Drive Grua Cat424v-3

8/11/2019 Drive Grua Cat424v-3

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BULLETIN 424VADJUSTABLE FREQUENCY

Flux Vector Control

OPERATIONand

MAINTENANCE

MANUALCATALOG 424V-3

BULLETIN 424V Software 14908-14912CATALOG 424V-3February 2002PUBLICATIONS DEPARTMENT

OAK CREEK, WI 53154


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2002 Morris Material Handling

All rights reserved. This notice applies to all copyrighted materials included with this product,including, but not limited to, this manual and software embodied within the product. This manual isintended for the sole use of the persons to whom it was provided, and any unauthorized distributionof the manual or dispersal of its contents is strictly forbidden. This manual may not be reproduced in

whole or in part by any means whatsoever without the expressed written permission of MorrisMaterial Handling.

DANGER, WARNING, CAUTION, andNOTEStatements

DANGER, WARNING, CAUTION, andNote statements are used throughout this manual toemphasize important and critical information. You must read these statements to help ensure safetyand to prevent product damage. The statements are defined below.

DANGER

DANGERindicates an imminently hazardous situation which, if not avoided, will result indeath or serious injury. This signal word is to be limited to the most extreme situations.

WARNING

WARNINGindicates a potentially hazardous situation which, if not avoided, could result indeath or serious injury.

CAUTION

CAUTIONindicates a potentially hazardous situation which, if not avoided, could result inminor or moderate injury. It may also be used to alert against unsafe practices.

NOTE: A NOTE statement is used to notify people of installation, operation, programming,

or maintenance information that is important, but not hazard-related.


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Disclaimer of Warranty

Morris Material Handling hereafter referred to as Company, assumes no responsibility for improperprogramming of a drive by untrained personnel. A drive should only be programmed by a trainedtechnician who has read and understand the contents of this manual. Improper programming of adrive can lead to unexpected, undesirable, or unsafe operation or performance of the drive. This mayresult in damage to equipment or personal injury. Company shall not be liable for economic loss,property damage, or other consequential damages or physical injury sustained by the purchaser or byany third party as a result of such programming. Company neither assumes nor authorizes any otherperson to assume for Company any other liability in connection with the sale or use of this product.

WARNING

Improper programming of a drive can lead to unexpected, undesirable, or unsafe operation or

performance of the drive.


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Smartorque Bulletin 424V (14908-14912) Instruction Manual- 02/05/02i

Contents

Welcome!

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii

Identifying Your Drive

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . viii

Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ix

Safety Recommendations and Practices for Crane and Hoist Users . . . . . . . . . . . .xiii

Chapter 1: Introduction

Introduction

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Assessing the System Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Assessing the Drive Environment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Bulletin 424V General Specifications

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

CDBM & CDBR Units

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

Minimum Resistor Ohmic Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

Installation/Wiring of CDBR/CDBM Braking Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

AC Reactor Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15

Interface Cards Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17

Interface Card Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17

Chapter 2: Installation

Bulletin 424V System Components And External Devices . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Long Time Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Installing the Drive

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

Bulletin 424V Dimensions/Heat LossOpen Chassis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

Chapter 3: Wiring

Bulletin 424V Wiring Practices

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Bulletin 424V Standard Connection Diagram

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Suggested Circuit Protection Specifications and Wire Size

. . . . . . . . . . . . . . . . . . . . . 3-6

Power Circuit Wiring Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

Wiring the Control Circuit

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

Control Input. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
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Additional Input Terminals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

Control Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

Control Circuit Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

Control Circuit Wiring Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

Wiring the Encoder Circuit

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19

Encoder Circuit Wiring Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19

Encoder Wiring Diagrams and Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20

Chapter 4: Programming Basic Features

Overview

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Checks Before Powering. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Using the Keypad

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Keypad LED and Button Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

Parameter Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

Initialization Set-up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

Auto-Tuning

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16

Chapter 5: Programming Advanced Features

Application

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

Preset Reference. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

Reference Limits

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

Sequence/Reference Source. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

Trim Control Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14

Acceleration/Deceleration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15

Accel/Decel Time Switching Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16

Torque Limit Accel/Decel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18

Phase Loss Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19

SVR (Speed Variation Error). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19

Jump Frequencies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20

Special Functions

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21

Quick Stop/Reverse Plug Simulation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22
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Micro-Positioning Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24

Travel Limits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25

Zero Servo. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27

Load Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28

Ultra-Lift. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30Torque Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32

No-Load Brake Start/Stop. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32

Load Float PG Monitor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35

PG Monitor Count. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-36

Shaft Oscillation Gain. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-37

PG Monitor Fault Time. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-37

Optional Digital Input Set-up (G5IN4 Digital Multi-Function Inputs) . . . . . . . . . . . . . . . . 5-45

Weight Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-49Setup Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-50

Slack Cable Detection

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-52

Delay Timers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-54

Inching Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-55

Tuning

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-56

DC Injection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-56

Automatic Slip Compensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-58

Automatic Speed Regulator (ASR) Tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-58

Torque Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-59

Speed/Torque Control Switching. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-61

Droop Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-62

Dwell Function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-63

S-Curve Acceleration/Deceleration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-64

Carrier Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-66

Factory Tuning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-67

Motor Parameters

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-68

Voltage/Frequency Pattern. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-68

Motor Set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-70

Motor 2 Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-71

Motor 2 Voltage/Frequency Pattern. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-71

Motor 2 Set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-72
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Option Parameters

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-73

Encoder (PG) Option Set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-73

AI-14 Set-up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-75

Digital Input Option Set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-76

Analog Output Option Set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-77

DO-02 Digital Output Set-up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-78

DO-08 Digital Output Set-up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-79

PO-36F Set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-80

CP-916 Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-81

Terminal Parameters

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-82

Digital Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-82

Digital Outputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-85

Digital OutputsFault Annunciate (H2-01~03=40). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-87

External Fault Response Selection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-89

Analog Inputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-90

Analog Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-92

Serial Communication Set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-93

Protection Parameters

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-94

Motor Overload. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-94

Stall Prevention. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-95Reference Detection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-97

Torque Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-99

Hardware Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-102

Automatic Reset. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-103

Example: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-104

Operator Parameters

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-105

Monitor Selection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-105

Keypad Key Selection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-107

Clear History. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-110

Monitor Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-111

Chapter 6: Troubleshooting Bulletin 424V

Troubleshooting the Drive

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

Maintenance and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
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Motor Faults and Corrective Actions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

Drive Faults and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

Troubleshooting Encoder Related Faults

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12

Fault Code: DevSpeed Deviation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12

Fault Code: PGOPulse Generator Signal Missing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13

Fault Code: PGO2Pulse Generator Signal Monitor Fault. . . . . . . . . . . . . . . . . . . . . . . . . . 6-14

Fault Code: SVRNoisy Encoder Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15

Fault Code: BE1Torque Proving Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16

Fault Code: BE3Brake Release Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16

Fault Code: BE6Brake Proving Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17

Fault Code: OCOver Current Fault. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18

Fault Display and Corrective Actions at Auto-tuning

. . . . . . . . . . . . . . . . . . . . . . . . . 6-19

Troubleshooting CDBR Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20

Power Section Check

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21

Power Off Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21

Braking Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23

Appendix A: Servicing Bulletin 424V

Service

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3

Service Policy For Small Drives, DBUs, and Other Electrical Components . . . . . . . . . . . . . A-3

Service Policy for Large Drives. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4

Morris Material Handling Limited Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-6

Bulletin 424V Parameter Listing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-7

Appendix B: Differences in Software Versions

Important Product Upgrade Information

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3

Changes in Software from 14906 to 14908/14909 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3

Changes in Software from 14908/14909 to 14911 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-4

Changes in Software from 14911 to 14912 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-6
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Smartorque Bulletin 424V (14908-14912) Instruction Manual - 02/05/01viii

Slack Cable Detection identifies slack cable conditions and adjusts outputs to immediately stoplowering.

Load Float Start & Stop, with the crane fully at rest (without electric brakes set), allows theprecise placement of critical loads without rollback or delays because of electric brakeoperation.

Motor Changeover Capability allows you to use one inverter for two motors (e.g., main andauxiliary hoists) with different motor characteristics.

A 120V Control Voltage Interface Card gives you direct access to a 120V user input device (e.g.,pendant) without adding electromechanical components.

Elapsed Time Counter (with fault history) indicates actual operation time, total power-up time,and the elapsed time between fault occurrences.

Identifying Your Drive

If you ever have to contact Morris Material Handling about your drive, first determine the model andserial numbers of your drive by looking at the nameplate shown below.

This nameplate is located on the side of the drive nearest to the keypad.

Bulletin 424VMorris Material HandlingMILWAUKEE, WISCONSIN

SERIAL NO.:

MODEL NO.:

A.C. INPUT

VOLTS: PHASE: 3

AMPS: HZ: 50/60

A.C. OUTPUT

VOLTS: PHASE: 3

AMPS: HZ: 0-400H.P.:

1263


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Morris Material Handling

PREFACE i

PREFACE

Operators, inspectors, and maintenance personnel of overhead traveling cranes, gantry cranes, monorail andunderhung cranes, storage/retrieval machines, overhead hoists, and overhead stacker cranes should read

and be familiar with the Safety Standard as listed below. Copies of these publications are available, at anominal cost, from the American Society of Mechanical Engineers at 22 Law Drive, Box 2300, Fairfield, NJ07007-2300, phone (800) 843-2763 or the American National Standards Institute at 11 West 42nd StreetNew York, NY 10036, phone (212) 642-4900.

ANSI/ASME B30.2 Overhead and Gantry Cranes (Top Running Bridge, Single or Multiple Girder, TopRunning Trolley Hoist)

ANSI/ASME B30.9 Slings

ANSI/ASME B30.10 Hooks

ANSI/ASME B30.11 Monorail and Underhung Cranes

ANSI/ASME B30.13 Storage/Retrieval (S/R) Machines and Associated Equipment

ANSI/ASME B30.16 Overhead Hoists (Underhung)

ANSI/ASME B30.17 Overhead and Gantry Cranes (Top Running Bridge, Single Girder, Underhung Hoist)

ANSI/ASME B30.18 Stacker Cranes (Top or Under Running Bridge, Multiple Girder, Top or Under Running

ANSI/ASME B30.21 Manually Lever Operated Hoists

ANSI Z244.1 Lockout/Tagout of Energy Sources

This manual is provided as a guide to personnel involved with the installation and testing procedure of this

equipment. We recommend that such personnel review and become familiar with the general procedures andinformation contained within this manual. In addition we recommend that this manual be kept readily availablefor reference before beginning installation or testing of this overhead crane.

Throughout the manual are safety precautions and instructions for awareness and information on potentiahazards. Due to the complexities of this crane and the environment in which it operates, situations may arisewhich are not directly discussed in detail in this manual. When such a situation arises, past experience,availability of equipment and common sense play a large part in what steps are to be taken. In addition, aMorris Material Handling representative is available to answer your questions and assist you upon request.

Please feel free to contact a Morris Material Handling representative at the following address:

Morris Material Handling315 W. Forest HIll AvenueOak Creek, WI 53154Telephone: 1-800-933-3001 or (414) 764-6200Fax: (414) 764-8446


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Revised 2/18/02

x

SIGN MAINTENANCE

Signs of various types are posted throughout this P&Hequipment to warn the end user of potential hazards, toidentify controls, systems and components, and toprovide useful information.

As these signs aid in the safe and efficient operation ofthis equipment, it is recommended that periodicinspection of all signs be included in the machinesinspection program.

If signs are missing, damaged or illegible, they shouldbe cleaned or replaced to ensure the safe and efficientoperation of this equipment. Contact your MorrisMaterial Handling representative for informationregarding signs.

See pages following for descriptions and part numbersfor reordering these signs.

MATERIAL SAFETY DATA SHEETS (MSDS)

In order to transfer MSDS information from our suppliersto our customers, Morris Material Handling will providethis service upon customer request. All customerrequests need to be specific because of the volume andcomplexity of the MSDS system. To correctly identify theappropriate MSDS, one of the following pieces ofinformation must be included: P&H part number, vendortrade name or vendor name. Inquiries concerningMSDS information can be addressed to our Sales orService representatives.

LOCKOUT/TAGOUT PROCEDURES

When performing inspection, maintenance or repair

work on Morris Material Handling equipment, alwaysfollow lockout/tagout procedures as required by OSHA29 CFR Part 1910.147 and outlined in ANSI Z244.1.

Lockout/tagout procedures are intended to protectpersonnel working on or around the equipment bypreventing accidental start up or exposure to hazardousenergy release such as electrical shocks.

The procedure requires that individual locks or tags areplaced on controls, shutoff switches, valves or otherdevices to prevent usage until the person who installedthe lock or tag removes it. Never attempt to operate anycontrol, switch, valve or other device when it is locked or

tagged out.

OSHA required lockout/tagout procedures include:

1. A documented and established site policy on thesteps to follow for lockout and tagout such as:

A.Notify all affected people including supervisorsbefore lockout or tagout is used.

B.Shut off the affected machine, equipment,system or function.

C.Disengage, isolate or release energy supply orsource.

D.Apply individual locks and/or tags on controls,switches, valves or other devices to preventusage.

E. Try or test the machine, equipment or system tocheck that the energy has been removed beforeservice or maintenance.

2. Employee training about the facilitys lockout/tagoutprocedures.

3. Identification and location of shutoff switches,controls, valves or other devices that isolatehazardous energy are predetermined at the sitefacilities.

4. After maintenance and service is finished and eachlock and/or tag has been removed by theappropriate individual and all affected people arenotified then restore energy or power.


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PREFACE x


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Revised 2/18/02

xii


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Safety Recommendations and Practices xi

Safety Recommendations and Practices

Crane and Hoist Users

FOREWORD

Morris Material Handling desires to assure safe andeconomical use of the equipment it produces. Thissection describes preventive maintenance, inspectionand specific safety recommendat ions for thatequipment.

The use of heavy equipment is subject to certainhazards that cannot be met by mechanical meansalone, but only by the exercise of intelligence, care andcommon sense. Once the equipment enters service inthe field, Morris Material Handling has no direct controlover its inspection, maintenance, or operation. For thisreason, safety in the field is the responsibility of theuser.

Most

accidents involving cranes and hoists are theresult of violating safety rules during operation and/orlack of inspection and maintenance procedures.

Morris Material Handling recognizes that mostcompanies who use cranes and hoists have a safetyprogram in their plants. If a conflict exists between a ruleset forth in this publication and a similar rule already setby an individual company, the more stringent of the twoshould be followed.

NOTICE

Morris Material Handling offers inspection andmaintenance programs through our MorrisMaterial Handling Service Centers locatedthroughout the country. For more information,please call 1-800-933-3001.

DANGERS, WARNINGS, CAUTIONS,NOTICES

Dangers, Warning, Cautions and Notices are usedthroughout your products Care and Operations manuals

to emphasize important and critical instructions.Dangers, Warnings and Cautions always precede theparagraph or item to which they apply; Notices alwaysfollow the paragraph of Item to which they apply.Dangers, Warnings, Cautions and Notices are definedas follows:

! DANGER

ind icates an imminent ly hazardous

situation which, if not avoided, will result in

death or serious injury. This signal word islimited to the most extreme situations.

! DANGERWARNING

indicates a potentially hazardous situation

which, if not avoided, could result in deathor serious injury.

! DANGERCAUTION

indicates a potentially hazardous situation

which, if not avoided, may result in minor ormoderate injury. It may also be used to alert

against unsafe practices.

NOTICE

Notice is used to notify people of installation,operation, or maintenance information which isimportant but not hazard-related.

DOS AND DO NOTS FOR SAFE CRANEAND HOIST OPERATION

General

The following warnings and operating practices areintended to help you avoid unsafe operating practiceswhich might lead to personal injury or property damage

DOs for Crane and Hoist Users

Do the following when operating lifting equipment

DO read the applicable equipment Safety Standardslisted in the front of this manual, and the instructionsprovided in the Operation and Maintenance manual

DO be familiar with controls, procedures andwarnings located on all lifting equipment.

DO maintain firm footing when operating liftingequipment.

DO make sure that the load slings or other approvedsingle attachments are properly sized and seated inthe hook saddle.

DO use hook latches.

DO make sure that the hook latch is closed and nosupporting any part of the load.


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Revised 2/18/02

xiv Crane and Hoist Users

DO make sure that the load is free to move and willclear all obstructions.

DO make sure that the hoist, bottom block and thehook are directly in line with the direction of loadingbefore making a lift.

DO make sure that the wire rope is in the sheave anddrum grooves.

DO take up all slack carefully, check the balance ofthe load, lift a few inches and check the load holdingaction before continuing.

DO make sure that the hook, bridge, trolley, carriageor shuttle travel is in the same direction as shown onthe controls.

DO make sure that all persons stay clear of asuspended load.

DO warn personnel of an approaching load.

DO avoid swinging of the load or load hook.

DO promptly report any malfunction, unusualperformance or damage of lifting equipment.

DO protect the wire rope from weld splatter or otherdamaging contaminants.

DO inspect lifting equipment on a regular basis,replace damaged or worn par ts , and keepappropriate maintenance records.

DO make sure that the limit switches functionproperly.

DO lower the bottom block to the ground or otherwisesecure it before attempting any repairs or adjustment

on the hoist units. DO use the equipment manufacturers recommended

replacement parts when repairing a hoist or crane.

DO use fuses of specified size as recommended bythe crane manufacturer.

DO install wire rope clamps correctly. See themanual provided with the equipment.

DO apply lubricant to the wire rope as recommendedby the manufacturer.

DO replace all protective guards and panels before

operating the crane.

DO NOTs For Crane And Hoist Users

The following should be observed when operating liftingequipment.

DO NOT use damaged lifting equipment, or liftingequipment which is not working correctly.

DO NOT use lifting equipment with twisted, kinked,damaged, or worn wire rope.

DO NOT use the wire rope as a sling, or wrap thewire rope around the load.

DO NOT operate lifting equipment unless the load iscentered under the hoist.

DO NOT apply the load to the tip of the hook.

DO NOT lift more than the rated load.

DO NOT lift a load if any binding prevents equal

loading on all load supporting ropes.

DO NOT use the load limiting feature to measure theload.

DO NOT use the crane or hoist to lift, support, ortransport people.

DO NOT allow the wire rope or hook to be used as aground for welding.

DO NOT allow the wire rope or hook to be touched bya live welding electrode.

DO NOT drag the wire rope or hook on the floor or

across other objects.

DO NOT allow your attention to be diverted fromoperating the lifting equipment.

DO NOT operate lifting beyond the limits of the wirerope travel.

DO NOT lift a load unless the wire rope is properlyseated in the sheaves or drum grooves.

DO NOT use limit switches as routine operationstops. They are emergency devices only.

DO NOT lift loads over people.

DO NOT apply a sudden load to the wire rope (suchas pushing a load off a ledge and allowing the wirerope to catch it).

DO NOT leave a suspended load unattended unlessspecific precautions have been taken.

DO NOT allow collision between two cranes orhoists, or between a crane or hoist and anyobstruction.

DO NOT adjust or repair lifting equipment unlessqualified to perform such maintenance.

DO NOT attempt to repair electrical apparatus or tomake other major repairs on the crane unlessspecific authorization has been received and thepower disconnect is locked out/tagged out.

DO NOT attempt to lengthen the wire rope, or repaira damaged wire rope.

DO NOT change fuse sizes.

DO NOT remove or obscure the warning or safetylabels, plates or tags furnished on any liftingequipment.


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Safety Recommendations and Practices x

OPERATOR QUALIFICATIONS

General

Only the following personnel should be permitted tooperate lifting equipment after reading this manual:

1. Appointed qualified operators.

2. Qualified maintenance and test personnel, when

required to do so in the performance of their duties.

3. Crane inspectors qualified to operate a crane

Operator Tests

Every employer should require that all persons who willbe authorized to operate lifting equipment must firstpass an examination which accurately measurespractical knowledge of cranes and hoists and propermethods to be used in attaching loads and operating thelift equipment.

PHYSICAL AND MENTAL CONDITION. 1.An operatormust possess good hearing, good vision (correctedor uncorrected), good depth perception especiallywhere load spotting is critical or at some distancefrom the operator.

2. An operator must not have any known healthcondition or disability which could cause inability toreact quickly.

3. An operator who is taking medication prescribed bya doctor must present written assurance from hisdoctor that the medication will not affect theoperators ability to operate the crane in a safe

manner.

4. An operator who is known, or suspected, to beunder the influence of alcohol or drugs must not beallowed to operate a crane.

5. The operator must be safe at all times

LOCKOUT/TAGOUT PROCEDURES

When performing inspection, maintenance or repairwork on Morris Material Handling equipment, alwaysfollow lockout/tagout procedures as required by OSHA

29 CFR Part 1910.147 and outlined in ANSI Z244.1.Lockout/tagout procedures are intended to protectpersonnel working on or around the equipment bypreventing accidental start up or exposure to hazardousenergy release such as electrical shocks.

The procedure requires that individual locks and tagsare placed on controls, shutoff switches, valves or otherdevices to prevent usage until the person who installedthe lock or tag removes it. Never attempt to operate anycontrol, switch, valve or other device when it is locked ortagged out.

OSHA required lockout/tagout procedures include:

1. A documented and established site policy on thesteps to follow for lockout and tagout such as:

A. Notify all affected people including supervisorsbefore lockout or tagout is used.

B. Shut off the affected machine, equipment, systemor function.

C. Disengage, isolate or release energy supply osource.

D. Apply individual locks and/or tags on controlsswitches, valves or other devices to prevenusage.

E. Try or test the machine, equipment or system tocheck that the energy has been removed beforeservice or maintenance.

2. Employee training about the facilitys lockout/tagouprocedures.

3. Identification and location of shutoff switchescontrols, valves or other devices that isolatehazardous energy are predetermined at the sitefacilities.

4. After maintenance and service is finished and eachlock and/or tag has been removed by the appropriateindividual and all affected people are notified thenrestore energy or power.

The policy shall give consideration to the followingcrane and hoist or lifting equipment areas:

1. Single crane runways or aisles.

2. Multiple crane runways or aisles.3. Cranes on adjacent runway or aisle.

4. Runway or installation disconnecting means.

5. Crane or equipment disconnecting means.

6. Work to be done on equipment.

7. Work to be done other than on a crane oequipment but within the path of a crane oequipment where its movement creates a hazard.

FALL PROTECTION

While working at heights when performing inspectionmaintenance or repair work on Morris Material Handlingequipment, always follow fall protection procedures asrequired by OSHA 29 CFR Part 126 subpart M.

Fall prevention practices and fall protection equipmenare intended to protect personnel working on or aroundthe equipment from exposure to falls.

An OSHA required fall protection program includes:


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xvi Crane and Hoist Users

1. A documented and established site policy andprocedures.

2. Conducting site assessments for fall hazards.

3. Selection of the proper fall protection system andequipment.

4. Training on fall protection procedures and theproper use of fall protection systems.

5. Inspecction and proper maintenance of fallprotection equipment.

6. Measures to prevent falling objects.

7. Rescue Plans.

INSPECTION

The first step to be taken before an inspectionprocedure is started, is to communicate with all personsthat the equipment is being removed from operation andsecure any/all lockout tagout procedures. Failure to

strictly follow this warning may lead to the injury or deatho f personne l . See LOCKOUT/TAGOUTPROCEDURES on page xvbefore proceeding withInspections.

A schedule for frequent and periodic inspection andlubrication should be established for your liftingequipment and it should be carefully followed. If youneed help on this, call ProCare for recommendations.

If duty service requirements exceed the duty servicerating of the machine, it may be necessary to increasethe frequency of inspections, with greater attention tothe need for parts replacement and repair. For purposes

of planning, there are three broad classes of service:

1.

Normal Service

... is use during a single work shiftthat involves:

Operation at less than 85 percent of rated load andnot more than 10 lifts per hour, or

Operations with randomly distributed loads within therated limit, or

Operation with uniform loads less than 65 percent ofrated load for not more than 25 percent of the time forelectrically operated or air operated equipment.

2.

Heavy Service

... involves operation within ratedload that exceeds normal service.

3.

Severe service

... involves normal or heavyservice in an environment that is unfavorable,harmful or detrimental to or for the operation of theequipment.

Due to widely varying conditions under which nearlyidentical machines may operated, P & H MaterialHandling cannot define the frequency at whichinspections and/or maintenance should be performed.

For this reason, all inspection, maintenance, andlubrication intervals recommended in any MorrisMaterial Handling Technical Publication representminimum safe intervals for normal conditions.Similar ly, inspect ions recommended here ( forfrequent, periodic, and when required) should beconsidered as normal operating conditions.

Frequent InspectionsFrequent inspections are visual examinations by theoperator or other designated personnel which areperformed as follows during operation of the liftingequipment. Records are not required.

normal service -- monthly

heavy service -- weekly to monthly

severe service -- daily to weekly

1. A designated person (usually the operator) shalldetermine whether the conditions during theoperating cycle are found to constitute a hazard. If

so, a more detailed inspection must be made toverify the initial inspection, and if necessary toschedule corrective maintenance.

2. Visually inspect the operating mechanisms forproper operation, proper adjustment and unusualsounds.

3. Inspect and verify the operation of upper limitdevices as follows:

Prior to the initial use of any lifting equipmentduring each shift, the operator shall verifyoperation of the primary upper limit device under

no-load conditions. Care shall be exercised thatthe block shall be inched into the limit tripmechanism, or run in at slow speed. If the devicedoes not operate properly, the operator shallimmediately notify the appointed person to repairor replace the switch/switch mechanism.

The limit device which controls the upper limit oftravel of the load block shall not be used as anormal operating control unless additionalmeans are provided to prevent damage fromovertravel. Never actuate them unnecessarilyduring normal crane operation. Unnecessary

operation of the limit switch can contribute topremature limit switch failure, resulting inpersonal injury or death.

4. If equipped with a brake hydraulic system, inspectthe tanks, valves, pumps, l ines and othercomponents of the hydraulic systems for leakage.

5. Inspect hooks and hook latches for wear damage.(See ASME/ANSI B30.10.)

6. Verify that the rope spools onto the drum properlyand that it is seated into all sheaves properly.


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Safety Recommendations and Practices xv

7. Inspect the wire rope as described in the operationand maintenance manual supplied with the liftingequipment.

Periodic Inspection

Visual inspection by an appointed person makingrecords of apparent external conditions to provide thebasis for a continuing evaluation, as follows:

normal service -- equipment in place, yearly

heavy service -- equipment in place, 1/2 year toyearly

severe service -- equipment in place, quarterly

A designated person shall determine whetherconditions found during inspection constitute a hazardand whether disassembly of equipment is required.

1. The following items must be checked for during theperiodic inspection:

A. Deformed, cracked or corroded structure.

B. Loose or missing bolts, nuts, pins or rivets.

C.Cracks or excessive wear to sheave and drums.

D.Worn, cracked, or distorted parts such as pins,bearing, wheels, shafts, gears, rollers, lockingand clamping devices, bumpers and stops.

E. Excessive wear of brake system parts.

F. Excessive wear of chain drive sprockets and/ortoo loose chain.

G.Deterioration of all moving electric components,

buttons or switches.H.Proper operation of all sensors.

I. Operation of limit switches that interrupt power orgive a warning. Each motion shall be inched intothe limit with no load on the equipment.

J. Rope reeving for proper rope, attachment todrum, number of wraps on drum and proper fitinto groove.

K. Warning and instruction labels for legibility.

2. Check the hook for the following:

A.Cracks.B. Wear (reducing the working area of hook by 10

percent).

C.A bend or twist exceeding 10 degrees from theplane of an unbent hook. (See Figure 1 on pagexvii).

D.An increase in throat opening exceeding 15percent , o r as recommended by themanufacturer (See Figure 1 ).

Figure 1: Examples of Hook Wear

If latch that is provided becomes inoperativebecause of wear or deformation, it shall bereplaced or repaired before the hook is put backinto service. If the latch fails to fully close thethroat opening, the hook shall be removed fromservice until repairs are made.

Hooks having any of the above shall be removedfrom service unless a qualified person approves

their use and initiates corrective action. Hooksapproved for continued use shall be subjected tofrequent inspection.

Inspection As Required

The third type of inspection is to be done after incidentsof sudden and unusual shock loads, unusual stress or idamage is suspected. All incidents which might affecoperat ion of the crane should be fol lowed byimmediately taking the crane out of service andperforming a thorough inspection of the crane, using anecessary non-destructive test methods. All repairs

should be made before the machine is returned toservice.

TROUBLESHOOTING

Before beginning a troubleshooting procedurecommunicate with all persons that the equipment isbeing removed from operation and secure any/allockout tagout procedures. Failure to follow this warningmay lead to the injury or death of personnel. SeeLOCKOUT/TAGOUT PROCEDURES on page xvbefore proceeding with Inspections.

Troubleshooting a crane or a hoist is a special conditionof inspection which is not always addressed in a regulainspection or preventive maintenance scheduleTroubleshooting is usually done as a result of acomplaint of an unknown source of abnormal operationor noise, or any other indicat ion of unusuaperformance.

Special procedures for troubleshooting should beestablished to perform the function safely for alpersonnel concerned. Refer to the Care and Operationsmanual furnished with your equipment.

C D


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xviii Crane and Hoist Users

OSHA requires adequate fall protection when workingsix (6) feet or move above the floor.

MAINTENANCE

The first step to be taken before a maintenanceprocedure is started, is to communicate with all personsthat the equipment is being removed from operation and

secure any/all lockou/tagout procedures. Failure tostrictly follow this warning may lead to the injury or deatho f personne l . See LOCKOUT/TAGOUTPROCEDURES on page xvbefore proceeding withmaintenance.

Refer to manuals furnished with the equipment formaintenance inst ruct ions, requirements andrecommendations; or contact a ProCare ServiceCenter.

Perform the following precautions before doingmaintenance on a crane.

1. Move the crane to a location where the followingwork can be performed without interfering withproduction work in the area.

2. Land the load if it is attached to the crane.

3. Tie off wire ropes attached to the drum.

4. Place all controllers in the OFF position.

5. Perform a lockout/tagout procedure on the powersource for the crane.

6. On inverter type crane controls, wait ten (10)minutes for stored energy in capacitors to dischargebelow 50VDC. Never short capacitors to ground, as

a dangerous situation could result.

7. Use warning signs and barriers on the floor beneaththe crane where overhead maintenance workcreates a hazard.

8. If the runway must remain energized, provide stopsor a signal person(s), located full time at a visualvantage point for observing the approach of anactive crane(s), to prohibit contact by the activecrane(s) with the idle crane; with personsperforming maintenance; and with equipment usedin performing maintenance.

9. Install a guard, such as wire mesh, betweenadjacent runways for the length of the establishedwork area to prevent contact between personsperforming maintenance and a crane on theadjacent runway.

10. Use hand lines for lifting or lowering material, tools,etc.

11. Fasten hand lines securely to the crane or buildingstructure, not to persons on the crane or on thebuilding.

12. Use adequate fall protection equipment.

Perform the following precautions before doingmaintenance on a crane runway, the runway supportstructure, the runway conductor system, and the areasof the building in the path of travel of the crane bridge ortrolley.

1. Perform a lockout/tagout procedure on the powersource for this crane.

2. Use warning signs and barriers on the floor beneaththe crane during maintenance work.

3. If the runway must remain energized, provide stopsor a signal person(s), located full time at a visualvantage point for observing the approach of anactive crane(s), to prohibit contact by the activecrane(s) with persons performing maintenance andwith equipment used in performing maintenance.

4. Install a guard, such as wire mesh, betweenadjacent runways for the length of the establishedwork area to prevent contact between persons

performing maintenance and a crane on theadjacent runway.

5. Use adequate fall protection equipment.

OPERATIONAL SAFETYRECOMMENDATIONS

1. The crane operator is responsible for safe operationof the crane. When there is any doubt about safety,stop the crane and do not handle loads until safeconditions have been restored.

2. Read the manual provided with the equipmentbefore attempting to operate the equipment.

3. Read the manual provided with the equipmentbefore attempting to maintain or lubricate theequipment.

4. Be alert at all times. Do not eat, read, sleep orotherwise divert your attention while operating acrane. Practical jokes should be absolutelyforbidden and the use of alcohol or other intoxicantsis not to be tolerated.

5. Keep the crane cab and access clear and clean. Do

not permit loose objects such as tools, bolts,boards, etc., in or on the crane.

6. Before leaving control of the crane, take thefollowing precautions:

A.Land the load.

B. Raise the lower block to the upper limit of travel.

C.For a cab operated crane, put the crane or hoistat the location for entering or leaving the crane.

D.Make sure the controls are in the OFF position.


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Safety Recommendations and Practices xi

E. Place the main power switch in the OFF position.

F. Visually check for any abnormal condition.

G.Set the brake and anchor outdoor cranessecurely to prevent movement caused by thewind.

H.For a cab or pulpit operated crane, notify theproper authority when leaving the cab or pulpit.

7. Before making a lift the operator should make surethat:

A. The load is well secured and that slings areadequate and properly arranged for the load.

B. Slings are not kinked and that the load isbalanced.

C.All loose items are removed from both the loadand crane.

D.The load will not contact any obstruction whilelifting or travelling.

E. Before starting a lift, be sure the hoist line isvertical, that slack in the line is removed slowly,and that all personnel are clear of the area.

8. Do not pass over personnel, with or without a load.Use warning devices to alert personnel ofapproaching loads.

9. Never move loads carried by magnets or vacuumdevices above anyone. Failure of power to themagnets or vacuum devices will cause loads orparts of loads, to drop unexpectedly unless abackup power supply is furnished. Failure toobserve this precaution may result in serious injury

or death of personnel.

10. Avoid sudden starts and stops. Do not bump intorunway stops.

11. Never use a crane for side pulling. This practice maycause electrical as well as mechanical damage,and may endanger personnel.

12. No one rides the crane while it is in operation exceptthe operator. If persons other than the operatormust ride on the crane during operation, notify theoperator prior to boarding the crane. Additionalpersonnel who ride on cranes must ride in the

operators cab while the crane is in motion.

13. Never permit anyone to ride on the hook, the load,or in a manbasket.

14. If you must stand up in the crane cab whennecessary to improve vision while making a lift ormoving a load in any direction, make sure you havegood footing.

15. Be sure to use warning devices such as a bell, horn,siren, or light before the crane is moved and when

approaching persons in the path of movement othe load.

16. When a load is first lifted, test holding brakes bylifting the load only a few inches above its startingposition and move the controller to the OFFposition. If the load holds, the brake is operatingproperly. If the brake does not function properlymaintain control of the load using the hoist moto

and lower it slowly to rest. Report the conditionimmediately, and do not make any other lifts untithe condition has been corrected.

17. Never exceed the rated load of the crane. Be sure toinclude the weight of any special handling devices below

the reeved in bottom block, such as load bars, magnets

grabs etc. when calculating the the total weight of a load

You must KNOW that the rated capacity of the crane is no

being exceeded when preparing to make a lift.

18. If a wire rope has been allowed to become slackmake sure that the rope is properly seated on thedrum and in the sheaves before lifting the next load

19. Never lower the bottom block beyond the poinwhere two full wraps of wire rope remain on thedrum.

20. Never block out safety devices, such as limiswitches, in order to allow operation of the crane ina manner not intended by the manufacturer.

21. Do not lift loads with unused sling hooks hangingloose.

22. Make sure slings and other load lifting devices areclear of objects below while travelling.

23. Make sure load slings, load chains or other loadlifting devices are fully seated in the saddle of thehook before moving the load.

24. When a duplex hook (double saddle hook) is useda double sling or choker should be used to assurethat the load is equally divided over both saddles.

25. If electrical power fails, place all controllers in theOFF position and keep them there until power isrestored. This will prevent sudden and unexpectedmovement when power is restored.

26. When two or more cranes are used for one lift, it is

important that:A. The lift and signals are carefully planned in

advance.

B. You obey ALL stop signals, regardless of whogives them.

C.Signals are accepted from only one person at atime (except for stop signals) unless speciaarrangements are made in advance for a specificlift.


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xx Crane and Hoist Users

27. Standard crane signals are used. Do not move loadunless the standard signals are clearly given, seen,and understood (See : Standard Hand Signals onpage xxi).

28. The hitcher (a person other than the operator whosecure the loads) is generally in the best position tounderstand how to move the load. The operatorshould pay particular attention to the directions the

hitcher gives.29. Never remove a DO NOT OPERATE tag from a

control without checking to see that it is safe to doso, even if you have placed the tag there yourself.Someone else may be depending on the tag toprevent the crane from being operated.

30. Use both hands when climbing a crane ladder.

31. Never depend on a holding brake to suspend a loadunless the operator is at the controls, alert, and in aposition of readiness to handle the load.

32. When a new wire rope has been installed, work light

loads for a short period of time to allow the wire ropeto adjust to work strains. Check the wire ropeattaching means for tightness after the short periodof time.

33. Never get on or off a crane when it is in motion.

34. Never attempt to adjust, repair, or lubricate movingmachinery.

35. Keep the machine clean. Oil or grease can causeserious falls. Dirt in working parts will causeaccelerated wear.

36. If all wire rope is removed from the drum, be sure it

is rewound in the correct direction to prevent wirerope damage and to ensure correct operation of thehoist limit switches.

37. When replacing wire rope, tie off the rope to supportits weight before releasing rope end connectors.

38. Repairs and adjustments should be made only byauthorized personnel. When a crane is beingrepaired, the maintenance person is in charge of allcrane movement and operation, and his instructionsshould be obeyed. Only if his instructions areunsafe should the operator question them and the

maintenance supervisor be contacted at once for adecision.

39. Never move or bump a crane or hoist that has awarning signal or sign displayed.

40. When a crane must be contacted and/or pushedwith another crane:

A.Make sure all persons involved and concernedare aware and warned that the crane will becontacted and pushed.

B. Contact and push the crane at the slowestpossible speed.


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Safety Recommendations and Practices xx

Figure 2: Standard Hand Signals


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c h a p t e r

1

Introduction


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Smartorque Bull. 424V (14908-14912) Instruction Manual 02/05/021-3

The instructions in the next three chapters apply to most Smartorque Bull. 424V crane, hoist, andmonorail applications. However, you need to carefully evaluate your specific situation and ensurethat you follow NEC codes and your local wiring practices.

These chapters tell you how to install Smartorque Bull. 424V and, to some extent, the components

that it interconnects. It explains how to: assess the drives environment, mount the drive, and wire thedrive circuits. Its important to develop a plan of attack for both the mounting and wiring sinceeach task has an effect on the other one. To assist you, Smartorque Bull. 424V Wiring Practicesis included.

NOTE: If your Smartorque Bull. 424V is part of a Morris Material Handling, pre-engineered

TCONTROLSmotor control panel, disregard this chapter and turn to Chapter 4.

WARNING

Do not touch any circuitry components while the main AC power is on. In addition, youmust wait until the red CHARGE LED is out before performing any service on that unit.(As you look at the face of the circuitry, the CHARGE LED is located in the lower rightcorner of the board.) It may take as long as 10 minutes for the charge on the main DC buscapacitors to drop to a safe level.

Do not check signals during operation.

Do not connect the main output terminals (T1, T2, T3) to the incoming, three-phase ACsource.

Do not connect the control board terminals, which are the 27 two-tiered terminals,directly to the 120VAC user input device.

Before executing Built-In Auto-Tuning, ensure that the motor is disconnected from the drivetrain and the electric brake is released. If the electric brake cannot be released, you mustensure that the brake is disengaged for the entire tuning process.


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Introduction

Assessing the System Requirements

You must know how youre going to use the drive before you start installation and wiring. You will

need to know your requirements for the following components: Speed control method(s)

Braking method(s)

Power source voltage, number of phases, and kVA rating

Power source location

Wire size

Grounding location and method

Assessing the Drive Environment

When you choose a location for Smartorque Bull. 424V, perform the following steps:5. Ensure that a 220V or 230V (-15% to +10%) three-phase power source is available for a 230V-

rated drive, and that a 380V, 400V, 415V, 440V, or 460V (-15% to +10%) three-phase powersource is available for a 460V-rated drive, and that a 500V, 575V, 600V (-15% to +10%) powersource is available for a 575V Drive.

6. Ensure the encoder is supplied with +12VDC.

7. If the amperage requirement is greater than 200 mA, provide an auxiliary power supply to theencoder.

8. Ensure that the drive-to-motor wiring distance is less than 250 ft. unless appropriate reactorsand/or filters are used.

9. If required, install reactors.

When connecting a drive (230V/460V/575V, R43122D33V (older units-R20136D33V)R43121D34V (older unit-R21080D34V) and R42456D32V and smaller) to a large-capacitypower supply transformer (500kVA or greater or more than 10 times the inverter kVA rating), orwhen switching a phase-advancing capacitor, excessive peak current can flow through the inputpower supply circuit. To prevent damage to the rectifier section in such cases, install a DC reac-tor between drive Terminals 1 and 2, or an AC reactor on the input side. Installing reactors alsoimproves the power factor on the power supply side.

10. Ensure that the encoder wiring is less than 300 feet, unless fiber optic cables are used.

11. Ensure that the encoder wiring is isolated from the power wiring.

12. Ensure that the encoder wiring shield is grounded at only one end (PG-X2 TA3).

13. Ensure that the drive circuit wiring is protected or isolated from:


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Ambient temperatures outside the range of +14 F to +113 F (-10 C to +45 C). (Consult Morris

Material Handling if you must exceed this temperature range.)

Rain or moisture

Corrosive gases or liquids

Direct sunlight

Severe mechanical vibration

14. Ensure that the drive is housed in an appropriate NEMA-rated enclosure.

15. For severe-duty applications (for examplelong lifts) or with 75-Up-or-greater motors, ensurethat the drive control system is adequately cooled, even though the ambient temperature limit isnot exceeded. For more information, contact Morris Material Handling.


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Smartorque Bull. 424V General Specifications

230V Class

460V Class

575V Class

230V, 460V and 575VClasses

Specification Specification Values and Information for Each 230V-Class Model (R20136D_V, R43122D_V)D

6

D

8

D

11

D

17

D

25

D

33

D

54

D

68

D

80

D130

D160

D224

D300

Rated current (A) 6 8 11 17.5 25 33 54 64 80 130 160 224 300

Capacity (kVA) 2.3 3.0 4.2 6.7 9.5 13 19 20 25 50 61 85 110

Specifi-

cation Specification Values and Information for Each 460V-Class Model (R21080D_V, R43121D_V)D1

D3

D5

D8

D11

D14

D21

D28

D34

D41

D52

D65

D80

D96

D128

D165

D224

D302

D450

D605

Rated

current (A)

1.8 3.4 4.8 8 11 14 21 27 34 41 52 65 80 96 128 165 224 302 450 605

Capacity(kVA)

1.4 2.6 3.7 6.1 8.4 11 16 21 26 31 40 50 61 73 98 130 170 230 340 460

Specifi-

cation Specification Values and Information for Each 460V-Class Model (R42456D_V)D3

D4

D6

D9

D12

D17

D22

D27

D32

D41

D52

D62

D77

D99

D130

D172

D200

Rated current(A)

3.5 4.1 6.3 9.8 12.5 17 22 27 32 41 52 62 77 99 130 172 200

Capacity(kVA)

2 3 5 7.5 10 15 20 25 30 40 50 60 75 100 125 150 200

Specification Specification Value and Information for All Models

Certification UL, CUL, CSA

Rated input power supply volts & freq 3-phase 200/208/220/230V or 300/400/415/440/460V or 500/575/600V

Allowable input voltage fluctuation +10% or -15% of nominal

Allowable input frequency fluctuation 5% of nominal

Control method Fully digital, flux vector control; sine-wave, pulse-widthmodulated

Maximum output voltage(VAC) Max output voltage 3-phase, 200/208/220/230V; 380/400/415/440/460V; 500/575/600V

(proportional to input voltage).

Rated frequency (Hz) Up to twice motor nameplate RPM (Ultra-Lift) 150 Hz max

Output speed control range 1000:1

Output frequency accuracy .01%with digital reference command.1%with analog reference command; 10 bits/10V

Frequency reference resolution Digital: .01 Hz; analog: .03 Hz (at 60 Hz)

Output frequency resolution .01 Hz

Overload capacity 150% of rated load for 1 min

Remote frequency reference sources 010VDC (20k); 420mA (250); 10VDC (optional); serial (optional)

Accel/decel times 0.1 to 25.5 sec2 sets; 4 parameters are independently adjustable


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Braking torque Approximately 120% if motor and inverter are sized 1:1; 150% or more with dynamic braking(optional)

Motor overload protection Electronic thermal overload relay; field-programmable

Overcurrent protection level (OC1) 200% of rated current

Circuit protection Ground fault and blown-fuse protection

Overvoltage protection level 400/800/1000VDC

Undervoltage protection level 190/380/546VDC

Heatsink overtemperature Thermostat trips at 105 C

Torque limit selection Separate functions for FORWARD, REVERSE, REGEN.; all selectable from 0300%)

Stall prevention Separate functions for accel, decel, at-speed, and constant horsepower region

Other protection features Speed deviation, overspeed, mechanical brake failure, lost output phase, failed-oscillator, PG-disconnect, mechanical overload, and roll-back detection

DC bus voltage indication Charge LED is on until DC bus voltage drops below 50VDC

Location Indoors; requires protection from moisture, corrosive gases, and liquids

Ambient operating temperature 14 to 113 F (-10 to 45 C) for open chassis

Storage temperature -4 to 140 F (-20 to 60 C)

Humidity 90% relative; noncondensing

Vibration 1 G less than 20 Hz; 0.2 G for 2050 Hz

Elevation 3300 Ft. (1000M) or less

Specification Specification Value and Information for All Models


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CDBM & CDBR Units

The CDBM and CDBR are designed to pass regenerative energy from an inverters DC bus to aresistor bank. The CDBM/CDBR operate when the voltage on the DC bus reaches a specific levelwhich turns on an internal transistor. This transistor stays on until the DC bus voltage drops to anappropriate level. The difference between the turn on and the turn off voltage is the hysteresisvoltage.

The CDBM/CDBR, and its associated dynamic braking resistor, are used to help the inverterdecelerate AC motors (dynamic braking) and to provide a path for motor regenerative energy underover hauling conditions, such as on a hoist.

Minimum Resistor Ohmic Values

The following chart should be used to determine minimum ohmic values for dynamic brakingresistors for different supply voltages.

Minimum Ohmic Value for Braking Resistor

Supply

Voltage

Turn

On

Voltage

CDBM-2015 CDBM-2022 CDBM-4030 CDBM-4045 CDBM-4090 CDBM-4220 CDBM

CDBR-2015B CDBR-2022B CDBR-2110 CDBR-4030B CDBR-4045B CDBR-4090 CDBR-4220 CDBR-

200V 330V 8.3 5.5 1.3

208V 345V 8.6 5.8 1.4

220V 365V 9.1 6.1 1.5

230V 380V 9.5 6.3 1.5

380V 630V 15.8 10.5 6.3 2.5

400V 660V 16.5 11.0 6.6 2.6

415V 690V 17.3 11.5 6.9 2.8

440V 730V 18.3 12.2 7.3 2.9

460V 760V 19.0 12.7 7.6 3.0

500 825V 20.6

575 950V 23.8


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CDBM & CDBR Braking Unit Specification

* Loading time rate can be used below 10% ED (max. 10 min.)

AC power supply for cooling fan is used only for models CDBR-2110 and CDBR-4220.

Braking Unit Model

CDBM

200V to 300V 308V to 460V 500V to 575V

2015 2022 4030 4045 4090 4220 5037

CDBR 2015B 2022B 2110 4030B 4045B 4090 4220 5037

Applicable Motor Output

HP (kW)

20

(15)

30

(22)

150

(110)

40

(30)

60

(45)

120

(90)

300

(220)

57

(37)

OutputCharac-teristics

Max. DischargeCurrent (A(peak value)*

40 60 250 40 60 100 250 40

RatedDischargeCurrent (A)

15 20 80 15 18 30 80 15

Braking StartVoltage

330/345/365/380V 3V 630/660/690/730/760V 6V 825V/950V 8V

Max.HysteresisError

Approx. 8V Approx. 16V Approx. 20V

PowerSupply

VDC 243 (1.35 x 200 x 0.9) to 400Vpeak

460 (1.35 x 380 x 0.9) to 800V peak 607 (1.35 x500 x0.9) to1000V

VAC

Single phase 200 to 220V 50Hz200 to 230V 60Hz

Singlephase 380to460V50Hz/60Hz

ProtectiveFunctions

Fin Overheat Thermostat

Power ChargeIndication

Charge lamp stays ON until bus voltage drops below 50V.

Environ-mentalConditions

Location Indoor (protected from corrosive gases and dust)

AmbientTemperature

+14 to 104F (-10 to +40C) (not frozen)

StorageTemperature

-4 to +140F (-20 to +60C)

Humidity 90%RH (non-condensing)

Vibration 1G at less than 20Hz, up to 0.2G at 20 to 50 Hz

Protective Configuration Wall-mounted enclosed type

Heat Loss (W) 32 38 129 54 59 94 135 70


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CDBM Braking Unit Dimensions

Figure 1-1: CDBM Dimensions

Model Number

Dimensions in inches (mm)

Overall Mounting

W H D W1 H1 d

CDBM-2015

5.53(140.5)

11.0(279.5)

5.91(150)

3.94(100)

10.24(260)

0.24(6)

CDBM-2022CDBM-4030

CDBM-4045

CDBM-4090 8.50(216)

14.50(368)

5.94(151)

7.09(180)

13.98(355)

CDBM-4220 10.63(270)

14.50(368)

7.25(184)

8.27(210)

13.98(355)

CDBM-5037 5.53(140.5)

11.0(279.5)

5.91(150)

3.94(100)

10.24(260)


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CDBR-B Braking Unit Dimensions

Figure 1-2: CDBR-B Dimensions

Model Number


Wt. in

lbs. (kg)Overall Mounting

W H D W1 H1 d

CDBR-2015B

5.51(140) 5.91(150) 5.45(138.5) 5.04(128) 5.43(138) .16(4)CDBR-2022BCDBR-4030B 7.79(3.54)

CDBR-4045B


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CDBR Braking Unit Dimensions

Figure 1-3: CDBR Dimensions

Model Number


Overall Mounting

W H D W1 H1 d

CDBR-2110 7.09(180)

14.57(370)

7.87(200)

5.51(140)

13.78(350)

0.24(6)CDBR-4090 8.66(220) 14.76(375) 7.87(200) 7.09(180) 13.98(355)

CDBR-4220 9.84(250)

14.76(375)

7.87(200)

8.27(210)

13.98(355)

CDBR-5037 5.51(140)

11.02(280)

6.29(160)

3.94(100)

10.23(260)


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Installation/Wiring of CDBR/CDBM Braking Unit

NOTE: Some Braking units have only a symbol labeling the terminal.

Most resistors do not have P0(r0) and B (s0) designators. Polarity does not matter on the resistor.

1. Wire N (s) on the CDBR/CDBM to N (s) on the drive.

2. Wire P (r) on the CDBR/CDBM to P(r) on the drive.

3. Wire the P0(r0) on the CDBR/CDBM to the dynamic braking resistor.

4. Wire B (s0) on the CDBR/CDBM to the dynamic braking resistor.

5. CDBR model #4220 has an internal fan. It requires terminals r and s to be wired to one phase ofthe 460V line voltage in order to power the fan.

6. Terminals 3 and 4 are the Cooling Fin Overheat Contact.

Thermoswitch contact rating: 250VAC, 1A max 30VDC, 1A max

7. Terminals 1, 2, 5 and 6 are used for MASTER/SLAVEOperation. Use twisted-pair wires of 14AWG or smaller for connection between 5, 6, and 1, 2 on the braking units. Parallel connectionis possible up to a maximum of 10 units. Refer to Figure 1-4 (page 1-14) for parallel connectionof braking units.

8. Set the Voltage Selection Jumper to match the voltage of the incoming power source.

9. Set the Master/Slave Jumper to Master for single unit operation.

10. For further information, refer to CDBR/CDBM manual.

WARNING

120 VAC is not needed for the control circuit to operate. If 120 VAC is applied to

terminals 1, 2, 5 or 6, DAMAGE TO THE UNIT WILL RESULT.


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Figure 1-4: CDBR/CDBM Parallel connection of Braking Unit


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AC Reactor Specifications

Reactors, both as input (line) and output (load) devices, protect adjustable frequency drives, motors,and other load devices against excessive voltage and current.

The following guidelines may help determine input and output reactor requirements:

Install an input reactor if the power source is greater than500kVA.

Install an output reactor if the distance between the drive and the motor exceeds 150 feet.

Install an output reactor if a device, such as a power limit switch, is used to disconnect the motorfrom the drive.

Install one output reactor per drive for a multiple-drive arrangement requiring reactor protection.

For a multiple drive arrangement, an input reactor for each drive is recommended for optimalprotection. However, if the drives are within two drive sizes of each other, a single input reactorcan be used. The reactor must be rated at an amperage equal to or greater than the sum of theamperage for all the drives.

230V Class

Model Number (Older Units) 230V Part Number Maximum Amps of Reactor

R43122D6 V R20136D6V REA230-2 8

R43122D8V R20136D8V REA230-2 8

R43122D11V R20136D11V REA230-3 12

R43122D17V R20136D17V REA230-5 18

R43122D25V R20136D25V REA230-7.5 25

R43122D33V R20136D33V REA230-10 35

R43122D54 V R20136D54V REA230-20 55

R43122D68V R20136D68V REA230-25 80

R43122D80V R20136D80V REA230-30 80

R43122D130V R20136D130V REA230-50 130

R43122D160V R20136D160V REA230-60 160

R43122D224V R20136D224V REA230-100 250

R43122D300V R20136D300V REA230-125 320


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460V Class

575V Class

Model Number (Older Units) 460V Part Number Maximum Amps of Reactor

R43121D1V R21080D1V REA460-1 2

R43121D3V R21080D3V REA460-2 4

R43121D5V R21080D5V REA460-5 8

R43121D8V R21080D8V REA460-5 8

R43121D11V R21080D11V REA460-7.5 12

R43121D14V R21080D14V REA460-10 18

R43121D21V R21080D21V REA460-15 25

R43121D28V R21080D28V REA460-20 35

R43121D34V R21080D34V REA460-25 35

R43121D41V R21080D41V REA460-30 45

R43121D52V R21080D52V REA460-40 55

R43121D65V R21080D65V REA460-50 80

R43121D80V R21080D80V REA460-60 80

R43121D96V R21080D96V REA460-75 100

R43121D128V R21080D128V REA460-100 130

R43121D165V R21080D165V REA460-150 200

R43121D224V R21080D224V REA460-200 250

R43121D302V R21080D302V REA460-250 320

R43121D450V R21080D450V REA460-400 500

R43121D605V R21080D605V REA460-500 600

Model Number 575V Part Number Maximum Amps of ReactorR42456D3V REA575-2 & 3 4

R42456D4V REA575-2 & 3 4

R42456D6V REA575-5 8

R42456D9V REA575-10 12

R42456D12V REA575-10 12

R42456D17V REA575-15 18

R42456D22V REA575-20 & 25 25

R42456D32V REA575-30 35

R42456D41V REA575-40 45

R42456D52V REA575-50 55R42456D62V REA575-60 & 75 80

R42456D77V REA575-60 & 75 80

R42456D99V REA575-100 100

R42456D130V REA575-150 160

R42456D172V REA575-200 200

R42456D200V REA575-200 200


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Interface Cards Specifications

SMARTORQUE Bulletin 424V is designed to interface directly with 120VAC user input andoutput devices via G5IF, G5IN4, and G5OUT. This eliminates the need for an additional interfacerelay or isolation circuitry.

G5IF has eight optically isolated drive terminals which can be used to connect with the user inputdevice. The Terminal 1 and 2 are always used for the directional run commands (Forward andReverse, Up and Down). The rest of six terminals are multi-function terminals, and are used forspeed control and other characteristics. With multi-function terminals you can assign variousfunctions and performance characteristics without having to rewire the drive.

G5OUT has two 240VAC, 1.5 Amp solid state relays for output indication devices. It includes twoprogrammable multi-function output ter

Drive Grua Cat424v-3

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