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Service Manual for Frequency Control System

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1. T5 011 T6 015 T7 018 MF11MB200 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 G 2 1 General Parameters P 2 1 10 Accel Time 1 2 5 P 2 1 10 Accel Time 1 2 5 P 2 1 10 Accel Time 1 2 5 P 2 1 11 Decel Time 1 2 5 P 2 1 11 Decel Time 1 2 5 P 2 1 11 Decel Time 1 2 5 G 2 2 Motor Parameters G 2 2 Motor Parameters G 2 2 Motor Parameters P 2 2 1 Motor Nom Volt 400 P 2 2 1 Motor Nom Volt 400 P 2 2 1 Motor Nom Volt 400 P 2 2 2 Motor Nom Freq 100 P 2 2 2 Motor Nom Freq 100 P 2 2 2 Motor Nom Freq 100 P 2 2 3 Motor Nom Speed 2830 P 2 2 3 Motor Nom Speed 2910 P 2 2 3 Motor Nom Speed 2890 P 2 2 4 Motor Nom Curr 21 P 2 2 4 Motor Nom Curr 31 P 2 2 4 Motor Nom Curr 36 P 2 2 5 Nom Flux Curr 12 P 2 2 5 Nom Flux Curr 15 P 2 2 5 Nom Flux Curr 15 P 2 2 6 Start Current 24 P 2 2 6 Start Current 32 P 2 2 6 Start Current 42 P 2 2 7 Current Limit 31 P 2 2 7 Current Limit 46 P 2 2 7 Current Limit 54 P 2 2 8 Min Freq S1 10 P 2 2 8 Min Freq S1 10 P 2 2 8 Min Freq S1 10 P 2 2 9 Min Freq S2 5 P 2 2 9 Min Freq S2 5 P 2 2 9 Min Freq S2 5 P 2 2 10 Max Freq S1 100 P 2 2 10 Max Freq S1 100 P 2 2 10 Max Freq S1 100 P 2 2 11 Max Freq S2 120 P 2 2 11 Max Freq S2 120 P 2 2 11 Max Freq S2 120 P 2 2 12 Ma
2. 44 2 4 3 Sensor bearing eee eee 14 7 3 Settings for non standard cases 45 24A ENCOde aeeiiaii iss 14 i f 8 Multicare Function c cccesceeeeeeeeees 46 2 5 EMC compatible grounding 0 15 8 1 Connections 4G 2 5 1 Construction connections cccceeeeeeeees 15 Bes Pat aren ig lS ete get eeead A Bde oy 252 Gabls CORNeCHONS oul ca cae 15 8 2 Setup seeteeecneeeecneeesseneeneentenseneeeneeneeeteneey 47 2 5 3 Shielded control cables cscessseeeeeeee 15 8 3 Test run without load eeeseeeeeeen 47 3 COMPONENTG ccssscsssssessesssssessesseesessseees 16 9 START UP PROCEDURE scsssee 48 Bx AVE ON serani art lids bestia ieee ead 16 9 1 Visual CHECKS secseecessesesseseeesseseeeneees 48 3 1 1 Power supply unit PSU ss 1005111000 110111101 17 9 2 Checks before the first test run 48 3 1 2 Control unit CSU eect eect eeeeeeeeeees 18 9 3 Test run without load c eee 49 3 1 3 Basic I O board Slot A eeeeeeeeeeeeeeneees 18 9 3 1 Functional test run for SSU 49 3 1 4 Relay Thermistor board Slot B 6 19 9 4 Test run With load 0 cee cee ceeeeeeeeeeeeeees 49 3 1 5 SSU Speed Supervision board Slot C 19 9 5 Test run with overload s s s 49 3 1 6 I O Extension board Slot D 20 9 6 Alter the test nis c hernias cceekiecdeine 49 3 2 Control v
3. s E E i F7 K7 G1 ar Fp M a H T SE E Al pa g S Z1_CM1 2243 x vene ar cil Zea gt x 2E E E I a 1 H gE 7mm 453 5 mm 17 85 in g 0 28 in 467 5 mm 18 41 in 018F 022F Weight 31 kg 68 Ibs F7 K7 G1 E 7 E g 3 F E E A1 3 g ei CM1 rai pola EEDEN JBE Z2 Z3 Z1 EE Tinm 453 5 mm 17 85 in 28 028i 467 5 mm 18 41 in Y 62 79 This document and the information contained herein is the exclusive property of R amp M Materials Handling Inc and represents a non public confidential and proprietary trade secret that may not be reproduced disclosed to third parties altered or otherwise employed in any manner whatsoever without the express written consent of R amp M Materials Handling Inc Copyright 2005 R amp M Materials Handling Inc All rights reserved R amp M Materials Handling Inc eLA M4501 Gateway Boulevard Wrens Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC 030F 045F 055F Weight 47 kg 102 Ibs Weight 80 k
4. 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 Sink Temp V4 15 Temperature of heat sink C MotorTemperature V4 16 Calculated motor temperature in percent of maximum 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 EE el ee Multimonitor N4 23 1 Multimonitor page shows motor current motor voltage and putput frequency in display in the same time Monitor variables can be changed if parameter P6 5 4 ChangeEnable Panel Control B5 1 Must not be used Off On Speed Reference R5 2 Speed reference for panel control Language S6 1 Keypad language English Application S6 2 Application Crane Parameter Sets 6 3 1 Not used see parameter group G4 1 Parameter backup Up to keypad 6 3 2 Save parameter settings up to keypad Down from keypad 6 3 3 Download parameter settings down from keypad 34 79 This document and the information contained herein is the exclusive property of R amp M Materials Handling Inc and represents a
5. P 937 328 5100 FAX 937 325 5319 D2FR18FR3S2 3x 32 ohm WIRING A B 2 5 OTHERS 0 75 3x 32 ohm OL230 ON230 Je o SS eS 1 3 1 6A ATS l E ROD1 X1 ee 4 47 gt P A S c11 6 C12 T y BLU BRN BLK BLU BRN BLK x M12 PE M11 PE 3 j Q Bi X11 8 F11 BRT1 BR 33 34 76 79 This document and the information contained herein is the exclusive property of R amp M Materials Handling Inc and represents a non public confidential and proprie lary trade secret that may not be reproduced disclosed to third parties altered or otherwise employed in any manner whatsoever without the express written consent of R amp M Materials Handling Inc Copyright 2005 R amp M Materials Handling Inc All rights reserved R amp M Materials Handling Inc RELY 4501 Gateway Boulevard Wrens Springfield Ohio 45502 PE P 937 328 5100 roms FAX 937 325 5319 D2FR24FR4S2 4x 32 ohm WIRING A 10 mm B 2 5 mm OTHERS 0 75 mm OL230 ON230 PE pa 12 A aE 3 18A 217 l F ROD1 x1 les 4 47 gt Z c11 6 C12 af 2 BLU BRN BLK BLU BRN BLK M12 PE M11 PE 3 Q X11 8 F11 BRT1 BRT2 33 34 9 77 79 This document and the information contained herein is the exclusive prop
6. 0 No 1 Yes 0 No 1 Yes 0 Not Zero Speed 1 Zero Speed 1 Ready 1 Run This document and the information contained herein is the exclusive property of R amp M Materials Handling Inc and represents a non public confidential and proprietary trade secret that may not be reproduced disclosed to third parties altered or otherwise employed in any manner whatsoever without the express written consent of R amp M Materials Handling Inc Copyright 2005 R amp M Materials Handling Inc All rights reserved 54 79 R amp M Materials Handling Inc 4501 Gateway Boulevard Springfield Ohio 45502 mem P 937 328 5100 meva FAX 937 325 5319 RM MATERIALS 10 3 2 Fault Counter V4 5 1 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 Overcurrent fault counter Overvoltage fault counter Earth fault counter Saturation trip fault counter Undervoltage fault counter When counter value is blinking then you can monitor fault counter values by pressing up and down arrows 55 79 Input line supervision fault counter Output phase supervision fault counter Braking chopper supervision fault counter Inverter undertemperature fault counter Inverter overtemperature fault counter Microprocessor watchdog fault counter IGBT temperature fault counter Profibus communication error fault counter Generator side cu
7. 52335543 EMC level N S D2V037NF 1004 52335548 EMC level 0 D2V045NF1N04 52335544 EMC level N S D2V045NF 1004 52335547 EMC level 0 D2V055NF1N04 52335545 EMC level N S D2V055NF 1004 52335546 EMC level 0 BOAR DS INCLUDED IN INVERTER D2V Basic O board NXOPTA6L 52335566 Slot A Relay Thermistor board NXOPTA3L 52335565 Slot B I O Extension board NXOPTB9L 52335564 Slot D SPEED SUPERVISION UNIT SSU not included in inverter D 2V Speed supervision unit SSUL 52335567 Slot C BRAK E SUPPLY CIRCUIT BREAKER F7 Protective switch GV2 ME08 52297213 Auxliary contact GV2 AN20 52275270 F71 Protective switch GV2 ME08 52297213 Auxliary contact GV2 AN20 52275270 af ajoa oa BRAK E CONTACTOR K7 Contactor LC1 D09D7 52303564 42VAC 1 1 1 1 1 1 1 1 1 1 1 1 1 CO1E7 52296542 48VAC 1 1 1 1 1 1 1 1 1 1 1 1 1 CO1F7 52296548 115VAC 1 1 1 1 1 1 1 1 1 1 1 1 1 58 79 This document and the information contained herein is the exclusive property of R amp M Materials Handling Inc and ri trade secret that may not be reproduced disc
8. 0 3s A1 S S K7 A2 m 18 48 F7 xg 33 34 153 154 X1 19 49 163 164 68 79 This document and the information contained herein is the exclusive property of R amp M Materials Handling Inc and represents a non public confidential and proprie ary trade secret that may not be reproduced disclosed to third parties altered or otherwise employed in any manner whatsoever without the express written consent of R amp M Materials Handling Inc Copyright 2005 R amp M Materials Handling Inc All rights reserved R amp M Materials Handling Inc eLA M4501 Gateway Boulevard Wrote Springfield Ohio 45502 P 937 328 5100 HANDLING aea FAX 937 325 5319 IN D2FR18F21R3S2 PET LC Z2 B 21 ohm A x B 2O Ai e L2 O O L1 Q c Z3 A U inom Fa ie een te V O F7 1 3 5 te gt gt CM1 Z1 Z2 Z3 AND CM1 NOT a a E X16 INCLUDED IN STANDARD OR 246 ow IT MODELS a OT D ais K7 2 j4 23 K7 55 K7 6 8 SET CG 1 2 0 3s 56l 3 ag 4 5 7 Y 5 DC DoE G1 4 6 7 D REITA A b O A at S1 11 S1 x1 33 4 g 12 S2 34 N DIAS 13 DIAS Ss 45 4 DIAA 14 DIA4 46 4 plas 16 ONE E 115 2 gt OK xa KAE234 D bd DID2 S11 252 OIS 4 DID3 S21 253 x1 4 DID4 12 54 5 AD OLE A DID5 S22 S5 16 Y 7 z 3 56 oe F SET 0 3s Al X K7 A2 X1 18 48 F7
9. 11 Freq 3 S2 40 P 2 3 11 Freq 3 S2 40 P 2 3 12 Zero Speed Curr 110 P2 3 12 Zero Speed Curr 110 P 2 3 12 Zero Speed Curr 110 P 2 3 13 Min Current Ref 90 P 2 3 13 Min Current Ref 90 P 2 3 13 Min Current Ref 90 P2 3 14 Accel Comp TC 0 1 P 2 3 14 Accel Comp TC 0 1 P2 3 14 Accel Comp TC 0 1 P 2 3 15 Ref Angle S1 768 P 2 3 15 Ref Angle S1 768 P 2 3 15 Ref Angle S1 768 P 2 3 16 Ref Angle S2 2000 P 2 3 16 Ref Angle S2 2000 P 2 3 16 Ref Angle S2 2000 P 2 3 17 Flux Curr Damp 200 P 2 3 17 Flux Curr Damp 200 P 2 3 17 Flux Curr Damp 200 P 2 3 18 Stop DC Freq 1 5 P 2 3 18 Stop DC Freq ts P 2 3 18 Stop DC Freq 1 5 P 2 3 19 Start Freq S1 1 5 P 2 3 19 Start Freq S1 1 P 2 3 19 Start Freq S1 1 P 2 3 20 Start Freq S2 0 5 P 2 3 20 Start Freq S2 0 5 P 2 3 20 Start Freq S2 0 5 P 2 3 21 Brake Stop Freq 1 P 2 3 21 Brake Stop Freq 1 P 2 3 21 Brake Stop Freq 1 P 2 3 22 ESR Point Freq 120 P 2 3 22 ESR Point Freq 120 P 2 3 22 ESR Point Freq 120 P 2 3 23 ESR Point Volt 120 P 2 3 23 ESR Point Volt 120 P 2 3 23 ESR Point Volt 120 P 2 3 24 IrAdd Motor 100 P 2 3 24 IrAdd Motor 100 P 2 3 24 IrAdd Motor 100 P 2 3 25 IrAdd Generator 100 P 2 3 25 IrAdd Generator 100 P 2 3 25 IrAdd Generator 100 P 2 3 26 Ramp Stretching 0 P 2 3 26 Ramp Stretching 0 P 2 3 26 Ramp Stretching 0 P 2 3 27 Switching Freq 3 6 P 2 3 27 Switching Freq 3 6 P 2 3 27 Switching Freq 3 6 P 2 3 28 DeadTime Comp 2200 P 2 3 28 DeadTime Comp 2200 P 2 3 28 DeadTime Comp 2200 P 2 3 29 DeadTimeCu
10. 14 3 1 Internal WiringS ceceeeeceeeceeeeeeeeeeeeeeees 64 13 SPARE PARTS LIST FOR HOISTING 14 3 2 Wiring Colours 2 ccnuieihetincdediaiiaid 64 INVERT ER AE EEEE EE 58 14 4 Circuit diagrams for braking resistors 73 14 DRAWINGS ccccccccccsecccccecseccsececcnsuesucecseueess 60 14 4 1 Internal WirinGS ccceeeeeeeeeeceeeeeeeeeeneeeees 73 14 1 Description of terminals cccceeeeee 60 14 5 Standard connections for pulse sensors 78 14 1 1 Power classes 002F 011F ee 60 3 79 This document and the information contained herein is the exclusive property of R amp M Materials Handling Inc and represents a non public confidential and proprietary trade secret that may not be reproduced disclosed to third parties altered or otherwise employed in any manner whatsoever without the express written consent of R amp M Materials Handling Inc Copyright 2005 R amp M Materials Handling Inc All rights reserved R amp M Materials Handling Inc RLA 4501 Gateway Boulevard Went Springfield Ohio 45502 HANDLING INC SESEEESE EEE FSFE g 4 179 P 937 328 5100 FAX 937 325 5319 This manual rev 5 0 is for inverter rev 5 1 with software Ind2V081 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 pro
11. 21 Brake Stop Freq 1 P 2 3 21 Brake Stop Freq 1 P 2 3 22 ESR Point Freq 120 P 2 3 22 ESR Point Freq 120 P 2 3 22 ESR Point Freq 120 P 2 3 23 ESR Point Volt 120 P 2 3 23 ESR Point Volt 120 P 2 3 23 ESR Point Volt 120 P 2 3 24 IrAdd Motor 100 P 2 3 24 IrAdd Motor 100 P 2 3 24 IrAdd Motor 100 P 2 3 25 IrAdd Generator 100 P 2 3 25 IrAdd Generator 100 P 2 3 25 IrAdd Generator 100 P 2 3 26 Ramp Stretching 0 P 2 3 26 Ramp Stretching 0 P 2 3 26 Ramp Stretching 0 P 2 3 27 Switching Freq 3 6 P 2 3 27 Switching Freq 3 6 P 2 3 27 Switching Freq 3 6 P 2 3 28 DeadTime Comp 2200 P 2 3 28 DeadTime Comp 2200 P 2 3 28 DeadTime Comp 2200 P 2 3 29 DeadTimeCurrLim 100 P 2 3 29 DeadTimeCurrLim 100 P 2 3 29 DeadTimeCurrLim 100 P 2 3 30 Brake Chopper Run P 2 3 30 Brake Chopper Run P 2 3 30 Brake Chopper Run 42 79 This document and the information contained herein is the exclusive property of R amp M Materials Handling Inc and represents a non public confidential and proprietary trade secret that may not be reproduced disclosed to third parties altered or otherwise employed in any manner whatsoever without the express written consent of R amp M Materials Handling Inc Copyright 2005 R amp M Materials Handling Inc All rights reserved R amp M Materials Handling Inc RELY 4501 Gateway Boulevard Wrote Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC 7 SPEED SUPERVISION SETTINGS SSU is a ho
12. 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 connection Main supply voltage terminals L1 Mains L1 L2 Mains L2 L3 Mains L3 PE Protective earth DC bus terminals B DC bus negative B DC bus positive Brake resistor positive R Brake resistor negative Motor output voltage terminals U T1 Motor U V T2 Motor V WITS Motor W 1 7 79 This document and the information contained herein is the exclusive property of R amp M Materials Handling Inc and represents a non public confidential and proprietary trade secret that may not be reproduced disclosed to third parties altered or otherwise employed in any manner whatsoever without the express written consent of R amp M Materials Handling Inc Copyright 2005 R amp M Materials Handling Inc All rights reserved DC R amp M Materials Handling Inc PCA ME 4501 Gateway Boulevard Wrote 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
13. 4 aa S 153 154 X1 19 49 163 164 69 79 This document and the information contained herein is the exclusive property of R amp M Materials Handling Inc and represents a non public confidential and proprietary trade secret that may not be reproduced disclosed to third parties altered or otherwise employed in any manner whatsoever without the express written consent of R amp M Materials Handling Inc Copyright 2005 R amp M Materials Handling Inc All rights reserved R amp M Materials Handling Inc RLA 4501 Gateway Boulevard Write Springfield Ohio 45502 mRempe P 937 328 5100 IN FAX 937 325 5319 D2FR24F 16R4S2 PET LC Z2 B 16 ohm A A B 2O Ai e L2 O O L1 Q c Z3 A U inom Fa ie een te V O F7 1 3 5 te gt gt CM1 Z1 Z2 Z3 AND CM1 NOT a a E X16 INCLUDED IN STANDARD OR 2 4 l6 IT MODELS a OT D ais K7 2 j4 23 KZ 5E K7 6 8 SET CG 1 2 0 3s 56l 3 ag 4 5 7 Y 5 DC G1 4 6 7 D REITA A b O A at S1 11 S1 x1 33 4 g 12 S2 34 N DIAS 13 DIAS Ss 45 4 DIAA 14 DIA4 46 4 plas 16 ONE E 115 2 gt OK xa KAE234 D bd DID2 S11 252 OIS 4 DID3 S21 253 x1 4 DID4 12 54 5 AD OLE A DID5 S22 S5 16 Y 7 z 3 56 Z 7 SET 0 3s Al X K7 A2 X1 18 48 F7 4 aa S 153 154 X1 19 49 163 164 70 79 This document and the in
14. 6 mm AWG 10 AWG 10 022F 037F 022F 022F 10 mm 10 mm 6 mm AWG 8 AWG 8 AWG 10 030F 037F O30F 045F 16 mm 10 mm AWG 6 AWG 8 045F 045F 16 mm 25 mm AWG 6 AWG 4 O55F 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 This document and the information contained herein is the exclusive property of R amp M Materials Handling Inc and represents a non public confidential and proprietary trade secret that may not be reproduced disclosed to third parties altered or otherwise employed in any manner whatsoever without the express written consent of R amp M Materials Handling Inc Copyright 2005 R amp M Materials Handling Inc All rights reserved 64 79 R amp M Materials Handling Inc 4501 Gateway Boulevard Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 RM MATERIALS HANDLING IN PE 7I L3 O L2 0 lt L1O X1 2T D 1 3 K7 2 4 K7 6 8 E1 E2 Ac a 5 7 oc 25 G1 D X1 31 4 32 AER S1 2 S2 4 DIA3 DIA4 DIAS e DID2 4 DID3 x1 ipa wo OLE JA DIDS 6 i ES WITH MULTICARE 26 23 ONEC S11 S21 S12 S22 ONE gt ES
15. CM1 Z1 Z2 Z3 AND CM1 NOT 2a INCLUDED IN STANDARD OR IT MODELS 11 S1 12 S2 a l 13 DIA3 E a J 14 DIA4 gt OK X1 KAE234 51 t4 52 253 254 O 55 O 56 A1 K7 A2 X118 48 453 154 X1 19 49 163 164 F7 33 34 66 79 This document and the information contained herein is the exclusive property of R amp M Materials Handling Inc and represents a non public confidential and proprietary trade secret that may not be reproduced disclosed to third parties altered or otherwise employed in any manner whatsoever without the express written consent of R amp M Materials Handling Inc Copyright 2005 R amp M Materials Handling Inc All rights reserved RM MATERIALS HANDLING IN R amp M Materials Handling Inc 4501 Gateway Boulevard Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 D2FR12F45R252 PE L e A L3 Q L2 L1 Q c WITH MULTICARE F7 4 3 5 te gt f Z1 Z2 Z3 AND CM1 NOT al al E X16 INCLUDED IN STANDARD OR 2 4 6 O IT MODELS y f 27 D 1 3 K7 24 123 K7 tt L2 s acy ja be Dc b z DC S G1 7 l D XTA 820 T L G 3 si 11 S1 p 52 O 12 S2 DIA3 O 13 DIA3 p PIAS Or 14 DIA4 4 DIAS ONE O gt OK KAE234 4 4 DID2 11 DID3 21 x1 4 DID4 S12 25 Q OLE 60 DIDS 22 l
16. Check password that password has value 2156 Check that parameter value is inside the limits Parameter value can not be changed in RUN state Parameter value change must be confirmed with Enter button 50 79 This document and the information contained herein is the exclusive property of R amp M Materials Handling Inc and represents a non public confidential and proprietary trade secret that may not be reproduced disclosed to third parties altered or otherwise employed in any manner whatsoever without the express written consent of R amp M Materials Handling Inc Copyright 2005 R amp M Materials Handling Inc All rights reserved R amp M Materials Handling Inc eLA M4501 Gateway Boulevard Wrens Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC 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 xx fault number appears on the display The drive includes an automatic fault reset operation the fault code stays on the display until the fault is removed and the controller released back to 0 position Some of the fault codes require to switch the power off before
17. Du dt filter should be as near inverter as possible w 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 connections may be split into two cables then the signal conductors 4pcs should go together in one cable and the supply and common 24V OV together in another cable The encoder cable s must be shielded round cable s and grounded 360 at both ends w 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 gr
18. Mid Volt U f Mid Freq U f Mid Freq U f Mid Freq U f Mid Freq Torque Boost On Torque Boost On Torque Boost Torque Boost On Rs Voltage Drop 200 Rs Voltage Drop 240 Rs Voltage Drop Rs Voltage Drop 130 Stop Function Ramping Stop Function Ramping Stop Function Stop Function Ramping rt rt rt rt Flux Current Kp 4000 Flux Current Kp 4000 Flux Current Kp Flux Current Kp 4000 Flux Current Ti 25 Flux Current Ti 25 Flux Current Ti Flux Current Ti 25 S2 Flux Control 100 S2 Flux Control 100 S2 Flux Control S2 Flux Control 100 Freq 0 1 Freq 0 1 Freq 0 Freq 0 1 Freq 1 3 Freq 1 3 Freq 1 Freq 1 3 Freq 2 S1 10 Freq 2 S1 10 Freq 2 S1 Freq 2 S1 10 Freq 3 S1 20 Freq 3 S1 20 Freq 3 S1 Freq 3 S1 20 Zero Flux Curr 80 Zero Flux Curr 80 Zero Flux Curr Zero Flux Curr 80 Stray Flux Curr 40 Stray Flux Curr 40 Stray Flux Curr Stray Flux Curr 40 Freq 2 S2 10 Freq 2 S2 10 Freq 2 S2 Freq 2 S2 10 Freq 3 S2 20 Freq 3 S2 20 Freq 3 S2 Freq 3 S2 40 Zero Speed Curr Zero Speed Curr Zero Speed Curr Zero Speed Curr Min Current Ref 90 Min Current Ref 90 Min Current Re
19. altered or oMa employed in any iane whatsoever wlfwun the express wri coremrt of RAM Materials Handling Inc Copyright 2005 R amp M Materials Handling Inc All rights reserved R amp M Materials Handling Inc RLA 4501 Gateway Boulevard Write Springfield Ohio 45502 Remp P 937 328 5100 INC FAX 937 325 5319 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 S2 Speed 2 P2 1 7 MS 2 Speed 3 P2 1 8 MS 3 Speed 4 P2 1 9 MS 4 1 6 1 EP2 control ITN gt a gt gt NAY gt ee am A Q VOY ee z A 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 running at maximum speed hold speed 1 6 2 EP3 control YYYY siaa c_coep3a ee 7 0 vA A Pushbutton controller position B Speed decelerate to zero step 1 drive minimum speed step 2 hold speed step 3 while running accelerate while running at maximum speed hold speed UN oO weer we 9 79 This document and the information contained herein is the exclusive property of R amp M Materials Handling Inc and represents a non public confiden
20. blinks and the display shows a fault code instead of frequency Check that green RUN status indicator is off Check that external connections and selected control method are according to application Parameters are properly set after factory tests and no adjustments are needed except for the parameters that depend on application Write down on the parameter list all the values that have been changed and at the end save parameters to User parameters see chapter User parameters 48 79 This document and the information contained herein is the exclusive property of R amp M Materials Handling Inc and represents a non public confidential and proprietary trade secret that may not be reproduced disclosed to third parties altered or otherwise employed in any manner whatsoever without the express written consent of R amp M Materials Handling Inc Copyright 2005 R amp M Materials Handling Inc All rights reserved R amp M Materials Handling Inc RELY 4501 Gateway Boulevard Wren Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC 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 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 is applied and counter clockwise if S2 is app
21. encoder does not have negative channels A and B EA and EB must be connected to OV at motor terminal box alternative connection In order to avoid fault situations the cable between the encoder and inverter must be as far as possible from the cables of motor and braking resistor minimum distance gt 20cm a shielded and twisted cable grounded the shield at both ends 360 grounding on inverter terminal the shield should be grounded always when going through terminals Some problems may occur when using shielded flat cable or in situations where the encoder cable has been placed too close lt 5cm to the motor cables and braking resistor cables 22 79 This document and the information contained herein is the exclusive property of R amp M Materials Handling Inc and represents a non public confidential and proprietary trade secret that may not be reproduced disclosed to third parties altered or otherwise employed in any manner whatsoever without the express written consent of R amp M Materials Handling Inc Copyright 2005 R amp M Materials Handling Inc All rights reserved R amp M Materials Handling Inc RELY 4501 Gateway Boulevard Wrens Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC 3 3 3 Proximity switch In modernisation cases there might be proximity switch as pulse sensor of motor Inverter needs information about the motor rotation speed for stall speed differe
22. encoder pulse number speed difference supervision settings F 63 Stall Supervision SSU has tripped to Stall Reset when 1s without pulses from pulse sensor encoder to X Fault 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 SSU board is damaged or SSU Reset switch power off and restart after the lamps of keypad X Fault relay is bypassed are off Check ES and RDY external connections OK input operation change SSU board 53 79 This document and the information contained herein is the exclusive property of R amp M Materials Handling Inc and represents a non public confidential and proprietary trade secret that may not be reproduced disclosed to third parties altered or otherwise employed in any manner whatsoever without the express written consent of R amp M Materials Handling Inc Copyright 2005 R amp M Materials Handling Inc All rights reserved RM R amp M Materials Handling Inc 4501 Gateway Boulevard Springfield Ohio 45502 MATERIALS mem P 937 328 5100 NE FAX 937 325 5319 F 65 SSU Watchdog SSU internal fault Reset switch power off and restart after the lamps of display interference fault between SSU board are off and control board Check component failure control board or SSU status System menu System info Expander boards SSU board I C SSU stat
23. in any manner whatsoever without the express written consent of R amp M Materials Handling Inc Copyright 2005 R amp M Materials Handling Inc All rights reserved R amp M Materials Handling eLA M4501 Gateway Boulevard Wrote Springfield Ohio 45502 P 937 328 5100 HANDLING aea FAX 937 325 5319 IN Inc 055F 2 x D2FR24F16R4S2 16 ohm 2 8 ohm Cc ml EE TT ew O F7 1 13 5 FTE T 3 5 te fe Z1 Z2 Z3 AND CM1 NOT a al fA X16 INCLUDED IN STANDARD OR 24 6 O IT MODELS r 27 D ToS K7 24 23 K7 ss N K7 6 8 SET ih 0 3s 56 3 Za ls 7 5262 72 82 ACZ K71 foc 5 5161 71 81 ous G1 423 C 6 7 gt X1 31 B28 NAL si 11 S1 s2 12 S2 piss 13 DIA3 DiA4 14 DIA4 DIAS gt OK KAE234 4 DID2 DID3 x1 DID4 5 A OLE VA DIDS 6 gt 13 af A1 ALL ES K7 K71 A2 A2 F11 h BRT1 X1 18 48 153 154 F11 X1 19 49 1463 164 BRT1 72 79 This document and the information contained herein is the exclusive property of R amp M Materials Handling Inc and represents a non public confidential and proprie ary trade secret that may not be reproduced disclosed to third parties altered or otherwise employed in any manner whatsoever without the express written consent of R amp M Materials Handling Inc Copyright 2005 R amp M Materials Handling Inc All rights reserve
24. limited to Drive maximum output current 1 minute value Min Freq S1 P2 2 8 Minimum frequency direction 1 0 Max Freq S2 Hz Hoisting application Smaller value than factory setting is not allowed to use Min Freq S2 P2 2 9 Minimum frequency direction 2 0 Max Freq S2 Hz Hoisting application Smaller value than factory setting is not allowed to use Max Freq S1 P2 2 10 Maximum frequency direction 1 0 250 Hz Max Freq S2 P2 2 11 Maximum frequency direction 2 0 250 Hz Max ESR freq P2 2 12 Maximum frequency when ESR activated 0 250 Hz Drive Selection P2 2 13 Application selection selection None causes F60 Parameter fault 0 None 1 Travel 2 Hoist Pulse Number P2 2 14 Pulse wheel pulse number 0 24 1 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 of motor nominal 0 100 voltage U f Mid Freq P2 2 17 Middle point frequency 0 250 Hz Torque Boost P2 2 18 Torque maximization Off On RS Voltage Drop P2 2 19 Relative value of motor stator impedance voltage drop Value of this 0 512 parameter is calculated by formula given below Motor Nom Flux current x Measured motor resistance phase to phase x 2217 Motor nominal voltage Stop Function P2 2 20 Stopping mode selection 0 Brake Ramping When the drive command is switched off
25. mode frequency limit in percentage of nominal 0 100 frequency Between 0 Hz and Freq 0 current control keeps motor current in value of P2 3 12 Zero Speed Current Freq 1 P2 3 5 Flux current mode frequency limit in percentage of nominal 0 100 frequency Between frequencies Freq 1 and Freq 2 drive is controlled with special flux current control method Freq 2 S1 P2 3 6 Mixed current voltage mode frequency limit in percentage of nominal 0 100 frequency in direction S1 Must not be changed Freq 3 S1 P2 3 7 U f control mode frequency limit in percentage of nominal frequency 0 100 in direction S1 Must not be changed Zero Flux Curr P2 3 8 Relative value of flux current of motor Typical value of this current 0 100 control method is 80 Parameter is not related to motor real physical values Must not be changed Stray Flux Curr P2 3 9 Relative value of stray flux current of motor Typical value of this 0 100 current control method is 40 Parameter is not related to motor real physical values Must not be changed Freq 2 S2 P2 3 10 Mixed current voltage mode frequency limit in percentage of nominal 0 100 frequency in direction S2 Must not be changed Freq 3 S2 P2 3 11 U f control mode frequency limit in percentage of nominal frequency 0 100 in direction S2 Must not be changed Zero Speed Curr P2 3 12 Relative value of motor current used in small frequencies of motor 0 250 nominal current Must not be changed Min Curr
26. of motor and braking resistor minimum distance gt 20cm a shielded and twisted cable grounded the shield at both ends 360 grounding on inverter terminal the shield should be grounded always when going through terminals 23 79 This document and the information contained herein is the exclusive property of R amp M Materials Handling Inc and represents a non public confidential and proprietary trade secret that may not be reproduced disclosed to third parties altered or otherwise employed in any manner whatsoever without the express written consent of R amp M Materials Handling Inc Copyright 2005 R amp M Materials Handling Inc All rights reserved R amp M Materials Handling Inc RELY 4501 Gateway Boulevard myoma Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC Some problems may occur 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 transferr
27. otherwise employed in any manner whatsoever without the express written consent of R amp M Materials Handling Inc Copyright 2005 R amp M Materials Handling Inc All rights reserved R amp M Materials Handling Inc RELY ME 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 s EG Power class 002 005 007 011 015 055 ge P 2 2 11 Max Freq S2 120 120 120 S2 ees P 2 2 14 Pulse Number 32 64 80 5 i Rotary switch S1 1 A D Switch S2 1 ON ON ON Switch S2 2 OFF OFF OFF Switch S2 3 OFF OFF OFF E Switch S2 4 ON ON ON 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 a
28. 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 F60 F66 F71 F72 N STOPLREADY Nl sTopL READY erpcsh Mg lt 2 A H8 1 lt A 78 1 1 Fault History lt P 57 Thermistor lt P Operation days Hox gt YF T m3 gt VY 0 lt 1 gt Fault Fault Possible cause Checking A B code F14 Overcurrent Inverter has measured too high current over Reset switch power off and restart after the lamps of display X 4 In in the motor output 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 135 maximum Reset has an additional 5s time delay x level 911Vdc Check supply voltage raised gt 1 35 x Un high Adjust the deceleration time longer overvoltage spikes at mains or not measure main supply voltage level and wave form while sinusoidal wave form not driving Deceleration time is too short motor insulation motor cable insulation phase ground phase phase braking resistor cable braking resistor type
29. 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 Flux Current Ti P2 3 2 The integration time of the flux current control Too small or too large O 1000 ms value results oscillation in the current control Must not be changed S2 Flux Control P2 3 3 Increases or decreases the Flux Current controller values P2 3 1 amp 2 0 100 to direction S2 Must not be changed Used in hoisting application This document and the information contained herein is the exclusive property of R amp M Materials Handling Inc and represents a non public confidential and proprietary Materials Handling Inc Copyright 2005 R amp M Mai trade secret that may not be reproduced disclosed to third parties altered or otherwise employed in any manner whatsoever without the express written consent of R amp M terials Handling Inc All rights reserved 32 79 RM R amp M Materials Handling Inc 4501 Gateway Boulevard Springfield Ohio 45502 MATERIALS meem P 937 328 5100 Ne FAX 937 325 5319 Freq 0 P2 3 4 Constant current
30. third parties altered or otherwise employed in any manner whatsoever without the express written consent of R amp M lary Materials Handling Inc Copyright 2005 R amp M Materials Handling Inc All rights reserved R amp M Materials Handling Inc PAMI 4501 Gateway Boulevard vea Opringfield Ohio 45502 mnene P 937 328 5100 mea FAX 937 325 5319 Save User Par B4 1 2 Saves Active Parameters in the Control Unit as User Parameters Final parameters for the application must be saved as User Parameters after start up Load User Par B4 1 3 Restores User Parameters to Active Parameters from the control unit memory User Parameters are the parameters which have been saved after start up E S 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 Ain1 Value V4 2 1 Value of analog input Ain1 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 ROB1 State V4 3 1 State of relay output ROB1 O OFF 1 ON ROB2 State K7 V4 3 2 State of relay output ROB2 K7 O OFF 1 ON ROC1 State V4 3 3 State of relay output ROC1 O OFF 1 ON ROD1 State V4 3 4 St
31. 00 HANDLING aea FAX 937 325 5319 INC Drive with maximum speed the motion must stop at once fault F62 Speed difference is activated Reconnect the disconnected signal wire to terminal X1 51 Set rotary switch S1 S3 value 2 steps smaller Drive with maximum speed The motion must stop after full speed is reached fault F64 Over speed is activated Set rotary switch S1 S3 back to original value 7 3 Settings for non standard cases Overspeed tripping frequency levels a pee Normal 1 Normal Tripping level selection S2 ESR ESR Range selection 2 1 together with S1 are used for setting the tripping frequency level at normal speed 2 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 1902Hz 1600Hz frequency of 1600 Hz settings are 118 9 of nominal speed Suitable maximum overspeed S2 2 OFF and S2 3 OFF detection level is 1600Hz 25 2000Hz S2 1 OFF and S2 4 OFF S1 F and S3 F ESR use If ESR is applied for 150 of S2 2 OFF and S2 3 OFF are according Che
32. 002NF1e000 6 5 10 6 13 D2V003NF1e000 8 12 6 13 D2V004NF1e000 10 15 6 13 D2VO05NF1e000 13 20 6 13 D2V007NF1e000 18 27 10 22 D2V011NF1e000 24 36 10 22 D2V015NF1e000 32 48 20 44 D2V018NF1e000 42 63 20 44 D2V022NF1e000 48 72 20 44 D2V030NF1e000 60 90 37 82 D2V037NF1e000 75 113 37 82 D2V045NF1e000 90 135 37 82 D2V055NF1e000 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 HII DC DC The main circuit diagram of D2V007 D2V055 16 79 This document and the information contained herein is the exclusive property of R amp M Materials Handling Inc and represents a non public confidential and proprietary trade secret that may not be reproduced disclosed to third parties altered or otherwise employed in any manner whatsoever without the express written consent of R amp M Materials Handling Inc Copyright 2005 R amp M Materials Handling Inc All rights reserved R amp M Materials Handling Inc 4501 Gateway Boulevard Springfield Ohio 45502 RM MATERIALS HANDLING INC P 937 328 5100 FAX 937 325 5319 DC L1 O GER H uh G K VAG UH_D VHD US g uL D
33. 0R0S4 for 002 005 is in own cubicle Power class Standard cubicle Cubicle size mm Braking resistor mm 002 005 EEO25 604 400 x 600 400 x 400 007 015 CC600E 600 x 1000 Included 018 030 KA220D2 1000 x 1000 Included 037 045 1 x KA220D2 1 x 1000 x 1000 Included 055 1 x H15BD02 1 x 1500 x 1000 Included 2 2 Braking resistor Inverter is delivered with external braking resistor Braking resistor types D2FR are equipped with cooling fans and thermistors Circuit diagrams are in appendix Power class Resistance ohm Type 002 005 90 D2HRO4F90ROS4 007 64 D2FRO6F64RO0S2 011 015 45 D2FR12F45R2S2 018 022 21 D2FR18F21R3S2 030 16 D2FR24F16R4S2 037 045 11 2 x D2RF18F21R3S2 055 8 2 x D2FR24F16R4S2 In case of 2 resistor units power supply to transformers has to be taken from the same phases 2 3 Power cabling 2 3 1 Shielded motor cable In crane application inverter fulfils EN61800 3 A11 IEC 1800 3 second environment radiated emission requirements without shielded motor cable In the second environment shielded motor cable is recommended to use in fixed installations especially in buildings However motor cables in crane and festoon power supplies are normally not shielded due to the practical reasons 2 3 2 Double collectors If the power is supplied to the crane via conductor rails double collectors are needed This ensures a reliable cont
34. 10 4 2 1 User parameters s e 29 1 7 Mechanical brake control 008 10 4 2 2 Default parameters 0 cccccccceeseeeeeees 29 18 EMC eid eaaa eaae EA E te doats 11 4 2 3 Keypad settings 0 0 00 eeeee 29 2 INSTALLATION ccccccccccececcecccceccceccceeeeese 12 4 2 4 Factory SettNngS ins sissi i i 29 2 1 Cubicles ee 12 5 PARAMETER DESCRIPTIONS 30 2 2 Braking resistor ereere 12 6 FACTORY DEFAULT PARAMETERS 38 2 3 Power cabling iii diss covets escseeicrenviecutsterctonstee 12 6 1 Factory default parameters for 100Hz 231 Shielded motor Cable ccccccccccccccececececcceeee 12 MOLOMS ea E A On Avdacdnasscet Severely 38 2 3 2 Double collectors cccceccceseesseeseeeseeseeaes 12 6 2 Factory default parameters for 120Hz 2 3 3 Cable Selection 0 0 ccc ccccccesseceecsseeeeeteeees 12 MOO E sc cee eE x ts ava dic cdenth a 41 2 3 4 Cable Protectio nsise iii 13 7 SPEED SUPERVISION SETTINGG 43 2 3 5 Cable length EPEE AT NE ETAT F ET 13 7 1 Standard settings AAEE EEATT 44 2 3 6 Du dt filters E A A emcee aemacaiaracseeaeeencan 14 7 1 1 Settings for sensor bearing lt fan Seah E AE 44 2 4 Signal cabling AEAEE aia AUUE EEE PE EE EE 14 7 1 2 Settings for pulse wheel speed sensor or 2 4 1 Shielded signal Cable s eee 14 encoder 24 ppr se van ciastsaienacian Oana ates 44 2 4 2 Reference signals E tual eeociviced vate cre cave tata 14 7 2 Functional test run for SSU
35. 17 Flux Curr Damp 40 P 2 3 17 Flux Curr Damp 40 P 2 3 17 Flux Curr Damp 40 P 2 3 17 Flux Curr Damp 200 P 2 3 18 Stop DC Freq 1 5 P 2 3 18 Stop DC Freq 1 5 P 2 3 18 Stop DC Freq 1 5 P 2 3 18 Stop DC Freq 1 5 P 2 3 19 Start Freq S1 1 5 P 2 3 19 Start Freq S1 1 5 P 2 3 19 Start Freq S1 1 5 P 2 3 19 Start Freq S1 1 5 P 2 3 20 Start Freq S2 0 5 P 2 3 20 Start Freq S2 0 5 P 2 3 20 Start Freq S2 0 5 P 2 3 20 Start Freq S2 05 P 2 3 21 Brake Stop Freq 2 P 2 3 21 Brake Stop Freq 2 P 2 3 21 Brake Stop Freq 1 5 P 2 3 21 Brake Stop Freq 1 P 2 3 22 ESR Point Freq 120 P 2 3 22 ESR Point Freq 120 P 2 3 22 ESR Point Freq 120 P 2 3 22 ESR Point Freq 120 P 2 3 23 ESR Point Volt 120 P 2 3 23 ESR Point Volt 120 P 2 3 23 ESR Point Volt 120 P 2 3 23 ESR Point Volt 120 P 2 3 24 IrAdd Motor 100 P 2 3 24 IrAdd Motor 100 P 2 3 24 IrAdd Motor 100 P 2 3 24 IrAdd Motor 100 P 2 3 25 IrAdd Generator 100 P 2 3 25 IrAdd Generator 100 P 2 3 25 IrAdd Generator 100 P 2 3 25 IrAdd Generator 100 P 2 3 26 Ramp Stretching 0 P 2 3 26 Ramp Stretching 0 P 2 3 26 Ramp Stretching 0 P 2 3 26 Ramp Stretching 0 P 2 3 27 Switching Freq 3 6 P 2 3 27 Switching Freq 3 6 P 2 3 27 Switching Freq 3 6 P 2 3 27 Switching Freq 3 6 P 2 3 28 DeadTime Comp 2200 P 2 3 28 DeadTime Comp 2200 P 2 3 28 DeadTime Comp 2200 P 2 3 28 DeadTime Comp 2200 P 2 3 29 DeadTimeCurrLim 100 P 2 3 29 DeadTimeCurrLim 100 P 2 3 29 DeadTimeCurrLim 100 P 2 3 29 DeadTimeCurrLim 100 P 2 3 30 Brake Chopper Run
36. 52299354 2 2 2 Z1 EF32010 52299352 2 2 2 72 W7427015 52299354 Te A Z3 W742701111 52300355 TTET Z2 W7427015 52299354 3 Z3 W7427015 52299354 4 59 79 This document and the information contained herein is the exclusive property of R amp M Materials Handling Inc and represents a non public confidential and proprietary trade secret that may not be reproduced disclosed to third parties altered or otherwise employed in any manner whatsoever without the express written consent of R amp M Materials Handling Inc Copyright 2005 R amp M Materials Handling Inc All rights reserved R amp M Materials Handling Inc RZA 4501 Gateway Boulevard Wrote Springfield Ohio 45502 PGE P 937 328 5100 INC FAX 937 325 5319 14 1 2 Power classes 015F 055F No Name 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 Name Description signal level 4 BL1 AC brake supply phase 1 kil 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 voltag
37. Defines ESR field weakening point voltage in percents of motor 0 250 nominal 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 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 1 Yes Run Always while drive is in ready state or only while running 0 Yes Ready 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 This document and the information contained herein is the exclusive property of R amp M Materials Handling Inc and represents a non public confidential and proprie trade secret that may not be reproduced disclosed to
38. English 2 11 2006 SERVICE MANUAL FOR FREQUENCY CONTROL SYSTEM RM MATERIALS HANDLING INC R amp M Materials Handling Inc 4501 Gateway Boulevard Springfield Ohio 45502 epee P 937 328 5100 were FAX 937 325 5319 RM MATERIALS w Read the instructions supplied with the product before installation and commissioning S Table of content Keep the instructions in a safe place for future reference 1 GENERAL fos cesccccccecibsccsciececetceteenetesersecreanarescer 5 3 3 4 Buffer amplifier KAE234 000 24 1 1 Technical data cccccccceceeeeeesssseeeeeeees 5 3 4 Brake controllers cccecccceceeeeeeeeeeees 25 1 2 Basic description c ccceeeeeeeeeeeeeeeee 6 BAA S A A ctrr atte te seodle Hs caneteeureeecs 25 1 3 Main component ccccceeeseeeteeeeeeeeee 6 3 4 2 ESD14 Tp ena e a aane 25 1 4 Functional description c cc eeeeeeees 7 4 PARAMETER ADJUSTMENTG 27 1 5 Factory code example Factory D2L 8 4 1 The display panel cececeeceeeeeeeeees 27 1 6 Description of the control modeg 8 4 1 1 Navigation on the control keypad 28 1 6 1 EP2 Control seinere ene ae enie 9 4 1 2 Value line editing ccceeceeeeeeeeeeeeeees 28 1 6 2 EPS CoOmtroli 3 2 2 56 Neetu oan i hace ep ee 9 4 2 Storing and restoring parameters 29 1 6 3 MSA Contolera eis
39. G INC R amp M Materials Handling Inc 4501 Gateway Boulevard Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 6 FACTORY DEFAULT PARAMETERS 6 1 Factory default parameters for 100Hz motors 002 004 005 007 T1 MF10MA200 400V 100Hz T2 MF10MB200 400V 100Hz T3 MF10MC200 400V 100Hz 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 Accel Time 1 2 5 P 2 1 10 Accel Time 1 2 5 Accel Time 1 2 5 Accel Time 1 2 5 Decel Time 1 2 5 Decel Time 1 2 5 Decel Time 1 2 5 Decel Time 1 2 5 r Parameters r Parameters r Parameters r Parameters Motor Nom Volt 400 Motor Nom Volt 400 Motor Nom Volt 400 Motor Nom Volt 400 Motor Nom Freq 100 Motor Nom Freq 100 Motor Nom Freq 100 Motor Nom Freq 100 Motor Nom Speed 2830 Motor Nom Speed 2790 Motor Nom Speed 2780 Motor Nom Speed 2860 Motor Nom Curr 4 8 Motor Nom Curr 9 4 Motor Nom Curr 10 7 Motor Nom Curr 18 Nom Flux Curr 3 2 Nom Flux Curr 6 2 Nom Flux Curr 6 3 Nom Flu
40. Kp 4000 P 2 3 2 Flux Current Ti 25 P 2 3 2 Flux Current Ti 25 P 2 3 2 Flux Current Ti 25 P 2 3 2 Flux Current Ti 25 P 2 3 3 S2 Flux Control 100 P 2 3 3 S2 Flux Control 100 P 2 3 3 S2 Flux Control 100 P 2 3 3 S2 Flux Control 100 P 2 3 4 Freq 0 1 P 2 3 4 Freq 0 1 P 2 3 4 Freq 0 1 P 2 3 4 Freq 0 1 P 2 3 5 Freq 1 3 P 2 3 5 Freq 1 3 P 2 3 5 Freq 1 3 P 2 3 5 Freq 1 3 P 2 3 6 Freq 2 S1 10 P 2 3 6 Freq 2 S1 10 P 2 3 6 Freq 2 S1 10 P 2 3 6 Freq 2 S1 10 P 2 3 7 Freq 3 S1 20 P 2 3 7 Freq 3 S1 20 P 2 3 7 Freq 3 S1 30 P 2 3 7 Freq 3 S1 20 P 2 3 8 Zero Flux Curr 80 P 2 3 8 Zero Flux Curr 80 P 2 3 8 Zero Flux Curr 80 P 2 3 8 Zero Flux Curr 80 P 2 3 9 Stray Flux Curr 40 P 2 3 9 Stray Flux Curr 40 P 2 3 9 Stray Flux Curr 40 P 2 3 9 Stray Flux Curr 40 P 2 3 10 Freq 2 S2 10 P 2 3 10 Freq 2 S2 10 P 2 3 10 Freq 2 S2 10 P 2 3 10 Freq 2 S2 10 P 2 3 11 Freq 3 S2 20 P 2 3 11 Freq 3 S2 20 P 2 3 11 Freq 3 S2 20 P 2 3 11 Freq 3 S2 40 P 2 3 12 Zero Speed Curr 120 P 2 3 12 Zero Speed Curr 110 P2 3 12 Zero Speed Curr 120 P 2 3 12 Zero Speed Curr 110 P 2 3 13 Min Current Ref 90 P 2 3 13 Min Current Ref 90 P 2 3 13 Min Current Ref 90 P 2 3 13 Min Current Ref 90 P2 3 14 Accel Comp TC 0 1 P 2 3 14 Accel Comp TC 0 1 P 2 3 14 Accel Comp TC 0 1 P 2 3 14 Accel Comp TC 0 1 P 2 3 15 Ref Angle S1 768 P 2 3 15 Ref Angle S1 768 P 2 3 15 Ref Angle S1 768 P 2 3 15 Ref Angle S1 768 P 2 3 16 Ref Angle S2 1536 P 2 3 16 Ref Angle S2 1536 P 2 3 16 Ref Angle S2 1536 P 2 3 16 Ref Angle S2 2000 P 2 3
41. L 65 79 D2HR04F90R0S4 Z2 B 90 ohm B i Lee O Z3 A U O ra E ow lt 2 CM1 Z1 Z2 Z3 AND CM1 NOT INCLUDED IN STANDARD OR IT MODELS 11 31 x1 33 0 12 S2 gt 34 L 13 DIA3 gt 45A 14 DIA4 C 46 16 15 gt OK x4 KAE234 51 O 4 52n 535 54 55 3 156 OY l7 AL K7 AQ 7 X1 118 48 153 154 X1 19 49 163 164 ary This document and the information contained herein is the exclusive property of R amp M Materials Handling Inc and represents a non public confidential and proprie trade secret that may not be reproduced disclosed to third parties altered or otherwise employed in any manner whatsoever without the express written consent of R amp M Materials Handling Inc Copyright 2005 R amp M Materials Handling Inc All rights reserved RM MATERIALS HANDLING IN R amp M Materials Handling Inc 4501 Gateway Boulevard Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 PE Sale L3 O L2 0 lt L10 c F7 l1 la 5 tou a 6 fa 246 i D 1 3 K7 2 4 K7 6 L1 L2 ac 5 oe P G1 l D X1 31 A A 32 8 WITH MULTICARE X1 26 BEA 123 125 feito feet ed ai S1 S2 DIA3 DIA4 DIA5 ONEC DID2 11 DID3 21 DID4 12 DIDS 22 ONE X11 3 4 ES ES iat X18 D2FROGF64ROS2 Z2 B 64 ohm B O O Z3 A U O E i oy TU ow
42. LY 4501 Gateway Boulevard Wrote Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC 1 GENERAL 1 1 Technical data Power class 002F 003F 004F OO5F OO7F 0114F O015F 018F 022F 030F 037F 045F 055F Power kVA at 400V 4 5 5 5 7 9 13 17 22 29 33 40 50 60 75 Output current In A 6 5 8 10 13 18 24 32 42 48 60 75 90 110 Max current 1min A 10 12 15 20 27 36 48 63 72 90 113 135 165 Overloadability Max output voltage 1 5 x In 1min 10min Equal to supply voltage Supply Supply voltage 380 500VAC Allowable voltage fluctuation 10 Nominal supply frequency Signal input levels Digital controls Encoder feedback Control features Control method Frequency control range Frequency command Limit switch functions Speed control range Speed accuracy Extended speed range Braking torque Protections Stall prevention Motor overload protection Overload protection Undervoltage blown fuse Overvoltage protection Momentary power loss Inverter overtemperature Mechanical brake Braking transistor Ground fault Overspeed stall Speed difference supervision Ambient conditions Ambient temperature Storage temperature 50 60HZz 5 S1 S2 DIA3 DIA4 DIA5 DID1 DID2 DID3 DID4 DID5 42 240VAC 15mA EA and EB 0 24V 3kQ floating differential inputs Open loop vector control 0 250Hz Motor potentiometer or 2 4 step controller Slowdown and stop limit inputs for both directio
43. P 2 2 3 Motor Nom Speed 3500 P 2 2 3 Motor Nom Speed 3480 P 2 2 4 Motor Nom Curr 22 P 2 2 4 Motor Nom Curr 31 P 2 2 4 Motor Nom Curr 37 P 2 2 5 Nom Flux Curr 12 P 2 2 5 Nom Flux Curr 15 P 2 2 5 Nom Flux Curr 15 P 2 2 6 Start Current 24 P 2 2 6 Start Current 32 P 2 2 6 Start Current 42 P 2 2 7 Current Limit 31 P 2 2 7 Current Limit 46 P 2 2 7 Current Limit 54 P 2 2 8 Min Freq S1 10 P 2 2 8 Min Freq S1 10 P 2 2 8 Min Freq S1 10 P 2 2 9 Min Freq S2 5 P 2 2 9 Min Freq S2 5 P 2 2 9 Min Freq S2 5 P 2 2 10 Max Freq S1 120 P 2 2 10 Max Freq S1 120 P 2 2 10 Max Freq S1 120 P 2 2 11 Max Freq S2 120 P 2 2 11 Max Freq S2 120 P 2 2 11 Max Freq S2 120 P 2 2 12 Max ESR Freq 120 P2 2 12 Max ESR Freq 120 P 2 2 12 Max ESR Freq 120 P 2 2 13 Drive Selection Hoist P 2 2 13 Drive Selection Hoist P 2 2 13 Drive Selection Hoist P 2 2 14 Pulse Number 64 P 2 2 14 Pulse Number 80 P 2 2 14 Pulse Number 80 P 2 2 15 Zero Freq Volt P 2 2 15 Zero Freq Volt P 2 2 15 Zero Freq Volt P 2 2 16 U f Mid Volt P 2 2 16 U f Mid Volt P 2 2 16 U f Mid Volt P 2 2 17 U f Mid Freq P 2 2 17 U f Mid Freq P 2 2 17 U f Mid Freq P 2 2 18 Torque Boost On P 2 2 18 Torque Boost On P 2 2 18 Torque Boost On P 2 2 19 Rs Voltage Drop 150 P 2 2 19 Rs Voltage Drop 180 P 2 2 19 Rs Voltage Drop 180 P 2 2 20 Stop Function Ramping P 2 2 20 Stop Function Ramping P 2 2 20 Stop Function Ramping G 2 3 Expert G 2 3 Expert G 2 3 Expert P 2 3 1 Flux Current Kp 4000 P 2 3 1 Flux Current Kp 4000 P 2 3 1 Flux Cur
44. P 2 3 30 Brake Chopper Run P 2 3 30 Brake Chopper Run P 2 3 30 Brake Chopper Run 38 79 This document and the information contained herein is the exclusive property of R amp M Materials Handling Inc and represents a non public confidential and proprietary trade secret that may not be reproduced disclosed to third parties altered or otherwise employed in any manner whatsoever without the express written consent of R amp M Materials Handling Inc Copyright 2005 R amp M Materials Handling Inc All rights reserved R amp M Materials Handling Inc eLA M4501 Gateway Boulevard Wrote Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC 39 79 This document and the information contained herein is the exclusive property of R amp M Materials Handling Inc and represents a non public confidential and proprietary trade secret that may not be reproduced disclosed to third parties altered or otherwise employed in any manner whatsoever without the express written consent of R amp M Materials Handling Inc Copyright 2005 R amp M Materials Handling Inc All rights reserved RM MATERIALS HANDLING INC R amp M Materials Handling Inc 4501 Gateway Boulevard Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319
45. Panel Control Bl R2 gt V off di gt 4i gt 41 4 OT al H a HH araczm aracz C4 lt a A V4 19 lt gt Monitoring lt gt output Frequency GI gt V19 gt V 0 00 Hz anaczs crop READY M stop READY G2 lt s A G22 lt s A P2 2 1 lt lt Parameters lt P Motor Parameters lt P Motor Nom Volt G3 gt Y P1 gt P20 gt Y 400 V 4 1 2 Value line editing My STOP READY Mode Edit Accept P2 2 1 lt change value value Motor Nom Volt A 400 V gt y Center WY WARNING Changing parameter settings during running may cause a hazardous situation Parameter settings must not be changed during running 28 79 This document and the information contained herein is the exclusive property of R amp M Materials Handling Inc and represents a non public confidential and proprietary trade secret that may not be reproduced disclosed to third parties altered or otherwise employed in any manner whatsoever without the express written consent of R amp M Materials Handling Inc Copyright 2005 R amp M Materials Handling Inc All rights reserved R amp M Materials Handling Inc eLA M4501 Gateway Boulevard Wrens Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC 4 2 Storing and restoring parameters 4 2 1 User parameters File User parameters is stored in inverter s control unit User para
46. Red Status PEE GREEN blinking blinking Everything is OK 0 5Hz 0 5Hz IEC Application Scheduler is running and Application is running blinking blinking IEC Application Scheduler is running 0 25Hz 0 5Hz and Application is NOT running OFF blinking IEC Application Scheduler and 0 5Hz Application are NOT running YELLOW BED o E Green Status ON PSU ready OFF PSU not ready A B C D E 3 1 3 Basic I O board Slot A Basic O Board is in CSU slot A It has two board levels one for electronics level signals terminals 1 10 and one for control voltage signals 42 240Vac NXOPTAG Basic I O board ID 52288046 Terminal Signal name Description 1 PUR Not used 2 15 V 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 S1 Digital input 42 240Vac 50 60Hz Direction S1 12 S2 Digital input 42 240Vac 50 60Hz Direction S2 13 DIA3 Digital input 42 240Vac 50 60Hz ae i eyereral 14 DIA4 Digital input 42 240Vac 50 60Hz uy ta ta Lis 16 17 i 15 DIA5 Digital input 42 240Vac 50 60Hz 1234567821 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 Co
47. Relay output Ged 8A nential open For fan of braking resistor unit 8 ROD1 m The threshold voltage for digital inputs DID1 DID5 is 35VAC LED Blinking Status Yellow 0 25Hz OK Yellow 4Hz Board internal fault or communication fault with control unit 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 3 3 Speed sensors 3 3 1 Sensor bearing Inverter 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 D YeELLow 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 20 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 MF13ZC200 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 can be used instead in emergency situations Signal name Sensor bearing
48. Starts motor if the keypad is the active control place 27 79 This document and the information contained herein is the exclusive property of R amp M Materials Handling Inc and represents a non public confidential and proprietary trade secret that may not be reproduced disclosed to third parties altered or otherwise employed in any manner whatsoever without the express written consent of R amp M Materials Handling Inc Copyright 2005 R amp M Materials Handling Inc All rights reserved R amp M Materials Handling Inc RELY 4501 Gateway Boulevard Wrote Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 Stop button Stops the motor if keypad is the active control place WY WARNING Changing parameter settings during running may cause a hazardous situation Parameter settings must not be changed during running HANDLING INC w WARNING Driving via display may cause a hazardous situation Panel control must not be used 4 1 1 Navigation on the control keypad onma osmem ocem Ms lt lt A H8 1 lt A 78 1 1 Fault History lt P 57 Themistor lt P Operation days H kx gt YF ThTI3 gt 5 Y 0 Onam M7 lt amp Active Faults FO stop LREADY arpegi M6 lt lt A 6 1 lt lt System Menu lt gt Application S1 S9 gt Y NlsroplrEapy stToplREAapy G5 lt 2 B5 1 Panel Control lt P
49. Wire colour between KAE234 and Terminal number wire colour motor plug 24V Red Brown KAE234 6 OV Black Green KAE234 2 A White White KAE234 1 B Blue not connected not connected 20 79 This document and the information contained herein is the exclusive property of R amp M Materials Handling Inc and represents a non public confidential and proprietary trade secret that may not be reproduced disclosed to third parties altered or otherwise employed in any manner whatsoever without the express written consent of R amp M Materials Handling Inc Copyright 2005 R amp M Materials Handling Inc All rights reserved R amp M Materials Handling Inc eLA M4501 Gateway Boulevard Wrens Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC 24V 5 ob eae RED BROWN K A ol 2 2 WHITE WHITE lt Le m ov o2 l m m 9 BLACK GREEN a w Critical damage if The supply voltage is over 28V or a short circuit between the signal and the supply or induction heating or hammer mounting In case of sensor damage the whole motor has to be changed Buffer amplifier must be located as close to the sensor bearing as possible maximum distance 2 5m The cable between the buffer amplifier and inverter must be as far as possible from the cables of motor and braking resistor minimum distance gt 20cm a shielded and twisted cable grounded the shield at both ends 360 groun
50. act 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 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 This document and the information contained herein is the exclusive property of R amp M Materials Handling Inc and represents a non public confidential and proprietary trade secret that may not be reproduced disclosed to third parties altered or otherwise employed in any manner whatsoever without the express written consent of R amp M Materials Handling Inc Copyright 2005 R amp M Materials Handling Inc All rights reserved 12 79 R amp M Materials Handling Inc RLA 4501 Gateway Boulevard Write Springfield Ohio 45502 PINGEee P 937 328 5100 INC FAX 937 325 5319 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
51. ade secret that may not be reproduced disclosed to third parties altered or otherwise employed in any manner whatsoever without the express written consent of R amp M Materials Handling Inc Copyright 2005 R amp M Materials Handling Inc All rights reserved R amp M Materials Handling Inc RELY ME 4501 Gateway Boulevard Wrenn Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC 14DRAWINGS 14 1 Description of terminals 14 1 1 Power classes 002F 011F No Name Description signal level a L1 L1 Power supply phase 1 E2 L2 Power supply phase 2 L3 L3 Power supply phase 3 B B Braking resistor R R Braking resistor U T1 U T1 Motor output phase 1 V T2 V T2 Motor output phase 2 W T3 W T3 Motor output phase 3 No Name Description signal level No Name Description signal level 1 BL1 AC brake supply phase 1 il 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 T12 Reserved for thermistors connections 34 T2 Thermistor input 5 OLE External control voltage 42 48 115 230Vac 35 ONE Neutral of external control voltage OLE 6 OLE External control voltage 42 48 115 230Vac 36 ONE Neutral of external control voltage OLE T RDY Stop with brake 37 ES External Sto
52. and represents a non public confidential and proprietary trade secret that may not be reproduced disclosed to third parties altered or otherwise employed in any manner whatsoever without the express written consent of R amp M Materials Handling Inc Copyright 2005 R amp M Materials Handling Inc All rights reserved R amp M Materials Handling Inc RELY 4501 Gateway Boulevard Wrens Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC 1 8 EMC The abbreviated EMC stands for the Electromagnetic Compatibility According to the European EMC directive the apparatus shall be so constructed that e The electromagnetic disturbance it generates does not exceed a level allowing other apparatus to operate as intended e The apparatus has an adequate level of intrinsic immunity of electromagnetic disturbance to enable it to operate as intended Declaration of conformity With the declaration of conformity the manufacturer informs that device is manufactured to fulfill required EMC standards CE mark The CE marking is a declaration by a manufacturer or importer located in the European Economic Area that a product complies with the safety and health requirements of the directive in question The manufacturer demonstrates for the authorities that the product complies with the safety requirements within the EU Environments Immunity and emission requirements are divided in two levels in the product standa
53. and resistance braking chopper operation F3 Earth fault Current measurement has sensed unbalance in Reset has an additional 5s time delay X motor phase currents Supervision level is 5 Check of inverter nominal current motor insulation not symmetric load motor cable insulation phase ground phase phase insulation failure in the motor or the cables F5 Charging switch Charging switch is open when START Check x command 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 Check x tripped during run ES and RDY external connections Fault is not stored into fault history F7 Saturation trip Very high overload or defective component Reset switch power off and restart after the lamps of display x are off Check motor and motor cable insulation 51 179 This document and the information contained herein is the exclusive property of R amp M Materials Handling Inc and represents a non public confidential and proprietary trade secret that may not be reproduced disclosed to third parties altered or otherwise employed in any manner whatsoever without the express written consent of R amp M Materials Handling Inc Copyright 2005 R amp M Materials Handling Inc All rights reserved RM MATERIALS HANDLING R amp M 4501 Materia
54. ate of relay output ROD1 O OFF 1 ON ROE1 State V4 3 5 State of relay output ROE1 O OFF 1 ON ROEZ2 State V4 3 6 State of relay output ROE2 O OFF 1 ON ROE3 State V4 3 7 State of relay output ROE3 O OFF 1 ON 64 4 Operate counters s SO Not used 64 5 Fault Counter s SO Fault Counter V4 5 1 Fault counter value 4 5 24 Total Faults V4 5 25 Total number of all faults S1 V4 7 1 1 State of digital input S1 0 0FF 1 ON S2 V4 7 1 2 State of digital input S2 0 0FF 1 ON DIA3 V4 7 1 3 State of digital input DIA3 0 0FF 1 ON DIA4 V4 7 1 4 State of digital input DIA4 0 0FF 1 ON DIA5 V4 7 1 5 State of digital input DIAS O OFF 1 ON OK V4 7 1 6 State of digital input OK O OFF 1 ON DID1 V4 7 1 7 State of digital input DID1 O OFF 1 ON DID2 V4 7 1 8 State of digital input DID2 O OFF 1 ON DID3 V4 7 1 9 State of digital input DID3 O OFF 1 ON DID4 V4 7 1 10 State of digital input DID4 O OFF 1 ON DID5 V4 7 1 11 State of digital input DIDS O OFF 1 ON Basic Board V4 7 3 State of board A inputs S1 S2 DIA3 DIA4 DIAS O OFF 1 ON Corresponding X1 8 9 10 11 12 terminals Extension Board V4 7 4 State of board D inputs DID1 DID2 DID3 DID4 DIDS O OFF 1 ON Corresponding X1 38 39 40 41 42 terminals Co 33 79 This document and the information contained herein is the exclusive property of R amp M Materials Handling Inc and represents a non public confidential and proprietary trade secret that may not be reproduced disclosed to third
55. aterials Handling Inc Copyright 2005 R amp M Materials Handling Inc All rights reserved R amp M Materials Handling Inc RLA 4501 Gateway Boulevard Write Springfield Ohio 45502 Remp P 937 328 5100 INC FAX 937 325 5319 3 4 Brake controllers 3 4 1 REC12 Brake control unit REC12 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 K7 K7 When the brake is opened the brake contactor K7 connects two phases of mains voltage to terminals L1 and L2 In addition the brake contactor shorts terminals a and b thus making the DC circuit To close the brake the brake contactor disconnects the supply to terminals L1 and L2 The released brake contactor also opens the brake coil DC circuit which speeds closing of the brake The purpose of the varistor there is overvoltage protection for K7 contacts and the brake coil 3 4 2 ESD141 Brake control unit ESD141 is a line voltage full half wave rectifier for DC brakes Voltage range 200 690Vac AG Ee Voltage Output voltage Upc Full wave 0 90 x Uac Half wave 0 45 x Uac Maximum current 1 25Adc continuous and 2 5Adc at ED5 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
56. atest revision may differ 11 A Braking resistor type A External resistor 12 0 Mounting 0 Standard panel 43 N ELE97 EMC level S Standard without EMC filters grounded network 0 IT network non grounded network N EMC Second environment grounded network 1 6 Description of the control modes There are three different control methods command modes available 1 EP2 Electronic motor potentiometer function Stepless control using a 2 step controller 2 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 S2 OK DIA3 DIA5 and DID1 DID5 It is not possible to chance the functions of the inputs separately The state of inputs can be checked from parameters V4 7 12 and V4 7 13 The input assignment according to the selected mode is explained in the following table Control mode EP EP3 MS Parameter P2 1 4 1 2 3 Signal Terminal S1 X1 8 S1 S1 S1 S2 X1 9 S2 S2 S2 OK X1 7 OK OK OK DIA3 X1 10 AP AP MS2 DIA4 X1 11 Not used HOLD MS3 DIAS X1 12 Not used not used MS4 DID1 X1 38 FWE FWE FWE DID2 X1 39 S11 S11 S11 DID3 X1 40 21 21 21 DID4 X1 41 12 12 12 DID5 X1 42 22 22 22 8 79 irade secret het inay Hot be tapreaiood Usiosed 18 third pertes
57. begin to accelerate at the same time once both brakes are opened Both drives end up running at the same reference speed after acceleration or deceleration EP hold situation speed correction is not possible at minimum speed or full speed The correction takes place whenever the two reference speed values deviate more than 1 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 Aout p X1 23 Ain1 Ain1 X1 26 Aout oV X1 25 Ain Ain pl X1 27 OV Z A 46 79 This document and the informat
58. ck from V4 8 2 that the nominal speed then the full ESR to normal speed settings detection level is 2793Hz 2400Hz pulse frequency is 1 5 1600Hz A 116 4 of ESR speed 2400Hz On the table the highest value under 3000HZz is 2793Hz Suitable maximum overspeed R detection level is 2400Hz 25 Correct switch settings are S2 4 ON and 3000Hz S3 4 Encoder with 600 ppr or over needs both encoder channels connected 45 79 This document and the information contained herein is the exclusive property of R amp M Materials Handling Inc and represents a non public confidential and proprietary trade secret that may not be reproduced disclosed to third parties altered or otherwise employed in any manner whatsoever without the express written consent of R amp M Materials Handling Inc Copyright 2005 R amp M Materials Handling Inc All rights reserved R amp M Materials Handling Inc RELY 4501 Gateway Boulevard Went Springfield Ohio 45502 PE P 937 328 5100 INC FAX 937 325 5319 8 Multicare Function Two inverter drives can be operated simultaneously in tandem mode by utilizing the multicare function The two drives are connected together using their analog outputs and analog inputs The analog output of one drive is connected to the analog input of the other drive and vice versa Both drives alter the voltage value of their own analog output signal according to run conditions whenever the multicare mode is select
59. contained herein is the exclusive property of R amp M Materials Handling Inc and represents a non public confidential and proprietary trade secret that may not be reproduced disclosed to third parties altered or otherwise employed in any manner whatsoever without the express written consent of R amp M Materials Handling Inc Copyright 2005 R amp M Materials Handling Inc All rights reserved R amp M Materials Handling Inc eLA M4501 Gateway Boulevard Wrens 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 WY Warning High voltages inside device Wait for at least five minutes after the supply voltage has been switched off before service actions Display in operating condition lights on indicates a dangerous voltage on the DC bus When display turns off the DC bus voltage is about 100V Note also that there is a dangerous voltage in the braking resistor always when the DC bus is charged ee Do not connect any voltage to the output terminals U V W Otherwise the inverter will be damaged ee The overload protection protects both the supply and the motor cables The fuses of the supply provide short circuit protection 9 1 Visual checks Check condition of cubicles Check that serial numbe
60. d R amp M Materials Handling Inc RLA 4501 Gateway Boulevard Write Springfield Ohio 45502 Nempe P 937 328 5100 INC FAX 937 325 5319 14 4 Circuit diagrams for braking resistors D2FRO6FROS2 D2FR12FR2S2 D2FR18FR3S2 D2FR24FR4S2 14 4 1 Internal wirings A B Other single 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 73 79 This document and the information contained herein is the exclusive property of R amp M Materials Handling Inc and represents a non public confidential and proprietary trade secret that may not be reproduced disclosed to third parties altered or otherwise employed in any manner whatsoever without the express written consent of R amp M Materials Handling Inc Copyright 2005 R amp M Materials Handling Inc All rights reserved R amp M Materials Handling Inc RELY 4501 Gateway Boulevard Wrens Springfield Ohio 45502 PE P 937 328 5100 roms FAX 937 325 5319 D2FRO6FROS2 32 ohm WIRING A 2 5 mm B 2 5 mm OTHERS 0 75 32 ohm OL230 ON230 A Se ae a S SH x1 1 3 1A ar ROD1 x1 ie 4 47 f c11 6 BLU BRN BLK M11 PE 3 X11 8 F11 BRT1 33 34 9 74 79 This document and the information contained herein i
61. d 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 Ain Value V2 1 12 3 is back at 0 V 8 3 Test run without load Display monitoring parameter Frequency reference V4 9 on both drives In EP mode accelerate the hoist up and down to any speed between the minimum speed and maximum speed and verify both drives display the same frequency reference 0 25 Hz when constant speed is reached Lower the frequency value of Max Freq S1 P2 2 10 of one drive temporarily about 20 Hz run in up direction and verify the faster hoist will slow down after accelerating Again check that both drives display the same frequency reference Return Max Freq S1 back to its original value Run both hoists up in tandem mode and stop one hoist by disconnecting the voltage from its upper stop limit terminal X1 41 the other hoist must stop and display Multicare Fault F70 Reconnect the voltage back to terminal X1 41 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 47 79 This document and the information
62. d difference overspeed or stall the speed supervision unit stops the motion immediately Protections Includes a motor thermal protection which is based on motor temperature measurement by Klixon placed in motor windings A great number of other protections included are shown in the technical data Tested parameters Inverter includes tested parameters with different motors for all power ratings This is a benefit which makes every inverter delivery a proven solution The tested and pre set motor parameters enable a quick start up in crane commissioning 1 3 Main components The main components are Power class A1 Inverter F7 Brake supply circuit breaker 007 055 K7 Brake contactor G1 Brake control unit REC12 002 011 G1 Brake control unit ESD141 015 055 F71 Circuit breaker for the second brake contactor 055 K71 Second brake contactor 055 The most important external components are R1 Braking resistor unit M1 Hoisting motor Y1 Mechanical brake A5 KAE234 Proximity switch buffer amplifier for speed sensor B5 Speed sensor B6 Thermal sensor for motor protection Overload protection device Control devices switches pushbuttons etc Limit switches 6 79 This document and the information contained herein is the exclusive property of R amp M Materials Handling Inc and represents a non public confidential and proprietary trade secret that may n
63. d voltage 10VDC 3 EB Threshold voltage 10VDC 4 EB Threshold voltage 10VDC 5 24V 24VDC short circuit protected 6 OV Common for encoder supply 0 yeLLow 28 ROC1 Relay output 250V 8A normal open 29 ROC1 _ Relay contact ROC1 closes when inverter is powered and no faults occurs Relay contact ROC1 opens if the SSU has tripped in Overspeed Speed difference Zero speed Relay test fault Watch dog fault LED Blinking Status Red 1Hz OK Yellow 0 25Hz OK Yellow 4Hz Board internal fault or communication fault with control unit 1 9 79 This document and the information contained herein is the exclusive property of R amp M Materials Handling Inc and represents a non public confidential and proprietary trade secret that may not be reproduced disclosed to third parties altered or otherwise employed in any manner whatsoever without the express written consent of R amp M Materials Handling Inc Copyright 2005 R amp M Materials Handling Inc All rights reserved RM MATERIALS HANDLING INC R amp M Materials Handling Inc 4501 Gateway Boulevard Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 3 1 6 I O Extension board Slot D NXOPTB9 I O Extension board ID 52305691 Terminal Signal name Description 1 DID1 Not used 2 DID2 42 240Vac 50 60Hz 3 DID3 42 240Vac 50 60Hz 4 DID4 42 240Vac 50 60Hz 5 DID5 42 240Vac 50 60Hz 6 COM Common for DID1 DID5 7 ROD1 a
64. ding on inverter terminal the shield should be grounded always when going through terminals 21 79 This document and the information contained herein is the exclusive property of R amp M Materials Handling Inc and represents a non public confidential and proprietary trade secret that may not be reproduced disclosed to third parties altered or otherwise employed in any manner whatsoever without the express written consent of R amp M Materials Handling Inc Copyright 2005 R amp M Materials Handling Inc All rights reserved R amp M Materials Handling Inc RELY 4501 Gateway Boulevard Wrote Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 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 D2L x1 V 55 red 24V Encoder 24 ppr A 51 yellow EA XILYJANI Standard connection terminal box D2L x 5 C55 Encoder 600 ppr or more XILYJANI In standard encoders there are also zero outputs Z Z which should be left disconnected If the
65. ductor cross sectional area A mm2 is given by formula l x 1 5 x Ip p xU A 2 43 where is the cable length m Ie is the motor current A at shaft power Pp p is the allowed voltage drop in U is the nominal motor voltage 1 3 79 This document and the information contained herein is the exclusive property of R amp M Materials Handling Inc and represents a non public confidential and proprietary trade secret that may not be reproduced disclosed to third parties altered or otherwise employed in any manner whatsoever without the express written consent of R amp M Materials Handling Inc Copyright 2005 R amp M Materials Handling Inc All rights reserved R amp M Materials Handling Inc eLA M4501 Gateway Boulevard Wrens Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC 2 3 6 Du dt filters If inverter is not mounted on the crane there has to be du dt filter at motor supply Also if total motor cable length sum of motor cables is over 100m with 002 005 or over 200m with 007 055 there has to be du dt filter at motor supply Power class Platthaus du dt filter Length mm Width mm Height mm Weight kg ID 002 003 ULC 910 920 100 110 180 1 2 52306553 004 005 ULC 914 931 125 110 200 3 52306554 007 018 ULC 918 951 155 125 225 7 52306555 022 045 ULC 923 927 190 135 260 12 52306556 055 ULC 942 1044 240 175 310 22 52306557 WY
66. e 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 2 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 DID4 S12 Stop limit signal direction 1 12 DIAS 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 Free NO contact of relay ROD1 18 K7 153 Free NO contact of K7 48 K7 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 E ee 21 PUR Not used 51 EA Encoder channel A 22 15V Not used 52 EA Encoder channel A 23 AIN1 Multicare speed reference input 0 10V 53 EB Encoder channel B 24 AIN2 Not used 54 EB Encoder channel B 25 AIN Common for analog inputs 55 24V 24V output for encoder 26 AOUT Multicare speed reference output 0 10V 56 ov Common for encoder supply 27 ov Common for analog output 57 24V External supply for Control module E 61 179 This document and the information contained herein is the exclusive property of R amp M Materials Handling Inc and represents a non publ
67. e information contained herein is the exclusive property of R amp M Materials Handling Inc and represents a non public confidential and proprietary trade secret that may not be reproduced disclosed to third parties altered or otherwise employed in any manner whatsoever without the express written consent of R amp M Materials Handling Inc Copyright 2005 R amp M Materials Handling Inc All rights reserved RM R amp M Materials Handling Inc 4501 Gateway Boulevard Springfield Ohio 45502 MATERIALS mem P 937 328 5100 meva FAX 937 325 5319 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 P 2 1 10 Accel Time 1 2 5 P 2 1 10 Accel Time 1 2 5 P 2 1 11 Decel Time 1 2 5 P 2 1 11 Decel Time 1 2 5 P 2 1 11 Decel Time 1 2 5 G 2 2 Motor Parameters G 2 2 Motor Parameters G 2 2 Motor Parameters P 2 2 1 Motor Nom Volt 460 P 2 2 1 Motor Nom Volt 460 P 2 2 1 Motor Nom Volt 460 P 2 2 2 Motor Nom Freq 120 P 2 2 2 Motor Nom Freq 120 P 2 2 2 Motor Nom Freq 120 P 2 2 3 Motor Nom Speed 3410
68. ed The table below shows the input receive and output send values during start acceleration stopping and in fault situation The multicare function is selected with an input parameter P2 1 5 In case of multicare fault a dedicated fault code F70 is issued If the operation of one drive is interrupted or the drive faults out for example upper limit fault the other drive will stop and show multicare fault F70 Programmable pushbuttons are used for multicare testing The multicare function is mainly designed for EP mode speed correction possible but it can also be used in MS multistep mode for run stop supervision without speed correction Ain value Input function Aout value Output function receive send 0 0 2 V__ Single drive selected Multicare function not used OV Direction signals S1 and S2 not active in multicare mode 0 3 0 7 V Brake open acknowledged acceleration not 0 5V Brake open acceleration not allowed allowed 0 8 1 0 V Acceleration allowed 1 0V Acceleration allowed 1 9 V Speed correction range 1 9 V Speed correction range 9V Acceleration acknowledged 9V Accelerating gt 9 5 V Fault acknowledged Immediate brake stop F70 10 V Fault Immediate brake stop 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
69. ed or otherwise employed in any manner whatsoever without the express written consent of R amp M Materials Handling Inc Copyright 2005 R amp M Materials Handling Inc All rights reserved R amp M Materials Handling Inc 4501 Gateway Boulevard Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 RM MATERIALS HANDLING INC 11TROUBLESHOOTING TABLE If inverter doesn t work but any fault doesn t found write down the following information before contacting to the supplier GENERAL INFORMATION WORK NUMBER CUSTOMER REFERENCE DATE PUT IN OPERATION DATE OF FAILURE SHORT DESCRIPTION OF FAILURE ERROR CODE INVERTER INFORMATION TYPE CODE ACCELERATION S TIME SERIALNUMBER DECELERATION S TIME CONTROL METHOD MIN FREQ Hz EP2 MAX FREQ Hz EP3 MS 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 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 56 79 This document and the information contained herein is the exclusive propert
70. ed 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 inverter via KAE234 buffer amplifier KAE234 must be located near the sensor usually in the connection box of the hoist or the motor Without a buffer amplifier some faulty pulses could activate the speed supervision of inverter Typically the problem would be a momentary lack of pulses or oscillations at the sensor output Usually the noise sensitivity increases when the sensor temperature rises KAE234 connection with sensor bearing f 69 20 24V x1 6 24V 30 6 255 t RED BROWN 24V a A Ema OUT 4 o 51 L WHITE WHITE EA ov gt o2 ji ov 7 56 BLACK GREEN ov 52 EA 4 YALYSANI 79 Buffer amplifier pulse output can be measured 24V 1V during driving The picture beside presents the pulse output O 1V 24 79 This document and the information contained herein is the exclusive property of R amp M Materials Handling Inc and represents a non public confidential and proprietary trade secret that may not be reproduced disclosed to third parties altered or otherwise employed in any manner whatsoever without the express written consent of R amp M M
71. ent Ref P2 3 13 Minimum value of motor current used in current control area of 0 100 motor nominal current Must not be changed Accel Comp TC P2 3 14 Acceleration compensation time constant which describes rotating 0 300s masses of drive system Physical description of this parameter is a time which is needed to accelerate rotating masses from zero to nominal frequency with motor nominal torque Must not be changed Ref Angle S1 P2 3 15 Voltage current angle difference S1 1536 equals 90 angle Used in 0 3000 direction changes Must not be changed Ref Angle S2 P2 3 16 Voltage current angle difference S2 1536 equals 90 angle Used in 0 3000 direction changes Must not be changed Flux Curr Damp P2 3 17 Flux Current Ctrl stabilator time constant in milliseconds Must not be 0 400 ms changed Stop DC Freq P2 3 18 Defines the frequency at witch DC braking starts 0 250 Hz Start Freq S1 P2 3 19 Defines the output frequency during brake opening delay to direction 0 Max Freq S2 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
72. erty of R amp M Materials Handling Inc and represents a non public confidential and proprie trade secret that may not be reproduced disclosed to third parties altered or otherwise employed in any manner whatsoever without the express written consent of R amp M lary Materials Handling Inc Copyright 2005 R amp M Materials Handling Inc All rights reserved R amp M Materials Handling Inc RELY 4501 Gateway Boulevard Wrens Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC 14 5 Standard connections for pulse sensors Standard connection with sensor bearing white EB blue ov V red A white B Z G blue m 4 m a ov black Standard connection with encoder 24 ppr terminal box V red A yellow z lt m a m a ov blue Standard connection with encoder 600 ppr or more terminal box D2L x1 V 55 xs a yellow EA _ N Bt 53 Z e paa EB A 52 7 black EA 9 B o 54 ov 56 Standard connection with proximity switch Baumer Sch nbuch D2L V brown A black XILYJANI blue 78 79 This document and the information contained herein is the exclusive property of R amp M Materials Handling Inc and represents a non public confidential and proprietary tr
73. f Min Current Ref 90 Accel Comp TC 0 1 Accel Comp TC 0 1 Accel Comp TC Accel Comp TC 0 1 Ref Angle S1 Ref Angle S1 Ref Angle S1 Ref Angle S1 Ref Angle S2 Ref Angle S2 Ref Angle S2 Ref Angle S2 Flux Curr Damp Flux Curr Damp Flux Curr Damp Flux Curr Damp Stop DC Freq Stop DC Freq Stop DC Freq Stop DC Freq Start Freq S1 Start Freq S1 Start Freq S1 Start Freq S1 Start Freq S2 Start Freq S2 Start Freq S2 Start Freq S2 Brake Stop Freq Brake Stop Freq Brake Stop Freq Brake Stop Freq ESR Point Freq ESR Point Freq ESR Point Freq ESR Point Freq ESR Point Volt ESR Point Volt ESR Point Volt ESR Point Volt IrAdd Motor IrAdd Motor IrAdd Motor IrAdd Motor IrAdd Generator IrAdd Generator IrAdd Generator IrAdd Generator Ramp Stretching Ramp Stretching Ramp Stretching Ramp Stretching Switching Freq Switching Freq Switching Freq Switching Freq DeadTime Comp DeadTime Comp DeadTime Comp DeadTime Comp DeadTimeCurrLim DeadTimeCurrLim DeadTimeCurrLim DeadTimeCurrLim Brake Chopper Brake Chopper Brake Chopper Brake Chopper g g T5 MF11MB200 460V 120Hz T6 MF13Z 200 460V 120Hz 41 79 E T7 MF13ZA200 460V 120Hz This document and th
74. f board in slot B 10501 4 Not used IU filtered V6 9 1 U phase current A IV filtered V6 9 2 V phase current A IW filtered V6 9 3 W phase current A U Temperature V6 9 4 Phase U temperature C V Temperature V6 9 5 Phase V temperature C W Temperature V6 9 6 Phase W temperature C Card Temperature V6 9 7 Card temperature C Power multimonitor V6 11 1 Output current values and power card temperature The memory of active faults can store the maximum of 10 faults in the 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 14 Counted operation days d T 2 Counted operation hours hh mm ss 36 79 This document and the information contained herein is the exclusive property of R amp M Materials Handling Inc and represents a non public confidential and proprietary trade secret that may not be reproduced disclosed to third parties altered or otherwise employed in any manner whatsoever without the express written consent of R amp M Materials Handling Inc Copyright 2005 R amp M Materials Handling Inc All rights reserved R amp M Materials Handling Inc RELY 4501 Gateway Boulevard Wrote Springfield Ohio 45502 P 937 328 5100 HANDLING mene FAX 937 325 5319 T 3 Outp
75. formation contained herein is the exclusive property of R amp M Materials Handling Inc and represents a non public confidential and proprietary trade secret that may not be reproduced disclosed to third parties altered or otherwise employed in any manner whatsoever without the express written consent of R amp M Materials Handling Inc Copyright 2005 R amp M Materials Handling Inc All rights reserved RM MATERIALS HANDLING IN R amp M Materials Handling Inc 4501 Gateway Boulevard Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 037F 045F 2 x D2FR18F21R3S2 21 ohm 2 11 ohm Cc a pee TT ew O F7 1 13 5 tE gt e Z1 Z2 Z3 AND CM1 NOT 2 al o X156 INCLUDED IN STANDARD OR 2 46 F IT MODELS 27 D J t 13 K7 2 4 23 K7 55 K7 SET 1 2 0 3s r4 mS ac ff 25 j 5 DC c G1 i 6 7 gt X1 31 R L NAL si 11 S1 SZ 12 S2 piss 13 DIA3 DiA4 14 DIA4 DIA5 gt OK KAE234 4 DID2 DID3 x1 DID4 5 OLE DID5 6 13 ah SET 0 3s A1 ES DI K7 A2 F11 BRT1 Xi 18 48 i 153 154 F11 X1 19 49 163164 BRT1 71 179 This document and the information contained herein is the exclusive property of R amp M Materials Handling Inc and represents a non public confidential and proprie lary trade secret that may not be reproduced disclosed to third parties altered or otherwise employed
76. g 176 Ibs Z2 G1 37 s 8 m 2 m 1 E 4 8 E g g 78 A1 6 m m e X erm C Y 0 9 4 37 a 8 S E m 8 3 m J 4 8 E E 8 x1 CM1 5 o j Z2 Z3 CERA aG 0Z1 en V F M X l j l ia Imm 453 5 mm 17 85 in Z3 Z4 m in 0 28 in B 467 5 mm 18 41 in s A1 F7 F71 K7 G1 K71 E ls E A H Seah sooTe e g ge O E X1 D ooo 0 E 7mm 453 5 mm 17 85 in g3 0 2Biny 467 5 mm 18 41 in 14 3 Circuit diagrams 002F 005F 007F 011F 015F 045F O55F 63 79 This document and the information contained herein is the exclusive property of R amp M Materials Handling Inc and represents a non public confidential and proprietary trade secret that may not be reproduced disclosed to third parties altered or otherwise employed in any manner whatsoever without the express written consent of R amp M Materials Handling Inc Copyright 2005 R amp M Materials Handling Inc All rights reserved R amp M Materials Handling Inc 4501 Gateway Boulevard Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 RM MATERIALS HANDLING INC 14 3 1 Internal wirings PE A B c D ner single Screened cables 002F 011F 002F 011F 002F 018F 002F 055F 002F 055F 002F 055F 002F 055F 2 5 mm 2 5 mm 2 5 mm 2 5 mm 1 5 mm 0 75 mm 8 x 0 5 mm AWG 14 AWG 14 AWG 14 AWG 14 AWG 16 AWG 20 8 x AWG 20 015F 018F 015F 018F 6 mm
77. herwise employed in any manner whatsoever without the express written consent of R amp M Materials Handling Inc Copyright 2005 R amp M Materials Handling Inc All rights reserved R amp M Materials Handling Inc RELY 4501 Gateway Boulevard Wrens Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC Standard connection with proximity switch Honeywell Colour if cable has been D2L V lengthened red brown A green green Zz mi G z m A ov black white 79 79 This document and the information contained herein is the exclusive property of R amp M Materials Handling Inc and represents a non public confidential and proprietary trade secret that may not be reproduced disclosed to third parties altered or otherwise employed in any manner whatsoever without the express written consent of R amp M Materials Handling Inc Copyright 2005 R amp M Materials Handling Inc All rights reserved
78. ials Handling Inc All rights reserved RM MATERIALS HANDLING INC R amp M Materials Handling Inc 4501 Gateway Boulevard Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 13SPARE PARTS LIST FOR HOISTING INVERTER S unit for slot C Inverter D2V includes boards for slots A B and D but does not include SSU speed supervision POS DESCRIPTION NAME REMARKS 002 003 004 005 007 011 015 018 022 030 037 045 055 INVERTER A1 Inverter D2V002NF1N04 52335533 EMC level N S D2V002NF 1004 52335558 EMC level 0 D2V003NF1N04 52335534 EMC level N S D2V003NF 1004 52335557 EMC level 0 D2V004NF1N04 52335535 EMC level N S D2V004NF 1004 52335556 EMC level 0 D2V005NF1N04 52335536 EMC level N S D2V005NF 1004 52335555 EMC level 0 D2V007NF1N04 D2V007NF 1004 52335537 52335554 EMC level N S EMC level 0 D2V011NF1N04 52335538 EMC level N S D2V011NF1004 52335553 EMC level 0 D2V015NF1N04 52335539 EMC level N S D2V015NF 1004 52335552 EMC level 0 D2V018NF1N04 52335540 EMC level N S D2V018NF 1004 52335551 EMC level 0 D2V022NF1N04 52335541 EMC level N S D2V022NF 1004 52335550 EMC level 0 D2V030NF1N04 52335542 EMC level N S D2V030NF 1004 52335549 EMC level 0 D2V037NF1N04
79. ials Handling Inc and represents a non public confidential and proprietary trade secret that may not be reproduced disclosed to third parties altered or otherwise employed in any manner whatsoever without the express written consent of R amp M Materials Handling Inc Copyright 2005 R amp M Materials Handling Inc All rights reserved ReM MATERIALS R amp M Materials Handling Inc 4501 Gateway Boulevard Springfield Ohio 45502 P 937 328 5100 HANDLING NG FAX 937 325 5319 Application id D6 8 4 1 1 See software sticker under display IND2V081 Industr2 Version D6 8 4 1 2 See software sticker under display IND2V081 8 10 Firmware interf D6 8 4 1 3 4 49 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 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 o
80. ic confidential and proprietary trade secret that may not be reproduced disclosed to third parties altered or otherwise employed in any manner whatsoever without the express written consent of R amp M Materials Handling Inc Copyright 2005 R amp M Materials Handling Inc All rights reserved R amp M Materials Handling Inc RELY ME 4501 Gateway Boulevard Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 MATERIALS HANDLING INC 14 2 Layouts dimensions and weights 002F 005F Weight 12 kg 27 Ibs x JE M E E 83 2 ica 2223 18mm 414 mm 16 30 in E 0 74 An 450 mm 17 72 in y 015F Weight 29 kg 64 Ibs xX R 3 F7 K7 G1 E g a igl jian 2 A1 A E E E EVSA BS Y a CM1 x jr z x1 i Eao uae Ai ff 3 z3 Z1 i EZ 7mm 453 5 mm 17 85 in og 0 28 in p 467 5 mm 18 41 in 007F 011F Weight 19 kg 42 Ibs
81. if Check braking resistor is broken braking resistor and insulation resistance braking chopper is broken measure braking transistor IGBT and free wheeling diodes braking resistor is not installed If resistor is OK then the chopper is broken Contact authorized service F 13 Inverter Temperature of heat sink is below acceptable Check X undertemperatur operating level 10 C 14 F ambient temperature e cubicle heating F 14 Inverter Temperature of heat sink is over acceptable Check X overtemperature operating level ambient temperature 90 C 194 F inverter cooling fan operation Overtemperature warning is issued when the cooling air flow through heat sink heat sink temperature exceeds 85 C 185 F heat sink is not dusty F 22 EEPROM Parameter save error After power off the inverter will automatically reset parameter X F23 checksum fault interference fault settings The drive does not work properly nor enable driving component failure control unit after this fault Check all parameter settings 24V voltage output loading If the fault comes again contact authorized service center F 24 Changed data Changes may have occurred in the different No special actions required Take a critical attitude to the X warning counter data due to mains interruption counter data F 25 Microprocessor interference fault Reset switch power off and restart after the lamps of display xX watchdog fault component failure control unit are off If the fault co
82. imized 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 nalf wave rectifier Full wave rectification is used to open the brake quickly Then the rectifier changes to a half wave type which reduces losses but is enough to keep the brake open There is a contactor to switch the line voltage on and off The same contactor also disconnects the DC voltage directly from the brake coil which guarantees that the brake closes fast Model 055F includes a 3 phase AC supply for the brake control Inverter controls this line and it is protected by an adjustable circuit breaker max 4 0A When a shoe brake is used brake closing is speeded up by capacitors They are connected in parallel with the brake via the brake contactor NC contacts The connection is partially ready in inverter Only the capacitors must be added outside inverter This connection can also be used to control 2 phase disk brakes or a separate KA372B brake control unit 1 0 79 This document and the information contained herein is the exclusive property of R amp M Materials Handling Inc
83. ion contained herein is the exclusive property of R amp M Materials Handling Inc and represents a non public confidential and proprietary trade secret that may not be reproduced disclosed to third parties altered or otherwise employed in any manner whatsoever without the express written consent of R amp M Materials Handling Inc Copyright 2005 R amp M Materials Handling Inc All rights reserved R amp M Materials Handling Inc RELY 4501 Gateway Boulevard Wren Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC 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 Max B2 1 12 2 0n 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 Rea
84. ist motion speed supervision unit which reads the pulse frequency from the hoist motor sensor bearing encoder or pulse sensor This pulse frequency is compared with a fixed oscillator frequency and inverter frequency reference As a result of frequency comparison there are three different speed supervision functions available overspeed supervision rush control stall supervision speed difference supervision Overspeed supervision F61 is totally implemented by hardware Switches S2 2 and S2 3 divide the full frequency range to four frequency areas Selected frequency area is the same for normal and ESR speeds The four frequency areas are each divided to lower and upper frequency ranges Switch S2 1 selects the frequency range at normal speed Switch S2 4 selects the frequency range at ESR speed Extended Speed Range The exact tripping frequency level is selected with rotary switches Switch S1 sets the tripping level at normal speed value shown in V4 8 1 Switch S3 sets the tripping level at ESR speed value shown in V4 8 2 Overspeed tripping levels are shown at display as of the nominal speed The overspeed setting should be 15 25 above the full speed Switches S2 2 and S2 3 select range for overspeed detection level Range of detection level is the same for both normal and ESR Extended Speed range use Fine adjustment for normal use is done by rotary switch S1 and switch S2 1 Fine adjustment for ESR use is done by
85. ive property of R amp M Materials Handling Inc and represents a non public confidential and proprietary trade secret that may not be reproduced disclosed to third parties altered or otherwise employed in any manner whatsoever without the express written consent of R amp M Materials Handling Inc Copyright 2005 R amp M Materials Handling Inc All rights reserved R amp M Materials Handling Inc eLA M4501 Gateway Boulevard Wrens Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC 10TROUBLESHOOTING w 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 10 1 Field repair actions The purpose of troubleshooting and field repair actions is primarily to determine whether the drive or external devices in fact cause the problems After that the next step is to detect the possibly damaged components inside the drive If any damage inside the drive is caused by the environment motor failure brake failure power supply problems etc it is very important to repair change faulty items to prevent reoccurring problems The best way to repair a faulty inver
86. levard Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 5 PARAMETER DESCRIPTIONS This manual describes parameters with software Ind2V081 Under control panel there is sticker for software version Parameters are assorted to Groups All Groups are not always listed in control panel Groups are shown in control panel according to password level and selected functions This feature makes visible parameter menu simple and only needed parameters are shown Letter front of the code number describes variable type 30 79 A Application E Expander R Reference B Button G Group S System C Counter Info T Trip Counter D DynACode P Parameter V Value Label Code Function Description Adjustment range G2 1 General Parameters Password P2 1 1 Default 768 Service 2156 shows also group G2 3 Expert Supply Voltage V2 1 2 Power unit nominal voltage F 380V 500V Device V2 1 3 Device Industrial Input Set P2 1 4 Input Set selection see chapter Control methods 1 EP 2 EP3 3 Multistep Analog Input Sel P2 1 5 Analog input selection 0 Not used 1 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
87. lied Check the function of the speed sensor see chapter Speed sensors Check the function of the speed supervision circuit See chapter Functional test drive for SSU Drive direction S1 at minimum speed for 5 to 10 seconds Accelerate to full speed Run 5 to 10 seconds Stop Repeat the same in direction S2 Check the frequency display to make sure that the frequency changes through the whole operational frequency range from minimum to nominal speed Check motor operation acceleration deceleration and braking accelerate to full speed direction S1 change to full speed direction S2 and full speed direction S1 again and stop Check limit switch functions drive direction S1 slowly and check the limit switch operations Re check using full speed Repeat the same check for direction S2 9 3 1 Functional test run for SSU e7 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 missing 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 Set rotary switch S1 S3 value 2 steps smaller Drive with maximum speed The motion mus
88. losed to third parties altered or otherwise employed in any manner wha epresents a non public confiden isoever without the express written consent of R amp M ial and proprietary Materials Handling Inc Copyright 2005 R amp M Materials Handling Inc All rights reserved R amp M Materials Handling Inc RELY 4501 Gateway Boulevard Wren Springfield Ohio 45502 P 937 328 5100 HANDLING mra FAX 937 325 5319 LC1 D09P7 52296643 230VAC 1 1 1 1 1 1 1 1 1 1 1 1 1 At K7 RC filter LA4 DA1E 52275256 42 48VAC 1 1 1 1 1 1 1 1 1 1 1 1 1 LA4 DA1U 52275257 115 230VAC 1 1 1 1 1 1 1 1 1 1 1 1 1 BRAKE CONTROL UNIT DC BRAKE G1 Brake control unit REC12 60010145 1 1 1 1 1 1 ESD141 60003098 1 1 1 1 1 1 1 SECOND BRAKE CONTACTOR K71 Contactor LC1 D09D7 52303564 42VAC 1 C01E7 52296542 48VAC 1 C01F7 52296548 115VAC 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 j LAD N04 52297548 1 COMPONENTS FOR EMC LEVEL N CM1 Y capacitor KC 307 00 52298693 42VAC 1 1 1 1 1 1 1 1 1 1 1 1 1 Z1 Ferrite RU2100 30 7 52299351 Emission level N 1 1 1 1 1 1 Z2 RH175285107 52297604 1 1 1 1 1 1 Z3 RH175285107 52297604 1 1 1 1 1 1 Z1 EF32010 52299352 2 2 2 72 W74270096 52299353 1 1 1 73 W7427015
89. ls Handling Inc Gateway Boulevard Springfield Ohio 45502 P 937 328 5100 NG FAX 937 325 5319 measure main circuit diodes and IGBT transistors 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 of keypad x operation 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 fault and x mains supply voltage interrupted start again Check mains input inverter fault can also cause an If mains supply is correct an internal failure has occurred undervoltage trip Contact authorized service external fault during run may cause an undervoltage trip F 10 Input line One input line phase is missing Check X supervision supply voltage mains connection F 11 Output phase Current supervision has sensed that at least Check X supervision one of the 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 of display X supervision failed Test pulse measures transistor collector are off voltage Fault appears
90. mes again contact service F 26 Power Unit Fault X F 31 IGBT Too high temperature in IGBT A hardware Reset switch power off and restart after the lamps of keypad X temperature temperature measurement has tripped are off Check motor loading brake operation inverter heatsink inverter cooling fan operation environment temperature F 32 Fan cooling fault Cooling fan of the frequency converter do not If the fault comes again contact authorized service x work when ON command has been given F 35 Application fault Run time exception in the application program Contact authorized service x F 36 Control Unit Faulty Control Unit Contact authorized service X F 37 Device changed Option board changed Reset the fault X F 38 Device added Option board added Reset the fault X F 39 Device removed Option board removed Reset the fault X F 40 Device unknown Unknown option board or drive Check board and drive type X F 41 IGBT Too high temperature in IGBT transistors Reset switch power off and restart after the lamps of keypad X tempetature long duration overload are off Check lowered cooling motor parameters 52 79 This document and the information contained herein is the exclusive property of R amp M Materials Handling Inc and represents a non public confidential and proprietary trade secret that may not be reproduced disclosed to third parties altered or otherwise employed in any manner whatsoever without the express written consen
91. meters 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 lt 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 w 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 parameters is stored in inverter s control unit Default parameters are saved at the factory and they should not be changed In default parameters there are the same parameter values as shown in parameter list delivered with inverter Since serial number 03L50700 Parameters can be restored from Default parameters with parameter B 4 1 1 Load Default Par Enter lt 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 w Parameters restored from Default parameters are reseted after po
92. mmon for 42 240Vac 50 60Hz 18 COM Common for 42 240Vac 50 60Hz The threshold voltage for digital inputs S1 S2 DIA3 DIA4 DIA5 and OK is 35VAC 1 8 79 This document and the information contained herein is the exclusive property of R amp M Materials Handling Inc and represents a non public confidential and proprietary trade secret that may not be reproduced disclosed to third parties altered or otherwise employed in any manner whatsoever without the express written consent of R amp M Materials Handling Inc Copyright 2005 R amp M Materials Handling Inc All rights reserved R amp M Materials Handling Inc PCA ME 4501 Gateway Boulevard Wrote Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC 3 1 4 Relay Thermistor board Slot B NXOPTA3 Relay Thermistor board ID 52305690 Terminal Signal name Description 21 ROB1 ee 22 ROB1 Relay output 250V 8A 23 ROB1 uu _ 25 REE __ Relay output 250V 8A normal open 26 ROB2 E 28 T1 Thermistor input double isolated 29 T2 Ririp 4 7KQ 3 1 5 SSU Speed Supervision board Slot C SSU is in CSU slot C see chapter Speed supervision settings SSU Speed supervision unit ID 52288044 Terminal Signal name Description 1 EA Threshold voltage 10VDC 2 EA Threshol
93. nce 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 fs Note that the Honeywell sensor cable is lengthened and the wire colours are not equal to other sensors However colour markings corresponding to the other sensors have been added to wire ends not necessarily if cable has been shortened afterwards The connection of Honeywell sensor and the cable markings are shown in the table below Signal name Sensor Cable Colour marking Terminal number l a 212 24V Red Brown Brown KAE234 6 20 Honeywell 3GT101DC PULSE Green Green Black KAE234 1 OV Black White Blue KAE234 2 40 Red poemi Sch nbuch INSOR ICDM 8802 Y3LHYJANI Honeywell 3GT101DC X3LHJANI Baumer IFRM08N1501 L Note the following details buffer amplifier must be located as close the proximity switch as possible maximum distance 3m sensor cable must be located as far from the motor cables and braking resistor cable as possible minimum distance gt 20cm In order to avoid fault situations the cable between the encoder and inverter must be as far as possible from the cables
94. ned herein is the exclusive property of R amp M Materials Handling Inc and represents a non public confidential and proprietary trade secret that may not be reproduced disclosed to third parties altered or otherwise employed in any manner whatsoever without the express written consent of R amp M Materials Handling Inc Copyright 2005 R amp M Materials Handling Inc All rights reserved R amp M Materials Handling Inc eLA M4501 Gateway Boulevard Wrote Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC 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 5 Factory code example Factory D2L D2L 007 F V 51 A 0 N HS01 ELE83 ELE83 ELE02 ELE97 1 3 4 6 7 8 9 10 11 12 13 Pos Code Feature Feature Available properties code 1 3 D2L HS01 Device name D2L 4 6 007 ELE83 Power rating class 002 055 ELE83 values are composed of two features Power rating class and Supply voltage T F ELE83 Supply voltage F 380 500 VAC 50 60 Hz e g 007F ELE83 value ELE02 value ELE02 value 8 V ELE02 Control voltage Y 42VAC 50 60 Hz F 115VAC 50 60 Hz 115 P 48VAC 50 60 Hz 48 V 230VAC 50 60 Hz 230 9 10 51 Revision code The l
95. ng Inc All rights reserved R amp M Materials Handling Inc eLA M4501 Gateway Boulevard Wrens Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC 1 2 Basic description Inverter has many advantages and offers many new features when compared to other inverter based systems which might be used in crane applications Inverter The specific crane features for the inverter hardware and the special software are achieved by combining the experience and know how of crane applications with the latest technology Crane user interface Interface with pre designed locations for typical crane functions The main part of this interface is carried out by a terminal strip which has separated sections for signals with main control and electronics voltage levels Brake control Includes the brake contactor for disk brakes Includes also DC rectifier Electrical Braking Includes a braking transistor and a braking resistor Control methods Can be controlled by the electronic potentiometer control with 2 step or 3 step pushbuttons the multistep control with 2 4 step controllers Limit switch functions Built in slowdown S11 S21 and stop limit switch S12 S22 functions for both running directions Speed supervision Inverter includes a speed supervision unit SSU which is separate from the inverter and not dependent on software This safety circuitry is used to monitor the speed of the motor In case of spee
96. ng the stop limit F 55 Board Fault Some of following board is missing Reset switch power off and restart after the lamps of keypad x A Basic I O board are off B Thermistor board Check D Expansion board board slots A B and D drive selection control mode F 56 Generator side Too short deceleration time Reset has an additional 5 s time delay x current limit generator side current limit Check deceleration time F 57 Thermistor fault Thermistor input in relay thermistor board has Check X detected motor overtemperature Fault appears motor cooling and loading when thermistor input has been open over 1s 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 X parameter has changed to 0 none F 61 Overspeed Fault SSU has tripped to Overspeed hardware Reset when 1s without pulses from pulse sensor encoder to X supervision Motor speed has increased SSU and controller at zero position above overspeed detection level 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 sensor encoder to X Fault SSU and controller at zero position Check pulse sensor encoder function and cabling pulse sensor
97. ngths 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 1 5 79 This document and the information contained herein is the exclusive property of R amp M Materials Handling Inc and represents a non public confidential and proprietary trade secret that may not be reproduced disclosed to third parties altered or otherwise employed in any manner whatsoever without the express written consent of R amp M Materials Handling Inc Copyright 2005 R amp M Materials Handling Inc All rights reserved R amp M Materials Handling Inc eLA M4501 Gateway Boulevard Wrote Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC 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 1min Weight Weight D2V In Imax kg Ibs D2V
98. non public confidential and proprietary trade secret that may not be reproduced disclosed to third parties altered or otherwise employed in any manner whatsoever without the express written consent of R amp M Materials Handling Inc Copyright 2005 R amp M Materials Handling Inc All rights reserved R amp M Materials Handling Inc AM ME 4501 Gateway Boulevard wrest Springfield Ohio 45502 P 937 328 5100 HANDLING a FAX 937 325 5319 Autom BackUp P6 3 4 Changes in parameters are automatically saved to Keypad settings Yes No Set 1 S6 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 S6 4 2 Actual parameter values are compared to file User parameters Value Par No User val of parameters can also be changed in this display Actual value Factory settings 6 4 3 Parameter file Factory settings is not used Keypad set S6 4 4 Actual parameter values are compared to parameter file saved in Keypad Password 6 5 1 Password for group S6 5 Parameter lock P6 5 2 Not used Change Enable Startup wizard P6 5 3 Not used No Multimon Items P6 5 4 Enables or disables chancing of variables in multimonitor page ChangeEnable N4 23 1 ChangeDisable Default page P6 6 1 Default page to which the display automatically moves as the Timeout time has expired or as the
99. ns Sn 100 Sn motor nominal slip 1 of nominal speed at speed range 10 100 1 3 of motor nominal slip at speed below 10 100 200 150 During acceleration and constant speed Thermistor based temperature measurement Fault is detected if the current momentarily exceeds 280 of rated current Fault is detected if DC voltage drops below 333V Fault is detected if DC voltage exceeds 911V Immediate fault stop Temperature sensor on the heat sink Circuit breaker Electronic supervision for the braking chopper and for the braking resistor Provided by electronic circuitry Independent measurement using sensor bearing pulse wheel or encoder 10 C 55 C 14 F 131 F for ED lt 60 40 C 60 C 31 F 140 F dry Humidity lt 95 RH no condensation Altitude Maximum 1000m at In Above 1000m In reduces 1 per each 100m Above 3000m consult factory Vibration Operation maximum displacement amplitude 3mm at 2 9Hz Maximum acceleration amplitude 0 5g 5m s at 9 200Hz Conforms to LV and EMC directives 5 79 This document and the information contained herein is the exclusive property of R amp M Materials Handling Inc and represents a non public confidential and proprietary trade secret that may not be reproduced disclosed to third parties altered or otherwise employed in any manner whatsoever without the express written consent of R amp M Materials Handling Inc Copyright 2005 R amp M Materials Handli
100. oltage transformet 0 20 10 TROUBLESHOOTING 2 ceeeeeeeeeeeerees 50 3 3 Speed SENSOMS cccccssseeeeessteessseees 20 10 1 Field repair actions cccccceeeeteeeeees 50 3 3 1 Sensor DEALING eee ceeeeteteteeeeeeeeeees 20 10 2 Typical functional problems 0 50 3 3 2 ENCOGGR a iwt acento 22 10 3 Inverter fault COdeS sc miducaccsrt aeons 51 3 3 3 Proximity SWitCH 0 0c cee eeteeeeeeeeee 23 10 3 1 Fault time data record ccceceseseeseeeees 54 2 79 This document and the information contained herein is the exclusive property of R amp M Materials Handling Inc and represents a non public confidential and proprietary trade secret that may not be reproduced disclosed to third parties altered or otherwise employed in any manner whatsoever without the express written consent of R amp M Materials Handling Inc Copyright 2005 R amp M Materials Handling Inc All rights reserved R amp M Materials Handling Inc RLA 4501 Gateway Boulevard Write Springfield Ohio 45502 mRemp P 937 328 5100 INC FAX 937 325 5319 103 2 Fault Countel 2 c2ac2accn wince nonin 55 14 1 2 Power classes 015F O55F ee 61 10 4 Inverter Alarm codes ceeseereeeeeeeees 55 14 2 Layouts dimensions and weights 62 11 TROUBLESHOOTING TABLE 005 56 14 3 Circuit diagrams ccccceseeseeesseeeeeees 63 AZ SERVICE se ccelccotnsc ies eee 57
101. or accelerates according to the acceleration ramp setting to the selected speed When the switch S1 S2 opens motor stops according to the deceleration ramp setting and the brake closes 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 S11 and S21 provide position dependent frequency limiting Any reason which opens contact RDY stops the operation of inverter In case of overload motor overheating etc the hoisting can be disabled by cutting the direction signal in terminal X1 8 Thermistor relay function which can be used when needed When the stop limit switch S12 or S22 opens K7 K71 in model 055F de energizes and the mechanical brake stops the motion Independent speed supervision unit SSU The speed measurement and supervision can be done either with encoder bearing sensor or proximity switch The measured signals are square wave pulses The frequency of the pulses is proportional to the speed of the motor and if the frequency is too high overspeed is detected If there are no pulses a stall situation is detected 7 79 This document and the information contai
102. ot be reproduced disclosed to third parties altered or otherwise employed in any manner whatsoever without the express written consent of R amp M Materials Handling Inc Copyright 2005 R amp M Materials Handling Inc All rights reserved Example layout HANDLING INC R amp M Materials Handling Inc RELY 4501 Gateway Boulevard Went Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 o 0Z1 1 4 Functional description Operation when power is switched on Stop limit switches 812 amp S22 and slow down limit switches S11 amp S21 are assumed to be normally closed as well as the emergency stop button ES The control voltage is supplied to X1 37 The main voltage is connected to inverter power supply and inverter wakes up If the control voltage is connected to RDY signal and the fault circuit is OK inverter is ready to operate in about 1 2 seconds If either of the direction signals S1 or S2 is on the display shows F6 and driving can begin only after the direction signals have been off for a while Normal operation For the description of the speed reference setting see chapter Control methods Hoisting lowering starts when switch S1 S2 closes Closing the contact ROB2 on A1 energizes K7 which opens the brake in model 055 the brake can be controlled also by K71 Mot
103. ounding should be used to minimize disturbances w If control cable length is over 100m from transformer to inverter or inverter is not mounted on the crane make sure that Basic I O board Slot A is at least revision 271G and I O Extension board Slot D is at least revision 266H 14 79 This document and the information contained herein is the exclusive property of R amp M Materials Handling Inc and represents a non public confidential and proprietary trade secret that may not be reproduced disclosed to third parties altered or otherwise employed in any manner whatsoever without the express written consent of R amp M Materials Handling Inc Copyright 2005 R amp M Materials Handling Inc All rights reserved R amp M Materials Handling Inc RELY 4501 Gateway Boulevard Wren Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC 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 kept as long as possible The distance between the resistor cables should be kept as low as possible to prevent the antenna behavior Cable le
104. p 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 DID3 S21 Slowdown signal direction 2 11 DIA4 Not used hold speed 3 41 DID4 S12 Stop limit signal direction 1 12 DIAS 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 Free NO contact of relay ROD1 18 K7 153 Free NO contact of K7 48 K7 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 E eee 21 PUR Not used 51 EA Encoder channel A 22 15V Not used 52 EA Encoder channel A 23 AIN1 Multicare speed reference input 0 10V 53 EB Encoder channel B 24 AIN2 Not used 54 EB Encoder channel B 25 AIN Common for analog inputs 55 24V 24V output for encoder 26 AOUT Multicare speed reference output 0 10V 56 ov Common for encoder supply 27 ov Common for analog output 57 24V External supply for Control module 60 79 This document and the information contained herein is the exclusive property of R amp M Materials Handling Inc and represents a non public confidential and proprietary trade secret that may not be reproduced disclosed to third parties altered or ot
105. parties altered or otherwise employed in any manner whatsoever without the express written consent of R amp M Materials Handling Inc Copyright 2005 R amp M Materials Handling Inc All rights reserved R amp M Materials Handling Inc R M 4501 Gateway Boulevard v Springfield Ohio 45502 MATERIALS meem P 937 328 5100 amea FAX 937 325 5319 Overspd Lim 1 V4 8 1 Overspeed limit 1 level Percent of Max Freq S2 0 140 Overspd Lim 2 V4 8 2 Overspeed limit 2 ESR value Percent of Max Freq S2 0 140 KOE e eee Se Phase U Curr V4 9 1 Phase U current of inverter output A Phase V Curr V4 9 2 Phase V current of inverter output A Phase W Curr V4 9 3 Phase W current of inverter output A Encoder Speed V4 9 4 Pulse frequency from pulse sensor Hz HeatSinkTempMax V4 9 5 Recorded heatsink temperature highest peak value during run C HeatSinkTempMin V4 9 6 Recorded heatsink temperature lowest peak value when power is C connected to drive IGBT Temp Max V4 9 7 Recorded calculated IGBT temperature highest peak value C IGBT Temperature V4 9 8 Actual IGBT temperature C SlipAdjustChange V4 9 9 Slip adjust difference compared to Slip adjust parameter Max Current V4 9 10 1 Recorded maximum current A 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
106. perly installed High voltages are present in this device Switch the power off and after the display turns off wait 5 minutes before opening the cover Insulation resistance test with a megger multimeter requires special precautions Do not make any measurements inside the device when it is connected to the main supply Do not touch the components on the circuit boards Electrostatic discharge may cause damage or destroy the IC circuits Check all ventilation holes are clear and unobstructed Check that hot air coming from the brake resistors does not cause any danger Do not make any inspections unless the supply has been disconnected by the main switch It is forbidden to use radiophones or portable phones near this device with the doors open All the doors and covers must be closed during crane operation Drive is not intended to be used in a low voltage public network which supplies domestic premises Radio frequency interference is expected if used in such a network This document and the information contained herein is the exclusive property of R amp M Materials Handling Inc and represents a non public confidential and proprietary trade secret that may not be reproduced disclosed to third parties altered or otherwise employed in any manner whatsoever without the express written consent of R amp M Materials Handling Inc Copyright 2005 R amp M Materials Handling Inc All rights reserved R amp M Materials Handling Inc RE
107. power is switched on to the keypad If the Default Page value is 0 the function is not activated i e the last displayed page remains on the keypad display Default page OM P6 6 2 Timeout time P6 6 3 The time after which the keypad display returns to default page Contrast P6 6 4 Display contrast Backlight time P6 6 5 Determines how long the backlight stays before going out Value 0 0 65535 min means Forever InternBrake Res P6 7 1 Must not be changed Not conn Fan Control P6 7 2 Must not be changed First start HMI ACK timeout P6 7 3 Not used HMI retry P6 7 4 Not used MWh counter C6 8 1 1 MWh counter can not be reseted PwOn Day Counter C6 8 1 2 Total number of power on days PwOn hour count C6 8 1 3 Total number of power on hours MWh Counter T6 8 2 1 MWh counter can be reseted Clr MWh Counter P6 8 2 2 Clear MWh counter T6 8 2 1 Not reset Reset PwOn Day Counter T6 8 2 3 Number of power on days PwOn hour count T6 8 2 4 Number of power on hours Clr Optime cntr T6 8 2 5 Clear trip counters T6 8 2 1 T6 8 2 4 Software package 16 8 3 1 See software sticker under display IND2V081 NXP_IND2V081 SystemSw version 16 8 3 2 12 47 9072 Firmware interf 16 8 3 3 4 53 System load 16 8 3 4 Load of CPU 35 79 This document and the information contained herein is the exclusive property of R amp M Mater
108. 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 B2 1 12 2 9 00V is given to Analog output Aout2 by this button Off On Ain 1 Value V2 1 12 3 Value of analog input Ain1 voltage V Min Value Volt 1 P2 1 12 4 Ain1 value when test voltage min has been selected in the other 0 10V drive Max Value Volt 1 P2 1 12 5 Ain1 value when test voltage max has been selected in 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 V Motor Nom freq P2 2 2 Nominal motor frequency fn from motor rating plate 0 250 Hz Motor Nom Speed P2 2 3 Nominal motor speed n from motor rating plate 0 6000 rpm Motor Nom Curr P2 2 4 Nominal motor current In from motor rating plate In multimotor drives nominal currents must be summarized Nom Flux Curr P2 2 5 Motor nominal flux current lo same as no load current or magnetizing current from motor rating plate In multimotor drives nominal fl
109. r Parameters r Parameters r Parameters Motor Nom Volt 460 P 2 2 1 Motor Nom Volt 460 Motor Nom Volt 460 Motor Nom Volt 460 Motor Nom Freq 120 P 2 2 2 Motor Nom Freq 120 Motor Nom Freq 120 Motor Nom Freq 120 Motor Nom Speed 3420 P 2 2 3 Motor Nom Speed 3370 Motor Nom Speed 3340 Motor Nom Speed 3440 Motor Nom Curr 49 P 2 2 4 Motor Nom Curr 9 3 Motor Nom Curr 11 Motor Nom Curr 19 Nom Flux Curr 3 2 P 2 2 5 Nom Flux Curr 6 2 Nom Flux Curr 6 3 Nom Flux Curr 12 Start Current 5 8 Start Current 10 Start Current Start Current 18 Current Limit 10 Current Limit 15 Current Limit 16 Current Limit 27 Min Freq S1 10 Min Freq S1 10 Min Freq S1 10 Min Freq S1 10 Min Freq S2 5 Min Freq S2 iS Min Freq S2 5 Min Freq S2 5 Max Freq S1 Max Freq S1 Max Freq S1 Max Freq S1 Max Freq S2 Max Freq S2 Max Freq S2 Max Freq S2 Max ESR Freq Max ESR Freq Max ESR Freq Max ESR Freq Drive Selection Drive Selection Drive Selection Drive Selection Pulse Number Pulse Number Pulse Number Pulse Number Zero Freq Volt Zero Freq Volt Zero Freq Volt Zero Freq Volt U f Mid Volt U f Mid Volt U f Mid Volt U f
110. r of the drive is the same as in delivery documents Check the switch settings on SSU see Chapter Speed Supervision Settings If necessary open the control box cover and adjust the SSU settings Check the cabling to braking resistor Check the cabling to motor brake thermistors and speed sensor Check motor type Check the wire terminations in the motor connection box Check connections for motor thermistors brake wear and speed sensor circuits Disconnect motor U V W and brake cables to prevent damage of inverter Measure insulation resistance of brake coil and motor windings each phase to ground Re connect motor and brake cables Check braking resistor s Terminals X1 21 27 and X1 51 57 are for electronics level signals Normally only shielded wires are connected to these terminals Check that no control or line voltage level wires are connected there 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
111. rd according to the environments First environment means environment that a includes domestic premises and also establishments directly connected to a low voltage power supply network Second environment means environment that includes all establishments other than those directly connected a low voltage power supply network fect PDS g o0 Fulfilled EMC standards e All products fulfil the immunity requirements defined in the EN 61800 3 Amendment 11 2000 for the second environment e N level products fulfil the emission requirements of the EN 61800 3 A11 2000 for the second environment 1 1 79 This document and the information contained herein is the exclusive property of R amp M Materials Handling Inc and represents a non public confidential and proprietary trade secret that may not be reproduced disclosed to third parties altered or otherwise employed in any manner whatsoever without the express written consent of R amp M Materials Handling Inc Copyright 2005 R amp M Materials Handling Inc All rights reserved R amp M Materials Handling Inc 4501 Gateway Boulevard Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 RM MATERIALS HANDLING INC 2 INSTALLATION 2 1 Cubicles Inverter is delivered with external braking resistor Braking resistor types D2FR are installed in the same cubicle as the inverter itself Braking resistor D2HR04F9
112. re equipped with pulse wheel speed sensor or encoder After adjustment check that parameters V 4 8 1 Overspd Lim 1 and V 4 8 2 Overspd Lim 2 have value between 115 and 125 Check that parameters P 2 2 2 Motor Nom Freq and P 2 2 3 Motor Nom Speed have correct values from motor type plate Settings for pulse wheel sensor or encoder 24 ppr Power class 002 055 002 055 P 2 2 11 Max Freq S2 50 100 60 120 P 2 2 14 Pulse Number 24 24 Rotary switch S1 4 7 Switch S2 1 ON ON Switch S2 2 ON ON Switch S2 3 OFF OFF Switch S2 4 ON ON Rotary switch S3 4 7 7 2 Functional test run for SSU Test run must be made without load e Disconnect the signal wire coming from the pulse sensor to terminal X1 51 e Drive with minimum speed The motion must stop within 1 s fault F63 stall supervision is activated 44 79 This document and the information contained herein is the exclusive property of R amp M Materials Handling Inc and represents a non public confidential and proprietary trade secret that may not be reproduced disclosed to third parties altered or otherwise employed in any manner whatsoever without the express written consent of R amp M Materials Handling Inc Copyright 2005 R amp M Materials Handling Inc All rights reserved R amp M Materials Handling Inc RELY 4501 Gateway Boulevard Wrote Springfield Ohio 45502 P 937 328 51
113. rent Kp 4000 P 2 3 2 Flux Current Ti 25 P 2 3 2 Flux Current Ti 25 P 2 3 2 Flux Current Ti 25 P 2 3 3 S2 Flux Control 100 P 2 3 3 S2 Flux Control 100 P 2 3 3 S2 Flux Control 100 P 2 3 4 Freq 0 1 P 2 3 4 Freq 0 1 P 2 3 4 Freq 0 1 P 2 3 5 Freq 1 3 P236 Freq 1 3 P 2 3 5 Freq 1 3 P 2 3 6 Freq 2 S1 10 P 2 3 6 Freq 2 S1 10 P 2 3 6 Freq 2 S1 10 P 2 3 7 Freq 3 S1 20 P 2 3 7 Freq 3 S1 20 P 2 3 7 Freq 3 S1 20 P 2 3 8 Zero Flux Curr 80 P 2 3 8 Zero Flux Curr 80 P 2 3 8 Zero Flux Curr 80 P 2 3 9 Stray Flux Curr 40 P 2 3 9 Stray Flux Curr 40 P 2 3 9 Stray Flux Curr 40 P 2 3 10 Freq 2 S2 10 P 2 3 10 Freq 2 S2 10 P 2 3 10 Freq 2 S2 10 P 2 3 11 Freq 3 S2 40 P 2 3 11 Freq 3 S2 40 P 2 3 11 Freq 3 S2 40 P2 3 12 Zero Speed Curr 110 P2 3 12 Zero Speed Curr 110 P 2 3 12 Zero Speed Curr 110 P 2 3 13 Min Current Ref 90 P 2 3 13 Min Current Ref 90 P 2 3 13 Min Current Ref 90 P 2 3 14 Accel Comp TC 0 1 P 2 3 14 Accel Comp TC 0 1 P2 3 14 Accel Comp TC 0 1 P 2 3 15 Ref Angle S1 768 P 2 3 15 Ref Angle S1 768 P 2 3 15 Ref Angle S1 768 P 2 3 16 Ref Angle S2 2000 P 2 3 16 Ref Angle S2 2000 P 2 3 16 Ref Angle S2 2000 P 2 3 17 Flux Curr Damp 200 P 2 3 17 Flux Curr Damp 200 P 2 3 17 Flux Curr Damp 200 P 2 3 18 Stop DC Freq 1 5 P 2 3 18 Stop DC Freq tS P 2 3 18 Stop DC Freq 1 5 P 2 3 19 Start Freq S1 1 5 P 2 3 19 Start Freq S1 1 P 2 3 19 Start Freq S1 1 P 2 3 20 Start Freq S2 0 5 P 2 3 20 Start Freq S2 0 5 P 2 3 20 Start Freq S2 0 5 P 2 3 21 Brake Stop Freq 1 P 2 3
114. rotary switch S3 and switch S2 4 Overspeed detection levels are shown at display panel as of nominal speed Overspeed setting should be 15 25 above the full speed Adjusted overspeed detection level for normal use is shown in parameter V4 8 1 Adjusted overspeed detection level for ESR use is shown in parameter V4 8 2 Speed difference supervision F62 compares the motor actual speed pulse frequency with Drive frequency reference In practice this means that the motor slip is measured and if that exceeds a limit supervision stops the motion Stall supervision F63 stops the motion if there are no pulses coming from the sensor when the brake is open K7 energised SSU relay test F64 SSU Relay is tested 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 overspeed limit is set over that value When a fault is detected the drive is prevented 43 79 This document and the information contained herein is the exclusive property of R amp M Materials Handling Inc and represents a non public confidential and proprietary trade secret that may not be reproduced disclosed to third parties altered or
115. rrLim 100 P 2 3 29 DeadTimeCurrLim 100 P 2 3 29 DeadTimeCurrLim 100 P 2 3 30 Brake Chopper Run P 2 3 30 Brake Chopper Run P 2 3 30 Brake Chopper Run 40 79 This document and the information contained herein is the exclusive property of R amp M Materials Handling Inc and represents a non public confidential and proprietary trade secret that may not be reproduced disclosed to third parties altered or otherwise employed in any manner whatsoever without the express written consent of R amp M Materials Handling Inc Copyright 2005 R amp M Materials Handling Inc All rights reserved RM MATERIALS HANDLING INC R amp M Materials Handling Inc 4501 Gateway Boulevard Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 6 2 Factory default parameters for 120Hz motors T1 002 T2 004 T3 005 T4 007 MF10MA200 460V 120Hz MF10MB20 0 460V 120Hz MF10MC200 460V 120Hz MF11MA200 460V 120Hz Label Code Default Label Code Default Label Code Default Label Code Default G 2 1 General Parameters G 2 1 General Parameters G 2 1 General Parameters G 2 1 General Parameters Accel Time 1 2 5 P 2 1 10 Accel Time 1 2 5 Accel Time 1 2 5 Accel Time 1 2 5 Decel Time 1 2 5 P 2 1 11 Decel Time 1 2 5 Decel Time 1 2 5 Decel Time 1 2 5 r Parameters G 2 2 Moto
116. rrent 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 Alarm code A 16 Motor overtemperature A50 Reference value alarm A 80 Multistep sequence alarm A 82 Overweight alarm A 83 Slack cable alarm 10 4 Inverter Alarm codes 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 Alarm is a sign of an unusual operating condition Alarm remains in the display for about 30 seconds 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 This document and the information contained herein is the exclusive property of R amp M Materials Handling Inc and represents a non public confidential and proprietary trade secret that may not be reproduced disclosed to third parties alter
117. s ONE 7 X11 3 f A1 ES ES ye K7 A2 F11 X11 8 BRT1 9 RDY E7 X1 18 48 f Gat aaa 153 154 X1 19 49 163 164 67 79 This document and the information contained herein is the exclusive property of R amp M Materials Handling Inc and represents a non public confidential and proprietary trade secret that may not be reproduced disclosed to third parties altered or otherwise employed in any manner whatsoever without the express written consent of R amp M Materials Handling Inc Copyright 2005 R amp M Materials Handling Inc All rights reserved RM MATERIALS HANDLING IN R amp M Materials Handling Inc 4501 Gateway Boulevard Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 PE ZL L3 O L2 O L1 0 X K7 55 SET 0 3s 56 3 G1 X1 314 ee Ty 210 13 5 r L 22 I gt I gt 1 gt j X y 7 7 7 26 I 23 1124 27 1 25 1 3 2 18 23 L 26 K7 6 8 1 2 ac 415 7 5 25 PEA 4 OC O 6 7 57 32 S1 A8 S2 Ad DIA3 A110 DIA4 11 DIAS A112 OK one O2 38 DID2 S11 1 39 L S 0103 S21 1 40 xt DID4 S12 444 uy OLE gt G DIDS S22 42 36 ONE xig 17 4 AT ES ES 37 A F11 X18 o BRT1 7 RDY 7 O 11 S1 12 S2 13 DIA3 14 DIA4 D2FR12F45R2S2 45 ohm Z1 Z2 Z3 AND CM1 NOT INCLUDED IN STANDARD OR IT MODELS gt OK KAE234 4 3 E SET
118. s the exclusive property of R amp M Materials Handling Inc and represents a non public confidential and proprie lary trade secret that may not be reproduced disclosed to third parties altered or otherwise employed in any manner whatsoever without the express written consent of R amp M Materials Handling Inc Copyright 2005 R amp M Materials Handling Inc All rights reserved RM MATERIALS HANDLING INC R amp M Materials Handling Inc 4501 Gateway Boulevard Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 D2FR12FR2S2 2x 45 ohm WIRING A 2 5 mm B 2 5 mm OTHERS 0 75 mm OL230 ON230 PE pa 12 Je Se ae a S SH x1 L 3 1A ar ROD1 X1 le 4 47 f 16 X11 8 33 c11 BLU BRN BLK M11 PE 3 F11 BRT1 34 75 79 This document and the information contained herein is the exclusive property of R amp M Materials Handling Inc and represents a non public confidential and proprie lary trade secret that may not be reproduced disclosed to third parties altered or otherwise employed in any manner whatsoever without the express written consent of R amp M Materials Handling Inc Copyright 2005 R amp M Materials Handling Inc All rights reserved RM MATERIALS HANDLING INC R amp M Materials Handling Inc 4501 Gateway Boulevard Springfield Ohio 45502
119. t of R amp M Materials Handling Inc Copyright 2005 R amp M Materials Handling Inc All rights reserved R amp M Materials Handling Inc RELY 4501 Gateway Boulevard Wrens Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC high environment temperature u f curve settings motor loading brake operation inverter heatsink inverter cooling fan operation environment temperature F43 Encoder failure Encoder failure Check X Subcodes Encoder cabling S1 EA is missing BaS opening y S2 EB is missing ncoder mechanical assembly Encoder type and pulse number S3 Both EA and EB are missing S4 EA and EB are crossconnected S5 SSU board is missing or system load is too high F44 Device changed Option board or control unit has been changed Reset the fault Option board parameters or all parameters are X to different type or different power rating set up to default values F45 Device added Option board of different type or drive of Reset the fault Option board parameters or all parameters are X different power rating added set up to default values F50 Reference value Analog input signal is out of selected range 1 Check X fault 9V or 2 10V Reference cable Control cable is broken Reference source Signal source has failed F 51 Stop limit Stop limit has tripped Reset keep controller at zero gt 300ms X Ensure that fault disappears after leavi
120. t stop after full speed is reached fault F64 Over speed is activated Set rotary switch S1 S3 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 Make sure that movement will not cause any danger to the environment or to the crane itself If the 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 If the 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 raised 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 should 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 Itis recommended to store the parameter settings in file User parameters see chapter User parameters 49 79 This document and the information contained herein is the exclus
121. ter is to replace it with a new one If the fault can be located it is also possible to replace some of the components When replacing an inverter or a Control unit with a new one the parameter list of the existing drive is needed so that the parameter settings can be copied to the new one If parameters have been copied to the keypad before damage it may be used for uploading the parameters to the spare part inverter requires same software versions 10 2 Typical functional problems Inverter does not start when mains is connected Check mains voltage between terminal L1 L2 and L3 Indicator Ready is on and Indicator Fault is off but motor does not run Check control mode selection Check voltage at run command terminals X1 8 and X1 9 Check state of digital inputs from parameter V4 7 12 Motor runs poorly Check that load is not over nominal Check that all cables are connected correctly and the junctions are reliable Check that all motor dependant parameters are correct Check the voltage of the slowdown limit switch input Check state of digital inputs from parameter V4 7 13 Check that motor s brake opens completely Check that minimum speed parameters do not have too small values Check u f curve tuning If the main girder is new it might be necessary to drive trolley several times with no load from end to end before beginning of u f curve tuning Some parameters are not accessible or changing is not possible
122. the actual load current is below inverter continuous current then the fuses and the supply cable may be dimensioned according to the load current Powercass fo fos GOA fos OOF OTT fos OH fo Continuous current Icont A 6 5 8 10 13 18 24 32 42 48 Fuse A Max motor cable length m 50 50 50 50 50 50 50 50 50 Motor cable 40 C mm 1 5 2 5 2 5 2 5 4 6 10 10 10 104 F AWG Braking resistor cable 40 C mm 2 5 2 5 2 5 2 5 2 5 2 5 2 5 4 4 104 F AWG Pors o o e OY Continuous current Icont A 60 75 90 110 Max motor cable length m 50 50 75 75 Motor cable 40 C mm 16 25 35 35 Braking resistor cable 40 C mm 10 10 16 16 104 F AWG 8 8 6 6 2 3 4 Cable protection To protect the supply cables against short circuit there must be fuses or motor circuit breakers MCCBs installed at the mains end of the supply 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 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 voltage drop in the cable For longer cables the required con
123. thus making the DC circuit 25 79 This document and the information contained herein is the exclusive property of R amp M Materials Handling Inc and represents a non public confidential and proprietary trade secret that may not be reproduced disclosed to third parties altered or otherwise employed in any manner whatsoever without the express written consent of R amp M Materials Handling Inc Copyright 2005 R amp M Materials Handling Inc All rights reserved R amp M Materials Handling Inc RELY 4501 Gateway Boulevard Write Springfield Ohio 45502 IG Eee P 937 328 5100 INC FAX 937 325 5319 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 26 79 This document and the information contained herein is the exclusive property of R amp M Materials Handling Inc and represents a non public confidential and proprietary trade secret that may not be reproduced disclosed to third parties altered or otherwise employed in any manner whatsoe
124. tial and proprietary trade secret that may not be reproduced disclosed to third parties altered or otherwise employed in any manner whatsoever without the express written consent of R amp M Materials Handling Inc Copyright 2005 R amp M Materials Handling Inc All rights reserved R amp M Materials Handling Inc RELY 4501 Gateway Boulevard Wren Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC 1 6 3 MS4 control oor z B c_coms4b ee 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 7 Mechanical brake control Inverter has a brake contactor to control electromechanical disk brake of hoisting motor The disk brake is opened and kept open during run by DC voltage When there is no voltage present the brake is closed and also kept closed by spring force The brake is controlled so that during starting the motor first generates 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 Inverter decelerates the motor to a stop according to the set deceleration time when the run command is switched off so the brake is used only as a holding brake This way brake wear is min
125. us SSU LED s If the fault comes again contact service F 66 SSU Overspeed SSU overspeed limit has been set over Check Limit 140 of maximum frequency set SSU overspeed limit under 140 of maximum frequency motor type plate parameters maximum frequency parameters F70 Multicare Fault Other inverter has tripped to fault or brake Check other hoisting inverter of other inverter has not been opened fault history Fault is not stored into fault history brake operation F71 Brake Control Load information from hoist control unitis Check Fault out of operation window Ain2 wiring settings of load measuring device F73 Both Dir Active Both direction signals are active at same Check time gt 500ms controller operation wiring of direction signals A Can be done by the user B Can be done only by manufacturer authorized personnel 10 3 1 Fault time data record When a fault occurs the fault number is displayed By pushing the menu button right here you will enter the Fault time data record menu indicated by T 1 T 13 In this menu some selected important data valid at the time of the fault are recorded The data available are Counted operation days Counted operation hours Output frequency Motor current Motor voltage Motor power Motor torque DC voltage Unit temperature Ready Run Direction Fault Warning At reference 0 speed hh mm ss 0 Not Ready 0 Not Running 0 0ff 1 On 0 No 1 Yes
126. ut frequency Hz T 4 Motor current A T 5 Motor voltage V T 6 Motor power T 7 Motor torque 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 Off 1 On Fault 0 No 1 Yes T 12 Warning O No 1 Yes At reference 0 No 1 Yes T 13 0 speed 0 Not Zero Speed 1 Zero Speed M8 Fault history The fault memory can store a maximum of 30 faults in the order of appearance The number of faults currently in the fault history is shown on the value line of the main page The order of the faults is indicated by the location indication in the upper left corner of the display The latest fault carries the indication F8 1 the second latest F8 2 etc The Fault time data record pages are accessible at each fault If there are 30 uncleared faults in the memory the next occurring fault will erase the oldest from the memory Pressing the Enter button for about 2 to 3 seconds resets the whole fault history 37 79 This document and the information contained herein is the exclusive property of R amp M Materials Handling Inc and represents a non public confidential and proprietary trade secret that may not be reproduced disclosed to third parties altered or otherwise employed in any manner whatsoever without the express written consent of R amp M Materials Handling Inc Copyright 2005 R amp M Materials Handling Inc All rights reserved RM MATERIALS HANDLIN
127. ux currents must be summarized Materials Handling Inc Copyright 2005 R amp M Mai This document and the information contained herein is the exclusive property of R amp M Materials Handling Inc and represents a non public confidential and proprie trade secret that may not be reproduced disclosed to third parties altered or otherwise employed in any manner whatsoever without the express written consent of R amp M lary terials Handling Inc All rights reserved 31 79 RM R amp M Materials Handling Inc 4501 Gateway Boulevard Springfield Ohio 45502 MATERIALS meem P 937 328 5100 Ne FAX 937 325 5319 Start Current P2 2 6 Start current Current level which is used in motor starting situation Hoisting application default value is motor s nominal current but not over nominal current of the inverter Current Limit P2 2 7 Defines the maximum motor current from the inverter If the output current exceeds the value set in parameter P2 2 7 the output frequency is lowered until the current drops below the current limit The rate of lowering the frequency depends on the current overshoot To avoid motor overloading set this parameter according to the rated current of the motor normally 1 5 2xI In multimotor drives nominal currents must be summarized Note The value must be
128. ver without the express written consent of R amp M Materials Handling Inc Copyright 2005 R amp M Materials Handling Inc All rights reserved R amp M Materials Handling Inc RLA 4501 Gateway Boulevard Write Springfield Ohio 45502 Rempe P 937 328 5100 INC FAX 937 325 5319 4 PARAMETER ADJUSTMENTS 4 1 The display panel vV 4 18 P 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 C RUN Motor is running blinks when ramping down Direction of motor rotation Motor is not running Power is on In case of a trip the symbol will not light up rom Drive is running outside of certain limit FAULT 9 Fault is on 0 term 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 iy Confirmation of selections Center Fault history reset Browse the main menu and the pages of submenus Edit values Move in menu Move cursor Enter and exit edit mode Start button
129. wer off unless they are not confirmed with Enter one 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 The 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 can 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 confirm with enter After restoring always check the motor parameters 4 2 4 Factory settings Factory settings are not used 29 79 This document and the information contained herein is the exclusive property of R amp M Materials Handling Inc and represents a non public confidential and proprietary trade secret that may not be reproduced disclosed to third parties altered or otherwise employed in any manner whatsoever without the express written consent of R amp M Materials Handling Inc Copyright 2005 R amp M Materials Handling Inc All rights reserved RM MATERIALS HANDLING INC R amp M Materials Handling Inc 4501 Gateway Bou
130. x Curr 12 Start Current 5 8 Start Current 10 Start Current 12 9 Start Current 18 Current Limit 10 Current Limit 15 Current Limit 16 Current Limit 27 Min Freq S1 10 Min Freq S1 10 Min Freq S1 10 Min Freq S1 10 Min Freq S2 5 Min Freq S2 5 Min Freq S2 5 Min Freq S2 5 Max Freq S1 Max Freq S1 Max Freq S1 Max Freq S1 Max Freq S2 Max Freq S2 Max Freq S2 Max Freq S2 P 2 2 12 Max ESR Freq 120 P 2 2 12 Max ESR Freq 120 P 2 2 12 Max ESR Freq 120 P 2 2 12 Max ESR Freq 120 P 2 2 13 Drive Selection Hoist P 2 2 13 Drive Selection Hoist P 2 2 13 Drive Selection Hoist P 2 2 13 Drive Selection Hoist P 2 2 14 Pulse Number 32 P 2 2 14 Pulse Number 32 P 2 2 14 Pulse Number 32 P 2 2 14 Pulse Number 64 P 2 2 15 Zero Freq Volt P 2 2 15 Zero Freq Volt P 2 2 15 Zero Freq Volt 0 P 2 2 15 Zero Freq Volt P 2 2 16 U f Mid Volt P 2 2 16 U f Mid Volt P 2 2 16 U f Mid Volt 6 5 P 2 2 16 U f Mid Volt P 2 2 17 U f Mid Freq P 2 2 17 U f Mid Freq P 2 2 17 U f Mid Freq 0 P 2 2 17 U f Mid Freq P 2 2 18 Torque Boost On P 2 2 18 Torque Boost On P 2 2 18 Torque Boost On P2 2 18 Torque Boost On P 2 2 19 Rs Voltage Drop 200 P 2 2 19 Rs Voltage Drop 240 P 2 2 19 Rs Voltage Drop 190 P 2 2 19 Rs Voltage Drop 130 P 2 2 20 Stop Function Ramping P 2 2 20 Stop Function Ramping P 2 2 20 Stop Function Ramping P 2 2 20 Stop Function Ramping G 2 3 Expert G 2 3 Expert G 2 3 Expert G 2 3 Expert P 2 3 1 Flux Current Kp 4000 P 2 3 1 Flux Current Kp 4000 P 2 3 1 Flux Current Kp 4000 P 2 3 1 Flux Current
131. x ESR Freq 120 P 2 2 12 Max ESR Freq 120 P 2 2 12 Max ESR Freq 120 P 2 2 13 Drive Selection Hoist P 2 2 13 Drive Selection Hoist P 2 2 13 Drive Selection Hoist P 2 2 14 Pulse Number 63 P 2 2 14 Pulse Number 80 P 2 2 14 Pulse Number 80 P 2 2 15 Zero Freq Volt P 2 2 15 Zero Freq Volt P 2 2 15 Zero Freq Volt P 2 2 16 U f Mid Volt P 2 2 16 U f Mid Volt P 2 2 16 U f Mid Volt P 2 2 17 U f Mid Freq P 2 2 17 U f Mid Freq P 2 2 17 U f Mid Freq P 2 2 18 Torque Boost On P 2 2 18 Torque Boost On P 2 2 18 Torque Boost On P 2 2 19 Rs Voltage Drop 150 P 2 2 19 Rs Voltage Drop 180 P 2 2 19 Rs Voltage Drop 180 P 2 2 20 Stop Function Ramping P 2 2 20 Stop Function Ramping P 2 2 20 Stop Function Ramping G 2 3 Expert G 2 3 Expert G 2 3 Expert P 2 3 1 Flux Current Kp 4000 P 2 3 1 Flux Current Kp 4000 P 2 3 1 Flux Current Kp 4000 P 2 3 2 Flux Current Ti 25 P 2 3 2 Flux Current Ti 25 P 2 3 2 Flux Current Ti 25 P 2 3 3 S2 Flux Control 100 P 2 3 3 S2 Flux Control 100 P 2 3 3 S2 Flux Control 100 P 2 3 4 Freq 0 1 P 2 3 4 Freq 0 1 P 2 3 4 Freq 0 1 P 2 3 5 Freq 1 3 P 2 3 5 Freq 1 3 P 2 3 5 Freq 1 3 P 2 3 6 Freq 2 S1 10 P 2 3 6 Freq 2 S1 10 P 2 3 6 Freq 2 S1 10 P 2 3 7 Freq 3 S1 20 P 2 3 7 Freq 3 S1 20 P 2 3 7 Freq 3 S1 20 P 2 3 8 Zero Flux Curr 80 P 2 3 8 Zero Flux Curr 80 P 2 3 8 Zero Flux Curr 80 P 2 3 9 Stray Flux Curr 40 P 2 3 9 Stray Flux Curr 40 P 2 3 9 Stray Flux Curr 40 P 2 3 10 Freq 2 S2 10 P 2 3 10 Freq 2 S2 10 P 2 3 10 Freq 2 S2 10 P 2 3 11 Freq 3 S2 40 P 2 3
132. y of R amp M Materials Handling Inc and represents a non public confidential and proprietary trade secret that may not be reproduced disclosed to third parties altered or otherwise employed in any manner whatsoever without the express written consent of R amp M Materials Handling Inc Copyright 2005 R amp M Materials Handling Inc All rights reserved R amp M Materials Handling Inc eLA M4501 Gateway Boulevard Wrens Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC 12SERVICE The drive does not require regular maintenance However the following actions are recommended Check fault history Find out reasons of possible faults Clear the fault history Clean the heat sink Prevent the dust to spread inside cubicles Lock the fans before blowing compressed air Check that there are no abnormal noises coming from the cooling fan Tighten all screws and connectors Clean dust from PC boards Check the speed supervision circuit only in hoisting inverter See chapter Functional test run for SSU 57 79 This document and the information contained herein is the exclusive property of R amp M Materials Handling Inc and represents a non public confidential and proprietary trade secret that may not be reproduced disclosed to third parties altered or otherwise employed in any manner whatsoever without the express written consent of R amp M Materials Handling Inc Copyright 2005 R amp M Mater

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