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19.12.2007

SERVICE MANUAL FOR FREQUENCY CONTROL SYSTEM

Summary of content (46 pages)

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English 19.12.
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R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 ! Read the instructions supplied with the product before installation and commissioning. # Keep the instructions in a safe place for future reference. Table of content 1 CAUTION....................................................... 3 2 GENERAL...................................................... 4 2.1 Technical data ........................................... 4 2.2 Basic description......
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R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 1 CAUTION # This manual rev6.0 is for inverter rev 1.0 with software D2S2V051. ! ! ! ! ! ! ! ! ! ! ! ! ! ! Before starting, read the instructions carefully. Verify all of the connections are in accordance to the drawings. Verify the motor supply is connected correctly, faulty connection will destroy the inverter. Check the device cover is properly installed.
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R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 2 GENERAL 2.1 Technical data Power class Power (kVA) at 400V Output current In (A) Max. current 1min (A) 002F 3.5 5.0 7.6 Overload ability Max. output voltage 1.
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R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 2.2 Basic description Inverter Crane user interface Brake control Electrical Braking Control modes Limit switch functions Protections 2.3 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. Interface with pre-designed locations for typical crane functions.
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R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 2.4 Functional description Operation when power is switched on - Stop limit switches S12 & S22 and slow down limit switches S11 & S21 are assumed to be normally closed, as well as the emergency stop button ES. The control voltage is supplied to X1:5 and X1:6. The main voltage is connected to inverter power supply and then inverter wakes up.
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R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 All control methods are available without any changes in the hardware or software. The control mode of inverter is selected by parameter P1.1.11 Input set, which has eight alternative settings: MS2 (stop-limit), MS2/MS3 (slow-limit), EP2 (stop-limit), EP2 (slow-limit), EP3, MS4, MS5 and AU (automation control). (See Chapter 5: parameter descriptions.
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R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 2.6.2 EP2-control c_coep2a A. Pushbutton / controller position B. Speed 0) 1) 2) “decelerate to zero” while starting “drive minimum speed” while running “hold speed” while running “accelerate” while running at maximum speed “hold speed” 2.6.3 EP3-control c_coep3a A. Pushbutton / controller position B.
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R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 2.6.5 MS5-control c_coms5b A. Controller position B. Speed 0) 1) 2) 3) 4) 5) “decelerate to zero” step 1 “drive minimum speed” step 2 “drive speed2” step 3 “drive speed3” step 4 “drive speed4” step 5 “drive maximum speed” 2.6.6 AU/PO-control S1 c_coms6a S2 A. Reference B.
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R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 2.8 Stop-limit operation Stop-limit function is available in MS2- (stop-lim), EP2- (stop-lim), and AU-control modes. Normally these inputs (S12 and S22) are "high" (limit switch closed, voltage present in the input).
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R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 2.10.1 EMC levels Three kinds of EMC levels are available, they are S, N and 0 level. • • • S-level: No manufacturer’s EMC solution is adopted and products will be used in other market areas than European Union (EU) when local power supply system is the grounded network.
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R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 3 INSTALLATION 3.1 Cubicles Wall mounting Standard cubicle EEC25.4025 002F 003F – 004F Through panel mounting Standard cubicle EEO25.
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R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 The table below is based on ED ≤ 60% (60% duty cycle) and an ambient temperature of +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.
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R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 3.2.6.2 005 – 022 Du/dt filter at motor supply is needed if - Motors are not made for inverter use Inverter is not mounted on the crane Number of motors is greater than 4 Total motor cable length is over 200m (660ft) Power class 002 – 003 004 – 005 007 – 018 022 3.
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R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 4 COMPONENTS 4.1 Inverter Inverter (D2S) includes a Power supply unit (PSS) and a Control unit (CSS), which are separate parts. PSS includes supply, brake resistor and motor connections. IGBTs are located within the PSS. Microprocessors and Application Special Integral Circuit (ASIC) Chip are located within the CSS. Same CSS can be used for all models of the D2S.
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R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 4.1.2 Control unit (CSS) Control unit (CSS) includes a control board with five board slots for option boards and a control keypad for parameter adjustments. Inverter uses only one of the existing slots and is used to connect I/O extension board. The CSS is connected to PSS through a connector. Green ON Red OFF Status Everything is OK.
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R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 5 PARAMETER ADJUSTMENTS 5.1 The display panel The display panel is used for: - Displaying the drive identification, electrical values, operating or fault parameters - Altering the parameter settings Meaning of the displays: Drive status indications: Motor is running, blinks when ramping down. Direction of motor rotation. Motor is not running. Power is on.
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R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 5.2 Navigation on the control keypad 5.2.1 Editing numerical settings ! WARNING! Changing parameter settings during running may cause a hazardous situation. Parameter settings must not be changed during running. button takes you into the edit mode. As an indication, the parameter value starts to blink. a. Pushing b. Two different methods are available to change values.
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R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 5.4.1 Voltage at low frequencies (U/f- curve) Following parameters need to be set for U/f setting. For listed motors, values of these parameters are stored into the inverter memory, but they can also be set manually or by Autotuning. The manual setting procedure is as follows: 5.4.1.
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R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 # Check minimum speed from the crane calculations. Minimum speed is not allowed to be under nominal slip S n = ( syncronspeed − nom.speed ) * nom. frequency syncronspeed 5.4.2 Autotuning Before Autotuning, - Check that there is no load on the crane. Set P1.1.1. “Password” = 2156 Set P1.2.2 “Motor selection” = 1 “Free Travel” Set Motor nameplate values P1.2.1, P1.2.4.1- P1.2.4.
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R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 6 PARAMETER DESCRIPTIONS This manual describes the parameters software version D2S1V051. Underneath the control panel there is sticker for software version. 6.1 General Description M1 Parameters G1.1 Parameters are assorted to Groups. All Groups are not always listed in control panel. Groups are shown in the control panel according to password level and selected functions.
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R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 P1.1.4 Minimum Freq 0.00 Max freq Hz The set minimum operating frequency. P1.1.5 Maximum Freq Min freq 120.00 Hz P1.1.6 Reverse Plugging 50 100 % The maximum frequency may not be higher than the motor nominal frequency for listed motors. See Chapter "Reverse plugging" P1.1.7 Stop Function 0 1 P1.1.
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R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 P1.2.4.3 Motor Nominal Flux Current 0.0 A Motor nominal flux current (Io), same as no-load current or magnetizing current from motor nameplate. In multimotor drives nominal flux currents must be summed up. P1.2.4.4 Current Limit 0.0 A Defines the maximum motor current from the inverter. If the output current exceeds the value set in parameter P1.2.4.
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R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 G1.3 I/O Parameters Code Name Min Max P1.3.1 ROA1 0 12 Unit Description 10.000 V State of relay output ROA1 (See Chapter "Relay output") 0 = Not Used 1 = Fault 2 = External Brake Control 3 = Run, current is fed to the motor, default 4 = Drive is ready to operate 5 = Drive is NOT ready to operate 6 = Fan. DC-link voltage is above braking chopper operating value –70V.
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R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 M2 Monitoring Code Name Min Max V2.1 K7 0 1 Unit Description V2.2 ROA1 0 1 State of relay output ROA1 V2.3 DID states .00000 .11111 State of digital input DID1-DID5, see note V2.4 Ain1 Input 0.00 10.00 V Value of analog input Ain1 V2.5 Motor Current A Measured motor current V2.6 Motor Voltage V Calculated motor voltage V2.7 °C Temperature of heat sink. V2.
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R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 S3.8.3 Software info I3.8.3.1 Software package I3.8.3.2 System SW version I3.8.3.3 Firmware interface I3.8.3.4 System load S3.8.4 Application info A3.8.4.1 Application A3.8.4.1. Application id 1 A3.8.4.1. Application version 2 A3.8.4.1. Firmware interface 3 S3.8.5 Hardware info I3.8.5.2 Unit voltage I3.8.5.3 Brake chopper I3.8.5.4 Brake resistor S3.8.6 Options S3.8.6.1 NXOPT E3.
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R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 6.2.1 Reverse Plugging When opposite drive command is active while the inverter is operating, the deceleration/acceleration ramp can be shorter than the normal ramp. Reverse plugging function is “on” if the driving frequency > 30% of the “Max Freq” (not the “Motor Nom Freq”).
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R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 6.2.3 Ramp stretching The inverter allows stretching the ramp on the generating side. The ramp stretching is adjustable as percentage of nominal deceleration distance. The default stretch of the normal ramp is 40% of the nominal deceleration distance. If the inverter cannot stop with the set ramp stretching, it will stop by brake and show fault code. F56 Generator side current limit.
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R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 7 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. ! Warning! High voltages inside device. Wait for at least five minutes after the supply voltage has been switched off before service actions.
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R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 7.3.1 Compact brake motors (MF06MA, MF06LA) Enter motor nominal voltage to parameter P1.2.1. Select correct motor type with parameter P1.2.2. Enter number of motors to parameter P1.2.3. Parameters in group G1.2.4. are not visible when motor type is selected with parameter P1.2.2. Values to those parameters are set automatically according the selected motor type. 7.3.
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R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 8 TROUBLESHOOTING ! 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.
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R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 8.3 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.
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R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.
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R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 9 TROUBLESHOOTING TABLE If the drive 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 ACCELERATION TIME, P1.1.2 DECELERATION TIME, P1.1.3 MIN FREQ, P1.1.4 MAX FREQ, P1.1.
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R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 10SERVICE The drive does not require regular maintenance.
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R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 11SPARE PARTS LIST # Inverter D2S includes only one I/O Extension board slot.
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R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 12DRAWINGS 12.1 Description of terminals and wirings The control unit of the frequency converter is integrated to the power unit in 002 and it is separated in bigger models. Control board and additional I/O board (NXOPTB9) connections are listed below.
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R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 12.2 Layouts, dimensions and weights 002F 003F - 004F AW Weight 3kg (7 lbs) Weight 11kg (24 lbs) K7 K7 X1 X1 CM1 300mm 330mm Z1 355mm 205mm 215mm A1 Z1 Z2 Z3 113mm 295mm 135mm 300mm 335mm 003F – 004F B0 005F B0 Weight 13 kg (29 lbs) Weight 22 kg (49 lbs) 166 mm (6.53 in) 346 mm (13.62 in) A1 18 mm (0.71 in) 414 mm (16.30 in) 450 mm (17.72 in) A1 212 mm (8.
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R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 015F B0 Weight 31 kg (68 lbs) A1 F7 K7 786 mm (30.94 in) 212 mm (8.35 in) K7 CM1 Z2 Z3 X1 A1 378 mm (14.88 in) Z1 188 mm (7.40 in) 580 mm (22.84 in) F7 378 mm (14.88 in) 166 mm (6.53 in) 007F – 011F B0 Weight 22 kg (49 lbs) X1 CM1 Z2 Z3 453.5 mm (17.85 in) 467.5 mm (18.41 in) 13 mm 7 mm (0.28 in) (0.51 in) (0.31 in) 8 mm Z1 7 mm (0.28 in) 453.5 mm (17.85 in) 467.
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R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 12.2.1 Internal wirings PE A B C D Other single wires Screened cables 002F – 011F 2.5 mm² AWG 14 002F – 011F 2.5 mm² AWG 14 002F – 018F 2.5 mm² AWG 14 002F – 022F 2.5 mm² AWG 14 002F – 022F 1.5 mm² AWG 16 002F – 022F 0.75 mm² AWG 20 002F – 022F 8 x 0.5 mm² 8 x AWG 20 015F-018F 6 mm² AWG 10 015F 6 mm² AWG 10 022F 6 mm² AWG 10 022F 10 mm² AWG 8 022F 10 mm² AWG 8 12.2.
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R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 12.
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