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SERVICE MANUAL FOR TRAVELING INVERTER

VARIATOR VT 007F

English

27.12.2005

This document and the information contained herein, is the exclusive property of Verlinde S.A. and represents a non-public, confidential and proprietary trade
secret that may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of
Verlinde S.A. Copyright © (2005) Verlinde S.A. All rights reserved. 06/2006
  SERVICE MANUAL FOR TRAVELING INVERTER
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DOCTNI70100-0 PS02379 27.12.2005
! Read the instructions supplied with the product before installation and commissioning.
# Keep the instructions in a safe place for future reference.

Table of content

1 Description of the inverter.............................................................................................................3

1.1 Connections.................................................................................................................................. 3
1.2 Technical characteristics .................................................................................................................... 3
1.3 Normal operation ........................................................................................................................... 3
1.4 Status indication leds (green and red) .................................................................................................. 4
1.5 Compact brake motors..................................................................................................................... 4
1.6 Programming switches ...................................................................................................................... 4
1.7 The EMC requirements (Not in use for deliveries in USA/Canada) ............................................................. 4
1.7.1 EMC filter connection to inverter for trolley travelling......................................................................... 4
1.7.2 EMC filter connection to inverter for bridge travelling......................................................................... 5
2 Control modes...............................................................................................................................6
2.1 MS-control (S4-1 = OFF) ............................................................................................................. 6
2.2 EP-control (S4-1 = ON)............................................................................................................... 6
3 Fault codes, troubleshooting..........................................................................................................7
4 Programming of the application parameters ..................................................................................8
4.1 Minimum speed, maximum speed and ramp time ..................................................................................... 8
4.1.1 Acceleration and deceleration ramp............................................................................................... 8
4.2 Selection of the motor type............................................................................................................... 9

This document and the information contained herein, is the exclusive property of Verlinde S.A. and represents a non-public, confidential and proprietary trade secret
that may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Verlinde S.A.
Copyright © (2005) Verlinde S.A. All rights reserved. 06/2006
  SERVICE MANUAL FOR TRAVELING INVERTER
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1 Description of the inverter

! There are high voltages inside the inverter (including the programming switches). Wait for at
least three minutes after the supply voltage has been switched off before any service actions.

1. Terminal X1
2. Red led (fault)
3. Green led (ok)
4. Programming switches

c_fcmo1b

1.1 Connections
All connections are made to terminal block X1 as follows:

! Crane power supply conductor rail must have double collectors.

Nbr Name Description
1 PE Protective earth.
2 L1 Mains, phase 1. 380-480V 50/60Hz.
3 L2 Mains, phase 2. 380-480V 50/60Hz.
4 L3 Mains, phase 3. 380-480V 50/60Hz.
5 U Motor, phase 1.
6 V Motor, phase 2.
7 W Motor, phase 3.
8 S1 Drive command. Direction 1. 48 or 115V 50/60Hz
9 S2 Drive command. Direction 2. 48 or 115V 50/60Hz
10 SP2/AP Speed 2 / Acceleration command. 48 or 115V 50/60Hz
11 ON Control voltage, neutral.

1.2 Technical characteristics

Technical data
Power range 0.75kW
Supply voltage 380 - 480 VAC +/-10%
Nominal supply frequency 48 – 62 Hz
Nominal current 2.4A
Digital control S1, S2, DI3
Max output voltage Equal to supply voltage
Control voltage range 48 VAC/115 +/- 10%. If control voltage is 230VAC, front
resistors (15k,2W) have to be connected to digital inputs
o o
Ambient temperature -10 C to 50 C
Humidity 95% N.C. (without dripping)
Degree of protection Frequency converter + cover (IP20)
Dimensions (WxHxD) 133x92x60mm
Altitude Output current must be reduced 1 % for every 100 m over
1000 m. For heights over 3000 m, manufacturer must be
consulted.
Pollution degree Pollution degree 2 according to NEMA ICS-1, IEC664 and
UL840
Vibration IEC68-2-6
Shock IEC68-2-27

1.3 Normal operation

The inverter goes into the ready-to-run state within one second after the power supply is connected. During running the inverter
follows the operator’s speed reference according to the set acceleration/deceleration ramp. During direction change the brake is

This document and the information contained herein, is the exclusive property of Verlinde S.A. and represents a non-public, confidential and proprietary trade secret
that may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Verlinde S.A.
Copyright © (2005) Verlinde S.A. All rights reserved. 06/2006
  SERVICE MANUAL FOR TRAVELING INVERTER
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kept open all the time. When drive command is switched off the inverter decelerates to zero according to the set ramp. Then the
motor current is cut-off and hence the brake closes.
1.4 Status indication leds (green and red)
The inverter indicates its operating state by two leds. Red led indicates “fault state” (driving is inhibited). Green led indicates
“ok-state”. Blinking of green led indicates that fault state has been active, but it has been recovered. Normal driving is however
possible also when green led is blinking (in other words, blinking of green led does not indicate “warning-state”).
1.5 Compact brake motors
This inverter is used with Compact brake motors, which have been especially designed for this use. The Compact brake motors
have the following special features:
$ Compact brake, which is opened by the magnetic force of the motor. When the magnetic force is removed (by cutting off the
motor current) the brake is closed by spring force.
$ High nominal frequency (80Hz…120Hz)
1.6 Programming switches

! WARNING!!! There are high voltages inside the inverter (including the programming switches).
Wait for at least three minutes after the supply voltage has been switched off before any service
actions.
The programming of the inverter is performed by dip-switches. The state of each switch is either OFF (0) or ON (1). There are
five parameters that are possible to set by the switches S1-S4.

S1 = Maximum speed

ON
S2 = Minimimum speed 1 2 3 4 S1
S3 = Acceleration / deceleration time DIP

S4 = Control mode and motor type

ON
1 2 3 4

S2
DIP
ON
1 2 3 4

S3
DIP

ON DIP

1 2 3 4
S4

1.7 The EMC requirements (Not in use for deliveries in USA/Canada)

The EMC requirement (both for immunity and for emissions) for inverter are set in EN61800-3 and its amendment 11 (2000),
which is the EMC product standard for “adjustable speed electrical power systems”. The EN61800-3 is identical with
IEC1800-3. Device satisfies the requirements when external EMC filter will be connected to inverter. The filters are selected as
follows.
1.7.1 EMC filter connection to inverter for trolley travelling.

c_kc310a

1. Supply
2. EMC filter KC-310-00
3. Inverter
4. Motor cable length max 3 m
5. 4 x 0,47 µF

This document and the information contained herein, is the exclusive property of Verlinde S.A. and represents a non-public, confidential and proprietary trade secret
that may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Verlinde S.A.
Copyright © (2005) Verlinde S.A. All rights reserved. 06/2006
  SERVICE MANUAL FOR TRAVELING INVERTER
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# Capacitors have to be placed as near the inverter as possible.

1.7.2 EMC filter connection to inverter for bridge travelling.

c_kc330a

1. Supply
2. EMC filter KC-330-00
3. Inverter
4. Motor cable length max 25 m
5. 4 x 1 µF
6. Input wires two times trough input ferrite rings

# Capacitors have to be placed as near the inverter as possible.

This document and the information contained herein, is the exclusive property of Verlinde S.A. and represents a non-public, confidential and proprietary trade secret
that may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Verlinde S.A.
Copyright © (2005) Verlinde S.A. All rights reserved. 06/2006
  SERVICE MANUAL FOR TRAVELING INVERTER
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2 Control modes
The signals from the controller (pendant, radio,…) control the inverter via the digital inputs (S1, S2 ja SP2/AP). There are two
possible control modes. The control mode is selected by switch S4-1.
2.1 MS-control (S4-1 = OFF)

c_coms2a

A. Push button position

B. Speed
$ S1 means “minimum speed forward”
$ S2 means “minimum speed reverse”
$ SP2 means “maximum speed”
$ When S1 and S2 are switched off the inverter decelerates to zero
2.2 EP-control (S4-1 = ON)

c_coep2a

A. Push button position

B. Speed
0. Decelerate
1. Hold speed
2. Accelerate

$ S1 means “drive forward”

$ S2 means “drive reverse”
$ AP means “acceleration”
$ When starting S1 and S2 mean “accelerate to minimum speed”
$ When S1 and S2 are switched off the inverter decelerates to zero
$ During running S1 and S2 mean “hold speed”

This document and the information contained herein, is the exclusive property of Verlinde S.A. and represents a non-public, confidential and proprietary trade secret
that may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Verlinde S.A.
Copyright © (2005) Verlinde S.A. All rights reserved. 06/2006
  SERVICE MANUAL FOR TRAVELING INVERTER
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3 Fault codes, troubleshooting

! WARNING!!! There are high voltages inside the inverter (including the programming switches).
Wait for at least three minutes after the supply voltage has been switched off before any service
actions.
When the inverter detects a fault situation it starts signalling the fault code by blinking the indication leds (green and red). The
blinking of the code is carried on until a new fault occurs or until power is switched off. The fault codes are explained in the table
below.

Fault code, color Fault. Possible cause. Checkings.

GREEN Overvoltage. Mains voltage is too high or ramp time is too short. Check the voltage of all
GREEN supply phases at the terminal X1. If they are ok then set a longer ramp by switch S3.
Stall supervision / overcurrent. Brake does not open properly or there is an obstackle
GREEN on the track. Check also that the setting of switch S4 is made according to the supplied
motor(s).
Deceleration ramp supervision. Deceleration ramp has not been followed. If the fault
GREEN occurs again set longer ramp time by switch S3. Check also the voltage of all supply
phases at the terminal X1.
Inverter overtemperature. Motor current is too high (bearing problem, obstacle on the
GREEN
track, brake does not open properly,…) or the ambient temperature is too high.
GREEN Undervoltage. Check the voltage of all supply phases at the terminal X1.
Short circuit. Switch the power off. Check the insulation of the motor cables and the motor
RED
windings.
RED Microprosessor fault. Switch the power off for 10 seconds. Then power-up the inverter.

# NOTE!!! The latest active fault is removed from the memory always when power is switched off.

! Inverter is not in a fault state, but driving is not possible:

$ Motor will not start if dc-bus voltage too high (above 745V), this occurs if any of line-to-line voltages exceeds
480V+10% = 528V
- If line voltage cannot be reduced, install drop-down transformer
$ Check the supply voltage phases at terminal X1.
$ Check the control signals at terminal X1.
$ Check that the control voltage level is correct. Rating plate is located on the left side of the inverter.
$ Check all parameters, especially the motor parameters (switch S4).
$ Check that the motor(s) corresponds the selected motor parameters.
$ Check that the microprocessor starts running. Both indication leds (green and red) blink once as the inverter is powered up.
After the one second initialising-time only the green led should be light.
$ Check that the brake opens and closes properly. Check the brake airgap if necessary.

This document and the information contained herein, is the exclusive property of Verlinde S.A. and represents a non-public, confidential and proprietary trade secret
that may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Verlinde S.A.
Copyright © (2005) Verlinde S.A. All rights reserved. 06/2006
  SERVICE MANUAL FOR TRAVELING INVERTER
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4 Programming of the application parameters

4.1 Minimum speed, maximum speed and ramp time
The adjustment ranges of maximum and minimum speed depend on the selected motor type (i.e. motor nominal frequency). The
speeds in the speed table A are used for the 100/120Hz motors and the speeds in the speed table B for the 80Hz motors.
The maximum speed and minimum speed and ramp time are set as follows:
Switch SPEEDTABLE A SPEEDTABLE B
S1 / S2 (100/120Hz motors) (80Hz motors)
-1 -2 -3 -4 Max speed Min speed Max speed Min speed
0 0 0 0 100 Hz 29 Hz 77 Hz 22 Hz
0 0 0 1 50 Hz 14 Hz 42 Hz 14 Hz
0 0 1 0 62 Hz 23 Hz 50 Hz 18 Hz
0 0 1 1 54 Hz 10 Hz 40 Hz 10 Hz
0 1 0 0 80 Hz 32 Hz 62 Hz 30 Hz
0 1 0 1 58 Hz 12 Hz 44 Hz 12 Hz
0 1 1 0 66 Hz 16 Hz 46 Hz 16 Hz
0 1 1 1 70 Hz 18 Hz 48 Hz 20 Hz
1 0 0 0 115 Hz *) 50 Hz 80 Hz 40 Hz
1 0 0 1 75 Hz 20 Hz 53 Hz 24 Hz
1 0 1 0 85 Hz 26 Hz 56 Hz 26 Hz
1 0 1 1 90 Hz 35 Hz 59 Hz 28 Hz
1 1 0 0 95 Hz 38 Hz 65 Hz 32 Hz
1 1 0 1 105 Hz *) 41 Hz 68 Hz 34 Hz
1 1 1 0 110 Hz *) 44 Hz 71 Hz 36 Hz
1 1 1 1 120 Hz *) 47 Hz 74 Hz 38 Hz
*) Speeds above 100Hz are only available when the inverter is connected in 460V mains.

EXAMPLE OF PARAMETER SETTING:

80Hz motor is connected to the inverter and 62Hz maximum
ON
1 2 3 4

th
speed is desired. That speed is located on the 5 row in the S1
DIP

speedtable B. The corresponding setting for S1 swithces is in

the same row in the leftmost columns of the table: 0-1-0-0 (off-
on-off-off).
Max speed set to 62Hz.

4.1.1 Acceleration and deceleration ramp

The acceleration and deceleration ramps are set by switch S3 as follows:

Switch S3 Acceleration/deceleration
-1 -2 -3 -4 ramp time
0 0 0 0 2.5 sec
0 0 0 1 3.5 sec
0 0 1 0 3.0 sec
0 0 1 1 5.0 sec
0 1 0 0 2.0 sec
0 1 0 1 8.0 sec
0 1 1 0 1.0 sec
0 1 1 1 7.5 sec
1 0 0 0 1.5 sec
1 0 0 1 4.0 sec
1 0 1 0 7.0 sec
1 0 1 1 6.5 sec
1 1 0 0 4.5 sec
1 1 0 1 6.0 sec
1 1 1 0 5.5 sec
1 1 1 1 0.5 sec

This document and the information contained herein, is the exclusive property of Verlinde S.A. and represents a non-public, confidential and proprietary trade secret
that may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Verlinde S.A.
Copyright © (2005) Verlinde S.A. All rights reserved. 06/2006
  SERVICE MANUAL FOR TRAVELING INVERTER
EUROBLOC 9
4.2 Selection of the motor type
The motor type is selected by switches S4-2, S4-3 and S4-4. There are several motor dependant parameters which are set
according to the selected motor (i.e. the operator selects a parameter set). The MF06-motors are selected as follows:

S4
Motor type Nominal frequency Nominal power
-2 -3 -4
0 0 0 MF06MA200 100Hz (120Hz) 0.3kW (0.37kW)
1 0 0 MF06MA100 80Hz 0.65kW
0 1 0 MF06LA200 100Hz (120Hz) 0.45kW (0.55kW)
1 1 0 MF06LA100 80Hz 0.65kW
0 0 1 2*MF06MA200 100Hz (120Hz) 2*0.3kW (2*0.37kW)

This document and the information contained herein, is the exclusive property of Verlinde S.A. and represents a non-public, confidential and proprietary trade secret
that may not be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Verlinde S.A.
Copyright © (2005) Verlinde S.A. All rights reserved. 06/2006