Konecranes Dmcs022 User manual

DMCS022 Upgrade Kit

Installation Instruction

020145en / Revision D / 2015-04-29

Original Instruction

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 other parties, altered or otherwise employed in any manner whatsoever without the express written

TABLE OF CONTENTS

1 INTRODUCTION................................................................................................................................... 3

1.1 About this manual......................................................................................................................... 3

1.2 About the upgrade kit usage......................................................................................................... 3

1.3 Waste treatment and recycling of removed material...................................................................... 3

2SAFETY................................................................................................................................................. 4

2.1 Before starting to work at the site.................................................................................................. 4

2.2 Main switch and emergency stop buttons...................................................................................... 4

2.3 After working at the site................................................................................................................. 4

3DESCRIPTION OF THE UPGRADE KIT............................................................................................... 5

3.1 Parts included in the kit................................................................................................................. 5

3.2 Required tools............................................................................................................................... 6

3.3 Terminal connections.................................................................................................................... 7

3.4 User interface................................................................................................................................ 8

3.5 EMC filter...................................................................................................................................... 8

4INSTALLATION..................................................................................................................................... 10

4.1 Preparations.................................................................................................................................. 10

4.2 Old frequency converter removal.................................................................................................. 10

4.3 Control voltage front resistors....................................................................................................... 11

4.4 By-passing the control voltage front resistor.................................................................................. 11

4.5 New frequency controller installation............................................................................................. 12

5 COMMISSIONING................................................................................................................................. 19

5.1 Old inverter parameter settings..................................................................................................... 19

5.2 Motor type..................................................................................................................................... 19

5.3 Traveling motor rating plate values............................................................................................... 19

5.4 Setting up the new inverter parameters......................................................................................... 19

6 TROUBLESHOOTING........................................................................................................................... 26

6.1 Purpose of troubleshooting........................................................................................................... 26

6.2 Problems and solutions................................................................................................................. 26

6.3 Fault codes and alarms................................................................................................................. 26

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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 other parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes Plc.

1 INTRODUCTION

1.1 About this manual

This manual offers guidance to the installation and start-up tasks of DynADrive 022 frequency converter

replacement.

As a maintenance technician, taking the time to read this manual will help you easily adopt the replacement

procedures. This manual is not intended as a substitute for proper training.

Please read through these instructions and make yourself familiar with all the steps before

proceeding.

More information can be found in the original Service Manuals of the specific device.

1.2 About the upgrade kit usage

This upgrade kit is designed only for DynADrive 022 frequency converter.

1.3 Waste treatment and recycling of removed material

The removed parts and packaging material shall be recycled according to local regulations. We recommend

recycling the frequency converter’s aluminum heat sink separately.

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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 other parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes Plc.

2 SAFETY

2.1 Before starting to work at the site

Before starting any work on the crane:

• Familiarize yourself with the equipment and its user instructions.

• Find out the location of the main switch and the emergency stop buttons.

• Evaluate the risks of the site and try to minimize them.

• Inform the site responsible that you will be working on the crane.

• Restrict access to the working area, if possible.

• Prevent unintentional use of the crane.

• Ensure that you have all the appropriate personal protection equipment. Use them as required.

2.2 Main switch and emergency stop buttons

Lock and tag the main switch when you need to switch it off during your work.

Electrical shock hazard

Touching live electrical circuit can cause serious injury.

Even though main switch is turned off, there may still be voltage inside electrical devices such as

inverters. Wait at least 5 minutes before opening covers.

2.3 After working at the site

Ensure that you leave the site in a safe condition:

• Ensure that the work area is clean.

• Remove any locks/tags from switches.

• Ensure that the crane functions normally.

• Inform the site responsible that you have finished the work.

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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 other parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes Plc.

3 DESCRIPTION OF THE UPGRADE KIT

3.1 Parts included in the kit

Part Name Qty. Image

Part 1 Frequency converter 1 pcs

Part 2 Mounting rack 1 pcs

Part 3 Installation accessory 1 pcs

Installation accessory

Part Name Qty. Image

Part 1 Cable tie 3 pcs

Part 2 Wire marker set 1 pcs

Part 3 Cleaning pad 1 pcs

Part 4 Wire end ferrule

2,5mm²

10 pcs

Part 5 M5 x 10 Flanged screw 10 pcs

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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 other parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes Plc.

3.2 Required tools

Item

No Name Image

1 Screwdriver, slot -head, 3,5 x 0,6mm

2 Wire strippers

3 Wire cutters

4 Crimping tool for wire end ferrules

5 Socket wrench, 8mm

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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 other parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes Plc.

3.3 Terminal connections

Table 1. Power terminals

Description of Terminal DynADrive 022

Terminal X2

DynA45 006 Power terminals

Power supply, phase 1 L1 L1

Power supply, phase 2 L2 L2/N

Power supply, phase 3 L3 L3

Motor supply, phase 1 U U/T1

Motor supply, phase 2 V V/T2

Motor supply, phase 3 W W/T3

Braking resistor, positive R+ R+

Braking resistor, negative R- R-

Protective earth PE PE

Table 2. Control terminals

DynADrive 022 DynA45 006

Description of Terminal Terminal

Description Control board

terminals

Drive command, direction 1 1 Drive command, direction 1 1

Drive command, direction 2 2 Drive command, direction 2 2

Speed 2 / Acceleration command 3 Speed 2 / Acceleration

command

Slowdown/Stop limit, direction 1 4 Common slowdown,

Slowdown/Stop limit, direction

Slowdown/Stop limit, direction 2 5 Common stop, Slowdown/

Stop limit, direction 2

Common DI1-5 6 Motor temperature

protection / External stop

Normally open relay contact 7 Common DI1-6 7

Normally open relay contact 8 Normally open relay contact 8

Empty 9 Normally open relay contact 9

Motor thermistor, T1 10

Motor Thermistor, T2 11

Terminal X1 and control board terminal pins may have different functions!

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reproduced, disclosed to other parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes Plc.

3.4 User interface

DynADrive 022 has 6 groups of DIP switches (S1-S6), whereas DynA45 006 has operating digital panel and

large menu structure. The correct parameter settings for DynA45 006 can be found in chapter:

"Commissioning".

DynADrive 022 DynA45 006

Switch Description No: Description

S1 Maximum driving frequency 1. Drive status

S2 Minimum driving frequency 2. Control selection

S3 Acceleration and

deceleration ramp times

3. Main menu

S4 Control mode and motor

type

4. Back/reset button

S5 Motor current limit 5. Navigation and confirmation (OK) buttons.

S6 Limit operation settings

3.5 EMC filter

DynADrive 022 has an external EMC filter package (KC310 / KC330), whereas DynA45 has an internal EMC

filter in the power supply. By default, the EMC level of the frequency converter is set to N by the manufacturer.

If the mains network is non-grounded (IT-network), the DynA45 006 frequency converter’s EMC level must be

changed to 0 by removing the filter capacitor disconnection screw.

Verify the type of electrical supply network from original electrical drawings.

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reproduced, disclosed to other parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes Plc.

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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 other parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes Plc.

4 INSTALLATION

4.1 Preparations

Before you start, be sure to take into account the following matters:

• If the crane is drivable, check the trolley/bridge driving directions before switching the main power off.

• Check that the main power switch is off (lock and tag procedure).

• Always follow all local safety regulations and instructions.

WARNING High voltage inside the device.

Wait for at least five minutes after the voltage supply has been switched of

before taking any service actions.

4.2 Old frequency converter removal

1If the trolley is operable (not broken), record the trolley driving directions.

2Push the main power off from the pendant or radio controller.

WARNING High voltage inside the Frequency converter.

Wait for at least five minutes after the voltage supply has been

switched of before taking any service actions.

3DynA45 006 has an internal EMC filter. The old EMC filter can be removed. Cut the ground wire and

the power supply wires (L1, L2, L3) right next to the connector and mark them with the yellow wire

marks (Part 17). The old EMC filter can remain on the DynADrive 022 body.

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reproduced, disclosed to other parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes Plc.

4Disconnect and mark the motor supply wires (U, V and W) with cable markers. If the DynADrive 022

has an external braking resistor, disconnect the braking resistor wires and remove the braking resistor.

Disconnect the control wires and mark them according to the next table.

Pin in

DynADrive 022

Connect to pin number in DynA45 006 Function

1 1 Drive command, direction 1

2 2 Drive command, direction 2

3 3 Speed 2 / Acceleration command

4 4 Slowdown/stop limit, direction 1

5 5 Slowdown/stop limit, direction 2

6 7 Common for Digital Inputs

7* 8 Normally open relay contact

8* 9 Normally open relay contact

10** Connect to OL10 signal Supply voltage for motor bi-metal

thermal protection

11** 6 Motor thermal protection

*) If there are no wires connected in pins 7 and 8 in DynADrive 022 , the relay is not in use and thus

must not be marked.

**)If the pins 10 and 11 are connected together, the motor thermal protection is not in use and thus

pin number 6 must be connected to OL10 signal. If there are two motors, there are two thermal

protection circuits which must be connected in series.

If there is a thermistor installed in the motor, a thermistor relay ,e.g. MSL, must be installed to

thermal protection circuit of the motor. Pin number 6 must be connected to OL10 via MSL.

5Loosen and remove the screws (4 pcs) holding the DynADrive 022 . Remove the DynADrive 022 and

the EMC-filter from the enclosure. Note: The old screws are self-tapping so they must not be re-used.

Use the delivered screws (part 8) instead.

6Strip all the wires up to 10 mm. If the wires have thin strands, use wire end ferrules (Part 21) as shown

in the picture.

4.3 Control voltage front resistors

The control voltage range in the DynADrive 022 was 48V - 115V. If the control voltage was 230V, the front

resistors were used to decrease the control voltage to 115V or 48V. In the DynA45 006 the control voltage

range is 42V - 230V. Therefore you must remove or by-pass the possible front resistors when upgrading the

DynADrive 022 to DynA45 006 .

If the front resistors are not removed or by-passed, the control inputs on the DynA45 006

frequency converter are not activated, even though voltage can be measured with a

multimeter.

4.4 By-passing the control voltage front resistor

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reproduced, disclosed to other parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes Plc.

1Remove the control signal wires from the top side of

the front resistor.

2Connect the control signal wires to the bottom side of

the front resistor. See the picture below.

Do not mix the order of the wires.

4.5 New frequency controller installation

1If the DynADrive 022 has an external braking resistor: install the braking resistor to suitable place

close to DynA45 006 in the crane. Install the braking resistor wire from the braking resistor to the

cubicle.

2Put 4 pcs , size M5 x 10 Flanged installation screws

into back plate. Leave screws loose. The installation

rack has slotted screw holes.

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reproduced, disclosed to other parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes Plc.

3Put the installation rack (part 2) into place . Tighten the

screws.

4Put 4 pcs, size M5 x 10 Flanged installation screws

into assembly rack. Leave screws loose. The inverter

has slotted screw holes.

5Put the DynA45 006 into place. Tighten the screws.

6Connect the power supply and motor wires in DynA45 according to electrical drawings.

7Connect extra grounding wire from new inverter PE(protective earth) terminal to ground. Wire length

should not exceed 10 cm. The wire size should be minimum of 2.5 mm². This extra grounding wire is

not delivered with the package.

8If the DynADrive 022 has an external braking resistor: Remove the internal braking resistor wires and

connect the braking resistor cable to DynA45 006 according to the electrical drawings.

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reproduced, disclosed to other parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes Plc.

9Connect the control wires according to the next instructions. Look at the original electrical drawings to

see how the original application is built. There are five different variations how control wires can be

connected.

Variation 1 - MS2+stop . EP2 or MS2 control with stop limit.

Figure 1. Old inverter + MS2 + stop

Figure 2. New inverter + MS2 + stop

Digital input 5 in DynA45 will be deactivated. No connection is needed.

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reproduced, disclosed to other parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes Plc.

Variation 2 - EP2+slow down. MS2 control method with slowdown limit switch. With DynA45 both

direction signals from limit switch must be connected in series as shown in below figures.

Figure 3. Old inverter + EP2 + slow down

Figure 4. New inverter + EP2 + slow down

Digital input 5 in DynA45 will be deactivated. No connection is needed.

Variation 3 - EP2 / MS2 + stop.

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reproduced, disclosed to other parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes Plc.

Figure 5. Old inverter + EP2 / MS2 + stop

Figure 6. New inverter + EP2 / MS2 + stop

Digital inputs 4 and 5 in DynA45 will be deactivated. No connection is needed.

Variation 4 - MS2 + 2-step limit switch.

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reproduced, disclosed to other parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes Plc.

Figure 7. Old inverter + MS2 + 2-step limit switch

Figure 8. New inverter + MS2 + 2-step limit switch

Variation 5 - EP2 + 2-step limit switch. With DynA45 the both slowdown direction signals from limit

switch must be connected in series.

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reproduced, disclosed to other parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes Plc.

Figure 9. Old inverter + EP2 + 2-step limit switch

Figure 10. New inverter + MS2 + 2-step limit switch

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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 other parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes Plc.

5 COMMISSIONING

5.1 Old inverter parameter settings

Write down the old parameter settings from the DynADrive 022 frequency converter in the table below.

Table 1: DynADrive 022 parameter settings

Dip

switch

position

Switch 1 Switch 2 Switch 3 Switch 4 Switch 5 Switch 6

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

OFF

5.2 Motor type

Record the motor type. You need to verify if you're motor is equipped with compact brake. This information is

later used on the commissioning steps. The commissioning steps are different with compact brake motors.

Motor type

Compact brake motor types

MF06MA200

MF06MA100

MF06LA200

MF06LA100

5.3 Traveling motor rating plate values

Record the traveling brake rating plate values for further use on commissioning.

Name Motor rating plate value

Motor Nom Volt [V]

Motor Nom Freq [Hz]

Motor Nom Speed [rpm]

Motor Nom Curr [A]

Nom Magnetizing Curr [A]

Motor Cos Phi

5.4 Setting up the new inverter parameters

Compare the DIP switch settings of the DynADrive 022 with the following tables and find correct settings for

the DynA45 006 parameter settings.

1At the DynA45 006 frequency converter; set parameter P1.1 to value 129. This sets the engineering

password level which is needed for parameter settings.

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reproduced, disclosed to other parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes Plc.

2Set the nominal driving frequency. Driving frequency depends on the chosen nominal frequency of the

motor. Use table 1 to determine which table must be used to set the maximum and minimum driving

frequencies. Note that switch S4-3 and S4-4 are not shown, because these were used for the IR-

compensation purpose in the DynADrive 022 inverter.

Table 3. Selecting Maximum and Minimum frequency table

DynADrive 022 Table Nominal Frequency

(Hz)

Switch S4

-1 -2

0 0 4 100/120

1 0 5 80

0 1 6 50/60

Table 4. Maximum and minimum frequency 100/120 Hz

DynADrive 022 Minimum frequency

(Hz) To P1.2

Maximum Frequency

(Hz) To P1.3

Switch S1

-1 -2 -3 -4

0 0 0 0 29 100

0 0 0 1 14 50

0 0 1 0 23 62

0 0 1 1 10 54

0 1 0 0 32 80

0 1 0 1 12 58

0 1 1 0 16 66

0 1 1 1 18 70

1 0 0 0 50 115

1 0 0 1 20 75

1 0 1 0 26 85

1 0 1 1 35 90

1 1 0 0 38 95

1 1 0 1 41 105

1 1 1 0 44 110

1 1 1 1 47 120

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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 other parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes Plc.