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Original instructions

SERVICE MANUAL FOR TRAVELING INVERTER

Service Manual for DMCS 022F
- - - -

SUPDOC_SM_DMCS055-0.ORD 25.3.2010
SUPDOC_SM_DMCS0550100-0 PS02379 25.3.2010
 R&M Materials Handling, Inc.
4501 Gateway Boulevard
Springfield, Ohio 45502
P.: (937) 328-5100
FAX: (937) 325-5319

Table of content

1 DESCRIPTION OF THE INVERTER .................................................................................................. 3

1.1 Connections............................................................................................................................................ 3
1.2 Technical characteristics ......................................................................................................................... 4
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)........................................................... 5
1.6.1 EMC filter connection to inverter for trolley travelling............................................................................ 5
1.6.2 EMC filter connection to inverter for bridge travelling. .......................................................................... 5
2 DESCRIPTION OF CONTROL MODES............................................................................................. 7
2.1 MS2-control (S6-1=OFF & S6-2=OFF) .................................................................................................... 7
2.2 EP2-control (S6-1=ON & S6-2=OFF) ...................................................................................................... 7
2.3 EP3-control (S6-1=OFF & S6-2=ON) ...................................................................................................... 8
2.4 MS4-control (S6-1=ON & S6-2=ON)........................................................................................................ 8
3 FAULT CODES, TROUBLESHOOTING............................................................................................. 9
1 PROGRAMMING OF THE APPLICATION PARAMETERS .............................................................. 10
3.1 Minimum speed, maximum speed and ramp time .................................................................................. 10
3.1.1 Example of parameter setting ............................................................................................................ 10
3.1.2 Acceleration and deceleration ramp................................................................................................... 11
3.1.3 Example of parameter setting: ........................................................................................................... 11
3.2 Stopping method ................................................................................................................................... 11
3.3 Control mode ........................................................................................................................................ 11
3.4 Slowdown speed ................................................................................................................................... 12
3.5 Speed2 and Speed3 ............................................................................................................................. 12
2 PROGRAMMING OF THE MOTOR PARAMETERS ........................................................................ 13
3.6 Defining the motor parameters .............................................................................................................. 13
3.6.1 Motor nominal voltage and frequency ................................................................................................ 13
3.6.2 IR-compensation ............................................................................................................................... 13
3.6.3 Motor nominal current ....................................................................................................................... 14

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 R&M Materials Handling, Inc.
4501 Gateway Boulevard
Springfield, Ohio 45502
P.: (937) 328-5100
FAX: (937) 325-5319

1 DESCRIPTION OF THE INVERTER

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

1.1 Connections
Control signals are connected to terminal block X1 as follows:

Nbr Name Description

1 S1 Drive command. Direction 1. 48 or 115V 50/60Hz
2 S2 Drive command. Direction 2. 48 or 115V 50/60Hz
3 DI3 Digital input. 48 or 115V 50/60Hz.
4 DI4 Digital input. 48 or 115V 50/60Hz.
5 DI5 Digital input. 48 or 115V 50/60Hz.
6 ONE Control voltage, neutral.
7 R01 Relay output
8 R02 Relay output
9 Empty
10 T1 Motor thermistor
11 T2 Motor thermistor

Power cabling is connected to terminal block X2 as follows:

Crane power supply conductor rail must have double collectors.

Nbr Name Description
1 L1 Mains, phase 1. 380-480V 50/60Hz.
2 L2 Mains, phase 2. 380-480V 50/60Hz.
3 L3 Mains, phase 3. 380-480V 50/60Hz.
4 U Motor, phase 1.
5 V Motor, phase 2.
6 W Motor, phase 3.
7 R+ Braking resistor, positive, see note
8 R- Braking resistor, negative, see note
9 PE Protective earth

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 R&M Materials Handling, Inc.
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Springfield, Ohio 45502
P.: (937) 328-5100
FAX: (937) 325-5319

Standard duty resistor must be disconnected when heavy duty resistor DMHR01F90
−.
is connected to terminals R+ and R−

1.2 Technical characteristics

Technical data
Power range 2.2 kW
Supply voltage 380 - 480 VAC +/-10%
Nominal supply frequency 48 – 62 Hz
Nominal current 5.1A
Digital control S1, S2, DI3, DI4, DI5
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 Relay output for brake contactor
o o
Ambient temperature -10 C to 50 C
Humidity 95% N.C. (without dripping)
Degree of protection Frequency converter + cover (IP20)
Dimensions (WxHxD) 134x195x123mm
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 Programming switches

S1 S2 S3
ON DIP ON DIP ON DIP

1 2 3 4 1 2 3 4 1 2 3 4

ON DIP ON DIP ON DIP

1 2 3 4 1 2 3 4 1 2 3 4
c_s022a

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

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Springfield, Ohio 45502
P.: (937) 328-5100
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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 device complies with the requirements of EN61800-3:2004 (IEC61800-3) for second environment, category
C3, when a dedicated external EMC filter is applied.

1.6.1 EMC filter connection to inverter for trolley travelling.

c_kc330ba

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

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

 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 µ F
6. Input wires two times through input ferrite rings.
7. Output ferrite ring RH175285107

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 R&M Materials Handling, Inc.
4501 Gateway Boulevard
Springfield, Ohio 45502
P.: (937) 328-5100
FAX: (937) 325-5319
KC-330-00 includes capacitors (4*1µF) and input ferrite rings (3 x EF 32008).

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

6/14 R&M Materials Handling, Inc. reserves the right to alter or amend the above information without notice.
 R&M Materials Handling, Inc.
4501 Gateway Boulevard
Springfield, Ohio 45502
P.: (937) 328-5100
FAX: (937) 325-5319

2 DESCRIPTION OF CONTROL MODES

2.1 MS2-control (S6-1=OFF & S6-2=OFF)

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 (S6-1=ON & S6-2=OFF)

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”

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Springfield, Ohio 45502
P.: (937) 328-5100
FAX: (937) 325-5319

2.3 EP3-control (S6-1=OFF & S6-2=ON)

c_coep3a

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

S1 means “drive minimum speed forward”

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”

2.4 MS4-control (S6-1=ON & S6-2=ON)

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)

8/14 R&M Materials Handling, Inc. reserves the right to alter or amend the above information without notice.
 R&M Materials Handling, Inc.
4501 Gateway Boulevard
Springfield, Ohio 45502
P.: (937) 328-5100
FAX: (937) 325-5319

3 FAULT CODES, TROUBLESHOOTING

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.

Overvoltage. Mains voltage is too high or deceleration ramp time is too short. Check
Green 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
Green
on the track. Check also the motor dependent parameters.
Deceleration ramp supervision. Deceleration ramp has not been followed. If the fault
Green 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
Green 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
Green
track, brake does not open properly,…) or the ambient temperature is too high.
Green 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
Red
motor windings.
Microprosessor fault. Switch the power off for 10 seconds. Then power-up the
Red
inverter.

 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:

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.

9/14 R&M Materials Handling, Inc. reserves the right to alter or amend the above information without notice.
 R&M Materials Handling, Inc.
4501 Gateway Boulevard
Springfield, Ohio 45502
P.: (937) 328-5100
FAX: (937) 325-5319

1 PROGRAMMING OF THE APPLICATION PARAMETERS

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

3.1 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 Table A Table B Table C

S1 / S2 (100/120Hz motors) (80Hz motors) (50/60Hz motors)
-1 -2 -3 -4 Max speed Min speed Max speed Min speed Max speed Min speed
(Hz) (Hz) (Hz) (Hz) (Hz) (Hz)
0 0 0 1 50 14 42 14 25 7
0 0 1 1 54 10 40 10 27 5
0 1 0 1 58 12 44 12 29 6
0 0 1 0 62 23 50 18 31 12
0 1 1 0 66 16 46 16 33 8
0 1 1 1 70 18 48 20 35 9
1 0 0 1 75 20 53 24 38 10
0 1 0 0 80 32 62 30 40 16
1 0 1 0 85 26 56 26 43 13
1 0 1 1 90 35 59 28 45 18
1 1 0 0 95 38 65 32 48 19
0 0 0 0 100 29 77 22 50 15
1) 2)
1 1 0 1 105 41 68 34 53 21
1) 2)
1 1 1 0 110 44 71 36 55 22
1) 2)
1 0 0 0 115 50 80 40 58 25
1) 2)
1 1 1 1 120 47 74 38 60 24
1) 100Hz may be exceeded only if line voltage is 440-480V mains.
2) 50Hz may be exceeded only if line voltage is 440-480V mains.

3.1.1 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-off-off).
ON
1 2 3 4

S1
DIP

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Springfield, Ohio 45502
P.: (937) 328-5100
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3.1.2 Acceleration and deceleration ramp

Acceleration and deceleration ramps are set by switch S3 as follows:

Switch S3 Ramp time (sec)

-1 -2 -3 -4
1 0 0 0 1.5
0 1 0 0 2.0
0 0 0 0 2.5
0 0 1 0 3.0
0 0 0 1 3.5
1 0 0 1 4.0
1 1 0 0 4.5
0 0 1 1 5.0
1 1 1 0 5.5
1 1 0 1 6.0
1 0 1 1 6.5
1 0 1 0 7.0
0 1 1 1 7.5
0 1 0 1 8.0

It is possible to reduce the deceleration ramp time by 30% if necessary. The fast deceleration ramp is activated by
switching S5-3 ON (1).

3.1.3 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.

ON DIP

S3
1 2 3 4
ON DIP
S5
1 2 3 4

3.2 Stopping method

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

3.3 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 S6-1 S6-2

MS2 0 0
EP2 1 0
EP3 0 1
MS4 1 1

The functions of all five digital inputs is assigned automatically according to the selected control mode:

MS2 EP2 EP3 MS4

DI1 S1 S1 S1 S1

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MS2 EP2 EP3 MS4
DI2 S2 S2 S2 S2
DI3 HSP AP HOLD SP2
DI4 S12 S11 AP SP3
DI5 S22 S21 S11/S21 HSP

Description of the control signals:

S1 Drive command forward

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

3.4 Slowdown speed

EP2 EP3

S2 S1

S21 S11

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 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)

3.5 Speed2 and Speed3

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

12/14 R&M Materials Handling, Inc. reserves the right to alter or amend the above information without notice.
 R&M Materials Handling, Inc.
4501 Gateway Boulevard
Springfield, Ohio 45502
P.: (937) 328-5100
FAX: (937) 325-5319

2 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
S4 Number of motors
Motor type Nominal voltage and frequency
settings 1 2 4
MF06MA200 400V 100Hz 460V 120Hz 0 00xx 10xx 11xx
MF06MA100 400V 80Hz 1010 10xx 11xx -
MF06LA200 400V 100Hz 460V 120Hz 10 10xx 11xx -
MF06LA100 400V 80Hz 1001 10xx 11xx -
MF06LB200 400V 100Hz 460V 120Hz 10 01xx - -
MF06LB100 400V 80Hz 1011 01xx - -
MF07LA200 380-415V 50Hz 460-480V 60Hz 100 00xx 10xx 11xx
MF07LA100 380-415V 50Hz 460-480V 60Hz 101 00xx 10xx 11xx
MF07LB200 380-415V 50Hz 460-480V 60Hz 100 00xx 01xx -
MF07LB100 380-415V 50Hz 460-480V 60Hz 101 00xx 10xx 11xx
MF07ZC200 380-415V 50Hz 460-480V 60Hz 110 10xx 11xx -
MF07ZC100 380-415V 50Hz 460-480V 60Hz 111 10xx 11xx -
MF09LA200 380-415V 50Hz 460-480V 60Hz 110 11xx - -
MF09LA100 380-415V 50Hz 460-480V 60Hz 111 01xx 11xx -
MF09LB200 380-415V 50Hz 460-480V 60Hz 101 11xx - -
MF09LB100 380-415V 50Hz 460-480V 60Hz 111 11xx - -

3.6 Defining the motor parameters

3.6.1 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 S4-1 S4-2 Speedtable

Voltage Frequency
400V 100Hz 0 0 A
460V 120Hz
400V 80Hz 1 0 B
380-415V 50Hz 0 1 C
440-480V 60Hz

3.6.2 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

0 f middle f (Hz)

Calculation of the IR-rate:

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IR - rate= I NOM ∗ RS * p * n
INOM Nominal current of the motor (one motor)
Rs Stator resistance, measured between inverter
terminals X2:4-5
P Number of polepairs
N Number of motors connected to inverter
Settings:
IR-rate Setting of S4
90 - S4-3 = 0 ; S4-4 = 0
60 - 89 S4-3 = 1 ; S4-4 = 0
40 - 59 S4-3 = 0 ; S4-4 = 1
- 37 S4-3 = 1 ; S4-4 = 1

m 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.

3.6.3 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 S5-1 S5-2

0…1.8A 0 0
1.9A…2.7A 1 0
2.8A…3.5A 0 1
>3.5A 1 1

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

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