Owner'S Manual For Travel Frequency Control System: BPP6-2QM4V3-76J0
Owner'S Manual For Travel Frequency Control System: BPP6-2QM4V3-76J0
Owner'S Manual For Travel Frequency Control System: BPP6-2QM4V3-76J0
1.12.2008
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08204
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J26492-0.ORD
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.
2/21
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R&M Materials Handling, Inc.
4501 Gateway Boulevard
Springfield, Ohio 45502
P.: (937) 328-5100
FAX: (937) 325-5319
This manual rev6.0 is for inverter rev 1.0 with software D2S2V051.
Before starting, read the instructions carefully.
Verify the motor supply is connected correctly, faulty connection will destroy the inverter.
High voltages are present in this device. Switch the power off and after the display turns off,
wait 5 minutes before opening the cover.
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 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.
3/21
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R&M Materials Handling, Inc.
4501 Gateway Boulevard
Springfield, Ohio 45502
P.: (937) 328-5100
FAX: (937) 325-5319
All R&M inverters with supply voltages other than 460 volts are supplied with an autotransformer to step-
up or step-down the voltage to 460 volts. 460-supply voltage will help eliminate faults and prevent high
voltage damage to the inverter.
All CMX007 inverters are supplied with an autotransformer regardless of voltage supply.
LOAD SIDE
LOAD SIDE WIRES (Output)
(Output to inverter)
4/21
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FAX: (937) 325-5319
1. Turn power on. Then measure the load side taps of the autotransformer to locate the taps closest to
460 volts (not to exceed 480V). These are ratio transformers – actual voltage may not be exactly 460
volts.
2. Turn off power. Then reconnect the three load side wires to the taps identified in step number 5.
(Example: 460 volt taps - see picture below)
3. Turn power on.
STEP 5. MEASURE VOLTAGE
PHASE TO PHASE
LOAD SIDE
(Output)
LINE SIDE
(Input)
NOTES:
Inverter acceleration and deceleration times should not be adjusted without contacting the factory.
R&M Materials Handling, Inc. recommends that both the NEC and CMAA guidelines for grounding be
followed.
National Electric Code 2005 states in 610.61 Grounding “The trolley frame and bridge frame shall not
be considered as electrically grounded through the bridge and trolley wheels and its respective tracks. A
separate bonding conductor shall be provided.”
CMAA #70 Section 5.14.7 states: “A minimum of two collectors for each runway conductor shall be
furnished with inverter use. Use of a grounding conductor is recommended.”
5/21
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R&M Materials Handling, Inc.
4501 Gateway Boulevard
Springfield, Ohio 45502
P.: (937) 328-5100
FAX: (937) 325-5319
Power class 002F 003F 004F 005F 007F 011F 015F 018F 022F
Power (kVA) at 400V 3.5 5.5 7.0 9.0 13 17 22 29 33
Output current In (A) 5.0 8 10 13 18 24 32 42 48
Max. current 1min (A) 7.6 12 15 20 27 36 48 63 72
Supply
Supply voltage 380-500Vac
Allowable voltage fluctuation +/- 10%
Nominal supply frequency 50/60Hz +/- 5%
Signal input levels
Digital controls S1, S2, DID3, DID4, DID5: 42 … 240Vac; 15mA
Control features
Control method Open loop vector control
Frequency control range 0 ... 250Hz
Frequency command Electronic potentiometer, 2-5-step controller or 0 … 10V analog signal
Limit switch functions Slowdown and stop limit inputs for both directions
Speed control range sN ... 100% (sN= motor nominal slip)
Speed accuracy 1% of nominal speed at speed range 10 ... 100%
1/3 of motor nominal slip at speed below 10%
Braking torque 150%
Protections
Motor overload protection Thermistor or Klixon thermostat based temperature measurement
Overload protection Fault is detected if the current momentarily exceeds 280% of rated current
Undervoltage / blown fuse Fault is detected if DC voltage drops below 333V
Overvoltage protection Fault is detected if DC voltage exceeds 911V
Momentary power loss Immediate fault stop
Inverter overtemperature Temperature sensor on the heat sink
Mechanical brake Circuit breaker (from 007 upward)
Ground fault Provided by electronic circuitry
Ambient conditions
Ambient temperature -10 C ... +50 C (14 F ... 122 F) for ED 40%
Storage temperature -40 C ... +70 C (-31 F ... 158 F) dry
Humidity <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/s²) at 9-200Hz
6/21
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4501 Gateway Boulevard
Springfield, Ohio 45502
P.: (937) 328-5100
FAX: (937) 325-5319
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.
Electrical Braking Includes a braking transistor and a braking resistor.
Control modes Can be controlled by
the electronic potentiometer control with 2-step or 3-step pushbuttons,
the multistep control with 2-5-step controllers.
the automation control using any control device with an 0-10V output (computer, radio, PLC)
Limit switch functions Built-in slowdown (S11, S21) or stop limit switch (S12, S22) functions for both running directions.
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.
A1 Inverter
F7 Brake supply circuit breaker
K7 Brake contactor
R1 Braking resistor unit
Z1, Z2, Z3 Ferrite rings (Depending on EMC level, optional)
CM1 Filtering capacitors (Depending on EMC level,
optional)
X1 Terminals
M1 Traveling motor(s)
Y1 Mechanical brake
B6 Thermal sensor for motor protection
Control devices (switches, pushbuttons etc.)
S11, S21, S12, S22 Limit switches
Example layout
7/21
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F7
A1
Z1 CM1 K7 Z2 Z3
X1
Normal operation
- For the description of the speed reference setting see Chapter “Control methods”. Travelling starts when switch
S1 or S2 closes. Closing the contact ROD1 on A1 energizes K7, which opens the brake. Motor accelerates
according to the acceleration ramp setting to the selected speed.
- When the switch S1 or S2 opens motor stops according to the deceleration ramp setting and the brake closes.
- R1 dissipates the regenerated energy during deceleration periods. The power supply to R1 is controlled by A1
Other features
- Thermistor relay function, which can be used as needed.
- When the stop limit switch S12 or S22 opens, K7 de-energizes and the mechanical brake stops the motion.
8/21
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P.: (937) 328-5100
FAX: (937) 325-5319
3.5.1 MS2-control
c_coms 2a
0) “decelerate to zero”
1) step 1 “drive minimum speed”
2) step 2 “drive maximum speed”
3.5.2 EP2-control
c_coep2a
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”
3.5.3 EP3-control
c _c oep3a
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0) “decelerate to zero”
1) step 1 “drive minimum speed”
2) step 2 “hold speed”
3) step 3 while running “accelerate”
while running at maximum speed “hold speed”
3.5.4 MS4-control
c_coms4b
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”
3.5.5 MS5-control
c_coms5b
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 speed4”
5) step 5 “drive maximum speed”
10/21
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4501 Gateway Boulevard
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P.: (937) 328-5100
FAX: (937) 325-5319
3.5.6 AU/PO-control
S1
c_coms6a
S2
A. Reference
B. Speed
AU control may be used with control device with an output in the range of 0 V – 10 V (for example radio
or PLC).
PO control may be used with a controller with potentiometer.
The operation is as follows:
Driving command S1 or S2 is given separately and means “drive minimum speed”
The speed linearly follows the analog input signal.
The slowdown function is available in MS2- (slow-lim), EP2- (slow-lim), EP3- and AU-control modes. It
can reduce maximum frequency at the both ends of the crane runway. When the function is active, the
reference slowdown frequency is set automatically by parameter P1.1.8 “Multistep freq2/Slowdown”.
The action in slowdown-limit area depends on parameter P1.5.1 “Slowdown Mode” settings. The
description on “Slowdown Mode” selections is shown as follows:
0 = Slow When the limit switch circuit is opened, the maximum speed is limited in both directions until the limit switch circuit is
closed.
1 = Fast When the limit switch circuit is opened during running the slowdown function is activated and the maximum speed is
limited in the present running direction. If the limit switch circuit is open when power is turned on, the maximum speed
is limited in both directions until the limit switch circuit is closed.
2 = Fast power up When the limit switch circuit is opened during running the slowdown function is activated and the maximum speed is
limited in the present running direction. When power is turned off, the limit switch status is saved in EEPROM. When
power is turned back on and limit switch circuit is open, driving is allowed the maximum speed in opposite direction.
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). When either of these
signals goes “down” (no voltage in the input), the motion is stopped by switching the motor current off
immediately and by opening the relay contact ROD1 (mechanical brake closes).
Restart may occur only after one second. Restart is only allowed to the direction opposite to the stop-
limit switch circuit being off. If both of these inputs are off restart is not permitted. Restart may be initiated
11/21
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R&M Materials Handling, Inc.
4501 Gateway Boulevard
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P.: (937) 328-5100
FAX: (937) 325-5319
only by a run command changing from off to on (= before restart both run commands must be off after
the one-second time has passed).
Inverter has a brake contactor to control electromechanical disk brake of the traveling motor. 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 first the motor 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 minimized. Only if a failure occurs or the emergency stop
button is pushed, the brake closes immediately stopping the motor.
The abbreviated "EMC" stands for the Electromagnetic Compatibility. According to the European EMC
directive "the apparatus shall be so constructed that:
The electromagnetic disturbance it generates does not exceed a level allowing other apparatus to
operate as intended
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 standard
according to the environments.
PDS
PDS
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.
12/21
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R&M Materials Handling, Inc.
4501 Gateway Boulevard
Springfield, Ohio 45502
P.: (937) 328-5100
FAX: (937) 325-5319
N-level: Manufacturer’s EMC solution is adopted to fit for Second Environment and products will be
used in EU when local power supply system is the grounded network.
0-level: No manufacturer’s EMC solution is adopted, products can be used in either EU or other
market areas when local power supply system is the non-grounded network.
The involved products are designed for Second Environment (Industrial Environment) only.
The disturbances emitting from the basic products are not filtered to the required level of
residential, commercial and light industrial (e.g. offices, gasoline station, retailer shops etc.)
environment (First Environment). In this sense, these products should not be used in First
environments. If you still want to use them in First environments, additional requirements
are needed, please contact product supplier.
EMC filters in N level products might cause disturbances on fault (leakage) current relay
13/21
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R&M Materials Handling, Inc.
4501 Gateway Boulevard
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P.: (937) 328-5100
FAX: (937) 325-5319
Button description
Browse the main menu and the pages of submenus
Edit values
Move in menu
Move cursor
Enter and exit edit mode
Start button
14/21
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Stop button
WARNING! Changing parameter settings during running may cause a hazardous situation.
Parameter settings must not be changed during running.
15/21
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P.: (937) 328-5100
FAX: (937) 325-5319
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.
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 inverter 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
new the one.
- Indicator “Ready” is on and indicator “Fault” is off, but motor does not run.
Check control mode selection
Check voltage at run command terminals
Check state of digital inputs from parameter V2.3
- Indicator “Ready” is on and indicator “Run” is on, but motor does not run.
Check motor cable connection
- 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 V2.3
Check that motor’s brake opens completely
Check that minimum speed parameters do not have too small values
For travelling application: check u/f-curve tuning and/or Autotuning. 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 and/or Autotuning.
- Some parameters are not accessible or changing is not possible
Check 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
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Springfield, Ohio 45502
P.: (937) 328-5100
FAX: (937) 325-5319
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 “Fx xx“ (x=
fault accounting number, xx = fault code 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 run is possible, for example F1 (overcurrent).
All faults are stored in the Fault History menu except F51 Stop-Limit, from there they can be seen if
necessary. The fault history store the last 5 fault codes.
Fault code is at the right side of the display.
17/21
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R&M Materials Handling, Inc.
4501 Gateway Boulevard
Springfield, Ohio 45502
P.: (937) 328-5100
FAX: (937) 325-5319
18/21
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R&M Materials Handling, Inc.
4501 Gateway Boulevard
Springfield, Ohio 45502
P.: (937) 328-5100
FAX: (937) 325-5319
19/21
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R&M Materials Handling, Inc.
4501 Gateway Boulevard
Springfield, Ohio 45502
P.: (937) 328-5100
FAX: (937) 325-5319
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
TYPE CODE ACCELERATION S
TIME, P1.1.2
SERIALNUMBER DECELERATION S
TIME, P1.1.3
CONTROL METHOD, P1.1.11 MIN FREQ, P1.1.4 Hz
EP2 MAX FREQ, P1.1.5 Hz
EP3
MS
MOTOR INFORMATION
TYPE CODE NOMINAL VOLTAGE S
SERIALNUMBER NOMINAL CURRENT S
NOMINAL
FREQUENCY
NOMINAL SPEED
POWER FACTOR
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
VOLTAGE L1 L2 L3
PHASE-TO-GROUND Vac Vac Vac
MEASURED
CONTROL VOLTAGE V
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P.: (937) 328-5100
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The drive does not require regular maintenance. However the following actions are recommended:
21/21
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