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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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.

3.4 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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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.

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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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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.