R&M Materials Handling ControlMaster LDR Frequency Control System Service Manual
ControlMaster LDR is a frequency control system designed for industrial crane usage to control the speed of the trolley and bridge movements. It is possible to use this frequency converter also with the CAN bus. The frequency converter shall be used only in crane applications. It also offers guidance to enable safe and efficient service. The product is designed to be safe when used correctly.
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DOC_SM_TDN0300100-0 PS18733 11/13/2029
English
Original instructions
SERVICE MANUAL FOR FREQUENCY CONTROL SYSTEM
ControlMaster® LDR
- - - -
159852 12.2013
SUPDOC_SM_TDN030-0.ORD 20/12/2013
English
Original instructions
SERVICE MANUAL FOR FREQUENCY CONTROL SYSTEM
ControlMaster® LDR
- - - -
159852 12.2013
SUPDOC_SM_TDN030-0.ORD 20/12/2013
R&M Materials Handling, Inc.
4501 Gateway Boulevard
Springfield, Ohio 45502
P.: (937) 328-5100
FAX: (937) 325-5319
2/68 R&M Materials Handling, Inc. reserves the right to alter or amend the above information without notice.
Table of contents
1 UPDATE HISTORY ............................................................................................................................ 4
2 GENERAL INTRODUCTION .............................................................................................................. 5
2.1 Foreword: About this manual ........................................................................................................................5
2.2 Symbols Used in this Manual .......................................................................................................................5
2.3 Safety Alert Symbols and Signal Words .......................................................................................................5
2.4 Questions and Comments ............................................................................................................................6
2.5 Manual Use ...................................................................................................................................................6
2.6 Terminology ..................................................................................................................................................7
2.7 Directives and standards ..............................................................................................................................8
2.7.1 CE/CSA/UL/CCC ......................................................................................................................................8
2.7.2 EMC ..........................................................................................................................................................9
3 SAFETY FIRST! ............................................................................................................................... 10
3.1 Personal protective equipment (PPE) .........................................................................................................10
3.1.1 Fall Protection .........................................................................................................................................10
3.2 Fire Safety ...................................................................................................................................................11
3.3 Main isolation switch ...................................................................................................................................11
3.4 Safety during maintenance .........................................................................................................................11
4 IDENTIFICATION............................................................................................................................. 13
4.1 Manufacturer ...............................................................................................................................................13
4.1.1 Main sticker .............................................................................................................................................13
4.2 Factory code example (Factory: TDN) ........................................................................................................14
4.3 R&M code example (R&M: ControlMaster® LDR, Factory: TDN) ..............................................................15
5 TECHNICAL DATA .......................................................................................................................... 16
6 CONSTRUCTION ............................................................................................................................ 17
6.1 Intended use of the frequency converter ....................................................................................................17
6.2 Main components ........................................................................................................................................18
6.2.1 Control panel ...........................................................................................................................................19
6.2.2 Terminal for program Connection Tool for TDN .....................................................................................19
6.2.3 Terminals ................................................................................................................................................20
6.2.4 Braking resistor .......................................................................................................................................25
6.2.5 EMC Filter ...............................................................................................................................................26
7 PREPARING THE PRODUCT FOR USE ......................................................................................... 29
7.1 Transport and storage.................................................................................................................................29
7.2 Safety precautions before installation .........................................................................................................29
7.3 Mounting .....................................................................................................................................................30
7.3.1 Dimensions .............................................................................................................................................30
7.3.2 Mounting .................................................................................................................................................31
8 USER INTERFACE .......................................................................................................................... 33
8.1 The display panel ........................................................................................................................................33
8.2 Display options ............................................................................................................................................33
8.2.1 Drive status .............................................................................................................................................33
8.2.2 Display messages ...................................................................................................................................33
8.3 Navigation on the control keypad ...............................................................................................................34
8.3.1 Panel buttons ..........................................................................................................................................34
8.4 Setting parameters ......................................................................................................................................35
8.4.1 Changing a parameter value...................................................................................................................35
9 PARAMETERS ................................................................................................................................ 36
9.1 General Parameter Description ..................................................................................................................37
4501 Gateway Boulevard
Springfield, Ohio 45502
P.: (937) 328-5100
FAX: (937) 325-5319
2/68 R&M Materials Handling, Inc. reserves the right to alter or amend the above information without notice.
Table of contents
1 UPDATE HISTORY ............................................................................................................................ 4
2 GENERAL INTRODUCTION .............................................................................................................. 5
2.1 Foreword: About this manual ........................................................................................................................5
2.2 Symbols Used in this Manual .......................................................................................................................5
2.3 Safety Alert Symbols and Signal Words .......................................................................................................5
2.4 Questions and Comments ............................................................................................................................6
2.5 Manual Use ...................................................................................................................................................6
2.6 Terminology ..................................................................................................................................................7
2.7 Directives and standards ..............................................................................................................................8
2.7.1 CE/CSA/UL/CCC ......................................................................................................................................8
2.7.2 EMC ..........................................................................................................................................................9
3 SAFETY FIRST! ............................................................................................................................... 10
3.1 Personal protective equipment (PPE) .........................................................................................................10
3.1.1 Fall Protection .........................................................................................................................................10
3.2 Fire Safety ...................................................................................................................................................11
3.3 Main isolation switch ...................................................................................................................................11
3.4 Safety during maintenance .........................................................................................................................11
4 IDENTIFICATION............................................................................................................................. 13
4.1 Manufacturer ...............................................................................................................................................13
4.1.1 Main sticker .............................................................................................................................................13
4.2 Factory code example (Factory: TDN) ........................................................................................................14
4.3 R&M code example (R&M: ControlMaster® LDR, Factory: TDN) ..............................................................15
5 TECHNICAL DATA .......................................................................................................................... 16
6 CONSTRUCTION ............................................................................................................................ 17
6.1 Intended use of the frequency converter ....................................................................................................17
6.2 Main components ........................................................................................................................................18
6.2.1 Control panel ...........................................................................................................................................19
6.2.2 Terminal for program Connection Tool for TDN .....................................................................................19
6.2.3 Terminals ................................................................................................................................................20
6.2.4 Braking resistor .......................................................................................................................................25
6.2.5 EMC Filter ...............................................................................................................................................26
7 PREPARING THE PRODUCT FOR USE ......................................................................................... 29
7.1 Transport and storage.................................................................................................................................29
7.2 Safety precautions before installation .........................................................................................................29
7.3 Mounting .....................................................................................................................................................30
7.3.1 Dimensions .............................................................................................................................................30
7.3.2 Mounting .................................................................................................................................................31
8 USER INTERFACE .......................................................................................................................... 33
8.1 The display panel ........................................................................................................................................33
8.2 Display options ............................................................................................................................................33
8.2.1 Drive status .............................................................................................................................................33
8.2.2 Display messages ...................................................................................................................................33
8.3 Navigation on the control keypad ...............................................................................................................34
8.3.1 Panel buttons ..........................................................................................................................................34
8.4 Setting parameters ......................................................................................................................................35
8.4.1 Changing a parameter value...................................................................................................................35
9 PARAMETERS ................................................................................................................................ 36
9.1 General Parameter Description ..................................................................................................................37
R&M Materials Handling, Inc.
4501 Gateway Boulevard
Springfield, Ohio 45502
P.: (937) 328-5100
FAX: (937) 325-5319
3/68 R&M Materials Handling, Inc. reserves the right to alter or amend the above information without notice.
9.2 PARAMETER DESCRIPTIONS ................................................................................................................. 38
9.2.1 Monitoring values (group 00) .................................................................................................................. 38
9.2.2 General ................................................................................................................................................... 39
9.2.3 Motor ....................................................................................................................................................... 39
9.2.4 U/f settings .............................................................................................................................................. 40
9.2.5 Brake control ........................................................................................................................................... 41
9.2.6 Protection ................................................................................................................................................ 41
9.2.7 CANopen ................................................................................................................................................ 42
9.2.8 Diagnostics and drive information........................................................................................................... 42
9.2.9 Fault codes ............................................................................................................................................. 43
10 COMMISSIONING ...................................................................................................................... 46
10.1 Visual checks .............................................................................................................................................. 46
10.2 Checks before the first run .......................................................................................................................... 47
10.2.1 Power-up procedure ........................................................................................................................... 47
10.3 Test-run without load .................................................................................................................................. 49
10.4 Test-run with load ....................................................................................................................................... 50
10.5 After the test-run ......................................................................................................................................... 51
11 OPERATING INSTRUCTIONS ................................................................................................... 52
11.1 Control methods.......................................................................................................................................... 52
11.2 Slowdown limit ............................................................................................................................................ 53
11.3 Stop limit ..................................................................................................................................................... 53
11.4 Determining movement direction ................................................................................................................ 53
12 MAINTENANCE .......................................................................................................................... 55
12.1 Replacing the fan ........................................................................................................................................ 55
12.2 Spare parts ................................................................................................................................................. 55
13 TROUBLESHOOTING ................................................................................................................ 56
13.1 Problems and solutions .............................................................................................................................. 56
13.2 Fault codes ................................................................................................................................................. 57
14 TAKING PRODUCT OUT OF OPERATION ................................................................................ 58
14.1 Disposal of waste materials ........................................................................................................................ 58
15 CABLES AND FUSES ................................................................................................................ 59
16 QUICK GUIDE ............................................................................................................................ 60
16.1 Visual checks .............................................................................................................................................. 60
16.2 Checks before the first test-run................................................................................................................... 60
16.3 Check motor parameters ............................................................................................................................ 61
16.3.1 Compact brake motors (MF06MA, MF06LA) ...................................................................................... 61
16.3.2 Other motors ....................................................................................................................................... 61
16.4 Auto-tuning.................................................................................................................................................. 61
16.5 Manual tuning ............................................................................................................................................. 61
16.6 Test-run without load .................................................................................................................................. 62
16.7 Test-run with load ....................................................................................................................................... 63
16.8 After the test-run ......................................................................................................................................... 63
17 APPENDIX: ELECTRICAL CONNECTIONS ............................................................................... 64
18 APPENDIX: DEFAULT PARAMETERS WITH COMPACT BRAKE MOTORS ........................... 68
4501 Gateway Boulevard
Springfield, Ohio 45502
P.: (937) 328-5100
FAX: (937) 325-5319
3/68 R&M Materials Handling, Inc. reserves the right to alter or amend the above information without notice.
9.2 PARAMETER DESCRIPTIONS ................................................................................................................. 38
9.2.1 Monitoring values (group 00) .................................................................................................................. 38
9.2.2 General ................................................................................................................................................... 39
9.2.3 Motor ....................................................................................................................................................... 39
9.2.4 U/f settings .............................................................................................................................................. 40
9.2.5 Brake control ........................................................................................................................................... 41
9.2.6 Protection ................................................................................................................................................ 41
9.2.7 CANopen ................................................................................................................................................ 42
9.2.8 Diagnostics and drive information........................................................................................................... 42
9.2.9 Fault codes ............................................................................................................................................. 43
10 COMMISSIONING ...................................................................................................................... 46
10.1 Visual checks .............................................................................................................................................. 46
10.2 Checks before the first run .......................................................................................................................... 47
10.2.1 Power-up procedure ........................................................................................................................... 47
10.3 Test-run without load .................................................................................................................................. 49
10.4 Test-run with load ....................................................................................................................................... 50
10.5 After the test-run ......................................................................................................................................... 51
11 OPERATING INSTRUCTIONS ................................................................................................... 52
11.1 Control methods.......................................................................................................................................... 52
11.2 Slowdown limit ............................................................................................................................................ 53
11.3 Stop limit ..................................................................................................................................................... 53
11.4 Determining movement direction ................................................................................................................ 53
12 MAINTENANCE .......................................................................................................................... 55
12.1 Replacing the fan ........................................................................................................................................ 55
12.2 Spare parts ................................................................................................................................................. 55
13 TROUBLESHOOTING ................................................................................................................ 56
13.1 Problems and solutions .............................................................................................................................. 56
13.2 Fault codes ................................................................................................................................................. 57
14 TAKING PRODUCT OUT OF OPERATION ................................................................................ 58
14.1 Disposal of waste materials ........................................................................................................................ 58
15 CABLES AND FUSES ................................................................................................................ 59
16 QUICK GUIDE ............................................................................................................................ 60
16.1 Visual checks .............................................................................................................................................. 60
16.2 Checks before the first test-run................................................................................................................... 60
16.3 Check motor parameters ............................................................................................................................ 61
16.3.1 Compact brake motors (MF06MA, MF06LA) ...................................................................................... 61
16.3.2 Other motors ....................................................................................................................................... 61
16.4 Auto-tuning.................................................................................................................................................. 61
16.5 Manual tuning ............................................................................................................................................. 61
16.6 Test-run without load .................................................................................................................................. 62
16.7 Test-run with load ....................................................................................................................................... 63
16.8 After the test-run ......................................................................................................................................... 63
17 APPENDIX: ELECTRICAL CONNECTIONS ............................................................................... 64
18 APPENDIX: DEFAULT PARAMETERS WITH COMPACT BRAKE MOTORS ........................... 68
R&M Materials Handling, Inc.
4501 Gateway Boulevard
Springfield, Ohio 45502
P.: (937) 328-5100
FAX: (937) 325-5319
4/68 R&M Materials Handling, Inc. reserves the right to alter or amend the above information without notice.
1 UPDATE HISTORY
Section Description Date Handled by
Whole document Figure improvements, textual improvements and updates. 11.2013 XJAASKPA
4501 Gateway Boulevard
Springfield, Ohio 45502
P.: (937) 328-5100
FAX: (937) 325-5319
4/68 R&M Materials Handling, Inc. reserves the right to alter or amend the above information without notice.
1 UPDATE HISTORY
Section Description Date Handled by
Whole document Figure improvements, textual improvements and updates. 11.2013 XJAASKPA
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Key Features
- Industrial Crane usage
- Trolley and bridge movement control
- CAN bus support
- Safety features
- EMC compliance
Related manuals
Frequently Answers and Questions
What is the ControlMaster LDR's intended use?
ControlMaster LDR is designed for industrial crane use to control the speed of the trolley and bridge movements.
What types of motor control methods can be used with the ControlMaster LDR?
The ControlMaster LDR can use MS and EP motor control methods. More information on these methods can be found in the chapter "Control methods".
Can the ControlMaster LDR be used with a CAN bus?
Yes, it is possible to use the ControlMaster LDR with a CAN bus.
What are some safety features of the ControlMaster LDR?
The ControlMaster LDR has safety features such as over-voltage protection, under-voltage protection, earth-fault protection, unit over-temperature protection, and unit under-temperature protection.
What is the EMC compliance of the ControlMaster LDR?
The ControlMaster LDR complies with the European EMC directive and has an internal EMC filter in the power supply.
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