R&M ControlMaster NXT, Owner'S Manual

Page 1: ...MANTENE70100 0 PS20537 23 4 2013 English Original instructions OWNER S MANUAL FOR FREQUENCY CONTROL SYSTEM ControlMaster NXT DOCMANTENE7 0 ORD 23 4 2013 ...

Page 2: ...C 6 2 SAFETY FIRST 7 2 1 Fire Safety 7 2 2 Main Isolation Switch 7 2 3 Emergency Stop 7 2 4 Intended use of the frequency converter 8 2 5 Limitations of use 8 3 IDENTIFICATION 9 3 1 Manufacturer 9 3 1 1 Main sticker 9 4 CONSTRUCTION 11 4 1 Main components 11 5 USER INTERFACE 12 5 1 Control Panel 12 5 2 Display options 12 5 2 1 Drive status 12 5 2 2 Control selection 13 5 2 3 Main menu 13 5 3 Navig...

Page 3: ...to crane operation and at all times comply with all of the applicable and prevailing safety and other standards rules and regulations 1 2 Symbols Used In This Manual Readers should familiarize themselves with the following symbols which are used in this manual Indicates that the crane is slowing down or is moving at its slowest speed Indicates that the crane is accelerating or moving at its highes...

Page 4: ...ING AND OR MAINTAINING SUCH PRODUCTS read and understand the contents of this manual and strictly adhere AND CONFORM THEIR CONDUCT WITH AND TO THE INFORMATION RECOMMENDATIONS AND warnings provided herein Note Keep these instructions in a safe accessible location for future reference by personnel operating the crane or exposed to crane operation Read and understand the contents of this manual prior...

Page 5: ...ing method Hoist Drive mechanism for lifting and lowering the load Main girder The main girder bridge is connected to the bridge end carriages Main isolation switch The main isolation switch is the power switch which the operator should normally use to turn off the power Power supply Power is supplied to the components via the power supply Qualified personnel One with necessary qualification based...

Page 6: ...rwriters Laboratories UL Canadian Standards Association CSA National Sanitation Foundation NSF and others UL The UL marking means that Underwriters Laboratories UL has tested representative samples of the product and determined that they meet UL s requirements These requirements are based primarily on UL s published and nationally recognized Standards for Safety CCC The China Compulsory Certificat...

Page 7: ...aware of main isolation switch functionality Even though one switch is turned off there may still be voltage present in some parts of the product This may result in exposure to electric shocks The operator shall not operate the product unless he or she knows the location of the main isolation switch CAUTION Avoid turning off the main isolation switch during load movement Sudden loss of power may c...

Page 8: ...the hook into a safe area lower the load and only then de energize the equipment for investigation The operator shall not operate the equipment unless he or she knows the location of the emergency stop button 2 4 Intended use of the frequency converter Travelling movements These frequency converters are designed for industrial crane usage for controlling the speed of trolley and bridge motors 2 5 ...

Page 9: ...ge range current and frequency range the product is able to provide at a specified output capacity 5 Control Indicates the acceptable voltage range and frequency of control signals that the product can be connected to 6 Serial number The serial number of the unit in an alphanumerical format 7 IP classification Indicates the ingress protection classification of the product 8 EMC level modified Indi...

Page 10: ...right to alter or amend the above information without notice Monday 2 Tuesday number 5 indicating Friday 12 Code Identification and feature information provided by the manufacturer 13 QR Code A two dimensional bar code in an optically readable form Note The term QR Code is a registered trademark of Denso Wave Incorporated in Japan and other countries ...

Page 11: ...with four arrow navigation buttons and buttons for back reset and confirmation used in navigating in the menu structure and in adjusting parameter values 3 Terminal for MCA cable MCA cable is used with Connection tool for TM 4 Main sticker Identification data 5 EMC fIlter screw EMC level of the frequency converter can be modified by removing the EMC filter screw 6 Power supply terminals 3 phase po...

Page 12: ...n navigating in the menu structure and in adjusting parameter values 1 Drive status 2 Drive control indication 3 Main menu 4 Back Reset button 5 Navigation and confirmation OK buttons 5 2 Display options 5 2 1 Drive status The drive status is located above the LCD display The status of the drive is indicated with different states The Ready state indicates that the drive is ready to start The Run s...

Page 13: ...ng forward The control DIR2 indicates that the motor is rotating backward The control I O indicates that the I O terminal block is the selected control place The control BUS1 indicates that the fieldbus is the selected control place BUS1 The control BUS2 indicates that the fieldbus is the selected control place BUS2 The control is selected when an arrow is pointing towards the corresponding text F...

Page 14: ... wanted menu items Activate the menu by pressing an arrow button Move between the menus and menu items by using the arrow buttons Select the parameter to be edited or save a new value by pressing OK Increase or decrease the activated value by using the up and down arrow buttons Navigate between menu options by using the right and left arrow buttons Reset and return the display to the previous mode...

Page 15: ...in display 5 3 3 Parameter menu In the parameter menu you can set the values for the parameters Parameters are shown according to password level Code Parameter name Range Default Unit Description Password level P1 1 Password 1 65535 0 Startup 47 Engineering 129 0 Accessing the parameter menu 1 Press back reset button until the display momentarily empties and the main selection arrow blinks 2 Press...

Page 16: ...erating date hour and minutes for the fault When a fault is active a fault code alternates with the main menu It is possible to navigate in the menu when the faults are active The display is returned to the fault menu if the navigation buttons has not been pressed When you are browsing between the faults the active faults are blinking in the display Press OK to reset the active fault If the fault ...

Page 17: ...Materials Handling Inc reserves the right to alter or amend the above information without notice 3 Press OK 4 Navigate between faults by using up and down buttons 5 Select the fault by pressing OK 6 Navigate fault information by using the right and left arrow buttons 7 Press Back Reset to return to the main display ...

Page 18: ...the device is moving above the preset slow speed the current speed will be held without accelerating or decelerating 1 Pushbutton released the motor does not turn 2 Pushbutton half pressed the motor accelerates until it reaches the preset slow speed 3 Pushbutton fully pressed the motor accelerates towards maximum speed 4 Pushbutton half pressed the current speed is held 5 Pushbutton fully pressed ...

Page 19: ...e or trolley at both ends of the runway or speed of the hook at up or down limit The slowdown limit signal is connected to DI4 terminal except for MS4 and MS5 control methods The limit switch contact is normally closed and control voltage is connected to the input When limit switch contact is opened the slowdown function is activated The slowdown function limits the output frequency If the driving...

Page 20: ...OPERATION 7 1 Disposal of waste materials Waste material from installation maintenance or dismantling shall be disposed of according to local regulations If the product is taken out of use the metal and electrical parts should be recycled In addition to local regulations liquids like oil grease and other chemicals shall never be spilled onto the ground or soil Used oil and grease shall be stored i...

Page 21: ... operating temperature 10 C no frost 50 C outside the cubicle 40 C Storage temperature 40 C 70 C Relative humidity 0 95 RH non condensing non corrosive no dripping water Air quality Chemical vapors Mechanical particles IEC 721 3 3 unit in operation class 3C2 IEC 721 3 3 unit in operation class 3S2 Altitude 100 load capacity no derating up to 1000m 1 derating for each 100m above 1000m max 2000m Vib...

Page 22: ...English Original Instruction INSTALLATION INSTRUCTION CMX 022 Upgrade Kit 031097en Revision D 2015 04 29 ...

Page 23: ...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 20 5 1 Old inverter parameter settings 20 5 2 Motor type 20 5 3 Traveling motor rating plate values 20 5 4 Setting up the new inverter parameters 20 6 TROUBLESHOOTING 29 6 1 Purpose of troubleshooting 29 6...

Page 24: ...oceeding 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 CMX 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 s...

Page 25: ...k 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 t...

Page 26: ... 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 5mm 10 pcs Part 5 M5 x 10 Flanged screw 10 pcs R M Materials Handling Inc 4501 Gateway Boulevard Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 5 34 R M Materials Handling Inc reserves the right to alter or amend the above information without notice ...

Page 27: ...pers 3 Wire cutters 4 Crimping tool for wire end ferrules 5 Socket wrench 8mm R M Materials Handling Inc 4501 Gateway Boulevard Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 6 34 R M Materials Handling Inc reserves the right to alter or amend the above information without notice ...

Page 28: ...2 2 Drive command direction 2 2 Speed 2 Acceleration command 3 Speed 2 Acceleration command 3 Slowdown Stop limit direction 1 4 Common slowdown Slowdown Stop limit direction 1 4 Slowdown Stop limit direction 2 5 Common stop Slowdown Stop limit direction 2 5 Common DI1 5 6 Motor temperature protection External stop 6 Normally open relay contact 7 Common DI1 6 7 Normally open relay contact 8 Normall...

Page 29: ...onfirmation OK buttons S6 Limit operation settings 3 5 EMC filter CMX 022 has an external EMC filter package KC310 KC330 whereas ControlMaster NXT 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 ControlMaster NXT 006 frequency converter s EMC level must be changed ...

Page 30: ...Materials Handling Inc 4501 Gateway Boulevard Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 9 34 R M Materials Handling Inc reserves the right to alter or amend the above information without notice ...

Page 31: ...roken record the trolley driving directions 2 Push 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 3 ControlMaster NXT 006 has an internal EMC filter The old EMC filter can be removed Cut the ground wire and the power supply wire...

Page 32: ...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 5 Loosen and remove the screws 4 pcs holding the CMX 022 Remove the CMX 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 6 Strip all the wires up to 10 mm If the wires h...

Page 33: ...l the braking resistor to suitable place close to ControlMaster NXT 006 in the crane Install the braking resistor wire from the braking resistor to the cubicle 2 Put 4 pcs size M5 x 10 Flanged installation screws into back plate Leave screws loose The installation rack has slotted screw holes R M Materials Handling Inc 4501 Gateway Boulevard Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 1...

Page 34: ... inverter PE protective earth terminal to ground Wire length should not exceed 10 cm The wire size should be minimum of 2 5 mm This extra grounding wire is not delivered with the package 8 If the CMX 022 has an external braking resistor Remove the internal braking resistor wires and connect the braking resistor cable to ControlMaster NXT 006 according to the electrical drawings R M Materials Handl...

Page 35: ...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 R M Materials Handling Inc 4501 Gateway Boulevard Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 14 34 R M Materials Handling Inc reserves the right to alter or amend the above information without notice ...

Page 36: ...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 R M Materials Handling Inc 4501 Gateway Boulevard Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 15 34 R M Materials Handling Inc reserves the right to alter or amend the above information without notice ...

Page 37: ...eeded Variation 3 EP2 MS2 stop Figure 5 Old inverter EP2 MS2 stop R M Materials Handling Inc 4501 Gateway Boulevard Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 16 34 R M Materials Handling Inc reserves the right to alter or amend the above information without notice ...

Page 38: ...be deactivated No connection is needed Variation 4 MS2 2 step limit switch R M Materials Handling Inc 4501 Gateway Boulevard Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 17 34 R M Materials Handling Inc reserves the right to alter or amend the above information without notice ...

Page 39: ...switch With ControlMaster NXT the both slowdown direction signals from limit switch must be connected in series R M Materials Handling Inc 4501 Gateway Boulevard Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 18 34 R M Materials Handling Inc reserves the right to alter or amend the above information without notice ...

Page 40: ...e 10 New inverter MS2 2 step limit switch R M Materials Handling Inc 4501 Gateway Boulevard Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 19 34 R M Materials Handling Inc reserves the right to alter or amend the above information without notice ...

Page 41: ...otor 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...

Page 42: ...s sets the engineering password level which is needed for parameter settings R M Materials Handling Inc 4501 Gateway Boulevard Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 21 34 R M Materials Handling Inc reserves the right to alter or amend the above information without notice ...

Page 43: ... 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 CMX 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...

Page 44: ... 1 28 59 1 1 0 0 32 65 1 1 0 1 34 68 1 1 1 0 36 71 1 1 1 1 38 74 Table 6 Maximum and minimum frequency 50 60 Hz CMX 022 Minimum frequency Hz To P1 2 Maximum Frequency Hz To P1 3 Switch S1 1 2 3 4 0 0 0 0 15 50 0 0 0 1 7 25 0 0 1 0 12 31 0 0 1 1 5 27 0 1 0 0 16 40 0 1 0 1 6 29 R M Materials Handling Inc 4501 Gateway Boulevard Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 23 34 R M Material...

Page 45: ...0 25 58 1 0 0 1 10 38 1 0 1 0 13 43 1 0 1 1 18 45 1 1 0 0 19 48 1 1 0 1 21 53 1 1 1 0 22 55 1 1 1 1 24 60 R M Materials Handling Inc 4501 Gateway Boulevard Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 24 34 R M Materials Handling Inc reserves the right to alter or amend the above information without notice ...

Page 46: ... from the value of the original delivery is not allowed Table 7 Acceleration and deceleration ramp times CMX 022 Acceleration and deceleration Ramp Time s Switch S3 1 2 3 4 0 0 0 0 2 5 0 0 0 1 3 5 0 0 1 0 3 0 0 1 1 5 0 1 0 0 2 0 1 0 1 8 0 1 1 0 1 0 1 1 1 7 5 1 0 0 0 1 5 1 0 0 1 4 1 0 1 0 7 1 0 1 1 6 5 1 1 0 0 4 5 1 1 0 1 6 1 1 1 0 5 5 1 1 1 1 0 5 4 At the ControlMaster NXT 006 frequency converter ...

Page 47: ...ng will take about 5 seconds 5 3 After auto tuning parameter P3 7 Autotuning 3 successfully done 6 only with compact brake motors Set motor control parameters P3 2 Motor nominal frequency in percent of motor nominal voltage P4 1 zero frequency voltage in percent of motor nominal voltage P4 2 U f mid voltage in percent of motor nominal voltage P4 3 U f mid frequency in Hz P4 4 Rs voltage drop in pe...

Page 48: ... corresponding parameter value for ControlMaster NXT 006 are given in table 6 Table 10 Control mode CMX 022 Control Method ControlMaster NXT 006 Switch S6 Parameter 1 2 P6 1 0 0 MS2 2 1 0 EP2 1 11 Set travel limit operation settings See chapter New frequency controller installation page 12 step 9 how the control wiring was in the old inverter and how the new inverter wiring was done In the new inv...

Page 49: ...ts the default password level which doesn t allow any changes to the parameters R M Materials Handling Inc 4501 Gateway Boulevard Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 28 34 R M Materials Handling Inc reserves the right to alter or amend the above information without notice ...

Page 50: ...terminal 1 DI1 and terminal 2 DI2 against the common terminal 7 Voltage should increase when button is pushed on the controller When the EMC screw is connected the frequency converter has RC filters connected to the power supply side to reduce disturbance to the network The capacitors of these filters may cause the RCD Residual Current Device to trip Therefore using RCD with frequency converter co...

Page 51: ...iring visually C 3 Earth Fault Short circuit in wiring Motor failed Check repair wiring Check replace motor A 8 System Fault Internal fault Switch off supply voltage If problem recurs replace inverter B 13 Under temperature Internal temperature too low Minimum operating temperature is 30ºC C 14 Overtemperature Internal heat sink temperature too high Wait for unit cooling down C 22 API EEPROM Check...

Page 52: ...ions If problem recurs replace inverter B 56 Generator Current Limit Deceleration Ramp Supervision Inverter cannot stop with the set ramp stretching Increase P1 8 Deceleration Time or P11 1 Ramp Stretching value C 57 Motor Overtemperature Motor temperature too high Digital input DIA4 deactivated when used for motor overtemperature protection Wait for motor cooling down Avoid running long periods a...

Page 53: ...o ENC2A B A 63 Stall Motor does not run Mechanical failure e g in gear Missing signal in ENC1A Check replace motor Check repair motor wiring Check hoist operation without load Check replace speed sensor connected to ENC1A A 64 Relay Error detected in ROB1 relay test circuit or the main contactor Check main contactor circuit wiring If problem recurs replace inverter A 71 Brake control Error detecte...

Page 54: ...chain and chain drive Check replace speed sensor connected to ENC2A B Lower the parameter P8 7 ENC2 Stall Pulse Limit value A 85 Load Sensor Fault Load sensor signal out of range Check repair load sensor wiring Check replace load sensor C Resetting column explanation A E stop activation deactivation B Hoist supply voltage switch OFF ON C Automatic when fault situation is over Table 12 ALARMS Code ...

Page 55: ...n Limit can be also by passed temporarily by activating the movement control more than 5 seconds 88 CCU fault Controlled common use fault Another device that is connected in CAN bus has an active fault 93 CCU activation Controlled common use activation Another device that is connected in CAN bus has caused the stopping R M Materials Handling Inc 4501 Gateway Boulevard Springfield Ohio 45502 P 937 ...