General Safety Instruction 2
General Safety Instruction 2
General Safety Instruction 2
This document and the information contained herein, is the exclusive property of Konecranes Plc 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 Konecranes Plc.
Copyright © (2010) Konecranes Plc. All rights reserved.
OWNER'S MANUAL FOR TRAVEL FREQUENCY
CONTROL SYSTEM
Table of contents
1 CAUTION ........................................................................................................................................... 3
1 GENERAL .......................................................................................................................................... 4
1.1 Technical data ........................................................................................................................................ 4
1.2 Basic description..................................................................................................................................... 5
1.3 Main components.................................................................................................................................... 5
1.4 Functional description ............................................................................................................................. 6
1.5 Description of the control modes ............................................................................................................. 6
1.5.1 MS2-control ........................................................................................................................................ 6
1.5.2 EP2-control ......................................................................................................................................... 6
1.5.3 EP3-control ......................................................................................................................................... 7
1.5.4 MS4-control ........................................................................................................................................ 7
1.5.5 MS5-control ........................................................................................................................................ 7
1.5.6 AU/PO-control ..................................................................................................................................... 8
1.6 Slowdown-limit operation ........................................................................................................................ 8
1.7 Stop-limit operation ................................................................................................................................. 8
1.8 Mechanical brake control ........................................................................................................................ 9
1.9 EMC ....................................................................................................................................................... 9
1.9.1 EMC levels.......................................................................................................................................... 9
1.9.2 Fulfilled EMC-standards ...................................................................................................................... 9
2 PARAMETER ADJUSTMENTS ........................................................................................................ 11
2.1 The display panel .................................................................................................................................. 11
3 TROUBLESHOOTING ..................................................................................................................... 13
3.1 Field repair actions................................................................................................................................ 13
3.2 Typical functional problems ................................................................................................................... 13
3.3 Inverter fault codes ............................................................................................................................... 13
4 TROUBLESHOOTING TABLE ......................................................................................................... 16
5 SERVICE ......................................................................................................................................... 17
This document and the information contained herein, is the exclusive property of Konecranes Plc and represents a non-public, confidential and proprietary trade secret that 2/17
may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes Plc.
Copyright © (2010) Konecranes Plc. All rights reserved.
OWNER'S MANUAL FOR TRAVEL FREQUENCY
CONTROL SYSTEM
1 CAUTION
m This manual rev7.0 is for inverter rev 1.0 with software D2S2V054.
Do not touch the components on the circuit boards. Electrostatic discharge may
cause damage or destroy the IC-circuits.
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 Konecranes Plc and represents a non-public, confidential and proprietary trade secret that 3/17
may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes Plc.
Copyright © (2010) Konecranes Plc. All rights reserved.
OWNER'S MANUAL FOR TRAVEL FREQUENCY
CONTROL SYSTEM
1 GENERAL
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
This document and the information contained herein, is the exclusive property of Konecranes Plc and represents a non-public, confidential and proprietary trade secret that 4/17
may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes Plc.
Copyright © (2010) Konecranes Plc. All rights reserved.
OWNER'S MANUAL FOR TRAVEL FREQUENCY
CONTROL SYSTEM
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
F7
A1
Z1 CM1 K7 Z2 Z3
X1
This document and the information contained herein, is the exclusive property of Konecranes Plc and represents a non-public, confidential and proprietary trade secret that 5/17
may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes Plc.
Copyright © (2010) Konecranes Plc. All rights reserved.
OWNER'S MANUAL FOR TRAVEL FREQUENCY
CONTROL SYSTEM
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.
1.5.1 MS2-control
c_coms2a
0) “decelerate to zero”
1) step 1 “drive minimum speed”
2) step 2 “drive maximum speed”
1.5.2 EP2-control
c_coep2a
0) “decelerate to zero”
1) while starting “drive minimum speed”
while running “hold speed”
This document and the information contained herein, is the exclusive property of Konecranes Plc and represents a non-public, confidential and proprietary trade secret that 6/17
may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes Plc.
Copyright © (2010) Konecranes Plc. All rights reserved.
OWNER'S MANUAL FOR TRAVEL FREQUENCY
CONTROL SYSTEM
1.5.3 EP3-control
c_coep3a
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”
1.5.4 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”
1.5.5 MS5-control
c_coms5b
A. Controller position
B. Speed
0) “decelerate to zero”
This document and the information contained herein, is the exclusive property of Konecranes Plc and represents a non-public, confidential and proprietary trade secret that 7/17
may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes Plc.
Copyright © (2010) Konecranes Plc. All rights reserved.
OWNER'S MANUAL FOR TRAVEL FREQUENCY
CONTROL SYSTEM
1.5.6 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.
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 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).
This document and the information contained herein, is the exclusive property of Konecranes Plc and represents a non-public, confidential and proprietary trade secret that 8/17
may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes Plc.
Copyright © (2010) Konecranes Plc. All rights reserved.
OWNER'S MANUAL FOR TRAVEL FREQUENCY
CONTROL SYSTEM
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.
1.9 EMC
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.
First environment means environment that
includes domestic premises and also
establishments directly connected to a low-
voltage power supply network.
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.
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.
0 level products fulfil the emission requirements (they might exceed the limit of N level products) of the
EN 61800-3 A11 2000 for the second environment
EMC filters in N level products might cause disturbances on fault (leakage) current
relay
This document and the information contained herein, is the exclusive property of Konecranes Plc and represents a non-public, confidential and proprietary trade secret that 10/17
may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes Plc.
Copyright © (2010) Konecranes Plc. All rights reserved.
OWNER'S MANUAL FOR TRAVEL FREQUENCY
CONTROL SYSTEM
2 PARAMETER ADJUSTMENTS
Power is on. In case of a fault, the symbol will not light up.
Fault is active
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
Stop button
This document and the information contained herein, is the exclusive property of Konecranes Plc and represents a non-public, confidential and proprietary trade secret that 11/17
may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes Plc.
Copyright © (2010) Konecranes Plc. All rights reserved.
OWNER'S MANUAL FOR TRAVEL FREQUENCY
CONTROL SYSTEM
This document and the information contained herein, is the exclusive property of Konecranes Plc and represents a non-public, confidential and proprietary trade secret that 12/17
may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes Plc.
Copyright © (2010) Konecranes Plc. All rights reserved.
OWNER'S MANUAL FOR TRAVEL FREQUENCY
CONTROL SYSTEM
3 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. Note also that
there is always a dangerous voltage in the braking resistor when the DC-bus is
charged.
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
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).
This document and the information contained herein, is the exclusive property of Konecranes Plc and represents a non-public, confidential and proprietary trade secret that 13/17
may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes Plc.
Copyright © (2010) Konecranes Plc. All rights reserved.
OWNER'S MANUAL FOR TRAVEL FREQUENCY
CONTROL SYSTEM
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.
to display value
F 13 Inverter Temperature of heat sink is below Check X
undertemperatu acceptable operating level -10°C (14°F) ambient temperature
re cubicle heating
F 14 Inverter Temperature of heat sink is over acceptable Check: X
overtemperature operating level +90°C (194°F). ambient temperature
Overtemperature warning is issued when inverter cooling fan operation
the heat sink temperature exceeds +85°C cooling air flow through heat sink
(185°F)
heat sink is not dirty
F 16 Parameter P1.4.1 has value “1” or “2” Change Parameter P1.4.1 to value “0” X
F 22 EEPROM Parameter save error After power off the inverter will automatically X
F 23 checksum fault interference fault reset parameter settings. The drive does not
work properly nor enable driving after this
component failure (control unit)
fault.
Check:
all parameter settings.
+24V voltage output loading
If the fault comes again, contact authorized
service center.
F 25 Microprocessor interference fault Reset: switch power off and restart after the X
watchdog-fault component failure (control unit) lamps of display are off.
If the fault comes again, contact service
center.
F 39 Device removed Option board removed. Reset the fault X
Check option board connection
F 40 Device unknown Unknown option board or drive. Check board and drive type. X
F 41 IGBT IGBT transistors is calculated to be over Reset: switch power off and restart after the X
temperature heated lamps of keypad are off. Check:
long duration overload motor loading
lowered cooling brake operation
high environment temperature inverter heatsink
inverter cooling fan operation
environment temperature
F 44 Device changed Option board changed. Reset the fault X
F 45 Device added Option board added. Reset the fault X
F 51 Stop limit S12 or S22 signal is inactive Reset: keep controller at zero >300ms. X
Check control mode selection P1.1.11
Check the state of inputs DID4 and DID5,
V2.3
Hoisting application: check Dold settings
F 55 Board fault Option board is missing or not working Reset: switch power off and restart after the X
lamps of display are off.
Check: Option board
F 56 Generator side The inverter cannot stop with the set ramp Reset has an additional 5 s time delay. X
current limit stretching, it will stop by brake and show Check:
F56
deceleration time
Too short deceleration time
F 60 Parameter fault “Motor selection” parameter P1.2.2 has Download parameters again X
value = “Not Used”
F 73 Both drive S1 and S2 signals on over 500ms in same Check: X
commands time digital I/O cabling
active The inverter stops according “Stop Function”
parameter
Short circuit in pendent cable
This document and the information contained herein, is the exclusive property of Konecranes Plc and represents a non-public, confidential and proprietary trade secret that 15/17
may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes Plc.
Copyright © (2010) Konecranes Plc. All rights reserved.
OWNER'S MANUAL FOR TRAVEL FREQUENCY
CONTROL SYSTEM
4 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
TYPE CODE ACCELERATION TIME, S
P1.1.2
SERIALNUMBER DECELERATION TIME, S
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 Ω Ω Ω
VOLTAGE L1 L2 L3
PHASE-TO-GROUND Vac Vac Vac
MEASURED
CONTROL VOLTAGE V
This document and the information contained herein, is the exclusive property of Konecranes Plc and represents a non-public, confidential and proprietary trade secret that 16/17
may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes Plc.
Copyright © (2010) Konecranes Plc. All rights reserved.
OWNER'S MANUAL FOR TRAVEL FREQUENCY
CONTROL SYSTEM
5 SERVICE
The drive does not require regular maintenance. However the following actions are recommended:
This document and the information contained herein, is the exclusive property of Konecranes Plc and represents a non-public, confidential and proprietary trade secret that 17/17
may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes Plc.
Copyright © (2010) Konecranes Plc. All rights reserved.