SERVICE MANUAL FOR TRAVELING INVERTER
Contents
1. DMCS007 Nbr Name Description 1 PE Protective earth 2 L1 Mains phase 1 380 480V 50 60Hz 3 L2 Mains phase 2 380 480V 50 60Hz 4 L3 Mains phase 3 380 480V 50 60Hz 5 U Motor phase 1 6 V Motor phase 2 7 Ww Motor phase 3 8 S1 Drive command Direction 1 48 or 115V 50 60Hz 9 S2 Drive command Direction 2 48 or 115V 50 60Hz 10 SP2 AP Speed 2 Acceleration command 48 or 115V 50 60Hz 11 ON Control voltage neutral w Standard duty resistor must be disconnected when heavy duty resistor DMHR01F90 is connected to terminals R and R 1 2 Technical characteristics Technical data DMCS007 Power range 0 75kW Supply voltage 380 480 VAC 10 5 Nominal supply frequency 48 62 Hz Nominal current 2 4A Digital control 1 S2 DI3 Max output voltage Equal to supply voltage Control voltage range 48 VAC 115 10 If control voltage is 230VAC front resistors 15k 2W have to be connected to digital inputs Output Ambient temperature 10 C to 50 C 3 9 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice i R amp M Materials Handling Inc R amp M 4501 Gateway Boulevard SESS Springfield Ohio 45502 HANDLING P 937 328 5100 INC FAX 937 325 5319 Technical data DMCS007 Humidity 95 N C without dripping Degree of protection Frequency converter cover IP20 Dim2. 26 56 26 30 11 1 0 1 1 90 35 59 28 32 12 1 1 0 0 95 38 65 32 33 14 0 0 0 0 100 29 77 22 35 8 1 1 0 1 105 41 68 34 37 16 METETE 110 44 71 36 39 17 1 lol olo 115 50 80 40 41 19 1 4 14 4 120 47 74 38 42 18 1 Speeds above 100Hz are only available when the inverter is connected in 440 480V mains EXAMPLE OF PARAMETER SETTING 80Hz motor is connected to the inverter and 62Hz maximum speed is desired That speed is located on the 5 row in the speedtable B The corresponding setting for S1 swithces is in the same row in the leftmost columns of the table 0 1 0 0 off on off off S1 dia NO pect Max speed set to 62Hz 4 1 1 Acceleration and deceleration ramp The acceleration and deceleration ramps are set by switch S3 as follows Switch S3 Acceleration deceleration 1 2 3 4 ramp time 1 0 0 0 1 5 sec 0 1 0 0 2 0 sec 0 0 0 0 2 5 sec 0 0 1 0 3 0 sec 0 0 0 1 3 5 sec 1 0 0 1 4 0 sec 1 1 0 0 4 5 sec 0 0 1 1 5 0 sec 1 1 1 0 5 5 sec 1 1 0 1 6 0 sec 1 0 1 1 6 5 sec 1 0 1 0 7 0 sec 0 1 1 1 7 5 sec 8 9 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc R amp M 4501 Gateway Boulevard MATERIAS Springfield Ohio 45502 HANDLING P 937 328 5100 INC FAX 937 325 5319 Switch S3 A
3. 3 m 5 4 x 0 47 uF S Capacitors have to be placed as near the inverter as possible 1 7 2 EMC filter connection to inverter for bridge travelling DMCS007 c_kc330a 1 Supply 2 EMC filter KC 330 00 3 Inverter 4 Motor cable length max 25 m 5 4x1uF 6 Input wires two times trough input ferrite rings S Capacitors have to be placed as near the inverter as possible 5 9 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice j R amp M Materials Handling Inc R amp M 4501 Gateway Boulevard MESES Springfield Ohio 45502 G iene P 937 328 5100 INC FAX 937 325 5319 2 DESCRIPTION OF CONTROL MODES 2 1 MS2 control S4 1 OFF gt gt D DERD VV Vv eee c_coms2a A Push button position B Speed S1 means drive minimum speed forward S2 means drive minimum speed reverse SP2 means maximum speed When S1 and S2 or are not active the inverter decelerates to zero 2 2 EP2 control S4 1 ON gt gt M RPL eee A Push button position B Speed 0 Decelerate 1 Maintain speed 2 Accelerate S1 means drive forward S2 means drive reverse AP means acceleration When starting S1 and S2 mean accelerate to minimum speed When S1 and S2 are not active the inverter decelerates to zero During r
4. sec REE suis tecnica nation E E E EE E Eaa 6 2 2 EP2 control S4 1 ON 00 2 cece eee cece eee e cette eee eee reece a eee e eee ected ce aaa e eats eee aaaeee sees eeeecaaaaeeeeeeeeseeenaaeeeeees 6 3 FAULT CODES TROUBLESHOOTING ssccasicaccustsasisantdaniedsidciesanianesunidcaieantianeoesisabisandaneniubdaaxeamdanes 7 4 PROGRAMMING OF THE APPLICATION PARAMETERS cccccccccccccccccececeeeeeeeeeeeceeeeeseeeeeeeeeees 8 4 1 Minimum speed maximum speed and ramp tiMe ccceeceeeeeeeeeecceeee eee eeeteeeaaaaeeeeeeeeteseaaaaeeeeeeeteneeaaaaes 8 4 1 Acceleration and deceleration tram pipita aa E E A eee N 8 4 2 Selection OF THE Motortype znana n a E N R N eae nee 9 2 9 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc 4501 Gateway Boulevard MATERIALS Springfield Ohio 45502 HANDLING SES P 937 328 5100 INC FAX 937 325 5319 1 DESCRIPTION OF THE INVERTER w There are high voltages inside the inverter including the programming switches Wait for at least three minutes after the supply voltage has been switched off before any service actions DMCS007 1 Terminal X1 2 Red led fault 3 Green led ok 4 Programming switches 1 1 Connections All connections are made to terminal block X1 as follows w Crane power supply conductor rail must have double collectors
5. EEN UUL JUUL IUU TUU again set longer ramp time by switch S3 Check also the voltage of all supply phases at the terminal X1 Inverter overtemperature Motor current is too high bearing problem obstacle on the track GREEN iit ii iji iji iji UL brake does not open properly or the ambient temperature is too high Undervoltage Check the voltage of all supply GREEN ULU UU phases at the terminal X1 Short circuit Switch the power off Check the RED U IUL 1WL_IUL_IUL_JLUL_ insulation of the motor cables and the motor windings RED UUU nL Microprocessor fault Switch the power off for 10 seconds Then power up the inverter er The latest active fault is removed from the memory always when power is switched off w If inverter is not in a fault state but driving is not possible e Motor will not start if dc bus voltage too high above 745V this occurs if any of line to line voltages exceeds 480V 5 508V o If line voltage cannot be reduced install drop down transformer Check the supply voltage phases at terminal X1 Check the control signals at terminal X1 Check that the control voltage level is correct Rating plate is located on the left side of the inverter Check all parameters especially the motor parameters switch S4 Check that the motor s corresponds the selected motor parameters Check that the microprocessor starts runni
6. English Original instructions SERVICE MANUAL FOR TRAVELING INVERTER Service Manual for DMCS 007F SUPDOC_SM_DMCS019 0 0RD 16 11 2010 R amp M MATERIALS HANDLING INC C_SM_DMCS0190100 0 PS02379 16 11 2010 R amp M Materials Handling Inc R amp M 4501 Gateway Boulevard SEES Springfield Ohio 45502 HANDLING AASA P 937 328 5100 INC FAX 937 325 5319 Table of contents 1 DESCRIPTION OF THE INVERTER sitsciveczscecsseciecttsetscccnpeciaatlesticaginagindttedinanpuandiadtlastnansiaabiadtiatbiaegiant 3 1 1 COMMECTIONS vices sescceeaceut nore stensteeceed eonsecmeeeesened a aaa aaaeaii aaia aa aaa 3 1 2 Technical eharacteniStiCS eenee ene er ete etree Meee ne E ee en ee eee eee 3 1 3 INoldagks je SI 1ccl ola enter th ten en nee rec re rr nr ny ne ec Torr 4 1 4 Status indication leds green anG red sasaa aaa E a ied el dello delice E 4 1 5 COMP ACU DFAKS MOLONS aana a A E N T A A N E 4 1 6 Programming SWITCHES nienean e EEEE EARE E EAEE EEEE EA a Ea E E a a de 4 1 7 Th EMG requirements amsser duet oa cacest sash Sustained devi N duster si dos A E N R 5 1 7 1 EMC filter connection to inverter for trolley tr veliNg svs 5 1 7 2 EMC filter connection to inverter for bridge travelling cccccceieccceeeeeeeeeeeeeeeteaeeeeeeeeettecaaaeeeeeeettneee 5 2 DESCRIPTION OF CONTROL MODES viivisccisetivinsindisdentensiniedideen dedenindaa bnleneebahsenentbradies 6 2 1 MS2 COMMON S42 ISO FY ssctee tie cts
7. cceleration deceleration 1 2 3 4 ramp time 0 1 0 1 8 0 sec 4 2 Selection of the motor type The motor type is selected by switches S4 2 S4 3 and S4 4 There are several motor dependant parameters which are set according to the selected motor i e the operator selects a parameter set The MFO06 motors are selected as follows 2 a a Motor type Nominal frequency Nominal power 0 0 0 MFO6MA200 100Hz 120Hz 0 3kW 0 37kW 1 0 0 MFO6MA100 80Hz 0 65kW o 1 0 MFO6LA200 100Hz 120Hz 0 45kW 0 55kW 1 1 0 MFO6LA100 80Hz 0 65kW o o 1 2 MFO6MA200 100Hz 120Hz 2 0 3kW 2 0 37kW 1 0 1 MFO6L 200 35 Hz 0 15kW 9 9 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice
8. ensions WxHxD 133x92x60mm Altitude Output current must be reduced 1 for every 100 m over 1000 m For altitudes over 3000 m manufacturer must be consulted Pollution degree Pollution degree 2 according to NEMA ICS 1 IEC664 and UL840 Vibration IEC68 2 6 Shock IEC68 2 27 1 3 Normal operation The inverter goes into the ready to run state within one second after the power supply is connected During running the inverter follows the operator s speed reference according to the set acceleration deceleration ramp During direction change the brake is kept open all the time When drive command is switched off the inverter decelerates to zero according to the set ramp and closes the mechanical brake 1 4 Status indication leds green and red The inverter indicates its operating state by two leds Red led indicates fault state driving is inhibited Green led indicates ok state Blinking of green led indicates that fault state has been active but it has been recovered Normal driving is however possible also when green led is blinking in other words blinking of green led does not indicate warning state 1 5 Compact brake motors This inverter is used with Compact brake motors which have been especially designed for this use The Compact brake motors have the following special features e Compact brake which is opened by the magnetic force of the motor When the magnetic force is removed by cutting off the motor cu
9. ng Both indication leds green and red blink once as the inverter is powered up After the one second initialising time only the green led should be light e Check that the brake opens and closes properly Check the brake airgap if necessary 7 9 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice b R amp M Materials Handling Inc R amp M 4501 Gateway Boulevard SEES Springfield Ohio 45502 HANDLING ANSE P 937 328 5100 INC FAX 937 325 5319 4 PROGRAMMING OF THE APPLICATION PARAMETERS 4 1 Minimum speed maximum speed and ramp time The adjustment ranges of maximum and minimum speed depend on the selected motor type i e motor nominal frequency The speeds in the speed table A are used for the 100 120Hz motors and the speeds in the speed table B for the 80Hz motors and in the speed table D for the 35Hz motors The maximum speed and minimum speed and ramp time are set as follows Switch SPEEDTABLE A SPEEDTABLE B SPEEDTABLE D S1 S2 100 120Hz motors 80Hz motors 35Hz motors 1 2 3 4 Max speed Hz Min speed Max speed Min speed Max speed Min speed Hz Hz Hz Hz Hz 0 0 0 1 50 14 42 14 19 9 0 0 1 1 54 10 40 10 20 4 0 1 0 1 58 12 44 12 21 5 0 0 1 0 62 23 50 18 22 13 0 1 1 0 66 16 46 16 23 6 0 1 1 1 70 18 48 20 25 7 1 0 0 1 75 20 53 24 26 10 0 1 0 0 80 32 62 30 28 15 1 0 1 0 85
10. rrent the brake is closed by spring force e High nominal frequency 80Hz 120Hz 1 6 Programming switches w WARNING There are high voltages inside the inverter including the programming switches Wait for at least three minutes after the supply voltage has been switched off before any service actions The programming of the inverter is performed by dip switches The state of each switch is either OFF 0 or ON 1 There are five parameters that are possible to set by the switches S1 S4 DMSC007 S1 AE a mer S2 S1 Maximum speed 5 S2 Minimimum speed S3 Acceleration deceleration time S3 S4 Control mode and motor type vect vect Z E O S4 hol oo rS 4 9 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc 4501 Gateway Boulevard MATERIAS Springfield Ohio 45502 HANDLING EE P 937 328 5100 INC FAX 937 325 5319 1 7 The EMC requirements The device complies with the requirements of EN61800 3 2004 IEC61800 3 for second environment category C3 when a dedicated external EMC filter is applied 1 7 1 EMC filter connection to inverter for trolley travelling DMCS007 c_kc310a 1 Supply 2 EMC filter KC 310 00 3 Inverter 4 Motor cable length max
11. unning S1 and S2 mean hold speed At maximum speed AP means hold speed 6 9 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice i R amp M Materials Handling Inc R amp M 4501 Gateway Boulevard MATERIAIS Springfield Ohio 45502 HANDLING 2 P 937 328 5100 INC FAX 937 325 5319 3 FAULT CODES TROUBLESHOOTING w There are high voltages inside the inverter including the programming switches Wait for at least three minutes after the supply voltage has been switched off before any service actions When the inverter detects a fault situation it stops running and starts signalling the fault code by blinking the indication leds green and red The blinking of the code is carried on until a new fault occurs or until power is switched off The fault codes are explained in the table below Fault code color Fault Possible cause Checkings DMCS007 Overvoltage Mains voltage is too high or ramp _ JL JL JL JL_Il time is too short Check the voltage of all supply GREEN phases at the terminal X1 If they are ok then ANNAN set a longer ramp by switch S3 Stall supervision overcurrent Brake does not open properly or there is an obstackle on GREEN ijLJULJULJULIU LIU the track Check also that the setting of switch S4 is made according to the supplied motor s Deceleration ramp supervision Deceleration ramp has not been followed If the fault occurs GR
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