!

"#$%&$'
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!

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SERVICE INSTRUCTIONS
TRAVELLING INVERTER

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servicing.

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EN DOCIKA20100-0 - 2 PS02379 Rev:25.2.2004

!" Read the instructions supplied with the travelling inverter before installation, commissioning or #" Keep the instructions in a safe place for future reference.
Table of content 1 GENERAL ......................................................................................................................................3 1.1 Technical data ............................................................................................................................... 3 1.2 Type mark coding........................................................................................................................... 3 1.3 Basic description ............................................................................................................................ 4 1.4 Main components........................................................................................................................... 4 1.5 Functional description ...................................................................................................................... 4 1.6 Control methods ............................................................................................................................ 5 1.6.1 Description of the control methods................................................................................................ 5 1.7 Mechanical brake control.................................................................................................................. 6 Start-up procedure........................................................................................................................7 2.1 Visual checks ................................................................................................................................ 7 2.2 Checks before the first test run ........................................................................................................... 7 2.3 Test run ....................................................................................................................................... 7 2.4 After the test run ........................................................................................................................... 8 Parameter adjustments ..................................................................................................................9 3.1 The display panel ........................................................................................................................... 9 3.2 Programming principles................................................................................................................... 10 3.3 Parameter settings ......................................................................................................................... 10 Parameter descriptions................................................................................................................12 Troubleshooting ..........................................................................................................................15 5.1 Inverter fault codes ....................................................................................................................... 15 Service ........................................................................................................................................18 Drawings .....................................................................................................................................19 7.1 Description of terminals .................................................................................................................. 19

4 5 6 7

$" Before starting read carefully instructions and this table. $" Verify all connections are according to drawings. $" Verify motor supply is connected correctly, wrong connection will destroy the inverter. $" Verify internal voltage selections of device are correct. $" Check device cover is properly installed and all ventilation holes are clear and uncovered. $" Check that hot air coming from brake resistors does not cause any danger. $" High voltages are present in this device. Do not make any inspections unless the supply has been disconnected by main switch. Before opening the device cover, wait at least 5 minutes after the display lamps turn off. $" Insulation resistance test with a megger requires special precautions. $" Do not make any measurements inside the device when it is connected to main supply. $" Do not touch the IC-circuits on the circuit boards. Static voltage discharge may destroy the components. $" It is forbidden to use radiophones and portable phones near this device with the doors open. $" All the doors and covers must be closed during crane in operation.

!" CAUTION

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1 GENERAL
1.1 Technical data
Power class Power (kVA) at 400V Output current In (A) Max. current 1min (A) Overloadability Max. output voltage Supply Supply voltage Allowable voltage fluctuation Nominal supply frequency Signal input levels Digital controls 040F 7 9 15

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1.5 x In , 1min/10min / 2.5 x In , 2s/20s (<50% speed) Equal to supply voltage

F-series 380-500VAC +/- 10% 50/60Hz +/- 5% S1, S2, DI3, DI4, DI5, OLE: 42 240VAC; 15mA

1.2 Type mark coding

DMCS040 can be summarized as a "crane traveling motor control system, which controls the speed by changing the frequency of supply voltage of a squirrel cage motor". A stepless speed adjustment can be achieved by this method. Type marking is shown below.

DMCS
DMCS 040 F 11 P

040
Device name Power rating class

11

040
Supply voltage

380 - 500VAC, 50/60Hz

Revision code Control voltage

Y P T V
N N

42VAC, 50/60Hz 48VAC, 50/60Hz 115VAC, 50/60Hz 230VAC, 50/60Hz Standard

Braking resistor type

EMC level S Standard, without EMC filters N EMC, Second Environment 0 IT Network

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1.3 Basic description
Inverter

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DMCS040 has many advantages and offers many new features, when compared to other inverter based systems, which might be used in crane applications.
The inverter in DMCS040 is a crane 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. The inverter uses vector calculation for several different motor control modes. All DMCS040 has exactly the same interface with pre-designed locations for all typical crane functions. The main part of this interface is carried out by a terminal strip, which has separated sections for signals with main and control voltage levels. DMCS040 includes the brake contactor. DMCS040 includes the braking transistor, which is dimensioned for every crane application. For resistor braking DMCS040 includes a braking resistor. DMCS040 can be controlled by the electronic potentiometer control with 2-step pushbuttons and by the multistep control with 2-4step controllers. Both these control methods are available with every DMCS040. DMCS040 has built-in limit switch functions for both running directions. DMCS040 includes a motor thermal protection, which is based on motor temperature measurement by thermistors placed in motor windings. The great number of other protections included in every DMCS040 are shown in the technical data.

Crane user interface

Brake control Electrical Braking

Control methods

Limit switch functions Protections

1.4 Main components

The main components are:
A1 K7 Inverter Brake contactor

The most important external components are:

R1 M1 Y1 B6 Braking resistor unit Traveling motor Mechanical brake Thermal sensor for motor protection Control devices (switches, pushbuttons etc.) Limit switches

1.5 Functional description

Operation when power is switched on $" The control voltage is supplied to X1:37. The main voltage is connected to inverter power supply and inverter wakes up. $" If either of the direction signals S1 or S2 is on, the DMCS040 display shows F52 and driving can begin only after the direction signals have been off for a while. Normal operation $" For the description of the speed reference setting see chapters 1.6 "Control methods" and 4 "Parameter Descriptions". $" Running starts when switch S1 (S2) closes. Closing the contact NXOPTB9 on A1 energizes K7, which opens the brake. DMCS040 accelerates according to the acceleration ramp setting to the selected speed. $" When the switch S1 (S2) opens DMCS040 stops according to the deceleration ramp setting and the brake closes. $" R1 dissipate the regenerated energy during deceleration. The power supply to R1 is controlled by A1. Other features $" The maximum speed can be limited by opening the slow down limit switches S11 and S21. The slowdown speed is adjustable by parameter. $" Thermistor relay function, which can be used when needed. $" When the stop limit switch S12 or S22 opens, K7 de-energizes and the mechanical brake stops the motion.
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1.6 Control methods
0 1 2 3 4 5 MS2 MS2 EP2 EP3 MS4 MS4

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There are five different control methods (command modes) available:

Multistep control (2 steps) Multistep control (2 steps) Electronic motor potentiometer function. Stepless control using a 2-step pushbutton controller. Electronic motor potentiometer function. Stepless control using a 3-step controller. Multistep control (4 steps) Multistep control (4 steps)

The control mode of DMCS040 is selected by parameter P1.1.7. The parameters assigns digital inputs S1, S2 and DI3-DI5.It is not possible to chance the functions of the inputs separately. The input assignment according to the selected mode is explained in the following table.
Control mode Parameter P1.1.7 Signal S1 S2 DI3 DI4 DI5 Terminal X1:38 X1:39 X1:40 X1:41 X1:42 S1 S2 HSP S12 S22 S1 S2 HSP S11 S21 S1 S2 AP S12 S22 S1 S2 AP S11 S21 S1 S2 HOLD AP S11/S21 S1 S2 SP2 SP3 HSP MS2 0 MS2 1 EP2 2 EP2 3 EP3 4 MS4 5

Desired speed levels for multi-step control mode are selected with following parameters
Speed Speed 1 Speed 2 Speed 3 Speed 4 Parameter P1.1.3. P1.1.5. P1.1.6. P1.1.4. Input S1/ S2 SP2 SP3 HSP

1.6.1 Description of the control methods

In EP-control there are two 2-step pushbuttons, one for each direction. The operation is as follows:
the rest position means standstill (0-position) during run the rest position means deceleration step one (switch S1 or S2) means hold speed when starting, step one means acceleration up to the minimum speed step two (switch AP) means acceleration (up to the maximum speed if desired) at the maximum speed step two means hold speed, because the maximum speed cannot be exceeded
up speed Pushbutton position rest = deceleration step 1 = hold speed step 2 = acceleration

pushbutton position down

time

In EP3-control there is a 3-step controller. The operation is as follows:

the rest position means standstill (0-position) step one (switch S1 or S2) is the minimum speed command step two (EP hold command) means hold speed step three (switch AP) means acceleration (up to the maximum speed if desired) when releasing the controller, step one means deceleration down to the minimum speed

EP-mode
up speed

Pushbutton position rest = stop step 1 = minimum speed step 2 = hold speed step 3 = acceleration time

pushbutton position down

EP3-mode

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up controller position down

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speed speed controller position time

MS-control has a 2 to 4-step controller. The operation is as follows:

each step has its own frequency the frequencies are freely selectable when controller is set to a certain step, the speed changes to equal value

MS-mode

1.7 Mechanical brake control

DMCS040 has a brake contactor to control electromechanical disk brake of traveling motor. The brake is controlled so that during starting the motor first 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. DMCS040 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 and the load.

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2 Start-up procedure

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If any problems or malfunctions occur during the start-up, refer to Chapter Troubleshooting, to find out the reason. All problems must be solved before continuing. For further information contact crane service.

!" Warning! High voltages inside device. Wait for at least five minutes after the supply voltage has
been switched off before service actions. Display in operating condition (lights on) indicates a dangerous voltage on the DC-bus. When display turns off, the DC-bus voltage is about 100V. Note also that there is a dangerous voltage in the braking resistor always when the DC-bus is charged.

#" Do not connect any voltage to the output terminals (U, V, W). Otherwise, the inverter will be damaged. #" The overload protection protects both the supply and the motor cables. The fuses of the supply provide short circuit
protection.

2.1 Visual checks Check condition of cubicle. Check that DMCS040 serial number is the same as in delivery documents. Check the cabling to motor, brake and thermistors. Check motor type. Check the wire terminations in the motor connection box Check connections for motor, thermistors and brake wear. Disconnect motor (U, V, W) and brake cables to prevent damage of inverter. Measure isolation resistance of brake coil and motor windings (each phase to ground). Re-connect motor and brake cables. Check braking resistor. 2.2 Checks before the first test run
Check power supply voltage (nominal voltage +/- 10%). Check control voltage (nominal voltage +/- 10%). Make sure that run commands are off (pushbuttons / controller (master switch) at zero position). Turn on power from main switch and control voltage switch. Within about 1 second the control panel should display "AC on", and then in about 1 second the display changes to motor output frequency "0.00" and green READY status indicator turns on. In a fault situation the red FAULT status indicator blinks and the display shows a fault code instead of frequency. Check that green RUN status indicator is off. Check that external connections and selected inputset P 1.1.7. are according to application. Parameters are properly set after factory tests and no adjustments are needed except for the parameters that depend on application. Write down to the parameter list all the values that have been changed and at the end save parameters to display file 2.

!" Warning! High voltages inside DMCS040.

2.3 Test run Make sure that movement will not cause any danger to the environment or to the crane itself. Avoid driving close to the limit areas. Check limit switches manually if possible. Check the run commands on display panel and correct traveling direction. The arrow rotates clockwise if S1 (right/forward) is applied and counter-clockwise if S2 (left/backward) is applied. Drive forward at minimum speed for 5 to 10 seconds. Accelerate to full speed. Run 5 to 10 seconds. Stop. Repeat the same in backward direction. Check the frequency display to make sure that the frequency changes through the whole operational frequency range from minimum to nominal speed.
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Check motor operation (acceleration, deceleration and braking): accelerate to full speed forward, change to full speed backward and full speed forward again and stop. Check limit switch functions: drive slowly to limit switches and check the slowdown or stop limit switch operations. Re-check using full speed. Repeat the same check for the other direction.

2.4 After the test run Record all parameter value changes in the parameter list. Make sure all remarks and setting values are recorded. It is recommended to store the parameter settings in the memory of the display panel, file 2.

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3 Parameter adjustments
3.1 The display panel

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RUN

STOP READY ALARM FAULT

I/ O t er m Keypad

V 4.17.

Motor Speed

2002 rpm
ready run fault

START

reset

STOP

select

enter

The display panel is used for:

Displaying the drive identification, electrical values, operating or fault parameters Altering the parameter settings Saving and restoring the parameter settings in the memory of the display panel
Meaning of the displays:
RUN

Motor is running, blinks when ramping down. Indicates the direction of motor rotation.

STOP

Indicates that motor is not running. Lights when power is on. In case of a trip, the symbol will not light up. Indicates that the drive is running outside of certain limit. Drive was stopped due to unsafe operating conditions I/O-terminals are the selected control place Keypad is the selected control place

READY
ALARM

FAULT
I/ O t e r m

Keypad

The signalling LEDs ready Lights when power is on. In case of a trip, the symbol will not light up. run Motor is running, blinks when ramping down. fault Indicates that unsafe operating conditions were encountered due to which Button description
reset

Reset active faults Switch between two latest displays Confirmation of selections Fault history reset Browse the main menu and the pages of submenus Edit values Move in menu Move cursor Exit and enter edit mode

select

enter

START

Start button Starts motor if the keypad is the active control place

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3.2 Programming principles

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The programming of DMCS040 is done by altering the parameter settings by the display panel. Moving from menu to menu is done by the browser buttons of the display panel and entering into a menu is done by the button. The parameter values can be edited by entering the Parameter Menu from the Main menu when the location indication G2 is visible on the first line of the display. Push the button once to move into the Parameter Group Menu. Locate the parameter group desired by using the and buttons. Push button again to enter the group and its parameters. Use again the and buttons to find the parameter you want to edit. Pushing the button takes you to the edit mode. As a sign of this, the parameter value starts to blink. You can now change the value in two different manners: 1. Set the new desired value with and buttons and confirm the change with button.Consequently, the blinking stops and the new value is at display. 2. Bush the button once again. Now you will be able to edit the value digit by digit. Confirm the change with . The value will not change unless the button is pushed. Pressing the button takes you back to the previous menu.
enter enter enter

!" WARNING! !" WARNING!

used.

Changing parameter settings during running can cause a hazardous situation. Parameter settings must not be changed during running. Driving via display can cause a hazardous situation. Panel control must not be

3.3 Parameter settings

Check that motor nominal parameters are correct. "# P1.2.1 Nominal voltage from motor rating plate "# P1.2.2 Nominal frequency from motor rating plate "# P1.2.3 Value from table x motor number. If motor type is not at table, use nominal current x motor number. "# P1.2.4 Value from table. "# P1.2.5 Value from table.

#" Start current value in table must be multiplied by number of motors.

Motor type Nominal voltage P 1.2.1. MF06MA100 MF06MA200 MF06LA100 MF06LA200 MF06LB100 MF06LB200 MF07LA100 MF07LA200 MF07LB100 MF07LB200 MF07ZC100 MF07ZC200 400V 400V 460V 400V 400V 460V 400V 400V 460V 380-415V 460-480V 380-415V 460-480V 380-415V 460-480V 380-415V 460-480V 380-415V 460-480V 380-415V 460-480V Nominal Frequency P 1.2.2. 80Hz 100Hz 120Hz 80Hz 100Hz 120Hz 80Hz 100Hz 120Hz 50Hz 60Hz 50Hz 60Hz 50Hz 60Hz 50Hz 60Hz 50Hz 60Hz 50Hz 60Hz Start Current / motor P 1.2.3. 2.3A 2.3A 2.3A 2.3A 2.3A 2.3A 0.9A 1.0A 1.3A 1.7A 1.9A 2.3A Zero frequency Voltage P 1.2.4. 12.8 % 14.3 % 7.8 % 8.1 % 8.2 % 10.3 % 8.5 % 15.0 % 5.5 % 15.0 % 4.0 % 7.0 % U/f Mid point Voltage P 1.2.5. 15.3 % 15.5 % 10.6 % 12.5 % 9.6 % 14.0 % 10.0 % 16.0% 7.5 % 16.0 % 6.5 % 12 %

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Motor type MF07XA100 MF07XA200 MF07XB100 MF07XB200 MF09LA100 MF09LA200 MF09LB100 MF09LB200 MF10L-200 Nominal voltage 400V 400V 460V 400V 400V 460V 380-415V 460-480V 380-415V 460-480V 380-415V 460-480V 380-415V 460-480V 380-415V 460-480V

(
Start Current / motor 4.3A 3.9A 7.9A 6.9A 3.0A 3.2A 4.2A 4.8A 7.3A 80Hz 100Hz 120Hz 80Hz 100Hz 120Hz 50Hz 60Hz 50Hz 60Hz 50Hz 60Hz 50Hz 60Hz 50Hz 60Hz 7.3 % 7.4 % 8.3 % 7.9 % 3.0 % 8.5 % 4.0 % 8.5 % 9.0 %

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Zero frequency Voltage U/f Mid point Voltage 10.5 % 12.9 % 12.1 % 12.3 % 6.0 % 10.0 % 6.5 % 10.0 % 14.0 %

Nominal Frequency

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4 Parameter descriptions
Label G1. Parameters G1.1 General Parameters Accel Time Decel Time Min Freq Max Freq Multist2/SlowSpd Multistep3 Input Set Stop Function P1.1.1 P1.1.2 P1.1.3 P1.1.4 P1.1.5 P1.1.6 P1.1.7 P1.1.8 Code

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Function/Description

Adjustment range

Acceleration ramp is defined from zero to max frequency P1.1.4. Minimum setting is 1s Deceleration ramp is defined from max frequency P1.1.4 to zero. Minimum setting is 1s Minimum frequency Maximum frequency 2nd preset speed. Multistep speed setting. / Speed when one of slow down limit switches (S11/S21) is open 3rd preset speed. Multistep speed setting. Input Set selection, see chapter 1.6 3rd preset speed Stopping mode selection 0: When the drive command is switched off the motion is stopped according to the set deceleration ramp. 1: When the drive command is switched off the motor current is cut off and the motion is stopped by the mechanical brake.. Multistep speed setting. Nominal motor voltage Un from motor rating plate

1-20 1-20 0 Max Freq 0 Max Freq 0-100% of Max Freq 0-100% of Max Freq 1-4 0-1

G1.2 Motor Parameters Motor Nom Volt P1.2.1 04=380V 05=400V 06=415V 07=440V 08=460V 09=480V 10=500V 0 250 Hz 0 3000 A

Motor Nom Freq Start Current Zero Freq Volt U/f Mid Volt G2. Monitoring G2.1. Digital Input S1 S2 DIA3 DIA4 DIA5 Output Frequency Motor Current Motor Voltage DC-Link Voltage Heat Sink Temp Freq Ref DIA States G3 Panel Control Panel Control Speed Reference M4 System Menu Language Application S4.3. Copy Parameters Parameters Sets Up to keypad

P1.2.2 P1.2.3 P1.2.4 P1.2.5

Nominal motor frequency fn from motor rating plate

V2.1.1. V2.1.2. V2.1.3. V2.1.4. V2.1.5. V2.2. V2.3. V2.4. V2.5. V2.6. V2.7. V2.8. P3.1. R3.2.

State of digital input S1 State of digital input S2 State of digital input DIA3 State of digital input DIA4 State of digital input DIA5 Output frequency to the motor Measured motor current Calculated motor voltage Measured DC-link voltage Measured heat sink temperature Frequency reference State of board A inputs, S1, S2, DIA3, DIA4, DIA5 Must not be used. Speed reference for panel control

0=OFF, 1=ON 0=OFF, 1=ON 0=OFF, 1=ON 0=OFF, 1=ON 0=OFF, 1=ON Hz % % V $C Hz

0=OFF, 1=ON

S4.1. S4.2

Language Application

English DMCS040

S4.3.1. S4.3.2.

Load and store parameters to Set1 or Set2 Store parameters to keypad

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Label Down from keypad Autom. BackUp S4.4. ParamComparison S4.4.1. S4.4.2. S4.4.3. S4.4.4. S4.5. Security Password Parameter Lock Startup wizard Multimon. Items S4.6. Keypad settings Default page P4.6.1. S4.5.1 P4.5.2. P4.5.3 P4.5.4. Code S4.3.3. P4.3.4.

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Adjustment range

Function/Description Load parameters from keypad Store changes automaticly Set1 Set2 Factory settings Keypad set Dont use

ChangeEnable No ChangeEnable Default page to which the display automatically moves as the Timeout time has expired or as the power is switched on to the keypad. If the Default Page value is 0 the function is not activated, i.e. the last displayed page remains on the keypad display.

Default page/OM Timeout time Contrast Backlight time S4.7 HW settings InternalBrakeRes Fan control HMI ACK timeout HMI retry S4.8.1. Total Counters MWh counter Op Day Counter Op. Hour counter S4.8.2. Trip counters MWh Counter Clr MWh Counter PwOn Day Counter PwOn hour Counter Clr Optime cntr S4.8.3. Software Software package SystemSw version Firmware interf. System load S4.8.4. Applications A4.8.4.1. DMCS040 Application id Version Firmware interf S4.8.5. Hardware Power unit Unit voltage Brake chopper Brake resistor S4.8.6. Expander boards A: B: State Program version

P4.6.2. P4.6.3. P4.6.4. P4.6.5. P4.7.1. P4.7.2 P4.7.3 P4.7.4 C4.8.1.1. C4.8.1.2. C4.8.1.3. T4.8.2.1. P4.8.2.2. T4.8.2.3. T4.8.2.4. P4.8.2.5. I4.8.3.1. I4.8.3.2. I4.8.3.3. I4.8.3.4. MWh counter, can not be reseted Operation day counter, can not be reseted Operation hour counter, can not be reseted MWh counter, can be reseted Clear MWh counter Operation day counter, can be reseted Operation hour counter, can be reseted Clear Operation time counters Software version System software version NXS_MDR1V020 11.35.5397 4.19 The time after which the keypad display returns to default page. Display contrast. Determines how long the backlight stays before going out.

D4.8.4.1.1 D4.8.4.1.2 D4.8.4.1.3 I4.8.5.1. I4.8.5.2. E4.8.5.3. E4.8.5.4. E4.8.6.1. E4.8.6.2. E4.8.6.2.1. E4.8.6.2.2

Application identification number Application version number Firmware interface number

Mdrive1 2.00 4.18

Type of expander board at slot A Type of expander board at slot B State of expander board at slot B Software version of expander board at slot B

No board NXOPTA3 RUN

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Label C: D: State Program version E: S4.8.7. Debug Not used in DMCS040 M5 Active faults Code E4.8.6.3. E4.8.6.4. E4.8.6.4.1. E4.8.6.4.2 E4.8.6.5.

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Adjustment range No board NXOPTB9 RUN No board

Function/Description Type of expander board at slot C Type of expander board at slot D State of expander board at slot D Software version of expander board at slot D Type of expander board at slot E

The memory of active faults can store the maximum of 10 faults in the order of appearance. button you will enter the Fault time data record menu indicated By pushing the by T.1-T.13. In this menu some selected important, data valid at the time of the fault, are recorded. T.1 T.2 T.3 T.4 T.5 T.6 T.7 T.8 T.9 T.10 T.11 T.12 T.13 M6 Fault history The fault memory can store a maximum of 30 faults in the order of appearance. The number of faults currently in the fault history is shown on the value line of the main page. The order of the faults is indicated by the location indication in the upper left corner of the display. The latest fault carries the indication F8.1, the second latest F8.2 etc. The Fault time data record pages are accessible at each fault. If there are 30 uncleared faults in the memory, the next occurring fault will erase the oldest from the memory. Pressing the Enter button for about 2 to 3 seconds resets the whole fault history. Counted operation days Counted operation hours Output frequency Motor current Motor voltage Motor power Motor torque DC voltage Unit temperature Ready Run Direction Fault Warning At reference 0-speed d hh:mm:ss Hz A V % % V $C 0=Not Ready 1=Ready 0=Not Running 1=Run 0=Off 0=No 0=No 0=No 1=On 1=Yes 1=Yes 1=Yes

0=Not Zero Speed 1=Zero Speed

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5 Troubleshooting

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supply voltage has been switched off before service actions. Display in operating condition (lights on) indicates a dangerous voltage on the DC-bus. When display turns off, the DC-bus voltage is about 100V. Note that there is a dangerous voltage in the braking resistor always when the DC-bus is charged. This chapter describes how to detect DMCS040 failures. The purpose is to find out which components are damaged and how to replace them to restore proper operation. Advice is also given to find possible external failures that affect DMCS040 function.

!" Warning! High voltages inside Frequency converter. Wait for at least five minutes after the

5.1 Inverter fault codes

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. DMCS040 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. When inverter fault supervision trips, the FAULT indicator turns on and the blinking fault code F xx (xx = fault number) appears on the display. The faults are stored to the fault history, from there they can be seen if necessary.
Fault code Fault Overcurrent Possible cause Inverter has measured too high current (over 4*In) in the motor output: sudden heavy load increase short circuit in the motor or cable not suitable motor wrong motor parameters Checking Reset: switch power off and restart after the lamps of display are off. Check: motor type and power rating parameters motor cables motor insulation brake operation motor loading Check: adjust the deceleration time longer measure main supply voltage level and wave form while not driving motor insulation motor cable insulation (phase-ground, phase-phase) braking resistor cable braking resistor type and resistance braking chopper operation Reset: switch power off and restart after the lamps of display are off. Check: motor insulation motor cable insulation (phase-ground, phase-phase) Reset: switch power off and restart after the lamps of display are off. Check: control unit and power unit connections charging resistors If the fault comes again, change the control unit. contact crane service. Reset: switch power off and restart after the lamps of display are off. Check: motor and motor cable insulation measure main circuit diodes and IGBT transistors If the fault comes again, change the power unit.

F1

F2

Overvoltage

DC-bus voltage has exceeded 135% maximum level, 911Vdc (F-series), 1258 Vdc (K-series) supply voltage raised >1.35 x Un (high overvoltage spikes at mains) deceleration time is too short

F3

Earth fault

Current measurement has sensed unbalance in motor phase currents. Supervision level is 5% of inverter nominal current not symmetric load insulation failure in the motor or the cables

F4 F5

Unknown Charging switch

Charging switch is open when START command becomes active interference fault component failure

F6 F7

Emergency Stop Saturation trip

Very high overload or defective component

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Fault code Fault Unknown Undervoltage

(
Checking -

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Possible cause DC-bus voltage has dropped below 65% of rectified supply voltage mains supply voltage <0.65 x Un inverter fault can also cause an undervoltage trip external fault during run may cause an undervoltage trip One input line phase is missing or supply voltage parameter is wrong Current supervision has sensed that one of the motor phases has no current

F8 F9

In case of temporary supply voltage break, reset the fault and start again. Check mains input. If mains supply is correct, an internal failure has occurred. Contact crane service. Check: Check: -

F 10 F 11

Input line supervision

supply voltage mains connection.

Output phase supervision

F 12

Braking chopper supervision

During run braking chopper have short test pulse every 1s period. Test pulse measures transistor collector voltage. Fault appears if braking resistor is broken braking chopper is broken braking resistor is not installed

F 13 F 14

Inverter undertemperature Inverter overtemperature

Temperature of heat sink is below acceptable operating level (10C /14F) Temperature of heat sink is over acceptable operating level +80C (176F). Overtemperature warning is issued when the heat sink temperature exceeds +75C (167F) Parameter restoring error interference fault component failure (control unit) faulty supply voltage programming

F 22 F 23

EEPROM checksum fault

F 24 F 25

Changed data warning Microprocessor watchdog-fault Power Unit Fault Fan cooling fault Memory fault Communication fault Application fault Control Unit Device changed Device added Device removed Device unknown IGBT temperature

Changes may have occurred in the different counter data due to mains interruption interference fault component failure (control unit)

motor cable connections measure motor phase currents and compare to display value Reset: switch power off and restart after the lamps of display are off. Check: braking resistor and cable resistance and insulation resistance measure braking transistor IGBT and free wheeling diodes If resistor is OK, then the chopper is broken Contact service Check ambient temperature cubicle heating Check: ambient temperature fan operation cooling air flow through heat sink heat sink is not dusty After power off the inverter will automatically load factory default parameter settings. Drive does not work properly nor enable driving after this fault. Check: all parameter settings. If the fault comes again, contact service. No special actions required. Take a critical attitude to the counter data. Reset: switch power off and restart after the lamps of display are off. If the fault comes again, contact service. If the fault comes again, contact service.

F 26 F 32 F 33 F 34 F 35 F 36 F 37 F 38 F 39 F 40 F 41

Cooling fan of the frequency converter do not work, when ON command has been given Run-time exception in the application program Faulty Control Unit. Option board changed. Different power rating of drive Option board added. Drive of different power rating added Option board removed. Drive removed Unknown option board or drive. Too high temperature in IGBT transistors. long duration overload lowered cooling high environment temperature Not used in DMCS040

Contact service.

Reset the fault Reset the fault Reset the fault Check board and drive type. Check: motor loading brake operation inverter heatsink inverter cooling fan operation environment temperature contact crane service.

F 48 F 50 F 51

EEprom CRC-fault Reference value fault Stop limit

Stop limit has tripped

Reset: keep controller at zero >500ms.

VERLINDE reserve the right to alter or amend the above information without notice.

03/2004

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Fault code Fault

(
Checking -

SERVICE MANUAL
Page 17

Possible cause

Ensure that fault disappears after leaving the stop limit.

F 52 F 53 F 54 F 55 F 56

Panel communication error Profibus communication error Profibus control fault Board Fault Generator side current limit

Poor connection between inverter and display panel Not used in DMCS040 Not used in DMCS040

Check the panel connection and optional cable. contact crane service. contact crane service.

Some of following board is missing: A=Basic I/O board D=Expansion board Too short deceleration time generator side current limit

Check board slots A and D Check: Check: -

deceleration time encoder pulses current limit setting motor cooling and loading thermistor connection. If expansion board thermistor input is not used, it should be shorted parameters the brake operation Contact service contact crane service. contact crane service. contact crane service. contact crane service. contact crane service. contact crane service. contact crane service. contact crane service. contact crane service. contact crane service.

F 57

Thermistor fault

Expansion board thermistor input has detected motor overtemperature

F 60 F 61 F 62 F 63 F 64 F 65 F 66 F 67 F 70 F 71 F 72

Parameter fault Overspeed Fault Speed Difference Fault Stall Supervision Fault SSU Relay Test Fault SSU Watchdog SSU Overspeed Limit Encoder channel B Multicare Fault Brake Control Fault Brake Feedback Fault

Inverter has lost parameters Not used in DMCS040 Not used in DMCS040 Not used in DMCS040 Not used in DMCS040 Not used in DMCS040 Not used in DMCS040 Not used in DMCS040 Not used in DMCS040 Not used in DMCS040 Not used in DMCS040

VERLINDE reserve the right to alter or amend the above information without notice.

03/2004

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6 Service
$" Check inverter fault history
Find out reasons of possible faults Clear the fault history

SERVICE MANUAL
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DMCS040 does not require regular maintenance. The following actions are recommended:

$" Clean the heat sink of the inverter

Prevent the dust to spread inside cubicles Lock the fans before blowing compressed air

$" Check that there are no abnormal noises coming from the cooling fans $" Tighten all screws and connectors $" Clean dust from PC-boards backup.

#" The parameters are saved in an EEPROM, which keeps the parameters in memory after power off without any battery

VERLINDE reserve the right to alter or amend the above information without notice.

03/2004

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7 Drawings
7.1 Description of terminals
No
L1 L2 L3 U V W B+ R31 32 33 34 35 36 38 39 40 41 42 47

(
Description, signal level
Power supply, phase 1 Power supply, phase 2 Power supply, phase 3 Motor output, phase 1 Motor output, phase 2 Motor output, phase 3 Braking resistor Braking resistor DC brake supply 1 DC brake supply 2 Thermistor input Thermistor input

SERVICE MANUAL
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Name
PE L1 L2 L3 U V W B+ RBD1 BD2 T1 T2

COM DI1 DI2 DI3 DI4 DI5 OLE PE

Neutral of external control voltage OLE Direction 1 run command Direction 2 run command Multi Function Input, see 1.6 Control methods Multi Function Input, see 1.6 Control methods Multi Function Input, see 1.6 Control methods External control voltage, 42/48/115/230Vac

VERLINDE reserve the right to alter or amend the above information without notice.

03/2004