R&M ControlMaster NXT Owner's Manual
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R&M ControlMaster NXT Owner's Manual

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Original instructions
OWNER'S MANUAL FOR FREQUENCY CONTROL
SYSTEM
ControlMaster NXT
- - - -
DOCMANTENE7-0.ORD 23.4.2013

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  • Page 1 English Original instructions OWNER'S MANUAL FOR FREQUENCY CONTROL SYSTEM ControlMaster NXT - - - - DOCMANTENE7-0.ORD 23.4.2013...

  • Page 2: Table Of Contents

    R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 Table of contents GENERAL INTRODUCTION ......................3 Foreword: About This Manual ......................... 3 Symbols Used In This Manual ......................... 3 Safety Alert Symbols and Signal Words ....................3 Questions And Comments ........................

  • Page 3: General Introduction

    R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 GENERAL INTRODUCTION Foreword: About This Manual This manual offers guidance to enable safe and efficient operation of the crane. As a crane operator, taking the time to read this manual will help you to prevent damage to the crane and load, and, most importantly, personnel situated close to the crane.

  • Page 4: Questions And Comments

    R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 Addresses situations not related to personal injury, such as likely or possible damage NOTICE to equipment. Shall Indicates that a rule is mandatory and must be followed. Should Indicates that a rule is a recommendation, the advisability of which depends on the facts in each situation.

  • Page 5: Terminology

    R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 Terminology The following terms and definitions may have been used in this manual: Authorized personnel Persons who are authorized by the owner and who have the necessary training to carry out operation or service actions.

  • Page 6: Directives And Standards

    R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 Directives and standards 1.8.1 CE/CSA/UL/CCC This product complies with one or more of the following requirements and directives described in this section. For more detailed information about which requirements the product meets, see the main sticker attached to the device.

  • Page 7: Safety First

    R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 SAFETY FIRST! Safety requirements must be understood and followed. Fire Safety In the event of a fire, only attempt to fight it if you can do so without putting yourself in danger. Turn the power off if it is possible to do so.

  • Page 8: Intended Use Of The Frequency Converter

    R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 Only use the emergency stop button to stop movement in the event of a product malfunction or other emergency situation. Using the emergency stop button can NOTICE cause the load to swing unexpectedly.

  • Page 9: Identification

    R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 IDENTIFICATION Manufacturer R&M Materials Handling Inc. Manufacturer: Address: 4501 Gateway Boulevard 45502 SPRINGFIELD, OH Note: For further information about the product, operational training or servicing, please contact the manufacturer or manufacturer’s representative.
  • Page 10 R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 Monday, 2 Tuesday, number 5 indicating Friday. Code Identification and feature information provided by the manufacturer. A two dimensional bar code in an optically readable form. QR Code™...

  • Page 11: Construction

    R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 CONSTRUCTION Main components The 003 model The 006 model Pos. Part Description Display LCD Display Navigation and Buttons with four arrow navigation buttons and buttons for back/reset and confirmation, used in navigating confirmation buttons in the menu structure and in adjusting parameter values.

  • Page 12: User Interface

    R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 USER INTERFACE Changing parameter settings during running may cause a hazardous situation. WARNING Parameter settings must not be changed during running. Control Panel The control panel contains: LCD display with backlight.

  • Page 13: Control Selection

    R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 5.2.2 Control selection The control selections are located below the LCD display. The control selections: The control DIR1 indicates that the motor is rotating forward. The control DIR2 indicates that the motor is rotating backward.

  • Page 14: Navigating In The Menu

    R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 Navigating in the menu The user interface consists of the following menus: The Monitoring menu allows you to view the monitoring values. The Parameter menu allows you to view and edit the parameter settings. The Fault history menu allows you to view the latest fault indications.

  • Page 15: Parameter Menu

    R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 Navigate between monitoring groups values by using the up and down buttons. Press OK to see monitoring value. Press Back/Reset to return to the main display. 5.3.3 Parameter menu In the parameter menu, you can set the values for the parameters.

  • Page 16: Fault History Menu

    R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 Navigate between parameters by using the right and left arrow buttons. Select the parameter by pressing OK. Edit the selected parameter by using the up and down arrow buttons.
  • Page 17 R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 Press OK. Navigate between faults by using up and down buttons. Select the fault by pressing OK. Navigate fault information by using the right and left arrow buttons. Press Back/Reset to return to the main display.

  • Page 18: Operating Instructions

    R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 OPERATING INSTRUCTIONS Control methods EP (Electronic Potentiometer) stepless pushbutton control Released (stop): The device doesn’t move or, if it is already moving, it will decelerate to a complete stop. Fully pressed (accelerate): The device accelerates continuously until the pushbutton is released or the maximum speed is reached.

  • Page 19: Slowdown-Limit

    R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 Multistep pushbutton control The motor moves at a speed corresponding to the force applied to the direction control. The motor moves at its slowest speed when the control is partially pushed and at its maximum speed when the control is fully pushed. Be tween the fastest and slowest positions, there are other preset speeds.

  • Page 20: Taking Product Out Of Operation

    R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 TAKING PRODUCT OUT OF OPERATION 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.

  • Page 21: Technical Data

    R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 TECHNICAL DATA Mains connection Supply voltage U 380 - 480V, -10%...+10% 3-phase Supply voltage frequency 45…66 Hz Connection to mains Once per minute or less (normal case) Motor connection Output voltage 0 —...
  • Page 22 English Original Instruction INSTALLATION INSTRUCTION CMX 022 Upgrade Kit 031097en / Revision D 2015-04-29...
  • Page 23 R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 TABLE OF CONTENTS INTRODUCTION........................... About this manual......................... About the upgrade kit usage......................Waste treatment and recycling of removed material..............SAFETY..............................Before starting to work at the site....................Main switch and emergency stop buttons..................

  • Page 24: Introduction

    R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 INTRODUCTION About this manual This manual offers guidance to the installation and start-up tasks of CMX 022 frequency converter replacement. As a maintenance technician, taking the time to read this manual will help you easily adopt the replacement procedures.

  • Page 25: Safety

    R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 SAFETY Before starting to work at the site Before starting any work on the crane: • Familiarize yourself with the equipment and its user instructions. •...

  • Page 26: Description Of The Upgrade Kit

    R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 DESCRIPTION OF THE UPGRADE KIT 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...

  • Page 27: Required Tools

    R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 Required tools Item Image Name Screwdriver, slot -head, 3,5 x 0,6mm Wire strippers Wire cutters Crimping tool for wire end ferrules Socket wrench, 8mm 6/34 R&M Materials Handling, Inc.

  • Page 28: Terminal Connections

    R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 Terminal connections Table 1. Power terminals Description of Terminal ControlMaster ®NXT Terminal X2 Power terminals Power supply, phase 1 Power supply, phase 2 L2/N Power supply, phase 3 Motor supply, phase 1 U/T1...

  • Page 29: User Interface

    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.
  • Page 30 R&M 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: Installation

    R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 INSTALLATION 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. •...

  • Page 32: Control Voltage Front Resistors

    R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 Disconnect and mark the motor supply wires (U, V and W) with cable markers. If the CMX 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.

  • Page 33: New Frequency Controller Installation

    R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 Remove the control signal wires from the top side of the front resistor. 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.
  • Page 34 Put the ControlMaster ®NXT 006 into place. Tighten the screws. Connect the power supply and motor wires in ControlMaster NXT according to electrical drawings. 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.
  • Page 35 R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 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.
  • Page 36 P.: (937) 328-5100 FAX: (937) 325-5319 Digital input 5 in ControlMaster NXT will be deactivated. No connection is needed. Variation 2 - EP2+slow down. MS2 control method with slowdown limit switch. With ControlMaster NXT both direction signals from limit switch must be connected in series as shown in below figures.
  • Page 37 Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 Digital input 5 in ControlMaster NXT will be deactivated. No connection is needed. Variation 3 - EP2 / MS2 + stop. Figure 5. Old inverter + EP2 / MS2 + stop 16/34 R&M Materials Handling, Inc.
  • Page 38 P.: (937) 328-5100 FAX: (937) 325-5319 Figure 6. New inverter + EP2 / MS2 + stop Digital inputs 4 and 5 in ControlMaster NXT will be deactivated. No connection is needed. Variation 4 - MS2 + 2-step limit switch. 17/34...
  • Page 39 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 ControlMaster NXT the both slowdown direction signals from limit switch must be connected in series.
  • Page 40 R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 Figure 9. Old inverter + EP2 + 2-step limit switch Figure 10. New inverter + MS2 + 2-step limit switch 19/34 R&M Materials Handling, Inc. reserves the right to alter or amend the above information without notice.

  • Page 41: Commissioning

    R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 COMMISSIONING Old inverter parameter settings Write down the old parameter settings from the CMX 022 frequency converter in the table below. Table 1: CMX 022 parameter settings Switch 1 Switch 2 Switch 3...
  • Page 42 R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 At the ControlMaster ®NXT 006 frequency converter; set parameter P1.1 to value 129. This sets the engineering password level which is needed for parameter settings. 21/34 R&M Materials Handling, Inc.
  • Page 43 R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 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.
  • Page 44 R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 Table 5. Maximum and minimum frequency 80 Hz CMX 022 Minimum Maximum Frequency frequency (Hz) To (Hz) To P1.3 Switch S1 P1.2 Table 6. Maximum and minimum frequency 50/60 Hz CMX 022 Minimum frequency Maximum Frequency...
  • Page 45 R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 CMX 022 Minimum frequency Maximum Frequency (Hz) To P1.2 (Hz) To P1.3 Switch S1 24/34 R&M Materials Handling, Inc. reserves the right to alter or amend the above information without notice.
  • Page 46 R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 Set acceleration and deceleration ramp time values. Acceleration and deceleration ramp time values for CMX 022 can be found in table 7. The corresponding value for ControlMaster ®NXT 006 must be set to parameters P1.7 and P1.8.
  • Page 47 R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 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...
  • Page 48 R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 (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.
  • Page 49 R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 At the ControlMaster ®NXT 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 . 28/34 R&M Materials Handling, Inc.

  • Page 50: Troubleshooting

    R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 TROUBLESHOOTING 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.
  • Page 51 R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 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.
  • Page 52 R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 Code Fault Possible cause Suggested solution Resetting Internal • Internal bus error • Switch off supply voltage Communication • If problem recurs, replace inverter Application Fault •...
  • Page 53 R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 Code Fault Possible cause Suggested solution Resetting Overspeed • Overspeed situation detected • Check supply voltage • Interference in speed signal • Check load measurement connected to ENC1A operation and calibration •...
  • Page 54 R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 Code Fault Possible cause Suggested solution Resetting Overload • Overload situation detected • Make sure that the load on • Worn chain or chain drive hook is not more than rated (chain hoist) load...
  • Page 55 R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 Code Alarm Possible cause Suggested solution Slack wire Slack wire function active. Load not calibrated Load calibration has Perform load not been done. calibration function. Programmable limit Programmable limit is...

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