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SERVICE MANUAL FOR TRAVELING INVERTER

English 27.12.2005

This document and the information contained herein, is the exclusive property of Verlinde S.A. 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 Verlinde S.A. Copyright (2005) Verlinde S.A. All rights reserved.

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Table of content 1

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2

DOCTNI40100-0 PS02379 27.12.2005

!" Read the instructions supplied with the product before installation and commissioning. #" Keep the instructions in a safe place for future reference.
Description of the inverter.............................................................................................................3 1.1 Connections.................................................................................................................................. 3 1.2 Technical characteristics .................................................................................................................... 3 1.3 Normal operation ........................................................................................................................... 4 1.4 Status indication leds (green and red) .................................................................................................. 4 1.5 Programming switches ...................................................................................................................... 4 1.6 The EMC requirements (Not in use for deliveries in USA/Canada) ............................................................. 4 1.6.1 EMC filter connection to inverter for trolley travelling......................................................................... 5 1.6.2 EMC filter connection to inverter for bridge travelling......................................................................... 5 Description of control modes .........................................................................................................6 2.1 MS2-control ................................................................................................................................ 6 2.2 EP2-control.................................................................................................................................. 6 2.3 EP3-control.................................................................................................................................. 6 2.4 MS4-control ................................................................................................................................ 7 Fault codes, troubleshooting..........................................................................................................8 Programming of the application parameters ..................................................................................9 4.1 Minimum speed, maximum speed and ramp time ..................................................................................... 9 4.1.1 Example of parameter setting ..................................................................................................... 10 4.1.2 Acceleration and deceleration ramp............................................................................................. 10 4.1.3 Example of parameter setting: .................................................................................................... 10 4.2 Stopping method ......................................................................................................................... 11 4.3 Control mode.............................................................................................................................. 11 4.4 Slowdown speed ......................................................................................................................... 11 4.5 Speed2 and Speed3 .................................................................................................................... 12 Programming of the motor parameters ........................................................................................13 5.1 Defining the motor parameters .......................................................................................................... 13 5.1.1 Motor nominal voltage and frequency.......................................................................................... 13 5.1.2 IR-compensation .................................................................................................................... 13 5.1.3 Motor nominal current............................................................................................................. 14

3 4

This document and the information contained herein, is the exclusive property of Verlinde S.A. 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 Verlinde S.A. Copyright (2005) Verlinde S.A. All rights reserved.

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1.Control terminal X1 2.Power terminal X2 3.Programming switches 4.Leds

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1 Description of the inverter

!" There are high voltages inside the inverter (including the programming switches). Wait for at
1 3 4 2

least three minutes after the supply voltage has been switched off before any service actions.

1.1 Connections
Control signals are connected to terminal block X1 as follows:
Nbr 1 2 3 4 5 6 7 8 9 10 11 Name S1 S2 DI3 DI4 DI5 ONE R01 R02 T1 T2 Description Drive command. Direction 1. 48 or 115V 50/60Hz Drive command. Direction 2. 48 or 115V 50/60Hz Digital input. 48 or 115V 50/60Hz. Digital input. 48 or 115V 50/60Hz. Digital input. 48 or 115V 50/60Hz. Control voltage, neutral. Relay output Relay output Empty Motor thermistor Motor thermistor

Power cabling is connected to terminal block X2 as follows:

!" Crane power supply conductor rail must have double collectors.
Nbr 1 2 3 4 5 6 7 8 9 Name L1 L2 L3 U V W R+ RPE Description Mains, phase 1. 380-480V 50/60Hz. Mains, phase 2. 380-480V 50/60Hz. Mains, phase 3. 380-480V 50/60Hz. Motor, phase 1. Motor, phase 2. Motor, phase 3. Braking resistor, positive, see note Braking resistor, negative, see note Protective earth

!" Standard duty resistor must be disconnected when heavy duty resistor DMHR01F90 is
connected to terminals R+ and R".
Technical data Power range Supply voltage Nominal supply frequency Nominal current

1.2 Technical characteristics

2.2 kW 380 - 480 VAC +/-10% 48 62 Hz 5.0A

This document and the information contained herein, is the exclusive property of Verlinde S.A. 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 Verlinde S.A. Copyright (2005) Verlinde S.A. All rights reserved.

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Technical data Digital control Max output voltage Control voltage range Output Ambient temperature Humidity Degree of protection Dimensions (WxHxD) Altitude

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S1, S2, DI3, DI4, DI5 Equal to supply voltage 48 VAC/115 +/- 10%. If control voltage is 230VAC, front resistors (15k,2W) have to be connected to digital inputs Relay output for brake contactor o o -10 C to 50 C 95% N.C. (without dripping) Frequency converter + cover (IP20)

134x195x123mm
Output current must be reduced 1 % for every 100 m over 1000 m. For heights over 3000 m, manufacturer must be consulted. Pollution degree 2 according to NEMA ICS-1, IEC664 and UL840 IEC68-2-6 IEC68-2-27

Pollution degree Vibration Shock

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 operators 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 Programming switches

S1
ON DIP 1 2 3 4 ON DIP

S2
ON DIP 1 2 3 4 ON DIP

S3
ON DIP 1 2 3 4 ON DIP

S4

S5

S6

The programming of the inverter is performed by dip-switches. The state of each switch is either OFF (0) or ON (1). It is possible to set he following parameters by the switches S1-S6. $" S1 = Maximum speed $" S2 = Minimimum speed $" S3 = Acceleration / deceleration time $" S4 = Motor frequency and IR-compensation $" S5 = Motor current, fast deceleration, stopping method $" S6 = Control mode, slowdown speed, speed2, speed3

1.6 The EMC requirements (Not in use for deliveries in USA/Canada)

The EMC requirement (both for immunity and for emissions) for inverter are set in EN61800-3 and its amendment 11 (2000), which is the EMC product standard for adjustable speed electrical power systems. The EN61800-3 is identical with IEC1800-3. Device satisfies the requirements when external EMC filter will be connected to inverter.

This document and the information contained herein, is the exclusive property of Verlinde S.A. 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 Verlinde S.A. Copyright (2005) Verlinde S.A. All rights reserved.

c_s022a

1 2 3 4

1 2 3 4

1 2 3 4

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SERVICE MANUAL FOR TRAVELING INVERTER

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1.6.1 EMC filter connection to inverter for trolley travelling.

c_kc330ba

KC-330-00 includes capacitors (4*1#F) and input ferrite rings (3 x EF 32008).

1. Supply 2. EMC filter KC-330-00 3. Inverter 4. Motor cable length max 3 m 5. 4 x 1 #F 6. Input wires two times through input ferrite rings.

#" Ferrite rings and capacitors must be placed as near the inverter as possible.
1.6.2 EMC filter connection to inverter for bridge travelling.

c_kc330ca

1. Supply 2. EMC filter KC-330-00 3. Inverter 4. Motor cable length max 1 m + 25 m 5. 4 x 1 #F 6. Input wires two times through input ferrite rings. 7. Output ferrite ring RH175285107

KC-330-00 includes capacitors (4*1#F) and input ferrite rings (3 x EF 32008).

#" Ferrite rings and capacitors must be placed as near the inverter as possible.

This document and the information contained herein, is the exclusive property of Verlinde S.A. 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 Verlinde S.A. Copyright (2005) Verlinde S.A. All rights reserved.

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2.1 MS2-control

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2 Description of control modes

c_coms2a

A. Pushbutton position B. Speed

$" S1 means drive minimum speed forward $" S2 means drive minimum speed reverse $" HSP means maximum speed $" When S1 and S2 or are not active the inverter decelerates to zero

2.2 EP2-control

c_coep2a

0. Decelerate 1. Maintain speed 2. Accelerate A. Pushbutton position B. Speed

$" S1 means drive forward $" S2 means drive reverse $" AP means accelerate $" When starting, S1 and S2 mean accelerate to minimum speed $" When S1 and S2 are not active the inverter decelerates to zero $" During running S1 and S2 mean hold speed $" At maximum speed AP means hold speed

2.3 EP3-control

c_coep3a

$" S1 means drive minimum speed forward

This document and the information contained herein, is the exclusive property of Verlinde S.A. 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 Verlinde S.A. Copyright (2005) Verlinde S.A. All rights reserved.

0. Decelerate 1. Minimum speed 2. Maintain speed 3. Accelerate A. Pushbutton position B. Speed

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2.4 MS4-control

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$" S2 means drive minimum speed reverse $" AP means accelerate $" HOLD means hold speed $" When S1 and S2 are not active the inverter decelerates to zero $" At maximum speed AP means hold speed

c_coms4a

A. Pushbutton position B. Speed

$" S1 means drive minimum speed forward $" S2 means drive minimum speed reverse $" SP2 means drive speed2 $" SP3 means drive speed3 $" HSP means drive maximum speed $" When S1 and S2 are not active the inverter decelerates to zero $" The highest active input sets the speed reference (i.e. if HSP is active SP2 and SP3 are ignored. If SP3 is active SP2 is ignored)

This document and the information contained herein, is the exclusive property of Verlinde S.A. 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 Verlinde S.A. Copyright (2005) Verlinde S.A. All rights reserved.

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3 Fault codes, troubleshooting

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 Green Green Green Green Green Green Red Red Fault. Possible cause. Checkings. Overvoltage. Mains voltage is too high or deceleration ramp time is too short. Check the voltage of all supply phases at the terminal X2. If they are ok, set a longer ramp by switch S3 (and S5-3). Stall supervision / overcurrent. Brake does not open properly or there is an obstackle on the track. Check also the motor dependent parameters. Deceleration ramp supervision. Deceleration ramp has not been followed. If the fault occurs again set longer ramp time by switch S3. Check also the setting of the motor nominal current (switch S5). Motor overtemperature. Check the type and the loading of the motor. If there is no sensor in the motor the inverter terminals X1:10-11 must be short circuited. Inverter overtemperature. Motor current is too high (bearing problem, obstacle on the track, brake does not open properly,) or the ambient temperature is too high. Undervoltage. Check the voltage of all supply phases at the terminal X2. Short circuit. Switch the power off. Check the insulation of the motor cables and the motor windings. Microprosessor fault. Switch the power off for 10 seconds. Then power-up the inverter.

!" There are high voltages inside the inverter (including the programming switches). Wait for at

$" Motor will not start if dc-bus voltage too high (above 745V), this occurs if any of line-to-line voltages exceeds 480V+10% = 528V - If line voltage cannot be reduced, install drop-down transformer $" Check the supply voltage phases at terminal X2. $" Check the drive command signal at terminal X1. $" Check the limit-switch 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 dependent parameters. $" Check that the motor(s) corresponds the selected motor parameters. $" Check that the brake opens and closes properly. Check the brake airgap if necessary. $% Inverter starts and opens the brake, but motor does not rotate. Check motor current parameter.

#" The latest active fault is removed from the memory always when power is switched off. !" If inverter is not in a fault state, but driving is not possible:

This document and the information contained herein, is the exclusive property of Verlinde S.A. 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 Verlinde S.A. Copyright (2005) Verlinde S.A. All rights reserved.

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4 Programming of the application parameters

!" Check that he wiring and the mechanical performance of the machinery is suitable for the
selected application parameters.

4.1 Minimum speed, maximum speed and ramp time

The adjustment ranges of maximum and minimum speed depend on the selected motor nominal frequency. Table A is for 100 and 120Hz motors, Table B for 80Hz motors and Table C for 50 and 60Hz motors. Maximum speed is set by the four switches of the switch-package S1 and minimum frequency by the four switches of the switch-package S2.
Switch S1/S2 Table A 100/120Hz motor Max freq Min freq Hz Hz 100 29 50 14 62 23 54 10 80 32 58 12 66 16 70 18 115 *) 50 75 20 85 26 90 35 95 38 105 *) 41 110 *) 44 120 *) 47

-1 0 0 0 0 0 0 0 0 1 1 1 1 1 1 1 1

-2 0 0 0 0 1 1 1 1 0 0 0 0 1 1 1 1

-3 0 0 1 1 0 0 1 1 0 0 1 1 0 0 1 1

-4 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1

*) 100Hz may be exceeded only if line voltage is 460-480V.

Switch S1/S2 Table B 80Hz motor Max freq Min freq Hz Hz 77 22 42 14 50 18 40 10 62 30 44 12 46 16 48 20 80 40 53 24 56 26 59 28 65 32 68 34 71 36 74 38 Table C 50/60Hz motor Max freq Min freq Hz Hz 50 15

-1 0 0 0 0 0 0 0 0 1 1 1 1 1 1 1 1

-2 0 0 0 0 1 1 1 1 0 0 0 0 1 1 1 1

-3 0 0 1 1 0 0 1 1 0 0 1 1 0 0 1 1

-4 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1

Switch S1/S2

-1 0

-2 0

-3 0

-4 0

This document and the information contained herein, is the exclusive property of Verlinde S.A. 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 Verlinde S.A. Copyright (2005) Verlinde S.A. All rights reserved.

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-1 0 0 0 0 0 0 0 1 1 1 1 1 1 1 1 -2 0 0 0 1 1 1 1 0 0 0 0 1 1 1 1

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Table C 50/60Hz motor Max freq Min freq Hz Hz 25 7 31 12 27 5 40 16 29 6 33 8 35 9 58 *) 25 38 10 43 13 45 18 48 19 53 *) 21 55 *) 22 60 *) 24

Switch S1/S2

-3 0 1 1 0 0 1 1 0 0 1 1 0 0 1 1

-4 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1

*) 50Hz may be exceeded only if line voltage is 460-480V.

4.1.1 Example of parameter setting

80Hz motor is connected to the inverter and 62Hz maximum speed is desired. That speed is located on the 5th row in the speed table 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-offoff).
ON DIP 1 2 3 4

S1

4.1.2 Acceleration and deceleration ramp

Acceleration and deceleration ramps are set by switch S3 as follows:
Switch S3 -1 -2 1 1 0 1 1 0 0 1 0 0 0 0 0 0 1 0 1 1 0 0 1 1 1 1 1 0 1 0 0 1 0 1 Ramp time (sec) -3 1 1 0 0 0 1 0 0 0 1 1 0 1 1 1 0 -4 1 0 0 0 0 0 1 1 0 1 0 1 1 0 1 1 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0 5.5 6.0 6.5 7.0 7.5 8.0

It is possible to reduce the deceleration ramp time by 30% if necessary. The fast deceleration ramp is activated by switching S53 ON (1).

4.1.3 Example of parameter setting:

Acceleration/deceleration time of 3 seconds is selected by setting switch S3=0-0-1-0. Fast deceleration (3sec is reduced to 2.1sec) is activated by switch S5-3=1.
This document and the information contained herein, is the exclusive property of Verlinde S.A. 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 Verlinde S.A. Copyright (2005) Verlinde S.A. All rights reserved.

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4.2 Stopping method

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S3 S5

ON

DIP

1 2 3 4 ON DIP

1 2 3 4

The motor can be stopped either by dynamic braking (=by a ramp) or by mechanical brake. When stopping by mechanical brake is selected and drive command is switched off the inverter immediately cuts off the motor current and opens the relay contact. The stopping method is selected by switch S5-4 as follows: $" S5-4 = 0 Stopping by a ramp $" S5-4 = 1 Immediate stopping by mechanical brake

4.3 Control mode

There are four different control modes available. The inverter operation in different control modes is explained in section 4. The control mode is selected by switches S6-1 and S6-2 according to the table below.
Control mode MS2 EP2 EP3 MS4 S6-1 0 1 0 1 S6-2 0 0 1 1

The functions of all five digital inputs is assigned automatically according to the selected control mode:
DI1 DI2 DI3 DI4 DI5 MS2 S1 S2 HSP S12 S22 EP2 S1 S2 AP S11 S21 EP3 S1 S2 HOLD AP S11/S21 MS4 S1 S2 SP2 SP3 HSP

Description of the control signals:

S1 AP S11 S12 SP2 HSP S2 HOLD S21 S22 SP3 Drive command forward Acceleration command Slowdown limit forward Stop-limit forward Speed2 High speed Drive command reverse Hold speed command Slowdown limit reverse Stop-limit reverse Speed3

4.4 Slowdown speed

EP2 S2 S21 S11 EP3 S1

Slowdown frequency is activated in EP2 and EP3 control modes when the slowdown limit circuit is opened. In EP2 there are separate inputs for both limit switch, therefore it is possible to drive high speed in the slowdown area in the safe direction. In EP3
This document and the information contained herein, is the exclusive property of Verlinde S.A. 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 Verlinde S.A. Copyright (2005) Verlinde S.A. All rights reserved.

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4.5 Speed2 and Speed3

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there is only one input and therefore the speed is limited in both directions in the slowdown area. There are two alternatives for the level of slowdown speed which are selected by switch S6-3 as follows: $" S6-3 = 0 Slowdown speed is 20% of the maximum speed (set by switch S1) $" S6-3 = 1 Slowdown speed is 35% of the maximum speed (set by switch S1) In MS4-control mode the lowest speed level is set by switch S2 and the highest level by switch S1. There are two alternative settings for the speed2 and speed3, which are set as a percentage of the maximum speed by switch S6-3 as follows: $" S6-3 = 0 Speed2 is 20% of maximum speed and speed3 is 40% of maximum $" S6-3 = 1 Speed2 is 30% of maximum speed and speed3 is 50% of maximum

This document and the information contained herein, is the exclusive property of Verlinde S.A. 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 Verlinde S.A. Copyright (2005) Verlinde S.A. All rights reserved.

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5 Programming of the motor parameters

The motor parameters are set by switches S4 and S5 according to the following table. Only the most common motor types are shown in the table. Settings for other motors can be defined when motor nominal frequency, voltage, current and the IR-rate are known.
S5 settings Motor type MF06MA100 MF06MA200 MF06LA100 MF06LA200 MF06LB100 MF06LB200 MF07LA100 MF07LA200 MF07LB100 MF07LB200 MF07ZC100 MF07ZC200 MF09LA100 MF09LA200 MF09LB100 MF09LB200 Nominal voltage and frequency 400V 400V 100Hz 400V 400V 100Hz 400V 400V 100Hz 380-415V 50Hz 380-415V 50Hz 380-415V 50Hz 380-415V 50Hz 380-415V 50Hz 380-415V 50Hz 380-415V 50Hz 380-415V 50Hz 380-415V 50Hz 380-415V 50Hz 80Hz 460V 120Hz 80Hz 460V 120Hz 80Hz 460V 120Hz 460-480V 60Hz 460-480V 60Hz 460-480V 60Hz 460-480V 60Hz 460-480V 60Hz 460-480V 60Hz 460-480V 60Hz 460-480V 60Hz 460-480V 60Hz 460-480V 60Hz S4 settings 1010 0000 1001 0010 1011 0010 0101 0100 0101 0100 0111 0110 0111 0110 0111 0101 Number of motors 1 2 4 10xx 11xx 00xx 10xx 11xx 10xx 11xx 10xx 11xx 01xx 01xx 00xx 10xx 11xx 00xx 10xx 11xx 00xx 10xx 11xx 00xx 01xx 10xx 11xx 10xx 11xx 01xx 11xx 11xx 11xx 11xx -

5.1 Defining the motor parameters

5.1.1 Motor nominal voltage and frequency

Motor nominal voltage and frequency are selected by switches S4-1 and S4-2 according to the following table:
Motor nominal Voltage Frequency 400V 100Hz 460V 120Hz 400V 80Hz 380-415V 50Hz 440-480V 60Hz S4-1 0 1 0 S4-2 0 0 1 Speedtable A B C

5.1.2 IR-compensation
By the IR-compensation the effect of the stator resistance at low frequencies is compensated by increasing the U/f-ratio. Typically the necessary amount of compensation (added voltage) is higher for small motors. The IR-compensation is set by switches S4-3 and S4-4. Estimation of the correct setting of IR-compensation is made by calculating the IR-rate of the motor.
S4 setting U(V)
ON DIP 1 2 3 4 ON DIP

1 2 3 4 ON DIP

1 2 3 4 ON DIP

1 2 3 4

f middle

f (Hz)

Calculation of the IR-rate:

IR - rate' I NOM & RS * p * n

INOM Nominal current of the motor (one motor)
This document and the information contained herein, is the exclusive property of Verlinde S.A. 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 Verlinde S.A. Copyright (2005) Verlinde S.A. All rights reserved.

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Rs P N

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Stator resistance, measured between inverter terminals X2:4-5 Number of polepairs Number of motors connected to inverter

Settings:
IR-rate 90 60 - 89 40 - 59 - 37 Setting of S4 S4-3 = 0 ; S4-4 = 0 S4-3 = 1 ; S4-4 = 0 S4-3 = 0 ; S4-4 = 1 S4-3 = 1 ; S4-4 = 1

#" For conical brake motors it is recommended to set the IR-compensation one step higher than the IR-rate indicates. The
reliable operation of the brake must be verified during start-up.

5.1.3 Motor nominal current

Motor nominal current is set by switches S5-1 and S5-2 as follows: $" Check the nominal current of the motor from the rating plate $" Calculate the total current by multiplying the current by the number of the motors $" Select the settings according to the table below
INOM,TOTAL 01.8A 1.9A2.7A 2.8A3.5A >3.5A S5-1 0 1 0 1 S5-2 0 0 1 1

For example: there are two 1.5A motors ( Setting is S5-1=0 and S5-2=1.

This document and the information contained herein, is the exclusive property of Verlinde S.A. 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 Verlinde S.A. Copyright (2005) Verlinde S.A. All rights reserved.

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