501 4 Not used IU filtered V6 9 1 U phase current A IV filtered V6 9 2 V phase current A IW filtered V6 9 3 W phase current A U Temperature V6 9 4 Phase U temperature C V Temperature V6 9 5 Phase V temperature W Temperature V6 9 6 Phase W temperature C Card Temperature V6 9 7 Card temperature C Power multimonitor V6 11 1 Output current values and power card temperature The memory of active faults can store the maximum of 10 faults in the order of appearance By pushing the button you will enter the Fault time data record menu indicated by T 1 T 13 In this menu some selected important data valid at the time of the fault are recorded T 1 Counte
22. drives end up running at the same reference speed after acceleration or deceleration EP hold situation speed correction is not possible at minimum speed or full speed The correction takes place whenever the two reference speed values deviate more than 1 96 or about 1 Hz One drive faulting out stops the other and the other drive will issue a multicare fault F70 When only one hoist is selected for operation the analog signal remains at zero volts and this disables the multicare mode in case of one hoist drive being faulty active fault is not cleared when a starting command is issued the analog signal would remain at 10 volts fault condition and both hoists would be inoperational The solution for allowing the operation of one hoist in single mode is to open up the analog connection between the two drives with the help of a small relay see picture below this relay must be capable of connecting DC current 8 1 Connections The analog output of one drive is connected to the analog input of the other drive and vice versa see below A shielded cable is used to establish the analog signal connection between two drives Both ends of the cable shield must be grounded using 360 degree grounding whenever possible 49 83 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc Inv 4501 Gateway Boulevard TUTUP Springfield Ohio 45502
23. form while not driving Deceleration time is too short motor insulation motor cable insulation phase ground phase phase braking resistor cable braking resistor type and resistance braking chopper operation F3 Earth fault Current measurement has sensed unbalance in Reset has an additional 5s time delay motor phase currents Supervision level is 5 of Check inverter nominal current motor insulation not symmetric load motor cable insulation phase ground phase 54 83 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R M MATERIALS HANDLING INC R amp M Materials Handling Inc 4501 Gateway Boulevard Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 insulation failure in the motor or the cables phase F5 Charging switch Charging switch is open when START command Check becomes active control unit and power unit connections interference fault charging resistors component failure If the fault comes again change the control unit F6 External Stop Either the ES or RDY signal has been tripped Check during run ES and RDY external connections Fault is not stored into fault history F7 Saturation trip Very high overload or defective component Reset switch power off and restart after the lamps of display are off Check motor and motor cable insulation measure main circuit diodes and IGBT transis
24. is on the D2L display shows F6 and driving can begin only after the direction signals have been off for a while Normal operation For the description of the speed reference setting see chapter Control methods Hoisting lowering starts when switch S1 52 closes Closing the contact ROB2 on A1 energizes K7 which opens the brake in model 055 the brake can be controlled also by K71 D2L accelerates according to the acceleration ramp setting to the selected speed When the switch S1 82 opens D2L stops according to the deceleration ramp setting and the brake closes R1 dissipates the regenerated energy during lowering periods The power supply to R1 is controlled by A1 If the braking resistor fan s are included in external resistor unit they start to operate when power is supplied to the braking resistors The cooling continues about 4 5 minutes after electrical braking to ensure that the temperature of the resistors drops below 150 C 302 F Other features Slowdown limit switches 511 and S21 provide position dependent frequency limiting Any reason which opens contact RDY stops the operation of inverter In case of overload motor overheating etc the hoisting can be disabled by cutting the direction signal in terminal X1 8 Thermistor relay function which can be used when needed When the stop limit switch 512 or 522 opens K7 K71 in model 055F de energizes and the mechanical brake stops the motion Independent speed superv
25. least five minutes after the supply voltage has been switched off before service actions Display in operating condition lights on indicates a dangerous voltage on the DC bus When display turns off the DC bus voltage is about 100V Note also that there is a dangerous voltage in the braking resistor always when the DC bus is charged Do not connect any voltage to the output terminals 0 V W Otherwise the inverter will be damaged The overload protection protects both the supply and the motor cables fuses of the supply provide short circuit protection 9 1 Visual checks Check condition of cubicles Check that D2L serial number is the same as in delivery documents Check the switch settings on SSU see Chapter Speed Supervision Settings f necessary open the control box cover and adjust the SSU settings Check the cabling to braking resistor Check the cabling to motor brake thermistors and speed sensor Check motor type Check the wire terminations in the motor connection box Check connections for motor thermistors brake wear and speed sensor circuits Disconnect motor U V W and brake cables to prevent damage of inverter Measure isolation resistance of brake coil and motor windings each phase to ground Re connect motor and brake cables Check braking resistor s Terminals X1 21 27 and X1 51 57 are for electronics level signals Normally only shielded w
26. occurs the fault number is displayed By pushing the menu button right here you will enter the Fault time data record menu indicated by T 1 T 13 In this menu some selected important data valid at the time of the fault are recorded The data available are T 2 Counted operation hours hh mm ss T 10 Ready OzNot Ready 1 Ready Run OzNot Running 1 Run 11 Direction 0 Off 1 On Fault 0 1 Yes 12 Warning 0 1 Yes At reference 0 1 Yes T 13 0 speed OzNot Zero Speed 1 2 Speed 57 83 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc Inv 4501 Gateway Boulevard ew Springfield Ohio 45502 P 937 328 5100 HANDLING edd FAX 937 325 5319 INC 10 3 2 Fault Counter Fault Counter Fault counter value Counter value is shown in format Fault counter value Fault number E g 12 01 means that there has been 12 pieces overcurrent faults When counter value is blinking then you can monitor fault counter values by pressing up and down arrows Overcurrent fault counter Overvoltage fault counter Earth fault counter Saturation trip fault counter Undervoltage fault counter Input line supervision fault counter Output phase supervision fault counter Braking chopper supervision fault counter Inverter undertemperature fault counter Inverter overtemperature fault counter Microprocessor watchdog fa
27. running at maximum speed hold speed 1 7 2 EP3 control SEN SEEN lt i coep3a NV 0 m A Pushbutton controller position B Speed 0 decelerate to zero 1 step 1 drive minimum speed 2 step 2 hold speed 3 step 3 while running accelerate while running at maximum speed 1 7 3 MS4 control hold speed 00 eee 10 83 c_coms4b R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc Inv 4501 Gateway Boulevard ew Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC A Controller position B Speed 0 decelerate to zero 1 step 1 drive minimum speed 2 step 2 drive speed2 3 step 3 drive speed3 4 step 4 drive maximum speed 1 8 Mechanical brake control D2L has a brake contactor to control electromechanical disk brake of hoisting motor The disk brake is opened and kept open during run by DC voltage When there is no voltage present the brake is closed and also kept closed by spring force The brake is controlled so that during starting the motor first generates torque and after that the brake is opened The same applies for stopping while the brake is being closed the motor still generates torque During a direction change the brake is kept open all the time D2L decele
28. separate KA372B brake control unit 1 9 EMC The shortening EMC stands for the Electro Magnetic Compatibility According to the EMC directive the apparatus shall be so constructed that e The electromagnetic disturbance it generates does not exceed a level allowing other apparatus to operate as intended e The apparatus has an adequate level of intrinsic immunity of electromagnetic disturbance to enable it to operate as intended Declaration of conformity With the declaration of conformity the manufacturer informs that device is manufactured to fulfill required EMC standards CE mark The CE marking is a declaration by a manufacturer or importer located in the European Economic Area that a product complies with the safety and health requirements of the directive in question The manufacturer demonstrates for the authorities that the product complies with the safety requirements 11 83 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R M MATERIALS HANDLING INC R amp M Materials Handling Inc 4501 Gateway Boulevard Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 within the EU Environments Immunity and emission requirements are divided in two levels in the product standard according to the environments First environment means environment that ae includes domestic premises and also estab
29. 0 mA MF11MA200 T4 64 NM768NR4 24V DC 20 mA MF11MB200 T5 64 NM768NR4 24V DC 20 mA MF13Z 200 T6 80 NM768NR5 24V DC 20 mA MF13ZA200 T7 80 NM768NR5 24V DC 20 mA MF13ZB200 T8 80 NM768NR5 24V DC 20 mA 132 200 T9 80 NM768NR5 24V DC 20 mA MF13X 200 TA 80 NM768NR5 24V DC 20 mA Sensor bearing requires KAE234 buffer amplifier If channel A is damaged channel B be used instead in emergency situations Signal name Sensor bearing Wire colour between KAE234 and Terminal number wire colour motor plug 24V Red Brown KAE234 6 OV Black Green KAE234 2 White White KAE234 1 B Blue not connected not connected X1 24V ES o6 2 24 30 y 55 L RED BROWN 24V A 1 OUT 4 51 O Q z WHITE WHITE 2 A oV ES 2 _0V 76 56 m I BLACK GREEN ov O 52 EA v Critical damage if The supply voltage is over 28V or a short circuit between the signal and the supply or induction heating or hammer mounting In case of sensor damage the whole motor has to be changed Buffer amplifier must be located as close to the sensor bearing as possible maximum distance 2 5m The cable between the buffer amplifier and D2L must be as far as possible from the cables of motor and braking resistor minimum distance gt 20 a shielded and twisted cable grounded the shield at both e
30. 1 1 1 1 1 1 1 1 1 board I O Extension board 9 52305691 Slot D 1 1 1 1 1 1 1 1 1 1 1 1 1 SPEED SUPERVISION UNIT SSU not included in inverter D2V Speed supervision SSU 52288044 Slot C 1 1 1 1 1 1 1 1 1 1 1 1 1 unit BRAKE SUPPLY CIRCUIT BREAKER F7 Protective switch GV2 ME08 52297213 1 1 1 1 1 1 1 1 1 Auxliary contact GV2 AN20 52275270 1 1 1 1 1 1 1 1 1 F71 Protective switch GV2 ME08 52297213 1 Auxliary contact GV2 AN20 52275270 1 BRAKE CONTACTOR Contactor LC1 D09D7 52303564 42 1 1 1 1 1 1 1 1 1 1 1 1 1 1 7 52296542 48 1 1 1 1 1 1 1 1 1 1 1 1 1 62 83 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc Inv 4501 Gateway Boulevard eT Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC CO1F7 52296548 115 Tf LC1 D09P7 52296643 230 At K7 RC filter LA4 DA1E 52275256 42 48VAC Pe prp LA4 DA1U 52275257 115 230 BRAKE CONTROL UNIT DC BRAKE G1 Brake control unit REC12 60010145 1 1 1 1 1 1 ESD141 60003098 T pesto parci oes eo SECOND BRAKE CONTACTOR K71 Contactor LC1 D09D7 52303564 42 1 CO1
31. 1 Gateway Boulevard TUTUP Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC 3 1 3 Basic I O board Slot A Basic is in CSU slot A It has two board levels one for electronics level signals terminals 1 10 and one for control voltage signals 42 240Vac NXOPTA6 Basic board ID 52288046 Terminal Signal name Description 1 PUR Not used 2 15V Not used 3 AIN1 Analog input 1 0 10V 4 AIN2 Not used 5 AIN Common for analog input and output signals 6 AOUT1 Not used 7 AOUT2 Analog output 2 0 10V 8 DOA1 Not used 9 OV I O ground terminal 10 24V Not used 11 51 Digital input 42 240Vac 50 60Hz Direction 51 12 S2 Digital input 42 240Vac 50 60Hz Direction S2 13 DIA3 Digital input 42 240Vac 50 60Hz 14 DIA4 Digital input 42 240Vac 50 60Hz 15 DIAS Digital input 42 240Vac 50 60Hz 16 OK Digital input 42 240Vac 50 60Hz OK signal OK input is connected straight to the ASIC Inverter is ready to operate when OK signal is active 1 17 COM Common for 42 240Vac 50 60Hz 18 COM Common for 42 240Vac 50 60Hz The threshold voltage for digital inputs 51 S2 DIA3 DIA4 DIA5 and OK is 35VAC 3 1 4 Relay Thermistor board Slot B NXOPTA3 Relay Thermistor board ID 52305690 Terminal Signal name Description 21 ROB1 m nd 22 ROB1 Relay output 250V 8A 23 ROB1
32. 1 Second brake contactor 055 The most important external components are R1 Braking resistor unit M1 Hoisting motor Y1 Mechanical brake A5 KAE234 Proximity switch buffer amplifier for speed sensor B5 Speed sensor B6 Thermal sensor for motor protection Overload protection device Control devices switches pushbuttons etc Limit switches Example Layout of D2L030 7 83 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice MATERIALS R amp M Materials Handling Inc Inv 4501 Gateway Boulevard Springfield Ohio 45502 P 937 328 5100 HANDLING medi FAX 937 325 5319 INC Al 1 5 Functional description Operation when power is switched on Stop limit switches 512 amp S22 and slow down limit switches 511 amp 521 are assumed to be closed as well as the emergency stop button ES The control voltage is supplied to X1 37 The main voltage is connected to inverter power supply and inverter wakes up If the control voltage is connected to RDY signal and the fault circuit is OK inverter is ready to operate in about 1 2 seconds If either of the direction signals S1 or S2
33. 2 Freq2 82 10 2 3 11 Freq 3 52 Freq 3 52 Freq 3 52 40 2 3 12 Zero Speed Curr Zero Speed Curr Zero Speed Curr P 2 3 13 Min Current Ref Min Current Ref Min Current Ref 90 P 2 3 14 Accel Comp TC Accel Comp TC Accel Comp TC 0 1 2 3 15 Ref Angle S1 Ref Angle S1 Ref Angle S1 2 3 16 Ref Angle S2 Ref Angle S2 Ref Angle S2 2 3 17 Flux Curr Damp Flux Curr Damp Flux Curr Damp 2 3 18 Stop DC Freq Stop DC Freq Stop DC Freq P 2 3 19 Start Freq 51 Start Freq 51 Start Freq S1 P 2 3 20 Start Freq 52 Start Freq S2 Start Freq S2 P 2 3 21 Brake Stop Freq Brake Stop Freq Brake Stop Freq P 2 3 22 ESR Point Freq ESR Point Freq ESR Point Freq 2 3 23 ESR Point Volt ESR Point Volt ESR Point Volt P 2 3 24 IrAdd Motor IrAdd Motor IrAdd Motor 2 3 25 IrAdd Generator IrAdd Generator IrAdd Generator P 2 3 26 Ramp Stretching Ramp Stretching Ramp Stretching 2 3 27 Switching Freq Switching Freq Switching Freq P 2 3 28 DeadTime Comp DeadTime Comp DeadTime Comp P 2 3 29 DeadTimeCurrLim DeadTimeCurrLim DeadTimeCurrLim P 2 3 30 Brake Chopper Brake Chopper Brake Chopper P 2 3 31 42 83 Aut
34. 2 3 Expei rt rt rt rt 2 3 1 Flux Current Flux Current Kp Flux Current Kp 4000 Flux Current Kp 4000 P 2 3 2 Flux Current Ti Flux Current Ti Flux Current Ti 25 Flux Current Ti 25 P 2 3 3 52 Flux Control 52 Flux Control 52 Flux Control 100 52 Flux Control 100 P 2 3 4 Freq 0 Freq 0 Freq 0 1 Freq 0 1 2 3 5 Freq 1 Freq 1 Freq 1 3 Freq 1 3 P 2 3 6 Freq 2 S1 Freq 251 Freq 2 81 10 Freq 251 10 2 3 7 Freq 3 S1 Freq 3 51 Freq 3 81 30 Freq 3 51 20 P 2 3 8 Zero Flux Curr Zero Flux Curr Zero Flux Curr 80 Zero Flux Curr 80 P 2 3 9 Stray Flux Curr Stray Flux Curr Stray Flux Curr 40 Stray Flux Curr 40 P 2 3 10 Freq 252 Freq 2 52 Freq2 52 10 Freq 2 52 10 2 3 11 Freq 3 52 Freq 3 52 Freq 3 52 20 Freq 3 52 40 2 3 12 Zero Speed Curr Zero Speed Curr Zero Speed Curr Zero Speed Curr P 2 3 13 Min Current Ref Min Current Ref Min Current Ref 90 Min Current Ref 90 2 3 14 Accel Comp TC Accel Comp TC Accel Comp TC 0 1 Accel Comp TC 0 1 2 3 15 Ref Angle 51 Ref Angle S1 Ref Angle S1 Ref Angle S1 P 2 3 16 Ref Angle S2 Ref Angle S2 Ref Angle S2 Ref
35. 23 3 3 3 Proximity switch sss 24 3 3 4 Buffer amplifier 234 25 3 4 Brake controllers 26 3 4 1 VRECA2 hte Rte 26 2412 EOD IAT i 26 4 PARAMETER ADJUSTMENTS 28 4 1 The display 28 4 1 1 Navigation on the control keypad 29 4 1 2 Value line editing sss 30 4 2 Storing and restoring parameters 31 4 2 1 User 31 4 2 2 Default parameters 31 4 2 3 Keypad 31 4 2 4 Factory 8 2 2202224 2201 31 5 PARAMETER DESCRIPTIONS 32 6 FACTORY DEFAULT PARAMETERS 41 6 1 Factory default parameters for 100Hz Meliore EET 41 6 2 Factory default parameters for 120Hz uec M 43 7 SPEED SUPERVISION SETTINGS 45 7 1 Standard 46 7 1 1 Settings for sensor bearing 46 7 1 2 Settings for pulse wheel speed sensor or encoder 24 2 2 0 46 7 2 Functional test run for SSU 47 7 3 Settings for non standard cases 47 8 Multicare Function
36. 28 5100 FAX 937 325 5319 HANDLING INC detection level is 1600Hz 25 S2 1 OFF 2 4 OFF 2000 2 S1 F 53 ESR use If ESR is applied for 150 of 52 2 and S2 3 OFF Check from V4 8 2 that the nominal speed then the full ESR according to normal speed settings detection level is pulse frequency is 1 5 1600Hz 2793 2 2400 2 116 4 of 2400Hz On the table the highest value under ESR speed 3000Hz is 2793Hz Suitable maximum overspeed detection level is 2400Hz 25 Correct switch settings are S2 4 ON 3000Hz and S3 4 Encoder with 600 ppr or over needs both encoder channels connected 48 83 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc Inv 4501 Gateway Boulevard TUTUP Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC 8 Multicare Function Two D2L drives can be operated simultaneously in tandem mode by utilizing the multicare function The two drives are connected together using their analog outputs and analog inputs The analog output of one drive is connected to the analog input of the other drive and vice versa Both drives alter the voltage value of their own analog output signal according to run conditions whenever the multicare mode is selected The table below shows the input receive and output send values during st
37. 4 5 Fault Counter Fault Counter R4 5 1 Fault counter value Fault number e g 12 01 means that F1 overcurrent has occurred 12 times Fault counter will reset by pushing reset button 3 seconds when Fault counter is selected in control panel Total Faults V4 5 2 Total number of all faults 64 7 Digital Input S1 V4 7 1 1 State of digital input S1 0 1 52 V4 7 1 2 State of digital input S2 0 1 ON DIA3 V4 7 1 3 State of digital input DIA3 0 1 DIA4 V4 7 1 4 State of digital input DIA4 0 1 DIA5 V4 7 1 5 State of digital input DIA5 0 1 V4 7 1 6 State of digital input OK 0 1 DID1 V4 7 1 7 State of digital input DID1 1 DID2 V4 7 1 8 State of digital input DID2 0 1 DID3 V4 7 1 9 State of digital input DID3 0 1 DID4 V4 7 1 10 State of digital input DID4 0 1 DID5 V4 7 1 11 State of digital input DID5 0 1 4 7 3 State of board A inputs 51 52 DIA3 DIA4 DIA5 0 1 Corresponding X1 8 9 10 11 12 terminals Extension Board V4 7 4 State of board D inputs DID1 DID2 DID3 DID4 DID5 0 1 Corresponding X1 38 39 40 41 42 terminals G4 8 SSU not used D2T Overspd Lim 1 V4 8 1 Overspeed limit 1 level Percent of Max Freq 52 0 140 96 Overspd Lim 2 V4 8 2 Overspeed limit 2 ESR value Percent of Max Freq S2 0 140 96 G4 9 Phase U Curr V4 9 1 Phase
38. 5 in 0 28 in 467 5 mm 18 41 in D2L 018F 022F Weight 31 kg 68 Ibs F7 K7 1 3 f Urt e gt 4 E 8 E E A1 2 E g 1 1 RENS b Isla d 2 Z3 21 7mm 453 5 mm 17 85 in E S 0 28 iny 467 5 mm 18 41 in 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 R M MATERIALS HANDLING INC D2L 055F Weight 80 kg 176 Ibs D2L 030F 045F Weight 47 kg 102 Ibs 6 A Z2 G1 3 55555 M 7 8 a 4 8 8 5 78 1 6 8 SEES 0 9 4 37 zz 8 3 8 1 1 8 B 22 23 E 71 6 E ff NA MNT 130 7 453 5 17 85 9 0 28 in NN 467 5 mm 18 41 in 1 F7 F71 K7 G1 K71 E e E c 8 oe 7 1 X1 gelee 0 0 oF 7mm 453 5 mm 17 85 in 58 02 467 5 mm 18 41
39. 6 10 22 D2V015NF1e000 32 48 20 44 D2V018NF1e000 42 63 20 44 D2V022NF1e000 48 72 20 44 D2V030NF1e000 60 90 37 82 D2V037NF 16000 75 113 37 82 D2V045NF 16000 90 135 37 82 D2V055NF 16000 110 165 61 135 e defines emission level 0 EMC level 0 N EMC level N S The main circuit diagram of D2V002 D2V005 BR B B UN ZX ZN L1 L2 O I TTA A A 17 83 BRK D UH_D uic ULD VLG VHD 1054 OU T1 2 1 0 WIT3 The main circuit diagram DC of D2V007 D2V055 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc Inv 4501 Gateway Boulevard TUTUP Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC BR DC AAA CIS LO UH D D WHD Ho 1 1 4 o UTI 4 4 o VTR Tis ttt 4 4 4 o BRK_G BRK D ULD wp DC 3 1 1 Power supply unit PSU Power supply unit PSU includes the main circuit components PSU has connectors for supply cables motor cables and braking resistor cables PSU also includes a D connector for CSU conn
40. 7 328 5100 FAX 937 325 5319 F 26 Power Unit Fault F 32 Fan cooling fault Cooling fan of the frequency converter do not work If the fault comes again contact authorized service when ON command has been given F 35 Application fault Run time exception in the application program Contact authorized service F 36 Control Unit Faulty Control Unit Contact authorized service F 37 Device changed Option board changed Reset the fault F 38 Device added Option board added Reset the fault F 39 Device removed Option board removed Reset the fault F 40 Device unknown Unknown option board or drive Check board and drive type F 41 IGBT tempetature Too high temperature in IGBT transistors Reset switch power off and restart after the lamps long duration overload of keypad are off Check lowered cooling motor parameters high environment temperature u f curve settings motor loading brake operation inverter heatsink inverter cooling fan operation environment temperature F 51 Stop limit Stop limit has tripped Reset keep controller at zero gt 300ms Ensure that fault disappears after leaving the stop limit F 55 Board Fault Some of following board is missing Reset switch power off and restart after the lamps A Basic I O board of keypad are off B Thermistor board Check D Expansion board board slots A B and D drive selection control mode F 56 Generator sid
41. 9 9 3 Motor Nom Curr 11 Motor Nom Curr 19 2 2 5 Nom Flux Curr 32 Nom Flux Curr 6 2 Nom Flux Curr 6 3 Nom Flux Curr 12 P 2 2 6 Start Current 5 8 Start Current 10 Start Current Start Current 18 P 2 2 7 Current Limit 10 Current Limit 15 Current Limit 16 Current Limit 27 P 2 2 8 Min Freq 51 10 Min Freq S1 10 Min Freq 51 10 Min Freq S1 10 P 2 2 9 Min Freq 52 5 Min Freq S2 5 Min Freq S2 5 Min Freq S2 5 P 2 2 10 Max Freq S1 Max Freq 51 Max Freq S1 Max Freq 51 2 2 11 Max Freq 52 Max Freq 52 Max Freq 52 Max Freq 52 2 2 12 Max ESR Freq Max ESR Freq Max ESR Freq Max ESR Freq P 2 2 13 Drive Selection Drive Selection Drive Selection Drive Selection 2 2 14 Pulse Number Pulse Number Pulse Number Pulse Number P 2 2 15 Zero Freq Volt Zero Freq Volt Zero Freq Volt Zero Freq Volt P 2 2 16 U f Mid Volt U f Mid Volt U f Mid Volt U f Mid Volt P 2 2 17 U f Mid Freq U f Mid Freq U f Mid Freq U f Mid Freq P 2 2 18 Torque Boost Torque Boost Torque Boost Torque Boost P 2 2 19 Rs Voltage Drop Rs Voltage Drop Rs Voltage Drop 190 Rs Voltage Drop P 2 2 20 Stop Function
42. Angle S2 2 3 17 Flux Curr Damp Flux Curr Damp Flux Curr Damp Flux Curr Damp 2 3 18 Stop DC Freq Stop DC Freq Stop DC Freq Stop DC Freq P 2 3 19 Start Freq S1 Start Freq 51 Start Freq S1 Start Freq 51 P 2 3 20 Start Freq S2 Start Freq 52 Start Freq S2 Start Freq 52 P 2 3 21 Brake Stop Freq Brake Stop Freq Brake Stop Freq Brake Stop Freq P 2 3 22 ESR Point Freq ESR Point Freq ESR Point Freq ESR Point Freq 2 3 23 ESR Point Volt ESR Point Volt ESR Point Volt ESR Point Volt P 2 3 24 IrAdd Motor IrAdd Motor IrAdd Motor IrAdd Motor P 2 3 25 IrAdd Generator IrAdd Generator IrAdd Generator IrAdd Generator P 2 3 26 Ramp Stretching Ramp Stretching Ramp Stretching Ramp Stretching 2 3 27 Switching Freq Switching Freq Switching Freq Switching Freq P 2 3 28 DeadTime Comp DeadTime Comp DeadTime Comp DeadTime Comp P 2 3 29 DeadTimeCurrLim DeadTimeCurrLim DeadTimeCurrLim DeadTimeCurrLim P 2 3 30 Brake Chopper Brake Chopper Brake Chopper Brake Chopper P 2 3 31 41 83 Autotuning Autotuning R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice Autotuning Autotuning R amp M Mat
43. E7 52296542 48 1 CO1F7 52296548 115 1 LC1 D09P7 52296643 230VAC 1 RC filter LA4 DA1E 52275256 42 48VAC 1 LA4 DA1U 52275257 115 230VAC 1 Auxliary contact LAD 8N20 52297562 1 LAD NO4 52297548 1 COMPONENTS FOR EMC LEVEL N CM1 Y capacitor KC 307 00 52298693 42VAC tl aa te EET RS ERECTAE eu Z1 Ferrite RU2100 30 7 52299351 Emissionlevel N 1 1 1 1 1 1 22 RH175285107 52297604 23 RH175285107 52297604 71 EF32010 52299352 21212 22 W74270096 52299353 23 W7427015 52299354 ZR S 112 21 2010 52299352 2 W7427015 52299354 Ciil 23 W742701111 52300355 22 W7427015 52299354 2 23 W7427015 52299354 63 83 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R M MATERIALS HANDLING INC 4501 Gateway Boulevard Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 14 DRAWINGS 14 1 Description of terminals 14 1 1 Power classes 002F 011F R amp M Materials Handling In Name Description signal level pp L1 L1 Power supply phase 1 L2 L2 Power supply phase 2
44. English 1 3 2005 SERVICE MANUAL FOR FREQUENCY CONTROL SYSTEM Control Master Plus Hoisting RM MATERIALS HANDLING INC R M MATERIALS HANDLING INC R amp M Materials Handling Inc 4501 Gateway Boulevard Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 v Read the instructions supplied with the product before installation and commissioning Keep the instructions in safe place for future reference Table of content T GENERAL rece dele 5 1 1 Technical 5 1 2 Type mark 6 1 3 Basic description 6 1 4 Main 7 1 5 Functional description 8 1 6 Control 9 1 7 Description of the control methods 10 1 7 1 2 dehet 10 1 7 2 gt Lure 10 1 7 3 4 0 10 1 8 Mechanical brake control 11 TOS EM aie ht tarts selec quis 11 2 INSTALLATION eee enne 13 2 1 Cubicles et tos 13 2 2 Braking resistor ones 13 2 9 Power cablingn sse nd ect retten 13 2 3 1 Shielded motor 13 2 3 2 Double Collector
45. L3 L3 Power supply phase 3 B B Braking resistor R R Braking resistor U T1 U T1 Motor output phase 1 V T2 V T2 Motor output phase 2 W T3 W T3 Motor output phase 3 No Description signal level No Description signal level 1 BL1 AC brake supply phase 1 1 BD1 DC brake supply 1 2 BL2 AC brake supply phase 2 32 BD2 DC brake supply 2 3 BL3 AC brake supply phase 3 33 Ti Thermistor input 4 T12 Reserved for thermistors connections 34 T2 Thermistor input 5 OLE External control voltage 42 48 115 230Vac 35 ONE Neutral of external control voltage OLE 6 OLE External control voltage 42 48 115 230Vac 36 ONE Neutral of external control voltage OLE 7 RDY Stop with brake 37 ES External Stop 8 S1 Direction 1 run command 38 DID1 Free input 9 52 Direction 2 run command 39 DID2 S11 Slowdown signal direction 1 10 DIA3 Accelerate speed 2 40 DID3 S21 Slowdown signal direction 2 11 DIA4 Not used hold speed 3 41 DIDA S12 Stop limit signal direction 1 12 DIA5 Not used speed 4 42 DID5 S22 Stop limit signal direction 2 13 43 14 44 15 K7 A1 Coil of brake contactor K7 45 ROB1 21 Not used 16 ROB1 22 Not used 46 ROB1 23 Not used 17 ROD1 28 Free NO contact of relay ROD1 47 ROD1 29 NO contact of relay ROD1 18 K7 153 NO contact of K7 48 7 154 Free NO contact of K7 19 K7 163 NO contact of K7 49 7 164 Free NO contact of K1 20 K71 13 NO contact of K71 50 K71 14 Free NO cont
46. N e HE 24V 1002 OUT 4 S1 m 8 WHITE wumE 5 2 ws NT ozo osla 79 BLACK GREEN ov 52 EA 30 04 7008 Buffer amplifier pulse output can be measured 24Vt 1V during driving The picture beside presents the pulse output 0x 1V 25 83 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc Inv 4501 Gateway Boulevard TUTUP Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 INC 3 4 Brake controllers 3 4 4 REC12 Brake control unit REC 12 is a line voltage half wave rectifier for DC brakes Voltage range 200 690Vac AC Line Voltage Output voltage Upc Half wave 0 45 x Uac Maximum current 1 25Adc K7 K7 L2 In addition the brake contactor shorts terminals a and b thus making the DC circuit To close the brake the brake contactor disconnects the supply to terminals L1 and L2 The released brake contactor also opens the brake coil DC circuit which speeds closing of the brake The purpose of the varistor there is overvoltage protection for K7 contacts and the brake coil 3 4 2 ESD141 Brake control unit ESD141 is a line voltage full half wave rectifier for DC brakes Voltage range 200 690Vac Voltage Output voltage Upc Full wave 0 90 x Unc Half wave 0 45 x Uac Maximum current 1 25Adc
47. OR HOISTING INVERTER reich 62 22 540 64 14 1 Description of terminals 64 14 1 1 Power classes 002F O11F 64 14 1 2 Power classes 015F 055F 65 14 2 Layouts dimensions and weights 66 14 3 Circuit diagrams eoo race t dcs 67 14 3 1 Internal 665 22 2 2 67 14 3 2 Wiring eei ierit tired 68 14 4 Circuit diagrams for braking resistors 77 14 4 1 Internal 665 2222 2 77 14 5 Standard connections for pulse sensors 82 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc Inv 4501 Gateway Boulevard TUTUP Springfield Ohio 45502 HANDLING INC SESEEES SESE 4 4 83 937 328 5100 FAX 937 325 5319 This manual rev 4 0 is for D2L rev 5 1 with software Ind2V070 Before starting read the instructions carefully Verify all of the connections are in accordance to the drawings Verify the motor supply is connected correctly faulty connection will destroy the inverter Check the device cover is properly installed High voltages are present in this device Switch the power off and after the display turns off wait 5 minutes before opening the cover Insulation resistance test with a megger requi
48. P 937 328 5100 HANDLING exi FAX 937 325 5319 INC D2L B 1 23 Aint X1 26 Aout X1 25 Ain X1 27 OV 8 2 Setup Verify the connection of analog inputs and outputs and cable shield grounding both ends Enable the multicare function in both drives parameter Analog Input Sel P2 1 5 Multicare Verify parameters P2 1 6 P2 1 10 and P2 2 8 P2 2 12 are the same for both drives Activate pushbutton Test Voltage B2 1 12 2 On in both drives this produces a test voltage of 9 V analog output for calibrating the maximum value of speed correction Read Ain Value V2 1 12 3 and use this value about 9 V for speed correction calibratation set Max Value Volt P2 1 12 5 both drives equal to received Ain Value this value is likely the same for both drives Activate pushbutton Test Voltage Min B2 1 12 1 On in both drives this produces a test voltage of 1 V analog output for calibrating the minimum value of speed correction Read Ain Value V2 1 12 3 again and use this value about 1V for speed correction calibration set Min Value Volt V2 1 12 4 both drives equal to received Ain Value this value again is likely the same for both drives Reset both programmable pushbuttons B2 1 12 1 Off and B2 1 12 2 Off both drives Check Value V2 1 12 3 is back at 0 V 8 3 Test run without load Display monitoring parameter Frequency referenc
49. SSU board is damaged or SSU relay is Reset switch power off and restart after the lamps 56 83 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc Inv 4501 Gateway Boulevard Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 MATERIALS HANDLING INC Fault bypassed of keypad are off Check ES and RDY external connections OK input operation change SSU board F 65 SSU Watchdog SSU internal fault Reset switch power off and restart after the lamps interference fault between SSU board and of display are off control board Check component failure control board or SSU board SSU status System menu System info Expander boards 550 status SSU LED s If the fault comes again contact service F 66 SSU Overspeed SSU overspeed limit has been set over 14096 of Check Limit maximum frequency set SSU overspeed limit under 14096 of maximum frequency motor type plate parameters maximum frequency parameters F 70 Multicare Fault Other D2L has tripped to fault or brake of other D2L Check other hoisting inverter has not been opened Fault is not stored into fault fault history history brake operation F 71 Brake Control Fault Load information from hoist control unit is out of Check operation window Ain2 wiring settings of load measuring device 10 3 1 Fault time data record When fault
50. STMENTS 4 1 The display panel V 4 18 22 Motor Speed 2002 rpm The display panel is used for Displaying the drive identification electrical values operating or fault parameters Altering the parameter settings Saving and restoring the parameter settings in the memory of the display panel Meaning of the displays Motor is running blinks when ramping down Direction of motor rotation STOP Motor is not running Power is on In case of a trip the symbol will not light up Drive is running outside of certain limit FAULT 4 Fault is on dm l O terminals are the selected control place Keypad is the selected control place The signalling LED s ready Power is on run Motor is running blinks when ramping down fault Fault trip Button description Reset active faults Switch between two latest displays 2 N Confirmation of selections Kenter Fault history reset Browse the main menu and the pages of submenus 9 45 Edit values Move in menu C 4 Move cursor Enter and exit edit mode 28 83 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc Inv 4501 Gateway Boulevard TUTUP Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC Start button Starts m
51. U V V W W U PHASE TO PHASE VAC VAC VAC Q Q VOLTAGE L1 L2 L3 PHASE TO GROUND VAC VAC VAC MEASURED CONTROL VOLTAGE V 60 83 Inv 4501 Gateway Boulevard Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 MATERIALS HANDLING INC 12 SERVICE R amp M Materials Handling Inc Inverter does not require regular maintenance The following actions are recommended Check inverter fault history Find out reasons of possible faults Clear the fault history Clean the heat sink of the inverter Prevent the dust to spread inside cubicles Lock the fans before blowing compressed air Check that there are no abnormal noises coming from the cooling fans Tighten all screws and connectors Clean dust from PC boards Check the speed supervision circuit only in hoisting inverter See chapter Functional test run for SSU 61 83 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc Inv 4501 Gateway Boulevard TUTUP Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC 13 SPARE PARTS LIST FOR HOISTING INVERTER Inverter D2V includes boards for slots A B and D but does not include SSU speed supervision unit for slot C
52. U current of inverter output A Phase V Curr V4 9 2 Phase V current of inverter output A Phase W Curr V4 9 3 Phase W current of inverter output A Encoder Speed V4 9 4 Pulse frequency from pulse sensor Hz HeatSinkTempMax v4 9 5 Recorded heatsink temperature highest peak value during run HeatSinkTempMin V4 9 6 Recorded heatsink temperature lowest peak value when power is connected to drive IGBT Temp Max V4 9 7 Recorded calculated IGBT temperature highest peak value IGBT Temperature V4 9 8 Actual IGBT temperature C SlipAdjustChange V4 9 9 Slip adjust difference compared to Slip adjust parameter G4 10 Max Current Max Current V4 9 10 1 Recorded maximum current A 36 83 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R M MATERIALS HANDLING INC R amp M Materials Handling Inc 4501 Gateway Boulevard Springfield Ohio 45502 937 328 5100 FAX 937 325 5319 Max Current Freq V4 9 10 2 Frequency at recorded maximum current Hz Max Current Torq V4 9 10 3 Torque at recorded maximum current Freq Ref V411 Frequency reference Hz Speed Req V4 12 Not used Distance counter V4 13 Not used m DC Link Voltage V4 14 Actual value of measured DC link voltage V Heat Sin
53. act of K71 21 PUR Not used 51 EA Encoder channel A 22 15V Not used 52 EA Encoder channel A 23 1 Multicare speed reference input 0 10V 53 Encoder channel B 24 AIN2 Not used 54 EB Encoder channel B 25 AIN Common for analog inputs 55 24V 24V output for encoder 26 AOUT Multicare speed reference output 0 10V 56 0v Common for encoder supply 27 OV Common for analog output 57 24V External supply for Control module BUSES 64 83 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc Inv 4501 Gateway Boulevard eB Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC 14 1 2 Power classes 015F 055F Description signal level 91 L11 Auxiliary power supply phase 1 92 L12 Auxiliary power supply phase 2 93 L13 Auxiliary power supply phase 3 No Name_ Description signal level No Description signal level 1 BL1 AC brake supply phase 1 31 BD1 DC brake supply 1 2 BL2 AC brake supply phase 2 32 BD2 DC brake supply 2 3 BL3 AC brake supply phase 3 33 t1 Thermistor input 4 712 Reserved for thermistors connections 34 T2 Thermistor input 5 OLE External control voltage 42 48 115 230Vac 35 ONE Neutral of externa
54. amp 2 0 100 96 to direction S2 Must not be changed Used in hoisting application Not used in traveling application D2T Freq 0 P2 3 4 Constant current mode frequency limit in percentage of nominal 0 100 96 frequency Between 0 Hz and Freq 0 current control keeps motor current in value of P2 3 12 Zero Speed Current Not used in traveling application D2T Freq 1 P2 3 5 Flux current mode frequency limit in percentage of nominal 0 100 96 frequency Between frequencies Freq 1 and Freq 2 drive is controlled with special flux current control method Not used in traveling application D2T Freq 2 S1 P2 3 6 Mixed current voltage mode frequency limit in percentage of nominal 0 100 frequency in direction S1 Must not be changed Not used in traveling application D2T Freq 3 S1 P2 3 7 U f control mode frequency limit in percentage of nominal frequency 0 100 96 in direction S1 Must not be changed Not used in traveling application D2T Zero Flux Curr P2 3 8 Relative value of flux current of motor Typical value of this current 0 100 control method is 80 96 Parameter is not related to motor real physical values Must not be changed Not used in traveling application D2T Stray Flux Curr P2 3 9 Relative value of stray flux current of motor Typical value of this 0 100 current control method is 40 96 Parameter is not related to motor real physical values Must not be changed Not used in traveling applicat
55. art acceleration stopping and in fault situation The multicare function is selected with an input parameter P2 1 5 In case of multicare fault a dedicated fault code F70 is issued If the operation of one drive is interrupted or the drive faults out for example upper limit fault the other drive will stop and show multicare fault F70 Programmable pushbuttons are used for multicare testing The multicare function is mainly designed for EP mode speed correction possible but it can also be used in MS multistep mode for run stop supervision without speed correction Ain1 Input function Aout Output function value receive value send 0 0 2V Single drive selected Multicare OV Direction signals S1 and S2 not function not used active in multicare mode 0 3 0 7 V Brake open acknowledged 0 5V Brake open acceleration not acceleration not allowed allowed 0 8 1 0 V Acceleration allowed 1 0V Acceleration allowed 1 9V Speed correction range 1 9 V Speed correction range 9v Acceleration acknowledged 9V Accelerating gt 9 5 V Fault acknowledged Immediate 10 V Fault Immediate brake stop brake stop F70 fault code issued The multicare function controls and monitors the following situations in multicare mode Both drives start nearly simultaneously the other drive has 0 5 seconds to respond and begin to accelerate at the same time once both brakes are opened Both
56. aterials Handling Inc 4501 Gateway Boulevard Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 D2L 002F 005F L1 D 4 djs K7 2 4 K7 6 8 L1 L2 ac 8 5 7 p b DC 61 j D 24132 1 OLE 52 DIA3 DIA4 DIAS DID2 DID3 DID4 DIDS ES A WITH MULTICARE 1 GN 23 25 Z1 X1 121 22 1 23 1 24 27 157 ONE 511 521 512 522 ONE gt ESL P a N D2HRO4FOOROS4 2 B 90 ohm 2 9 O Z3 A U CM1 1 Z1 Z2 Z3 AND CM1 NOT INCLUDED IN STANDARD OR IT MODELS 1 234 51 4 152 153 154 155 156 2 1 18 48 453 154 x1 19 49 163 164 69 83 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R M MATERIALS HANDLING INC R amp M Materials Handling Inc 4501 Gateway Boulevard Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 D2FROGF64ROS2 PETI I 5 64 ohm we Pd L2 L1 U E oci oa V O F7 1 3 5 tE 21 22 23 AND CM1 NOT diui 1 INCLUDED IN STANDARD OR 24 6 gZ H p IT MODELS d 27 D 2A 34 123 2 4 2123 6 8 L1 12
57. c 4501 Gateway Boulevard Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 R M MATERIALS HANDLING INC D2L011 D2L015 D2L018 T5 MF11MB200 460V 120Hz T6 MF13Z 200 460V 120Hz T7 MF13ZA200 460V 120 2 Label Code Default Label Code Default Label Code Default G 2 1 General Parameters G 2 1 General Parameters G 2 1 General Parameters P 2 1 10 Accel Time 1 2 5 Accel Time 1 2 5 P 2 1 10 Accel Time 1 2 5 2 1 11 Decel Time 1 2 5 Decel Time 1 2 5 Decel Time 1 2 5 G 2 2 Motoi r Parameters r Parameters r Parameters P 2 2 1 Motor Nom Volt 460 Motor Nom Volt 460 Motor Nom Volt 460 P 2 2 2 Motor Nom Freq 120 Motor Nom Freq 120 Motor Nom Freq 120 2 2 3 Motor Nom Speed 3410 Motor Nom Speed 3500 Motor Nom Speed 3480 2 2 4 Motor Nom Curr 22 Motor Nom Curr 31 Motor Nom Curr 37 P 2 2 5 Nom Flux Curr 12 Nom Flux Curr 15 Nom Flux Curr 15 P 2 2 6 Start Current 24 Start Current 32 Start Current 42 P 2 2 7 Current Limit 31 Current Limit 46 Current Limit 54 P 2 2 8 Min Freq 51 10 Min Freq S1 10 Min Freq 51 10 P 2 2 9 Min Freq 52 5 Min Freq S2 5 Min Freq S2 5 P 2
58. ce R M MATERIALS HANDLING INC R amp M Materials Handling Inc 4501 Gateway Boulevard Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 14 2 Layouts dimensions and weights 66 83 358 mm 14 09 in 580 mm 22 84 in 346 mm 13 62 in 6 _ 166 mm 6 53 in _ 212 mm 8 35 in 0 24 in 188mm 740in _ 0 31 in D2L 002F 005F Weight 12 kg 27 Ibs K7 G1 M Z1 CMT 1 Ia px nn 1l wd Z2 Z3 18 mm 414 16 30 0 71 450 mm 17 72 in D2L 015 Weight 29 kg 64 Ibs F7 K7 G1 Ur A1 CM1 4 NET da 22 Z3 21 7 mm 453 5 mm 17 85 in 0 28 in 467 5 18 41 D2L 007F 011F Weight 19 kg 42 Ibs 8 F7 K7 G1 38 A1 1 8 E E g N wo 71 1 aes M acd H X1 E L 7mm 453 5 mm 17 8
59. ce Reconnect the disconnected signal wire to terminal X1 51 Set rotary switch 51 53 value 2 steps smaller Drive with maximum speed The motion must stop after full speed is reached Set rotary switch 51 53 back to original value 600 6467Hz 1200 12935Hz 9600 70722Hz 324 350 S1 Normal 378 408 441 Tripping level 476 selection 514 555 S2 ESR 599 647 698 755 815 880 ESR Range selection 951 TIMID O 52 1 together with 51 are used for setting the tripping frequency level at normal speed 52 4 together with S3 are used for setting the tripping frequency level at ESR speed If ESR is not used set S2 4 S3 equal to S2 1 and S1 Pulse frequency can be calculated from formula Motor rpm x Pulses per rev 60 Example Normal use A 3000 rpm motor with 32 pulses per On the table the highest value under Check from V4 8 1 that the revolution has a full speed pulse 2000Hz is 1902Hz Suitable switch detection level is frequency of 1600 Hz settings are 1902Hz 1600Hz 118 9 of nominal speed Suitable maximum overspeed 52 2 and S2 3 OFF 47 83 R amp M Materials Handling Inc reserves the right to alter or amend the above information without ice R amp M Materials Handling Inc Inv 4501 Gateway Boulevard TUTUP Springfield Ohio 45502 P 937 3
60. continuous and 2 5Adc at 5 xA Set 0 3s 26 83 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc Inv 4501 Gateway Boulevard ew Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC When the brake is opened the brake contactor K7 connects two phases of mains voltage to terminals 1 2 and 3 which makes the device a full wave rectifier The full wave mode is used to get the brake open fast In addition the brake contactor shorts terminals 4 and 5 thus making the DC circuit After a time delay normally 0 3s the delayed contact of the brake contactor opens which disconnects the supply from terminal 3 and the rectifier changes to a half wave type Half wave operation prevents heating of the brake coil and is enough to keep the brake open To close the brake the brake contactor disconnects the supply to terminals 1 and 2 The released brake contactor also opens the brake coil DC circuit which speeds closing of the brake The purpose of the varistor there is overvoltage protection for K7 contacts and the brake coil 27 83 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc Inv 4501 Gateway Boulevard TUTUP Springfield Ohio 45502 P 937 328 5100 HANDLING i mv 937 325 5319 4 PARAMETER ADJU
61. ction 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 MCCBs If there are no other regulations the values given in this section can be used to dimension fuses three phase 400V supply 60 63 50 16 6 10 8 The overload protection of inverter protects both the supply and the motor cables The fuses of the supply provide the short circuit protection 2 3 5 Cable length The maximum motor cable lengths in the preceding table are based on 150 of inverter rated current current during acceleration and a 2 5 96 voltage drop in the cable For longer cables the required conductor cross sectional area A mm2 is given by formula l 15 x Ip 2 43 where is the cable length m le is the motor current at shaft power Pe 14 83 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc Inv 4501 Gateway Boulevard Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 MATERIALS HANDLING INC p is the allowed voltage drop in U is the nominal motor voltage 2 3 6 Du dt filters If D2L is not mounted on the crane there has to be du dt filter at motor supply Also if total motor cable length sum of motor cab
62. cuit breaker Electronic supervision for the braking chopper and for the braking resistor Provided by electronic circuitry Independent measurement using sensor bearing pulse wheel or encoder 10 C 55 C 14 F 131 F for ED lt 60 40 C 60 C 31 F 140 F dry lt 95 RH no condensation Maximum 1000m at In Above 1000m In reduces 1 per each 100m Above 3000m consult factory Operation maximum displacement amplitude 3mm at 2 9Hz Maximum acceleration amplitude 0 5g 5m s at 9 200Hz Conforms to LV and EMC directives R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R M MATERIALS 4501 Gateway Boulevard Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC 1 2 mark coding R amp M Materials Handling Inc D2L can be summarized as a crane hoisting motor control system which controls the speed by changing the frequency of supply voltage of a squirrel cage motor A stepless speed adjustment can be achieved by this method Type marking is shown below D2L 007 F V 51 A 0 D2L Device name 007 Power rating class 002 055 F Supply voltage F 380 500VAC 50 60Hz V Control voltage Y 42VAC 50 60Hz P 48VAC 50 60Hz T 115VAC 50 60Hz V 230VAC 50 60Hz 51 Revision code The latest revision may differ External resistor 0 Moun
63. d User Par B4 1 3 Restores User Parameters to Active Parameters from the control unit memory User Parameters are the parameters which have been saved after start up G4 1 4 Factory Default Save Default Par B4 1 4 1 Saves Active Parameters in the Control Unit as Default Parameters Default Parameters are the parameters which must be saved in the factory For factory use only G4 2 Analog I O Ain1 Value V4 2 1 Value of analog input 1 0 10V Ain2 Value V4 2 2 Value of analog input Ain2 0 10V Aout1 Value V4 2 3 Value of analog output Aout1 0 20 mA Aout2 Value V4 2 4 Value of analog output Aout2 0 10V G4 3 Relay output State V4 3 1 State of relay output ROB1 0 1 ROB2 State K7 V4 3 2 State of relay output ROB2 K7 0 1 ROC1 State V4 3 3 State of relay output ROC1 0 1 35 83 R amp M Materials Handling Inc Inv 4501 Gateway Boulevard Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC ROD1 State V4 3 4 State of relay output ROD1 0 1 State V4 3 5 State of relay output ROE1 0 1 ROE2 State V4 3 6 State of relay output ROE2 0 1 State V4 3 7 State of relay output ROE3 0 1 G4 4 Operate counters Not used G
64. d operation days d T2 Counted operation hours hh mm ss T 3 Output frequency Hz 4 Motor current A T 5 Motor voltage V T 6 Motor power 96 T 7 Motor torque 96 T 8 DC voltage V T 9 Unit temperature C T 10 Ready O Not Ready 1 Ready Run O Not Running 1 Run T 11 Direction 0 1 Fault O No 1 Yes 39 83 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc Inv 4501 Gateway Boulevard TUTUP Springfield Ohio 45502 P 937 328 5100 HANDLING ONG FAX 937 325 5319 T 12 Warning 0 1 At reference O No 1 T 13 0 0 Zero Speed 1 2 Speed 8 Fault history The fault memory can store a maximum of 30 faults in the order of appearance The number of faults currently in the fault history is shown on the value line of the main page The order of the faults is indicated by the location indication in the upper left corner of the display The latest fault carries the indication F8 1 the second latest F8 2 etc The Fault time data record pages are accessible at each fault If there are 30 uncleared faults in the memory the next occurring fault will erase the oldest from the memory Pressing the Enter button for about 2 to 3 seconds resets the whole fault history 40 83 R amp M Materials Handling Inc reserves the right to alter or amend the abo
65. diagrams are in appendix D2L Resistance ohm Type 002 005 90 D2HROA4F90R0S4 007 64 D2FROGF64R0S2 011 015 45 D2FR12F45R2S2 018 022 21 D2FR18F21R3S2 030 16 D2FR24F16R4S2 037 045 11 2 x D2RF18F21R3S2 055 8 2 x D2FR24F 16RA4S2 In case of 2 resistor units power supply to transformers has to be taken from the same phases 2 3 Power cabling 2 31 Shielded motor cable In crane application inverter fulfils EN61800 3 A11 IEC 1800 3 second environment radiated emission requirements without shielded motor cable In the second environment shielded motor cable is recommended to use in fixed installations especially in buildings However motor cables in crane and festoon power supplies are normally not shielded due to the practical reasons Shielded motor cable is essential to use if installation is requested to fulfil the first environment emission requirements 2 3 2 Double collectors If the power is supplied to the crane via conductor rails double collectors are needed This ensures a reliable contact with the rail in all circumstances Short interruptions and sparks between the conductor rail and the collector may cause nuisance tripping other undesired operations and in worst case even permanent damage to components 13 83 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc Inv 4501 Gateway Bouleva
66. e V4 9 on both drives In EP mode accelerate the hoist up and down to any speed between the minimum speed and maximum speed and verify both drives display the same frequency reference 0 25 Hz when constant speed is reached Lower the frequency value of Max Freq S1 P2 2 10 of one drive temporarily about 20 Hz run in up direction and verify the faster hoist will slow down after accelerating Again check that both drives display the same frequency reference Return Max Freq S1 back to its original value Run both hoists up in tandem mode and stop one hoist by disconnecting the voltage from its upper stop limit terminal X1 41 the other hoist must stop and display Multicare Fault F70 Reconnect the voltage back to terminal X1 41 Repeat the same test with the other hoist Check both hoists operate normally in tandem mode and single mode when reaching the slow down and end stop limit in both directions 50 83 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc Inv 4501 Gateway Boulevard TUTUP Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC 9 START UP PROCEDURE 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 v Warning High voltages inside device Wait for at
67. e Too short deceleration time Reset has an additional 5 s time delay current limit generator side current limit Check deceleration time F 57 Thermistor fault Thermistor input in relay thermistor board has Check detected motor overtemperature Fault appears motor cooling and loading when thermistor input has been open over 15 thermistor connection If expansion board thermistor input is not used it should be shorted motor parameters the brake operation F 60 Parameter fault Inverter has lost parameters Drive selection Download parameters from keypad parameter has changed to 0 none F 61 Overspeed Fault SSU has tripped to Overspeed hardware Reset when 1s without pulses from pulse supervision Motor speed has increased above sensor encoder to SSU and controller at zero overspeed detection level position Check function and cabling maximum frequency setting parameters SSU settings F 62 Speed Difference SSU has tripped to Speed Difference Reset when 1s without pulses from pulse Fault sensor encoder to SSU and controller at zero position Check pulse sensor encoder function and cabling pulse sensor encoder pulse number speed difference supervision settings F 63 Stall Supervision SSU has tripped to Stall Reset when 15 without pulses from pulse Fault sensor encoder to SSU and controller at zero position Check brake operation pulse sensor encoder function and cabling stall supervision settings F 64 SSU Relay Test Relay in
68. e above information without notice Checking Check motor load if no overload exists then check motor temperature model parameters Check reference cable reference source Check controller Check Overweight limit value Check Slack cable limit value R amp M Materials Handling Inc 4501 Gateway Boulevard Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 R M MATERIALS HANDLING INC 11 INVERTER TROUBLESHOOTING TABLE If inverter doesn t work but any fault doesn t found write down the following information before contacting to the supplier R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice GENERAL INFORMATION WORK NUMBER CUSTOMER REFERENCE DATE PUT IN OPERATION DATE OF FAILURE SHORT DESCRIPTION OF FAILURE ERROR CODE INVERTER INFORMATION TYPE CODE ACCELERATION SERIALNUMBER DECELERATION S TIME CONTROL METHOD MIN SPEED Hz EP2 MAX SPEED Hz EP3 MS MOTOR INFORMATION TYPE CODE NOMINAL VOLTAGE S SERIALNUMBER NOMINAL CURRENT S U F CURVE NOMINAL Travelling inverter FREQUENCY Zero freq volt NOMINAL SPEED U f Mid volt POWER FACTOR U f Mid freq Hz PULSE SENSOR PULSE REV Hoisting inverter MEASURED VALUES INVERTER MOTOR VOLTAGE L1 L2 L1 L3 L2 L3 NOMINAL CURRENT
69. ection Main supply voltage terminals L1 Mains L1 L2 Mains L2 L3 Mains L3 PE Protective earth DC bus terminals B DC bus negative B DC bus positive Brake resistor positive R Brake resistor negative Motor output voltage terminals U T1 Motor U V T2 Motor V W T3 Motor W 18 83 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc Inv 4501 Gateway Boulevard eB Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC 3 1 2 Control unit CSU Control unit CSU includes a control board with five board slots for option boards and a control keypad for parameter adjustments CSU is connected to PSU through a D connector Yellow Red Status pum blinking blinking Everything is OK ee 0 5Hz 0 5Hz IEC Application Scheduler is running and Application is running blinking blinking IEC Application Scheduler is running 0 25Hz 0 5Hz and Application is NOT running OFF blinking IEC Application Scheduler and 0 5Hz Application are NOT running RED Status ON PSU ready OFF PSU not ready A B C D E 19 83 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc Inv 450
70. ed accuracy Extended speed range Braking torque Protections Stall prevention Motor overload protection Overload protection Undervoltage blown fuse Overvoltage protection Momentary power loss Inverter overtemperature Mechanical brake Braking transistor Ground fault Overspeed stall Speed difference supervision Ambient conditions Ambient temperature Storage temperature Humidity Altitude Vibration 5 83 002F 004 005F 007 011 015 018F 022F 030F 037 045 055 4 5 5 5 7 9 13 17 22 29 33 40 50 60 75 6 5 8 10 13 18 24 32 42 48 60 75 90 110 10 12 15 20 27 36 48 63 72 90 113 135 165 1 5 x In 1min 10min Equal to supply voltage 380 500VAC 1096 50 60Hz 5 51 S2 DIA3 DIA4 DIAS DID1 DID2 0103 DID4 0105 42 240VAC 15mA and 0 24V floating differential inputs Open loop vector control 0 250Hz Motor potentiometer or 2 4 step controller Slowdown and stop limit inputs for both directions Sn 100 Sn motor nominal slip 196 of nominal speed at speed range 10 10096 1 3 of motor nominal slip at speed below 1096 100 200 150 During acceleration and constant speed Thermistor based temperature measurement Fault is detected if the current momentarily exceeds 280 of rated current Fault is detected if DC voltage drops below 333V Fault is detected if DC voltage exceeds 911V Immediate fault stop Temperature sensor on the heat sink Cir
71. ept as long as possible The distance between the resistor cables should be kept as low as possible to prevent the antenna behavior Cable lengths should be kept as short as possible to minimize coupling capacitances and inductances 2 5 3 Shielded control cables Shielded control cables should be grounded in both ends The shield must be connected to the ground using the largest possible surface area Extra intermediary terminators cutting the shield are not allowed the shield should be as integrity as possible Spare conductors should be grounded in the both ends All shielded cable shields should be 360 grounded 16 83 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R M MATERIALS HANDLING INC R amp M Materials Handling Inc 4501 Gateway Boulevard Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 3 COMPONENTS 3 1 Inverter Inverter D2V includes Power supply unit PSU and Control unit CSU which are separate parts PSU includes supply brake resistor and motor connections IGBTs are placed to PSU Microprocessors and ASIC are placed to CSU Same CSU can be used in every power class 1 Weight Weight D2V In Imax kg Ibs D2V002NF 1e000 6 5 10 6 13 2 003 1 000 8 12 6 13 2 004 1 000 10 15 6 13 D2VO05NF 1e000 13 20 6 13 D2V007NF1e000 18 27 10 22 D2V011NF1e000 24 3
72. erials Handling Inc 4501 Gateway Boulevard Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 R M MATERIALS HANDLING T5 021011 T6 D2L015 T7 D2L018 MF11MB20 0 400V 100Hz MF13Z 200 400V 100Hz MF13ZA200 400V 100Hz Label Code Default Label Code Default Label Code Default G 2 1 General Parameters G 2 1 General Parameters 2 1 General Parameters P 2 1 10 Accel Time 1 2 5 Accel Time 1 2 5 P 2 1 10 Accel Time 1 2 5 2 1 11 Decel Time 1 2 5 Decel Time 1 2 5 Decel Time 1 2 5 G 2 2 Motoi r Parameters r Parameters r Parameters P 2 2 1 Motor Nom Volt 400 Motor Nom Volt 400 Motor Nom Volt 400 P 2 2 2 Motor Nom Freq 100 Motor Nom Freq 100 Motor Nom Freq 100 2 2 3 Motor Nom Speed 2830 Motor Nom Speed 2910 Motor Nom Speed 2890 2 2 4 Motor Nom Curr 21 Motor Nom Curr 31 Motor Nom Curr 36 P 2 2 5 Nom Flux Curr 12 Nom Flux Curr 15 Nom Flux Curr 15 P 2 2 6 Start Current 24 Start Current 32 Start Current 42 P 2 2 7 Current Limit 31 Current Limit 46 Current Limit 54 P 2 2 8 Min Freq 51 10 Min Freq S1 10 Min Freq 51 10 P 2 2 9 Min Freq 52 5 Min Freq S2 5 M
73. es how long the backlight stays before going out Value 0 0 65535 means Forever InternBrake Res P6 7 1 Must not be changed Not conn Fan Control P6 7 2 Must not be changed Continuos HMI ACK timeout 6 7 3 Not used HMI retry P6 7 4 Not used MWh counter C6 8 1 1 MWh counter can not be reseted PwOn Day Counter C6 8 1 2 Total number of power on days PwOn hour count C6 8 1 3 Total number of power on hours MWh Counter T6 8 2 1 MWh counter can be reseted MWh Counter P6 8 2 2 Clear MWh counter T6 8 2 1 Not reset Reset PwOn Day Counter T6 8 2 3 Number of power on days PwOn hour count T6 8 2 4 Number of power on hours Optime cntr T6 8 2 5 Clear trip counters T6 8 2 1 T6 8 2 4 Software package 16 8 3 1 See software sticker under display IND2V070 IND2V070 SystemSw version 16 8 3 2 12 34 8256 Firmware interf 16 8 3 3 4 45 System load 16 8 3 4 Load of CPU 96 Application id D6 8 4 1 1 See software sticker under display IND2V070 Industr2 Version D6 8 4 1 2 See software sticker under display IND2V070 7 00 Firmware interf D6 8 4 1 3 4 44 Power unit 16 8 5 1 Power unit id code Unit voltage 16 8 5 2 Nominal voltage of D2V 500V Brake chopper E6 8 5 3 There is brake chopper in D2V Yes Brake resistor E6 8 5 4 No braking resistor inside D2V No 38 83 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc
74. f inputs can be checked from parameters V4 7 12 and V4 7 13 The input assignment according to the selected mode is explained in the following table Control mode EP EP3 MS Parameter P2 1 4 1 2 3 Signal Terminal 51 1 8 51 51 51 52 X1 9 52 52 52 X1 7 OK OK OK DIA3 X1 10 AP AP MS2 DIA4 X1 11 Not used HOLD MS3 DIA5 X1 12 Not used not used MS4 DID1 X1 38 FWE FWE FWE DID2 X1 39 511 511 511 DID3 X1 40 S21 S21 S21 DID4 X1 41 512 512 512 DID5 X1 42 522 522 522 Desired speed levels for multi step control mode are selected with following parameters Speed Parameter Input Speed 1 P2 2 8 P2 2 9 S1 52 Speed 2 2 1 7 MS2 Speed 3 P2 1 8 MS 3 Speed 4 P2 1 9 MS 4 9 83 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc 4501 Gateway Boulevard Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 R M MATERIALS HANDLING INC 1 7 Description of the control methods 1 7 1 EP2 control gt gt B 5 0 ee c_coep2a A Pushbutton controller position B Speed 0 decelerate to zero 1 while starting drive minimum speed while running hold speed 2 while running accelerate while
75. he rate of lowering the frequency depends on the current overshoot To avoid motor overloading set this parameter according to the rated current of the motor normally 1 5 2xl In multimotor drives nominal currents must be summarized Note The value must be limited to Drive maximum output current 1 minute value Min Freq S1 P2 2 8 Minimum frequency direction 1 0 Max Freq S2 Hz Hoisting application D2L Smaller value than factory setting is not allowed to use Min Freq 52 P2 2 9 Minimum frequency direction 2 0 Max Freq S2 Hz Hoisting application D2L Smaller value than factory setting is not allowed to use Max Freq S1 P2 2 10 Maximum frequency direction 1 0 250Hz Max Freq 52 P2 2 11 Maximum frequency direction 2 0 250 Hz ESR freq P2 2 12 Maximum frequency when ESR activated 0 250Hz Drive Selection P2 2 13 Application selection selection None causes F60 Parameter fault 0 1 Travel 2 Hoist Pulse Number P2 2 14 Pulse wheel pulse number 0 24 Not used in travelling application D2T 1 2 36 2 48 3 72 4 32 5 64 6 80 7 102 8 600 9 1000 10 1024 11 2000 Zero Freq Volt P2 2 15 Output voltage at zero frequency of motor nominal voltage 0 40 U f Mid Volt P2 2 16 Voltage in the selected middle point frequency 9o of motor nominal 0 100 voltage U f Mid Freq P2 2 17 Middle point frequency 0
76. hould be changed back to their original values 9 6 After the test run Record all parameter value changes in the parameter list Make sure all remarks and setting values are recorded tis recommended to store the parameter settings in file User parameters see chapter User parameters 52 83 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc Inv 4501 Gateway Boulevard TUTUP Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC 10 TROUBLESHOOTING v Warning High voltages inside Frequency converter Wait for at least five minutes after the supply voltage has been switched off before service actions The display in the operating condition lights on indicates a dangerous voltage on the DC bus When display turns off the DC bus voltage is approximately 100V Note also that there is always a dangerous voltage in the braking resistor when the DC bus is charged This chapter describes how to detect inverter failures The purpose is to find out which components are damaged and how to replace them to restore proper operation Advice is also given to find possible external failures that affect inverter function 10 1 Field repair actions The purpose of troubleshooting and field repair actions is primarily to determine whether the problems are in fact caused by inverter or external devices After that the next
77. ht to alter or amend the above information without notice
78. in 14 3 Circuit diagrams D2L 002F 005F D2LO007F O011F D2L015F 045F D2L055F 14 3 1 Internal wirings PE A B Other single Screened cables wires 002F 011F 002F 011F 002F 018F 002F 055F 002F 055F 002F 055F 002F 055F 2 5 2 5 mm 2 5 mm 2 5 mm 1 5 mm 0 75 mm 8x0 5 mn AWG 14 AWG 14 AWG 14 AWG 14 AWG 16 AWG 20 8x AWG 20 67 83 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc 4501 Gateway Boulevard Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 R M MATERIALS HANDLING INC 015F 018F 015F 018F 6 mm 6 mm AWG 10 AWG 10 022F 037F 022F 022F 10 mm 10 mm 6 mm AWG 8 AWG 8 AWG 10 030F 037F 030F 045F 16 mm 10 mm AWG 6 AWG 8 045F 045F 16 mm 25 mm AWG 6 AWG 4 055F 075F 055F 055F 25 mm 35 mm 16 mm AWG 4 AWG 2 AWG 6 14 3 2 Wiring colours Single wires Screened cable board A Screened cable board C PE Green Yellow PUR Grey EA Grey A Black 15V Pink EA Pink B Black AIN1 Green EB Green ONE White AIN2 Yellow EB Yellow Others Red AIN Blue 24V Brown AOUT2 Red OV White OV White 24V Brown 68 83 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R M MATERIALS HANDLING INC R amp M M
79. in Freq S2 5 P 2 2 10 Max Freq S1 Max Freq 51 Max Freq S1 2 2 11 Max Freq 52 Max Freq 52 Max Freq 52 2 2 12 Max ESR Freq Max ESR Freq Max ESR Freq P 2 2 13 Drive Selection Drive Selection Drive Selection P 2 2 14 Pulse Number Pulse Number Pulse Number P 2 2 15 Zero Freq Volt Zero Freq Volt Zero Freq Volt 2 2 16 U f Mid Volt U f Mid Volt U f Mid Volt P 2 2 17 U f Mid Freq U f Mid Freq U f Mid Freq P 2 2 18 Torque Boost Torque Boost Torque Boost P 2 2 19 Rs Voltage Drop Rs Voltage Drop Rs Voltage Drop 180 P 2 2 20 Stop Function Stop Function Stop Function Ramping G 2 3 Expei rt rt rt P 2 3 1 Flux Current Kp Flux Current Kp Flux Current Kp 4000 P 2 3 2 Flux Current Ti Flux Current Ti Flux Current Ti 25 P 2 3 3 52 Flux Control 52 Flux Control 52 Flux Control 100 P 2 3 4 Freq 0 Freq 0 Freq 0 1 P 2 3 5 Freq 1 Freq 1 Freq 1 3 P 2 3 6 Freq 2 51 Freq 2 51 Freq 2 51 10 P 2 3 7 Freq 3 S1 Freq 3 51 Freq 3 51 20 2 3 8 Zero Flux Curr Zero Flux Curr Zero Flux Curr 80 P 2 3 9 Stray Flux Curr Stray Flux Curr Stray Flux Curr 40 P 2 3 10 Freq 252 Freq 2 5
80. ion D2T Freq 2 52 P2 3 10 Mixed current voltage mode frequency limit in percentage of nominal 0 100 frequency in direction S2 Must not be changed Not used in traveling application D2T Freq 3 S2 P2 3 11 U f control mode frequency limit in percentage of nominal frequency 0 100 96 in direction S2 Must not be changed Not used in traveling application D2T Zero Speed Curr P2 3 12 Relative value of motor current used in small frequencies 96 of motor 0 250 96 nominal current Must not be changed Not used in traveling application D2T Min Current Ref P2 3 13 Minimum value of motor current used in current control area 96 of 0 100 96 motor nominal current Must not be changed Not used in traveling application D2T Accel Comp TC P2 3 14 Acceleration compensation time constant which describes rotating 0 300 s masses of drive system Physical description of this parameter is a time which is needed to accelerate rotating masses from zero to nominal frequency with motor nominal torque Must not be changed Not used in traveling application D2T Ref Angle S1 P2 3 15 Voltage current angle difference S1 1536 equals 90 angle Used in 0 3000 direction changes Must not be changed Not used in traveling application D2T Ref Angle S2 P2 3 16 Voltage current angle difference S2 1536 equals 90 angle Used 0 3000 direction changes Must not be changed Not used in traveling application D2T
81. ipped with pulse wheel speed sensor or encoder After adjustment check that parameters V 4 8 1 Overspd Lim 1 and V 4 8 2 Overspd Lim 2 have value between 115 and 125 Check that parameters P 2 2 2 Motor Nom Freq and P 2 2 3 Motor Nom Speed have correct values from motor type plate Settings for pulse wheel sensor or encoder 24 ppr 46 83 D2L 002 055 002 055 P 2 2 11 Max Freq 2 50 100 60 120 P 2 2 14 Pulse Number 24 24 Rotary switch S1 4 7 Switch S2 1 ON ON Switch S2 2 ON ON Switch S2 3 OFF OFF Switch S2 4 ON ON Rotary switch S3 4 7 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc Inv 4501 Gateway Boulevard Springfield Ohio 45502 HANDLING 937 328 5100 INC FAX 937 325 5319 7 2 Functional test run for SSU Test run must be made without load Disconnect the signal wire coming from the pulse sensor to terminal X1 51 Drive with minimum speed The motion must stop within 1 s fault F63 stall supervision is activated fault F62 Speed difference is activated fault F64 Over speed is activated 7 3 Settings for non standard cases Overspeed tripping frequency levels Area selection Range selection Normal 52 1 300 Drive with maximum speed the must stop at on
82. ires are connected to these terminals Check that no control or line voltage level wires are connected there 9 2 Checks before the first test run Check power supply voltage nominal voltage 10 Check control voltage nominal voltage 10 Make sure that run commands are off pushbuttons controller master switch at zero position Turn on power from main switch and control voltage switch Within about 1 second the control panel should display AC on and then in about 1 second the display changes to motor output frequency 0 00 and green READY status indicator turns on Ina fault situation the red FAULT status indicator blinks and the display shows fault code instead of frequency Check that green RUN status indicator is off Check that external connections and selected control method are according to application Parameters are properly set after factory tests and no adjustments are needed except for the parameters that depend on application Write down to the parameter list all the values that have been changed and at the end save parameters to User parameters see chapter User parameters 9 3 Test run without load Make sure that movement will not cause any danger to the environment or to the crane itself Avoid driving close to the limit areas 51 83 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc In
83. ision unit SSU The speed measurement and supervision can be done either with encoder bearing sensor or proximity switch The measured signals are square wave pulses The frequency of the pulses is proportional to the speed of the 8 83 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc Inv 4501 Gateway Boulevard TUTUP Springfield Ohio 45502 P 937 328 5100 HANDLING i sre 937 325 5319 motor and if the frequency is too high overspeed is detected If there are no pulses a stall situation is detected If the actual speed differs too much from the supply frequency of the motor the speed difference supervision stops the motion Proximity switch buffer amplifier A5 amplifies the sensor pulses and filters out disturbances The amplifier is located close to the sensor 1 6 Control methods There are three different control methods command modes available 1 EP2 Electronic motor potentiometer function Stepless control using a 2 step controller 2 EP3 Electronic motor potentiometer function Stepless control using a 3 step controller 3 MS Multistep control 4 steps The control mode of inverter is selected by parameter P2 1 4 See chapter Control methods The parameters assigns digital inputs S1 52 OK DIA3 DIA5 and DID1 DID5 It is not possible to chance the functions of the inputs separately The state o
84. k Temp V4 15 Temperature of heat sink ec MotorTemperature V4 16 Calculated motor temperature in percent of maximum 96 Motor Power V4 17 Calculated actual power of nominal power of unit Motor Voltage V4 18 Calculated motor voltage V Motor Torque V4 19 Calculated motor torque motor nominal torque positive when motoring negative when generating Motor Current V4 20 Measured motor current A Motor Speed V4 21 Calculated motor speed rpm Output Frequency V4 22 Output frequency to the motor Hz G4 23 Multimonitor Multimonitor N4 23 1 Multimonitor page shows motor current motor voltage and putput frequency in display in the same time Monitor variables can be changed if parameter P6 5 4 ChangeEnable G5 Panel Control Panel Control B5 1 Must not be used Off On Speed Reference R5 2 Speed reference for panel control M6 System Menu Language S6 1 Keypad language English Application 56 2 Application Crane S6 3 System settings Parameter Sets S6 3 1 Not used see parameter group G4 1 Parameter backup Up to keypad 86 3 2 Save parameter settings up to keypad Down from keypad 56 3 3 Download parameter settings down from keypad Param BackUp P6 3 4 Changes in parameters are automatically saved to Keypad settings Yes No 56 4 ParamComparison Set 1 86 4 1 Actual parameter values are compared to Default parameters Value of Par No Default val parameters can also be changed in this display Actual value Set 2 86 4 2 Actual para
85. l control voltage OLE 6 OLE External control voltage 42 48 115 230Vac 36 ONE Neutral of external control voltage OLE 7 RDY Stop with brake 37 ES External Stop 8 S1 Direction 1 run command 38 DID1 Free input 9 S2 Direction 2 run command 39 DID2 S11 Slowdown signal direction 1 10 DIA3 Accelerate speed 2 40 0103 S21 Slowdown signal direction 2 11 DIA4 Not used hold speed 3 41 DIDA S12 Stop limit signal direction 1 12 DIA5 Not used speed 4 42 DID5 S22 Stop limit signal direction 2 13 43 14 44 15 K7 A1 Coil of brake contactor K7 45 1 21 Not used 16 ROB1 22 Not used 46 ROB1 23 Not used 17 ROD1 28 Free NO contact of relay ROD1 47 ROD1 29 NO contact of relay ROD1 18 K7 153 Free NO contact of K7 48 7 154 Free NO contact of K7 19 K7 163 Free NO contact of K7 49 K7 164 Free NO contact of K1 20 K71 13 Free NO contact of K71 50 K71 14 Free NO contact of K71 peu 21 PUR Not used 51 Encoder channel 22 15V Not used 52 EA Encoder channel A 23 AIN1 Multicare speed reference input 0 10V 53 EB Encoder channel B 24 AIN2 Not used 54 EB Encoder channel B 25 AIN Common for analog inputs 55 24V 24V output for encoder 26 AOUT Multicare speed reference output 0 10V 56 0v Common for encoder supply 27 OV Common for analog output 57 24V External supply for Control module meae 65 83 R amp M Materials Handling Inc reserves the right to alter or amend the above information without noti
86. l methods 1 2 3 Multistep Analog Input Sel P2 1 5 Analog input selection 0 Not used Not used in D2T 1 2 Multicare 2 Load 3 Multicare amp Load Slow speed freq P2 1 6 Speed when one of slow down limit switches S11 S21 is open 0 250 Hz Multistep 2 freq P2 1 7 2 preset speed Multistep speed setting 0 250 Hz Multistep 3 freq P2 1 8 3 preset speed Multistep speed setting 0 250 Hz Multistep 4 freq P2 1 9 4 preset speed Multistep speed setting 0 250 Hz Accel Time 1 P2 1 10 Acceleration ramp is defined from zero to motor nominal frequency 1 300 s P2 2 2 Shorter values than the factory setting must not be used Decel Time 1 P2 1 11 Deceleration ramp is defined from motor nominal frequency P2 2 2 1 300 s to zero Shorter values than the factory setting must not be used G2 1 12 Multicare Test Voltage Min B2 1 12 1 1 00V is given to Analog output Aout2 by this button Off On Test Voltage Max 2 1 12 2 9 00V is given to Analog output Aout2 by this button Off On Ain 1 Value V2 1 12 3 Value of analog input Ain1 voltage V Min Value Volt P2 1 12 4 Ain1 value when test voltage min has been selected in the other 0 10V drive Max Value Volt 2 1 12 5 Ain1 value when test voltage max has been selected the other 0 10V drive G2 2 Motor Parameters Motor Nom Volt P2 2 1 Nominal motor voltage Un from motor rating plate 0 750 Motor Nom freq P2 22 Nominal motor frequency fn from motor rating plate 0 250Hz Moto
87. les is over 100m with D2L002 D2L005 or over 200m with D2L007 D2L055 there has to be du dt filter at motor supply D2L Platthaus du dt filter Length mm Width mm Height mm Weight kg ID 002 003 ULC 910 920 100 110 180 1 2 52306553 004 005 ULC 914 931 125 110 200 3 52306554 007 018 ULC 918 951 155 125 225 7 52306555 022 045 ULC 923 927 190 135 260 12 52306556 055 ULC 942 1044 240 175 310 22 52306557 v Du dt filter Should be as near D2L as possible Note All control cables must be placed as far from the motor and braking resistor cables as possible 2 4 Signal cabling 2 4 1 Shielded signal cable It s recommended to use twisted pair and braided shielded signal cables Foil type shield is not sufficient enough in crane applications because of poor mechanical durability Cable insulation material effects to cable capacitance Recommended cable capacitance between signal signal and signal ground is equal or less than 100pF m 31pF ft It is not recommended to use shielded flat cable because its capacitance is extremely high and this may cause high frequency interference 2 4 2 Reference signals Shielded round cables must be used for analog reference signals The shield is to be grounded only at one end of the cable 2 4 3 Sensor bearing The cable for the sensor bearings must be shielded round cable and grounded 360 at both ends 2 4 4 Encoder The encoder connec
88. lishments directly connected to a low voltage power supply network Second environment means environment that mox includes all establishments other than those directly connected a low voltage power supply network Fulfilled EMC standards e Inverter fulfils the immunity requirements defined in the EN 61800 3 Amendment 11 2000 for the second environment e Inverter fulfils the emission requirements of the EN 61800 3 A11 2000 for the second environment 12 83 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc Inv 4501 Gateway Boulevard Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 MATERIALS HANDLING INC 2 INSTALLATION 2 1 Cubicles D2L is delivered with external braking resistor Braking resistor types D2FR are installed in the same cubicle as the D2L itself Braking resistor D2HRO4F90RO0SA for 021002 D2L005 is in own cubicle D2L Standard cubicle Cubicle size mm Braking resistor mm 002 005 EEO25 604 400 x 600 400 x 400 007 015 600 600 1000 Included 018 030 KA220D2 1000 x 1000 Included 037 045 1 x KA220D2 1 x 1000 x 1000 Included 055 1 xH15BD02 1 x 1500 x 1000 Included 2 2 Braking resistor D2L is delivered with external braking resistor Braking resistor types D2FR are equipped with cooling fans and thermistors Circuit
89. meter values are compared to User parameters Value Par No User val of parameters can also be changed in this display Actual value Factory settings 56 4 3 Parameter Factory settings is not used Keypad set 86 4 4 Actual parameter values are compared to parameter saved in Keypad S6 5 Security Password 86 5 1 Password for group 56 5 Parameter lock P6 5 2 Not used Change Enable Startup wizard P6 5 3 Not used No 37 83 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc PAVI 4501 Gateway Boulevard Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC Multimon Items P6 5 4 Enables or disables chancing of variables in multimonitor page ChangeEnable N4 23 1 ChangeDisable Default page P6 6 1 Default page to which the display automatically moves as the Timeout time has expired or as the power is switched on to the keypad If the Default Page value is 0 the function is not activated i e the last displayed page remains on the keypad display Default page OM P6 6 2 Timeout time P6 6 3 The time after which the keypad display returns to default page Contrast P6 6 4 Display contrast Backlight time P6 6 5 Determin
90. minal Signal name Description 1 DID1 Not used 2 DID2 42 240Vac 50 60Hz ri 3 DID3 42 240Vac 50 60Hz YELLOW 4 DID4 42 240Vac 50 60Hz 5 DIDS 42 240Vac 50 60Hz 6 Common for DID1 DID5 7 Pt Relay output 230V normaj open For fan of braking resistor unit 8 ROD1 The threshold voltage for digital inputs DID1 DID5 is 35VAC LED Blinking Status Yellow 0 25Hz OK Ter Yellow 4Hz Board internal fault or communication fault with control unit MEME 3 2 Control voltage transformer Power of control voltage transformer has to be n 50VA 50VA min 250VA n number of inverters This power does not have to be added to otherwise needed transformer power 21 83 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc Inv 4501 Gateway Boulevard Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC 3 3 Speed sensors 3 3 1 Sensor bearing D2L needs information about the motor rotation speed for stall speed difference and overspeed supervision Order codes of the bearing sensors are shown in the table below Motor type Motor code Pulses per revolution Order code Supply voltage Max load MF10MA200 T1 32 NM768NR3 24V DC 20 mA MF10MB200 T2 32 NM768NR3 24V DC 20 mA MF10MC200 T3 32 NM768NR3 24V DC 2
91. minal voltage IrAdd Motor P2 3 24 With small speeds and heavy load the hoist movement does not 0 200 have enough voltage to produce sufficient torque Raising the value of this parameter increases the voltage Must not be changed Not used in traveling application D2T IrAdd Generator P2 3 25 If motor voltage at generator area is too high reducing value of 0 200 parameter decreases the voltage Ramp Stretching P2 3 26 See Chapter Ramp Stretching Not used in hoisting 0 50 Switching Frequency P2 3 27 Must not be changed from factory setting 3 6 kHz DeadTime Comp P2 3 28 Dead time compensation time delay Parameter value does not tell 0 10000 the actual time used in compensation DeadTime CurrLim P2 3 29 Parameter that is used to control the current waveform in dead time 0 1000 compensation Brake Chopper P2 3 30 Defines when braking chopper is allowed to be activated 17 Yes Run Always while drive is in ready state or only while running 0 Yes Ready Autotuning P2 3 31 See Chapter Autotuning Not used in hoisting application D2L G4 Monitoring G4 1 Parameter backup Load Default Par B4 1 1 Restores Default Parameters to Active Parameters from the Control Unit memory Default Parameters are the parameters which have been saved in the factory Save User Par B4 1 2 Saves Active Parameters in the Control Unit as User Parameters Final parameters for the application must be saved as User Parameters after start up Loa
92. nds 360 grounding D2L terminal the shield should be grounded always when going through terminals 22 83 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc Inv 4501 Gateway Boulevard Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 MATERIALS HANDLING INC 3 3 2 Encoder Standard encoder has 24 pulses per revolution It is also allowed to use 600 1000 1024 2000 or 2048 ppr encoders but then there has to be both channels connected Order code for 24 ppr encoder is NM701NR28 Encoder connection examples are shown below All signal wires shall be included inside a single shielded cable Power supply to the encoder may also be included in the same cable Standard connection terminal box V red Encoder 24 ppr At yellow ES z lt m 2 m a ov blue Standard connection terminal box D2L x1 V 155 red 24V Encoder 600 ppr or more 51 yellow _ 53 2 EB m G A 52 4 r black EA m B 54 white EB ov 56 blue OV tj In standard encoders there are also zero outputs Z Z which should be left disconnected If the encoder does not have negative channels A and B EA and EB must be connected to OV at motor terminal box alternative connection In order to avoid fault situations the cable between
93. ng R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice Autotuning R amp M Materials Handling Inc Inv 4501 Gateway Boulevard ePE Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC 7 SPEED SUPERVISION SETTINGS SSU is a hoist motion speed supervision unit which reads the pulse frequency from the hoist motor sensor bearing encoder or pulse sensor This pulse frequency is compared with a fixed oscillator frequency and D2L frequency reference As a result of frequency comparison there are three different speed supervision functions available overspeed supervision rush control Stall supervision speed difference supervision Overspeed supervision F61 is totally implemented by hardware Switches 52 2 and 52 3 divide the full frequency range to four frequency areas Selected frequency area is the same for normal and ESR speeds The four frequency areas are each divided to lower and upper frequency ranges Switch S2 1 selects the frequency range at normal speed Switch S2 4 selects the frequency range at ESR speed Extended Speed Range The exact tripping frequency level is selected with rotary switches Switch 51 sets the tripping level at normal speed value shown V4 8 1 Switch S3 sets the tripping level at ESR speed value shown in V4 8 2 Overspeed tripping levels are shown at display as of the nominal speed
94. otor if the keypad is the active control place Stop button Stops the motor if keypad is the active control place v WARNING Changing parameter settings during running can cause a hazardous situation Parameter settings must not be changed during running v WARNING Driving via display can cause a hazardous situation Panel control must not be used 4 1 1 Navigation on the control keypad 78 1 1 23 _ Fault History 57 Thermistor gt Operation days v HiloHxx gt Y 0 A erc 4 _ Active Faults v A erae eroe 4 56 1 lt _ System Menu Application v 51959 gt Y Crane ipm T Panel Control lt P Panel Control v Bl R2 gt Y off error erc A v4 19 m5 Monitoring lt P Output Frequency v Gbv9 gt Y 0 00 Ez A gramm A erar error G2 m 62 2 m 2 2 1 5 i Parameters lt P Motor Parameters lt P Motor Nom Volt v 1 gt Y 5 0 Y 400 29 83 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc Inv 4501 Gateway Boulevard Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 MATERIALS HANDLING INC 4 1 2 Value line edi
95. otuning Autotuning R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice Autotuning R amp M Materials Handling Inc 4501 Gateway Boulevard Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 R M MATERIALS HANDLING INC 6 2 Factory default parameters for 120Hz motors T1 D2L002 T2 D2L004 T3 D2L005 T4 D2L007 MF10MA200 460V 120 2 MF10MB200 460V 120Hz MF10MC200 460V 120 2 MF11MA200 460V 120Hz Label Code Default Label Code Default Label Code Default Label Code Default G 2 1 General Parameters G 2 1 General Parameters G 2 1 General Parameters G 2 1 General Parameters P 2 1 10 Accel Time 1 2 5 Accel Time 1 2 5 Accel Time 1 2 5 Accel Time 1 2 5 P 2 1 11 Decel Time 1 2 5 Decel Time 1 2 5 Decel Time 1 2 5 Decel Time 1 2 5 2 2 Moto r Parameters Parameters r Parameters Parameters P 2 2 1 Motor Nom Volt 460 Motor Nom Volt 460 Motor Nom Volt 460 Motor Nom Volt 460 P 2 2 2 Motor Nom Freq 120 Motor Nom Freq 120 Motor Nom Freq 120 Motor Nom Freq 120 P 2 2 3 Motor Nom Speed 3420 Motor Nom Speed 3370 Motor Nom Speed 3340 Motor Nom Speed 3440 P 2 2 4 Motor Nom Curr 4
96. owdown S11 S21 and stop limit switch 812 S22 functions for both running directions 6 83 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc Inv 4501 Gateway Boulevard UTE Springfield Ohio 45502 HANDLING INC 937 328 5100 FAX 937 325 5319 Speed supervision D2L includes a speed supervision unit SSU which is separate from the inverter and not dependent on software This safety circuitry is used to monitor the speed of the motor In case of speed difference overspeed or stall the speed supervision unit stops the motion immediately Protections D2L includes a motor thermal protection which is based on motor temperature measurement by thermistors placed in motor windings A great number of other protections included in every D2L are shown in the technical data Tested parameters D2L includes tested parameters with different motors for all power ratings This is a benefit which makes every D2L delivery a proven solution The tested and pre set motor parameters enable a quick start up in crane commissioning 1 4 Main components The main components are D2L 1 Inverter F7 Brake supply circuit breaker 007 055 K7 Brake contactor G1 Brake control unit REC12 002 011 G1 Brake control unit ESD141 015 055 F71 Circuit breaker for the second brake contactor 055 K7
97. r Nom Speed P2 2 3 Nominal motor speed n from motor rating plate 0 6000 rpm Motor Nom Curr 2 2 4 Nominal motor current In from motor rating plate In multimotor drives nominal currents must be summarized 32 83 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc Inv 4501 Gateway Boulevard ePE Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC Nom Flux Curr 2 2 5 Motor nominal flux current lo same as no load current or magnetizing current from motor rating plate In multimotor drives nominal flux currents must be summarized With traveling application D2T If motor nominal flux current lo is not available it can be measured See chapter u f curve tuning Start Current P2 2 6 Start current Current level which is used in motor starting situation Hoisting application D2L default value is motor s nominal current but not over nominal current of the D2L Travelling application D2T default value is 8096 of motors nominal current but not over 8096 of nominal current of the D2T With compact brake motors minimum value is 3A motor even if it s over nominal current of the D2T Current Limit P2 2 7 Defines the maximum motor current from the inverter If the output current exceeds the value set in parameter P2 2 7 the output frequency is lowered until the current drops below the current limit T
98. rates the motor to a stop according to the set deceleration time when the run command is switched off so the brake is used only as a holding brake This way brake wear is minimized Only if a failure occurs or the emergency stop button is pushed the brake closes immediately stopping the motor and the load Models 002F 011F have a built in REC12 brake control unit which is a line voltage half wave rectifier The half wave type rectifier reduces losses and is enough to open the brake There is a contactor to switch the line voltage on and off Models 015F 055F have a built in ESD141 brake control unit which is a line voltage full half wave rectifier Full wave rectification is used to open the brake quickly Then the rectifier changes to a half wave type which reduces losses but is enough to keep the brake open There is a contactor to switch the line voltage on and off The same contactor also disconnects the DC voltage directly from the brake coil which guarantees that the brake closes fast Model 055F includes a 3 phase AC supply for the brake control D2L controls this line and it is protected by an adjustable circuit breaker max 4 0A When a shoe brake is used brake closing is speeded up by capacitors They are connected in parallel with the brake via the brake contactor NC contacts The connection is partially ready in D2L Only the capacitors must be added outside D2L This connection can also be used to control 2 phase disk brakes or a
99. rd Springfield Ohio 45502 P 937 328 5100 HANDLING medi FAX 937 325 5319 INC 2 3 3 Cable selection Cabling for inverter can be done using normal crane cables All the cables must be dimensioned according to local regulations Ambient temperature cabling method size of bunches etc and allowable current for the cable in use must be taken into consideration If there are no other regulations following values can be used three phase 400V supply The table below is based on ED lt 60 and ambient temperature 40 C 104 F A higher ambient temperature may require increased cable sizes The input current does not exceed the continuous current Icont of inverter so it is selected to be the dimensioning current If the actual load current is below inverter continuous current then the fuses and the supply cable may be dimensioned according to the load current Powerclass 77 002 04 007 04 05 048 022 6 5 10 50 1 5 14 2 5 14 003 Continuous current 8 10 18 24 32 42 48 Pra A s Max motor cable length m 50 50 50 50 50 50 50 Motor cable 40 C mm 2 5 2 5 4 6 10 10 10 104 F Braking resistor cable 40 C mm 2 5 2 5 2 5 2 5 2 5 4 4 104 F Continuous current Icont A 75 90 110 Fa Max motor cable length m 50 75 75 Motor cable 40 25 35 35 Braking resistor cable 40 C mm 10 16 16 2 3 4 Cable prote
100. res special precautions Do not make any measurements inside the device when it is connected to the main supply Do not touch the components on the circuit boards Static voltage discharge may cause damage or destroy the IC circuits Check all ventilation holes are clear and uncovered Check that hot air coming from the brake resistors does not cause any danger Do not make any inspections unless the supply has been disconnected by the main switch It is forbidden to use radiophones or portable phones near this device with the doors open the doors and covers must be closed during crane operation Inverter is not intended to be used on a low voltage public network which supplies domestic premises Radio frequency interference is expected if used on such a network R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc Inv 4501 Gateway Boulevard TUTUP Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC 1 GENERAL 1 1 Technical data Power class Power kVA at 400V Output current In A Max current 1min Overloadability Max output voltage Supply Supply voltage Allowable voltage fluctuation Nominal supply frequency Signal input levels Digital controls Encoder feedback Control features Control method Frequency control range Frequency command Limit switch functions Speed control range Spe
101. rresponding to the other sensors have been added to wire ends not necessarily if cable has been shortened afterwards The connection of Honeywell sensor and the cable markings are shown in the table below Signal name Sensor Cable Colour marking Terminal number a12 24V Red Brown Brown KAE234 6 29 Honeywell 3GT101DC PULSE Green Green Black KAE234 1 OV Black White Blue KAE234 2 40 Sch nbuch INSOR ICDM 8802 S3LS3ANI Honeywell 3GT101DC S3LS3ANI M8x1 Baumer IFRM08N1501 L Note the following details buffer amplifier must be located as close the proximity switch as possible maximum distance 3m sensor cable must be located as far from the motor cables and braking resistor cable as possible minimum distance 20cm In order to avoid fault situations the cable between the encoder and D2L must be as far as possible from the cables of motor and braking resistor minimum distance gt 20 shielded and twisted cable grounded the shield at both ends 360 grounding on D2L terminal the shield should be grounded always when going through terminals 24 83 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc Inv 4501 Gateway Boulevard Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 MATERIALS HANDLING INC Some problems may occur
102. rvice F 13 Inverter Temperature of heat sink is below acceptable Check undertemperature operating level 10 C 14 F ambient temperature cubicle heating F 14 Inverter Temperature of heat sink is over acceptable Check overtemperature operating level ambient temperature 90 C 194 F inverter cooling fan operation Overtemperature warning is issued when the heat cooling air flow through heat sink sink temperature exceeds 85 C 185 F heat sink is not dusty F 22 EEPROM checksum Parameter save error After power off the inverter will automatically load F 23 fault interference fault factory default parameter settings D2T does not component failure control unit work properly nor enable driving after this fault Check all parameter settings 24V voltage output loading If the fault comes again contact authorized Service F 24 Changed data Changes may have occurred in the different counter No special actions required Take a critical attitude warning data due to mains interruption to the counter data F 25 Microprocessor interference fault Reset switch power off and restart after the lamps watchdog fault component failure control unit of display are off If the fault comes again contact service 55 83 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R M MATERIALS HANDLING INC R amp M Materials Handling Inc 4501 Gateway Boulevard Springfield Ohio 45502 P 93
103. s 13 2 3 3 Cable 14 2 3 4 Cable 14 2 3 5 Cable length nite tnt 14 2 3 6 Du dt filters eet itte 15 24 Signal cCablinpg emet 15 2 4 1 Shielded signal cable 15 2 4 2 Reference 15 2 4 3 Sensor 15 2 4 4 Encoder is t tution 15 2 5 EMC compatible grounding 16 2 5 1 Construction connections 16 2 5 2 Cable 16 2 5 3 Shielded control cables 16 3 1 17 17 3 1 1 Power supply unit PSU 18 3 1 2 Control unit CSU 19 3 1 3 Basic I O board Slot 20 3 1 4 Relay Thermistor board Slot B 20 3 1 5 SSU Speed Supervision board Slot C 20 2 83 3 1 6 Extension board Slot D 21 3 2 Control voltage transformer 21 3 3 Speed 22 3 3 1 Sensor 22 952 EnCOUGE caeca Meese
104. sing Drive with minimum speed The motion must stop within set time fault F63 stall supervision is activated Drive with maximum speed the motion must stop at once fault F62 Speed difference is activated Reconnect the disconnected signal wire to terminal X1 51 Setrotary switch 51 53 value 2 steps smaller Drive with maximum speed The motion must stop after full speed is reached fault F64 Over speed is activated Set rotary switch 51 53 back to original value 9 4 Test run with load Note three loads are required Nominal load 100 for normal operation Limited load for ESR optional An adequate extra load for dynamic overload testing and to test the ESR load limit sure that movement will not cause any danger to the environment or to the crane itself Ifthe optional extended speed range ESR is used check that the load limit is correctly set and hoisting with bigger loads is prevented Drive in both directions at minimum and maximum speeds Ifthe fan tube resistor unit is included check that fan s starts to blow when driving down with nominal load and continues to blow for about 4 5 minutes after stopping 9 5 Test run with overload If an overload test has to be performed during crane commissioning minimum frequencies should be risen for duration of the commissioning to 20Hz Minimum frequencies can be changed with parameters P2 2 8 and 2 2 9 After testing minimum frequencies s
105. step is to detect the possibly damaged components inside inverter If any damage inside inverter is caused by the environment motor failure brake failure power supply problems etc it is very important to repair change faulty items to prevent further damage The best way to repair a faulty inverter is to replace it with a new one If the fault can be located it is also possible to replace some of the inverter components Always if any power component inside the inverter is damaged it is also recommended to change the component that controls the damaged component In the smallest models replacing components except for the PC boards is not recommended due to cost When replacing an inverter or a Control unit with a new one the parameter list of the existing inverter is needed so that the parameter settings can be copied from the existing inverter If parameters have been copied to the keypad before damage it may be used for uploading the parameters to the spare part inverter requires same software versions 10 2 Typical functional problems nverter does not start when mains is connected Check mains voltage between terminal L1 L2 and L3 Led Ready is on and led Fault is off but motor does not run Check control mode selection Check voltage at run command terminal X1 8 and X1 9 Check state of digital inputs from parameter V4 7 12 Motor runs poorly Check that load is not over nominal Check that all cables are connec
106. ted correct and the junctions are reliable Check that all motor depending parameters are correct Check voltage at slow down terminals X1 39 and X 40 Check state of digital inputs from parameter V4 7 13 Check that motor s brake opens Check that minimum speed parameters do not have too small values Check u f curve tuning If the main girder is new it might be necessary to drive trolley several times with no load from end to end before beginning of u f curve tuning 53 83 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R M MATERIALS HANDLING INC R amp M Materials Handling Inc 4501 Gateway Boulevard Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 Some parameters are not accessible or changing is not possible Check password Check that parameter value is inside the limits Parameter can not be changed in RUN state Parameter change must be confirmed with Enter button 10 3 Inverter fault codes If any of the following failures is found the inverter displays the fault code and closes the mechanical brake causing the movement to stop If several faults occur one after another the latest one is displayed the others are stored to fault history page When inverter fault supervision trips the FAULT indicator turns on and the blinking fault code F xx fault number appears on the display D2T includes an automatic fault reset opera
107. ters is stored in inverter s control unit Default parameters are saved at the factory and they should not be changed In default parameters there are the same parameter values as shown in parameter list delivered with inverter Since serial number 03L50700 Parameters can be restored from Default parameters with parameter B 4 1 1 Load Default Par Enter press Enter After restoring always check the motor parameters Parameters in use can be compared to Default parameters by parameter S 6 6 1 Value 0 at parameter S 6 6 1 means that parameters in use are identical to Default parameters v Parameters restored from Default parameters are reseted after power off unless they are not confirmed with Enter by one Easiest way to restore Default parameters permanently is to compare parameters to Default parameters by parameter S 6 6 1 and adjust them to the same value 4 2 3 Keypad settings File Keypad settings is stored in keypad Default value for parameter P 6 5 4 is On This makes every change to be stored to file Keypad settings whole parameterset can be stored to file Keypad setting with parameter S 6 5 1 Up to keypad Select gt press gt All param blinks on display confirm with enter Parameters be restored from keypad s file Keypad settings with parameter S 6 5 2 Down from keypad Select gt press gt All param blinks on display
108. the encoder and D2L must be as far as possible from the cables of motor and braking resistor minimum distance gt 20 shielded and twisted cable grounded the shield at both ends 360 grounding on D2L terminal the shield should be grounded always when going through terminals Some problems may occur when using shielded flat cable or in situations where the encoder cable has been placed too close 5 to the motor cables and braking resistor cables 23 83 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc 4501 Gateway Boulevard Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 R M MATERIALS HANDLING INC 3 3 3 Proximity switch In modernisation cases there might be proximity switch as pulse sensor of motor D2L needs information about the motor rotation speed for stall speed difference and overspeed supervision Type markings of the speed supervision sensors not needed in applications with bearing sensor or encoder and fixing distance from the pulse wheel air gap are shown in the table below Proximity switch air gap Honeywell 3GT101DC 0 5 1 0 mm Sch nbuch INSOR88 ICDM 8802 0 5 0 1 mm Baumer IFRM08N1501 L 0 5 0 1 mm 5 Note that the Honeywell sensor cable is lengthened and the wire colours not equal to other 35 sensors However colour markings co
109. ting Edit Accept P2 2 1 change value value Motor Nom Volt A 400 V v Center v WARNING Changing parameter settings during running may cause a hazardous situation Parameter settings must not be changed during running 30 83 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc Inv 4501 Gateway Boulevard Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 MATERIALS HANDLING INC 4 2 Storing and restoring parameters 4 2 1 User parameters File User parameters is stored in inverter s control unit User parameters are recommended to save after final set up The whole parameterset can be stored to User parameters with parameter B 4 1 2 Save User Par Enter press Enter Parameters can be restored from User parameters with parameter B 4 1 3 Load User Par Enter lt press Enter After restoring always check the motor parameters Parameters in use can be compared to User parameters by parameter S 6 6 2 v Parameters restored from User parameters are reseted after power off unless they are not confirmed with Enter one by one Easiest way to restore User parameters permanently is to compare parameters to User parameters by parameter S 6 6 2 and adjust them to the same value 4 2 2 Default parameters File Default parame
110. ting 0 Standard panel N level S Standard without EMC filters N EMC Second Environment 0 IT Network 1 3 Basic description D2L has many advantages and offers many new features when compared to other inverter based systems which might be used in crane applications inverter in D2L is a crane inverter The specific crane features for the inverter hardware and the special software are achieved by combining the experience and know how of crane applications with the latest technology The inverter uses vector calculation for several different motor control modes Crane user interface All D2L has exactly the same interface with pre designed locations for typical crane functions The main part of this interface is carried out by a terminal strip which has separated sections for signals with main control and electronics voltage levels Brake control D2L include the brake contactor for disk brakes D2L also includes it s own DC rectifier Electrical Braking D2L includes the braking transistor which is dimensioned for every crane application For resistor braking D2L includes a braking resistor Control methods D2L can be controlled by the electronic potentiometer control with 2 step or 3 step pushbuttons and by the multistep control with 2 4 step controllers Both these control methods are available with every D2L Limit switch functions D2L has built in sl
111. tion the fault code stays on the display until the fault is removed and the controller released back to 0 position Some of the fault codes require to switch the power off before run is possible The faults are stored to the fault history from there they can be seen if necessary The fault history can store last 30 fault codes Following exceptions exist when storing faults to the fault history not stored faults F6 F70 repeated faults are stored only once F50 F51 F55 60 66 F71 F72 A a STOP READY mm Fault History Ql cTOP READY 8 1 57 Thermistor Ql STOP READY T8 1 1 5 lt P Operation days Fault Fault Possible cause Checking code F 1 Overcurrent Inverter has measured too high current over 4 In in Reset switch power off and restart after the lamps the motor output of display are off sudden heavy load increase Check short circuit in the motor or cable brake operation not suitable motor motor type and power rating wrong motor parameters parameters motor cable connection motor insulation motor loading F2 Overvoltage DC bus voltage has exceeded 13596 maximum Reset has an additional 5s time delay level 911Vdc Check supply voltage raised 71 35 x Un high Adjust the acceleration time longer overvoltage spikes at mains or not measure main supply voltage level and wave sinusoidal wave form
112. tions may be split into two cables then the signal conductors 4pcs should go together in one cable and the supply and common 24V 0V together in another cable The encoder cable s must be shielded round cable s and grounded 360 at both ends v Note All shielded cables must be placed as far from the motor cables as possible gt 20cm Shielding must be continuous The pigtail the end to be connected of the shield should not be used instead 360 grounding should be used to minimize disturbances 15 83 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc Inv 4501 Gateway Boulevard ePE Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC v If control cable length is over 100m from transformer to inverter or inverter is not mounted on the crane make sure that Basic board Slot A is at least revision 271G and Extension board Slot D is at least revision 266H 2 5 EMC compatible grounding 2 5 1 Construction connections All metal construction parts of the cubicle must be electrically connected to each other using largest possible surface area Paint to paint connection must not be used 2 5 2 Cable connections Control cables and power cables should be separated and routed separately for eliminating noise coupling The distance between braking resistor cables and the other cables should be k
113. tors If the fault comes again change the power unit F8 System fault System fault due to component failure or faulty Reset switch power off and restart after the lamps operation of keypad are off Check read fault extension code and contact authorized service If the fault comes again change the D2V F9 Undervoltage DC bus voltage has dropped below 333Vdc In case of temporary supply voltage break reset the mains supply voltage interrupted fault and start again Check mains input inverter fault can also cause an undervoltage If mains supply is correct an internal failure has trip occurred external fault during run may cause an Contact authorized service undervoltage trip F 10 Input line One input line phase is missing Check supervision supply voltage mains connection F 11 Output phase Current supervision has sensed that one of the Check supervision motor phases has no current motor cable connections measure motor phase currents and compare to display value F 12 Braking chopper Braking chopper or braking resistor circuit has Reset switch power off and restart after the lamps supervision failed Test pulse measures transistor collector of display are off voltage Fault appears if Check braking resistor is broken braking resistor and insulation resistance braking chopper is broken measure braking transistor IGBT and free braking resistor is not installed wheeling diodes If resistor is OK then the chopper is broken Contact authorized se
114. ult counter IGBT temperature fault counter Profibus communication error fault counter Generator side current limit fault counter Thermistor fault counter Overspeed fault counter Speed difference fault counter Stall supervision fault counter Sum counter of following faults F4 F5 F8 F22 F23 F24 F26 F32 F33 F34 F35 F36 F37 F38 F39 F40 F48 F50 F54 F55 F60 F64 F65 F71 F72 V4 5 2 Total Faults Total number of all faults 58 83 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R M MATERIALS HANDLING INC R amp M Materials Handling Inc 4501 Gateway Boulevard Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 10 4 Inverter Alarm codes Alarm is a sign of an unusual operating condition Alarm remains in the display for about 30 seconds Alarm code A 16 Motor overtemperature A 50 Reference value alarm A 80 Multistep sequence alarm A 82 Overweight alarm A 83 Slack cable alarm 59 83 Possible cause Mathematical motor temperature model has detected motor overheating Motor is overloaded Analog input signal is out of selected range 1 9V or 2 10V control cable is broken signal source has failed Controller does not operate accurately Motor load is over adjusted value Motor load is under adjusted value R amp M Materials Handling Inc reserves the right to alter or amend th
115. v 4501 Gateway Boulevard TUTUP Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC Check limit switches manually if possible Check the run commands on display panel and correct the drum rotating direction The arrow rotates clockwise if S1 up is applied and counter clockwise if S2 down is applied Check the function of the speed sensor see chapter Speed sensors Check the function of the speed supervision circuit See chapter Functional test drive for SSU Drive upwards at minimum speed for 5 to 10 seconds Accelerate to full speed Run 5 to 10 seconds Stop Repeat the same in down direction Check the frequency display to make sure that the frequency changes through the whole operational frequency range from minimum to nominal speed Check motor operation acceleration deceleration and braking accelerate to full speed up change to full speed down and full speed up again and stop Check limit switch functions drive up slowly and check the slowdown and stop limit switch operations Re check using full speed Repeat the same check for down direction If the optional ESR is used check the maximum frequency 9 3 1 Functional test run for SSU er Note Test run for SSU must be made without load Disconnect the signal wire coming from the pulse sensor to terminal X1 51 All the SSU faults will be reseted automatically after one second when the pulses from the pulse sensor are mis
116. ve information without notice R amp M Materials Handling Inc 4501 Gateway Boulevard Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 R M MATERIALS HANDLING INC 6 FACTORY DEFAULT PARAMETERS 6 1 D2L002 D2L004 Factory default parameters for 100Hz motors D2L005 D2L007 T1 MF10MA200 400V 100Hz T2 MF10MB200 400V 100Hz T3 MF10MC200 400V 100 2 T4 MF11MA200 400V 100Hz Label Code Default Label Code Default Label Code Default Label Code Default G 2 1 General Parameters G 2 1 General Parameters G 2 1 General Parameters G 2 1 General Parameters P 2 1 10 Accel Time 1 2 5 Accel Time 1 2 5 P 2 1 10 Accel Time 1 2 5 Accel Time 1 2 5 2 1 11 Decel Time 1 2 5 Decel Time 1 2 5 Decel Time 1 2 5 Decel Time 1 2 5 G 2 2 Motoi r Parameters r Parameters r Parameters r Parameters 2 2 1 Motor Nom Volt 400 Motor Nom Volt 400 Motor Nom Volt 400 Motor Nom Volt 400 P 2 2 2 Motor Nom Freq 100 Motor Nom Freq 100 Motor Nom Freq 100 Motor Nom Freq 100 2 2 3 Motor Nom Speed 2830 Motor Nom Speed 2790 Motor Nom Speed 2780 Motor Nom Speed 2860 2 2 4 Motor Nom Curr 4 8 Motor Nom Curr 9 4 Motor Nom Curr 10 7 Motor Nom Curr 18 2
117. verspeed limit is set over that value When a fault is detected the drive is prevented 45 83 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc Inv 4501 Gateway Boulevard Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 MATERIALS HANDLING INC 7 1 Standard settings 7 1 1 Settings for sensor bearing The table below indicate the SSU settings for standard cases Motors with nominal frequency 100Hz or 120Hz are equipped with bearing sensor After adjustment check that parameters V 4 8 1 Overspd Lim 1 and V 4 8 2 Overspd Lim 2 have value between 115 and 125 Max Freq S2 is normally set to 120Hz also when nominal frequency and Max freq S1 are 100Hz Check that parameters P 2 2 2 Motor Nom Freq and P 2 2 3 Motor Nom Speed have correct values from motor type plate Settings for sensor bearings st D2L 002 005 007 011 015 055 P 2 2 11 Freq 52 120 120 120 2 2 14 Pulse Number 32 64 80 sa IX Rotary switch S1 1 A D Switch S2 1 ON ON ON Switch S2 2 OFF OFF OFF Switch S2 3 OFF OFF OFF Switch S2 4 ON ON ON LE Rotary switch S3 1 A D 7 1 2 Settings for pulse wheel speed sensor or encoder 24 ppr The table below indicate the SSU settings for standard cases Motors with nominal frequency 50Hz or 60Hz are equ
118. when using shielded flat cable or in situations where the encoder cable has been placed too close lt 5cm to the motor cables and braking resistor cables Cabling methods and distances determine the best way to ground the shielded cable at both ends or only at one end Buffer amplifier pulse output can be measured during driving If the pulse sequence is not uniform and for instance longer pulses occur every now and then the reason may be one of following an incorrect air gap proximity switch the sensor is not properly on the top of the pulse wheel proximity switch disturbances are transferred to the sensor cable the pulse wheel is faulty Honeywell 3GT101DC Hall sensor requires tooth movement past the sensor A motionless tooth can not generate a pulse 3 3 4 Buffer amplifier KAE234 The speed sensor proximity switch or sensor bearing is connected to D2L via KAE234 buffer amplifier KAE234 must be located near the sensor usually in the connection box of the hoist or the motor Without a buffer amplifier some faulty pulses could activate the speed supervision of D2L Typically the problem would be a momentary lack of pulses or oscillations at the sensor output Usually the noise sensitivity increases when the sensor temperature rises KAE234 connection with sensor bearing 69 20 x1 24 6 RAV 30 0 155 5006 5 BROW

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