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
consent of Konecranes Plc. Copyright © (2014) Konecranes Plc. All rights reserved.
020145en / Revision D / 2015-04-29

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

2 SAFETY................................................................................................................................................. 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

3 DESCRIPTION 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

4 INSTALLATION..................................................................................................................................... 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.
Copyright © (2014) Konecranes Plc. All rights reserved.
020145en / Revision D / 2015-04-29

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.

3/31
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.
Copyright © (2014) Konecranes Plc. All rights reserved.
020145en / Revision D / 2015-04-29

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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reproduced, disclosed to other parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes Plc.
Copyright © (2014) Konecranes Plc. All rights reserved.
020145en / Revision D / 2015-04-29

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 10 pcs

2,5mm²

Part 5 M5 x 10 Flanged screw 10 pcs

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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.
Copyright © (2014) Konecranes Plc. All rights reserved.
020145en / Revision D / 2015-04-29

3.2 Required tools

Item Image
Name
No

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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reproduced, disclosed to other parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes Plc.
Copyright © (2014) Konecranes Plc. All rights reserved.
020145en / Revision D / 2015-04-29

3.3 Terminal connections

Table 1. Power terminals

Description of Terminal DynADrive 022 DynA45 006 Power terminals

Terminal X2

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

X1 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 3

command

Slowdown/Stop limit, direction 1 4 Common slowdown, 4

Slowdown/Stop limit, direction
1

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

Stop limit, direction 2

Common DI1-5 6 Motor temperature 6

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!

7/31
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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.
Copyright © (2014) Konecranes Plc. All rights reserved.
020145en / Revision D / 2015-04-29

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 3. Main menu

deceleration ramp times

S4 Control mode and motor 4. Back/reset button

type

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.

8/31
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.
Copyright © (2014) Konecranes Plc. All rights reserved.
020145en / Revision D / 2015-04-29

9/31
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.
Copyright © (2014) Konecranes Plc. All rights reserved.
020145en / Revision D / 2015-04-29

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.

High voltage inside the device.

WARNING 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

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

2 Push the main power off from the pendant or radio controller.
High voltage inside the Frequency converter.
WARNING Wait for at least five minutes after the voltage supply has been
switched of before taking any service actions.

3 DynA45 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.
Copyright © (2014) Konecranes Plc. All rights reserved.
020145en / Revision D / 2015-04-29

4 Disconnect 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 Connect to pin number in DynA45 006 Function

DynADrive 022

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.

5 Loosen 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.

6 Strip 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

11/31
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.
Copyright © (2014) Konecranes Plc. All rights reserved.
020145en / Revision D / 2015-04-29

1 Remove the control signal wires from the top side of

the front resistor.

2 Connect 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

1 If 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.

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

into back plate. Leave screws loose. The installation
rack has slotted screw holes.

12/31
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.
Copyright © (2014) Konecranes Plc. All rights reserved.
020145en / Revision D / 2015-04-29

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

screws.

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

into assembly rack. Leave screws loose. The inverter
has slotted screw holes.

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

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

7 Connect 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.

8 If 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.

13/31
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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.
Copyright © (2014) Konecranes Plc. All rights reserved.
020145en / Revision D / 2015-04-29

9 Connect 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.

14/31
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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.
Copyright © (2014) Konecranes Plc. All rights reserved.
020145en / Revision D / 2015-04-29

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.

15/31
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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.
Copyright © (2014) Konecranes Plc. All rights reserved.
020145en / Revision D / 2015-04-29

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.

16/31
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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.
Copyright © (2014) Konecranes Plc. All rights reserved.
020145en / Revision D / 2015-04-29

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.

17/31
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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.
Copyright © (2014) Konecranes Plc. All rights reserved.
020145en / Revision D / 2015-04-29

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

Figure 10. New inverter + 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.
Copyright © (2014) Konecranes Plc. All rights reserved.
020145en / Revision D / 2015-04-29

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 1 Switch 2 Switch 3 Switch 4 Switch 5 Switch 6

switch
position -1 -2 -3 -4 -1 -2 -3 -4 -1 -2 -3 -4 -1 -2 -3 -4 -1 -2 -3 -4 -1 -2 -3 -4

ON

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.

1 At 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.
Copyright © (2014) Konecranes Plc. All rights reserved.
020145en / Revision D / 2015-04-29

2 Set 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 Maximum Frequency

(Hz) To P1.2 (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

20/31
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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.
Copyright © (2014) Konecranes Plc. All rights reserved.
020145en / Revision D / 2015-04-29

Table 5. Maximum and minimum frequency 80 Hz

DynADrive 022 Minimum Maximum Frequency

frequency (Hz) To (Hz) To P1.3
Switch S1 P1.2
-1 -2 -3 -4

0 0 0 0 22 77

0 0 0 1 14 42

0 0 1 0 18 50

0 0 1 1 10 40

0 1 0 0 30 62

0 1 0 1 12 44

0 1 1 0 16 46

0 1 1 1 20 48

1 0 0 0 40 80

1 0 0 1 24 53

1 0 1 0 26 56

1 0 1 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

DynADrive 022 Minimum frequency Maximum Frequency

(Hz) To P1.2 (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

0 1 1 0 8 33

0 1 1 1 9 35

1 0 0 0 25 58

1 0 0 1 10 38
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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.
Copyright © (2014) Konecranes Plc. All rights reserved.
020145en / Revision D / 2015-04-29

DynADrive 022 Minimum frequency Maximum Frequency

(Hz) To P1.2 (Hz) To P1.3
Switch S1

-1 -2 -3 -4

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

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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.
Copyright © (2014) Konecranes Plc. All rights reserved.
020145en / Revision D / 2015-04-29

3 Set acceleration and deceleration ramp time values. Acceleration and deceleration ramp time values
for DynADrive 022 can be found in table 7. The corresponding value for DynA45 006 must be set to
parameters P1.7 and P1.8. The original value for the Acceleration and deceleration ramp time can be
found from the original electrical drawings. Default value for trolley acceleration time is 3,5s and bridge
acceleration time 4,5s.
Reducing of the acceleration or deceleration ramp time from the value of the original
delivery is not allowed.

Table 7. Acceleration and deceleration ramp times

DynADrive 022 Acceleration and

deceleration
Switch S3 Ramp Time (s)
-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 DynA45 006 frequency converter; Set P1.9=drive selection, to value 1=travel or 2=travel
compact brake motor.

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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.
Copyright © (2014) Konecranes Plc. All rights reserved.
020145en / Revision D / 2015-04-29

5 If you set P1.9=drive selection to value 1=travel on the step 4, autotune the inverter. After autotuning,
go to step 8. Steps 6 and 7 are done only with compact brake motors.
AUTOTUNING
5.1 Ensure that parameters P3.1 (Motor Nominal Voltage), P3.2 (Motor Nominal Frequency), P3.4
(Motor Nominal Current), P3.5 (Motor Nominal Flux Current), P3.6 (Motor Cos Phi) are equal to
the motor rating plate values If motor no-load current is not known, set P3.5 (Motor Nominal Flux
Current) equal to zero. Auto-tuning then uses motor cos phi for calculations instead of no-load
current.
5.2 Set parameter P3.7 (Autotuning) = 1. Auto-tuning will start right after the parameter change. RUN
indicator on the display turns on (and STOP indicator turns off). Autotuning 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 percent of motor nominal voltage.

Table 8. Motor control parameters

Compact DynADrive 022 DynA45 006

brake
motors Switch S4 Parameter

-1 -2 -3 -4 P3.2 P4.1 P4.2 P4.3 P4.4

MF06MA200 0 0 0 0 100/120 10% 14% 10% 0%

Hz

MF06MA100 1 0 1 0 80 Hz 9% 16% 8% 0%

MF06LA200 0 0 1 0 100/120 8% 12% 10% 0%

Hz

MF06LA100 1 0 0 1 80 Hz 6% 12% 8% 0%

7 (only with compact brake motors)Set motor nominal current. You can set the parameter according to
this table or look the real value from the motor rating plate.

Table 9. Motor nominal current

DynADrive 022 Motor nominal DynA45 006

current limit
Switch S5 Parameter

-1 -2 P3.4

0 0 0…1,8A 1,8A

0 1 1,9…2,7A 2,7A

1 0 2,8…3,5A 3,5A

1 1 >3,5A 5,6A

8 At the DynA45 006 frequency converter; Set P3.8=Start DC-Current. If you have multiple motors,
motor current values must be must be multiplied by the number of motors.

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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.
Copyright © (2014) Konecranes Plc. All rights reserved.
020145en / Revision D / 2015-04-29

9 At the DynA45 006 frequency converter; Set P3.9=current limit to 8.4A. This is the maximum allowed
temporary over current for one minute of time.

10 Set the control mode. The control mode settings in DynADrive 022 and the corresponding parameter
value for DynA45 006 are given in table 6.

Table 10. Control mode

DynADrive 022 Control Method DynA45 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
inverter you need to set correct parameters in order to set travel limits to work. After setting the
parameters, test the limit functions.

Old DynADrive 022 inverter Original limit DynA45 006 parameter

control board connections settings
P6.2 P6.3 P6.4

X1:4 / DIA4 X1:5 / DIA 5 S11 , S21 3

X1:4 / DIA4 X1:5 / DIA 5 OL10 0 0 1

X1:3 / DIA3 S11, S21 3

12 At the DynA45 006 frequency converter; set parameter P1.1 to value 0. This sets the default password
level which doesn't allow any changes to the parameters .

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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.
Copyright © (2014) Konecranes Plc. All rights reserved.
020145en / Revision D / 2015-04-29

6 TROUBLESHOOTING

6.1 Purpose of troubleshooting

The purpose of troubleshooting is primarily to determine whether problems are caused by the frequency
converter or external devices. It is also possible that a faulty external device has caused damage to the
frequency converter. In that case it is very important to repair or change any faulty devices to prevent recurring
problems.

6.2 Problems and solutions

Sr. Product Suggested solution
no.

1 The frequency converter is on Make sure that the front resistors on the control voltage circuit
READY status but motor does not have been removed or by-passed according to the instructions
run or just jerks but control voltage in Control voltage front resistors (page 11).
can be measured from the
terminals.

2 The frequency converter does not • Measure the main voltage between terminals L1, L2 and L3.
start (not in READY status) when it See electrical drawings for the correct value.
is started. • Make sure that there are no devices causing disturbance
connected to the same voltage supply as the crane, such as
big motors or welding devices.
• Make sure all motor cables have proper connection.
• Make sure that no limit switch or operation is not active.
• Measure the control voltage in direction command 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 controlled
cranes is not recommended.

3 The motor runs poorly: trolley/bridge • Check that the load is not over nominal.
does not move as it supposed to • Check that all cables are correctly connected and not loose.
move. • Check that all motor parameters are correctly set.
• Check that the U/f-curve parameters (P4.2, P4.3 and P4.4) are
correctly set.
• Check that the motor’s brake opens completely.

6.3 Fault codes and alarms

When the frequency converter detects an unacceptable situation it stops the current movement and indicates a
warning or fault code. First digits of the fault code indicates the order f the code, e.g. F1 means the latest fault.
Next two digits are indicating the fault code. At active fault situation FAULT arrow and fault code are blinking. If
there are several active faults, they all are blinking in history browsing.

Some of the faults are reset automatically by the software, while others may require the frequency converter to
be powered down. The causes of the fault(s) must be resolved and both drive commands have to be on the
OFF position for 0.5s before the motor can be started again. In a case of over current fault the supply voltage
must be switched off and back on before it is possible to resume operation.

The warning and fault code numbers and corresponding warnings and faults, possible causes and suggested
solutions are listed in the following table.
26/31
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.
Copyright © (2014) Konecranes Plc. All rights reserved.
020145en / Revision D / 2015-04-29

Table 11. FAULT CODES

Code Fault Possible cause Suggested solution Resetting

1 Overcurrent • Motor failed • Check/replace motor A

• Short circuit in motor wiring • Check/repair motor wiring.

2 Overvoltage • Too high supply voltage • Measure supply voltage and C

• Braking resistor failed check hoist supply voltage
• Break in braking resistor from hoist type plate
wiring • Measure braking resistor
resistance
• Check braking resistor and
wiring visually

3 Earth Fault • Short circuit in wiring • Check/repair wiring A

• Motor failed • Check/replace motor

8 System Fault • Internal fault • Switch off supply voltage B

• If problem recurs, replace
inverter

13 Under temperature • Internal temperature too low • Minimum operating C

temperature is -30ºC

14 Overtemperature • Internal heat sink • Wait for unit cooling down C

temperature too high

22 API EEPROM • Internal parameter save error • Switch off supply voltage B
Checksum • If problem recurs, replace
inverter

23 POW EEPROM • Internal parameter save error • Switch off supply voltage B
Checksum • If problem recurs, replace
inverter

24 Counter fault • Internal counter error • Switch off supply voltage B

• If problem recurs, replace
inverter

25 API Microprocessor • Internal watchdog error • Switch off supply voltage B

Watchdog • If problem recurs, replace
inverter

26 POW • Internal watchdog error • Switch off supply voltage B

Microprocessor • If problem recurs, replace
Watchdog inverter

34 Internal Bus • Internal bus error • Switch off supply voltage B

Communication • If problem recurs, replace
inverter

35 Application Fault • Internal application error • Switch off supply voltage B

• If problem recurs, replace
inverter

41 IGBT • Internal IGBT temperature • Wait for unit cooling down C

Overtemperature too high

52 Parameter Fault • Wrong parameter setting. • Check parameter P1.9 Drive C

P1,9 Drive Selection = 0 Selection

27/31
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.
Copyright © (2014) Konecranes Plc. All rights reserved.
020145en / Revision D / 2015-04-29

Code Fault Possible cause Suggested solution Resetting

53 CAN • CAN Communication is not • Switch off supply voltage C

Communication working from all devices that are
Fault connected to CAN bus
• Check CAN-bus wiring and
termination resistor settings
• Check CAN-communication
parameters

55 Board Fault • API3 is not installed or not • Switch off supply voltage B
working properly • Check API3 supply voltage
• Check API3 wiring
connections
• If problem recurs, replace
inverter

56 Generator Current • Inverter cannot stop with the • Increase P1.8 Deceleration C
Limit/Deceleration set ramp stretching Time or P11.1 Ramp
Ramp Supervision Stretching value

57 Motor • Motor temperature too high • Wait for motor cooling down C
Overtemperature • Digital input DIA4 • Avoid running long periods at
deactivated when used for low speed
motor overtemperature • Check motor temperature
protection protection wiring

58 Overvoltage • Overvoltage regulator has C

Regulator Timeout been active for 5 sec

59 Overvoltage at Start • Too high supply voltage • Measure supply voltage and C
check hoist supply voltage
from hoist type plate

60 Power unit fault • Power unit has stopped • Switch off supply voltage B
running • Check power unit wiring
• E-stop during running • If problem recurs, replace
inverter

61 Overspeed • Overspeed situation detected • Check supply voltage A

• Interference in speed signal • Check load measurement
connected to ENC1A operation and calibration
• Check sensor cable
grounding and inverter PE-
connections
• Check/replace speed sensor
connected to ENC1A

28/31
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.
Copyright © (2014) Konecranes Plc. All rights reserved.
020145en / Revision D / 2015-04-29

Code Fault Possible cause Suggested solution Resetting

62 Speed difference • Speed difference situation • Check supply voltage A

detected • Check load measurement
• Load measured too low in operation and calibration
ESR use • Check hoist operation
• Mechanical failure e.g. in without load
gear • Check sensor cable
• Interference or missing grounding and inverter PE-
signal in ENC1A connections
• Sensor channels ENC2A-B • Check/replace speed sensor
connected wrong way connected to ENC1A
• Interference or missing • Swap connections between
signal in ENC2A-B ENC2A and ENC2B
• Check/replace speed sensor
connected to ENC2A-B

63 Stall • Motor does not run. • Check/replace motor A

Mechanical failure e.g. in • Check/repair motor wiring
gear • Check hoist operation
• Missing signal in ENC1A without load
• Check/replace speed sensor
connected to ENC1A

64 Relay • Error detected in ROB1 • Check main contactor circuit A

relay, test circuit or the main wiring
contactor • If problem recurs replace
inverter

71 Brake control • Error detected in brake • Check/repair brake control A

control circuit circuit wiring
• Check brake coil resistance
• Replace brake if not ok
• If problem recurs replace
inverter

73 Both Direction • S1 and S2 controls active at • Check/repair control circuit C

Commands Active the same time wiring
• Fault in control circuit/ • Check/replace pendant
controller controller

77 CRC • Internal safety parameter • Switch off supply voltage B

fault • If problem recurs, replace
inverter

29/31
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.
Copyright © (2014) Konecranes Plc. All rights reserved.
020145en / Revision D / 2015-04-29

Code Fault Possible cause Suggested solution Resetting

82 Overload • Overload situation detected • Make sure that the load on C

• Worn chain or chain drive hook is not more than rated
(chain hoist) load
• Load sensor out of • Check/replace chain and
calibration chain drive
• Load sensor failed • Recalibrate load sensor by
• Mechanical failure in gear performing load calibration
(chain hoist) function
• If problem recurs after re-
calibration, replace load
sensor and perform offset
correction and calibration
• Check hoist gear operation
by observing noise, vibration
and so on

84 Clutch supervision • Clutch slipping detected • Check/adjust clutch A

(chain hoist) adjustment
• Worn chain or chain drive • Check/replace chain and
(chain hoist) chain drive
• Missing pulses in signal • Check/replace speed sensor
connected to ENC2A-B connected to ENC2A-B
• Parameter P8,7 ENC2 Stall • Lower the parameter P8,7
Pulse Limit value too high ENC2 Stall Pulse Limit value

85 Load Sensor Fault • Load sensor signal out of • Check/repair load sensor C
range wiring
• Check/replace load sensor

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 Alarm Possible cause Suggested solution

6 External Stop ES-signal not active. Lift E-stop button.

51 Stop Limit Stop limit activated. • Run to the other

Break in limit switch direction
wiring. Limit switch • Check/repair limit
failed. switch wiring
• Check/replace limit
switch

54 Limit fault Wrong limit switch Check limit switch

active. Frequency too operation and wiring.
low to detect direction.

83 Slack wire Slack wire function

active.

86 Load not calibrated Load calibration has Perform load

not been done. calibration function.

30/31
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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.
Copyright © (2014) Konecranes Plc. All rights reserved.
020145en / Revision D / 2015-04-29

Code Alarm Possible cause Suggested solution

87 Programmable limit Programmable limit is • Run other direction

active disabling driving in • Set the
either direction programmable limit to
other position
• Limit can be also by-
passed temporarily
by activating the
movement control
more than 5 seconds

88 CCU fault Controlled common Another device that is

use fault. connected in CAN bus
has an active fault.

93 CCU activation Controlled common Another device that is

use activation. connected in CAN bus
has caused the
stopping.

31/31
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.
Copyright © (2014) Konecranes Plc. All rights reserved.