SERVICE MANUAL FOR

DYNACON VECTOR II
CONTROL VOLTAGE UNIT
D2R REV 5.2 CON3V040
HU4.07.0095en / rev. A / 01.07.2011

This document and the information contained herein, is the exclusive property of Konecranes Plc and represents a non-public, confidential and proprietary trade secret that may not be
reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes Plc. Copyright © (2011) Konecranes Plc.
All rights reserved.
HU4.07.0095en / Rev. A / 01.07.2011 / Con3V040

m CAUTION:

1. Before starting, read the instructions carefully.

2. Verify that all of the connections are in accordance to the drawings.

3. Check that the device cover is properly installed.

4. High voltages are present in this device. Switch the power off and after the display turns off,
wait 5 minutes before opening the cover.

5. Insulation resistance test with a megger requires special precautions.

6. Do not make any measurements inside the device when it is connected to the main supply.

7. Do not touch the components on the circuit boards. Static voltage discharge may cause
damage or destroy the IC-circuits.

8. Check that all of the ventilation holes are clear and uncovered.

9. Do not make any inspections unless the supply has been disconnected by the main switch.

10. It is forbidden to use radiophones or portable phones near this device with the doors open.

11. All the doors and covers must be closed during crane operation.

This manual is valid for DynACon revision 5.2. The release number of this document is HU4.07.0095en. The
parameter numbers are based on the software version Con3V040.

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This document and the information contained herein, is the exclusive property of Konecranes Plc and represents a non-public, confidential and proprietary trade secret that may not
be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes Plc. Copyright © (2011)
Konecranes Plc. All rights reserved.
HU4.07.0095en / Rev. A / 01.07.2011 / Con3V040

Table of contents

1 GENERAL .................................................................................................................................................. 4
1.1 Technical data ................................................................................................................................... 4
1.2 Type mark coding .............................................................................................................................. 5
1.3 Basic description................................................................................................................................ 6
1.4 Main components .............................................................................................................................. 6
1.5 Functional description........................................................................................................................ 7
1.6 EMC ................................................................................................................................................... 8
1.6.1 Fulfilled EMC-standards ................................................................................................................ 8
2 INSTALLATION ......................................................................................................................................... 9
2.1 Cooling............................................................................................................................................... 9
2.2 Power cabling .................................................................................................................................... 9
2.3 Sinus filter ........................................................................................................................................ 10
2.4 EMC compatible grounding ............................................................................................................. 10
3 START-UP PROCEDURE ....................................................................................................................... 11
3.1 Visual checks................................................................................................................................... 11
3.2 Test run............................................................................................................................................ 11
3.3 After the test run .............................................................................................................................. 11
4 PARAMETER ADJUSTMENTS............................................................................................................... 12
4.1 Control keypad operation................................................................................................................. 12
4.1.1 Navigation on the control keypad ................................................................................................ 13
4.1.2 Value line editing ......................................................................................................................... 13
4.1.3 Special button functions............................................................................................................... 14
4.2 Passwords ....................................................................................................................................... 15
4.3 Basic parameters adjustment .......................................................................................................... 15
4.3.1 Automatic mode ........................................................................................................................... 15
5 PARAMETER DESCRIPTIONS............................................................................................................... 16
6 COMPONENTS........................................................................................................................................ 19
6.1 DynACon spare parts list ................................................................................................................. 19
6.2 Inverter............................................................................................................................................. 19
6.2.1 Inverter main circuit diagram ....................................................................................................... 19
6.2.2 Power supply unit (PSU).............................................................................................................. 20
6.2.3 Control unit (CSU) ....................................................................................................................... 20
6.2.4 Relay / Thermistor board (Slot B) ................................................................................................ 21
6.2.5 Profibus board (Slot E) ................................................................................................................ 22
7 TROUBLESHOOTING ............................................................................................................................. 23
7.1 Field repair actions .......................................................................................................................... 23
7.2 Troubleshooting actions................................................................................................................... 23
7.3 Inverter fault codes .......................................................................................................................... 24
7.3.1 Fault time data record.................................................................................................................. 28
7.3.2 Fault Counter ............................................................................................................................... 28
8 SERVICE .................................................................................................................................................. 29
8.1 DC-bus electrolytic capacitors ......................................................................................................... 29
8.1.1 Re-forming after a long storage period ........................................................................................ 29
9 DRAWINGS.............................................................................................................................................. 30
9.1 Description of terminals ................................................................................................................... 30
9.2 Layouts, dimensions and weights.................................................................................................... 31
9.3 Circuit diagrams............................................................................................................................... 32

3/32
This document and the information contained herein, is the exclusive property of Konecranes Plc and represents a non-public, confidential and proprietary trade secret that may not
be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes Plc. Copyright © (2011)
Konecranes Plc. All rights reserved.
HU4.07.0095en / Rev. A / 01.07.2011 / Con3V040

1 GENERAL

1.1 Technical data

Power class 022F 045F
Power (kVA) at 400 V 33 60
Output current In (A) 48 90
Max. current 1min (A) 72 135

Overloadability 1.5 x In, 1min/10min

Max. output voltage

AC-supply Equal to supply voltage
DC-supply DC supply voltage x 0.8

Supply
Supply voltage 380-500 VAC or 513-800 VDC
Supply frequency 45 - 66 Hz or DC

Control features
Control principle Vector control
Control modes Profibus-DP, keypad, automatic

Protections
Overload protection Fault is detected if the current momentarily exceeds 280% of rated current
Undervoltage / blown fuse Fault is detected if DC voltage drops below 333 V or in special applications 200 V
Overvoltage protection Fault is detected if DC voltage exceeds 911 V
Momentary power loss Immediate fault stop
Inverter overtemperature Temperature sensor on the heat sink
Earth fault Provided by electronic circuitry
Supply side short circuit protection External fuses or circuit breaker

Ambient conditions
Ambient temperature -10°C ... +40°C (14°F ... 104°F) for ED≤100%
Storage temperature -40°C ... +60°C (-40°F ... 140°F) dry. Power on >1h in a year.
Humidity <95%RH (no condensation)
Altitude Maximum 1000m at In. Above 1000m: In reduces 1% per each 100 m.
Above 3000m: consult factory.
Vibration Operation: maximum displacement amplitude 1mm at 5 – 15.8 Hz.
Maximum acceleration amplitude 1G (9.81 m/s²) at 15.8 – 150 Hz

Conforms to LV and EMC directives.

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This document and the information contained herein, is the exclusive property of Konecranes Plc and represents a non-public, confidential and proprietary trade secret that may not
be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes Plc. Copyright © (2011)
Konecranes Plc. All rights reserved.
HU4.07.0095en / Rev. A / 01.07.2011 / Con3V040

1.2 Type mark coding

D2R Device name

D2R

045 Power rating class

022F, 045F

F Supply voltage
F 380 - 500 VAC, 50/60 Hz

0 Control voltage
0 42 - 230 VAC, 50/60 Hz

52 Revision code
The latest revision may differ

D2R 045 F V 52 E R 0 D L
Braking type
E No braking E

Mounting
R Spread mounting R

Supply network
0 Unlimited (non-grounded network) 0

Boards Reserved board slots

D Profibus B, E D

Special
L Varnished boards L

5/32
This document and the information contained herein, is the exclusive property of Konecranes Plc and represents a non-public, confidential and proprietary trade secret that may not
be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes Plc. Copyright © (2011)
Konecranes Plc. All rights reserved.
HU4.07.0095en / Rev. A / 01.07.2011 / Con3V040

1.3 Basic description

DynACon is a power converter designed to supply control voltage to auxiliary loads. It can be connected to
AC-supply or in common DC-bus.

1.4 Main components

The main components are:
Position Description
A1 Inverter

The most important external components:

Position Description
F1 DC-bus fuse (positive) Only in DC-supply
F2 DC-bus fuse (negative) Only in DC-supply
Sinus filter

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This document and the information contained herein, is the exclusive property of Konecranes Plc and represents a non-public, confidential and proprietary trade secret that may not
be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes Plc. Copyright © (2011)
Konecranes Plc. All rights reserved.
HU4.07.0095en / Rev. A / 01.07.2011 / Con3V040

1.5 Functional description

Charging of the DC-bus AC-supply
Internal charging circuit can be used. Connect Supply voltages to line
terminals (L1, L2, L3).
DC-supply
DC-bus needs to be charged with external charging circuit before DynACon
can start.

Operation in start Automatic mode

situation After DC-bus is charged, the DynACon starts automatically. Voltage level is
set by parameter P2.1.6 DC Start Limit.
Panel mode
DynACon can be started from the start button of the panel 1 second after the
DC-bus is charged. After successful start DynACon will stay in RUN-state.
Profibus mode
DynACon can be started via Profibus 1 second after the DC-bus is charged.

Operation in stop Automatic mode

situation DynACon stops automatically if DC-bus voltage drops below the value
defined in parameter P2.1.7 DC Stop Limit and restarts when voltage rises
above P2.1.6 DC Start Limit.
Panel mode
DynACon can be stopped from the stop button of the panel. DynACon stops
automatically if DC-bus voltage drops below the value defined in parameter
P2.1.7 DC Stop Limit.
Profibus mode
DynACon can be stopped via Profibus by disabling the RUN command.
DynACon stops automatically if DC-bus voltage drops below the value
defined in parameter P2.1.7 DC Stop Limit.

Start is possible only after power off if the control place is changed to Automatic by parameter P2.1.8 or
“select+enter” button combination. Power off is also needed if P2.1.6 DC Start Limit is changed.
If the control place is changed to Profibus by parameter P2.1.8 Control Place start is possible after the RUN
command has been disabled.

7/32
This document and the information contained herein, is the exclusive property of Konecranes Plc and represents a non-public, confidential and proprietary trade secret that may not
be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes Plc. Copyright © (2011)
Konecranes Plc. All rights reserved.
HU4.07.0095en / Rev. A / 01.07.2011 / Con3V040

1.6 EMC
"EMC" stands for the Electro Magnetic Compatibility. According to the EMC directive "the apparatus shall be
so constructed that:
a) The electromagnetic disturbance it generates does not exceed a level allowing other apparatus to
operate as intended
b) The apparatus has an adequate level of intrinsic immunity of electromagnetic disturbance to enable it to
operate as intended."
Technical The technical construction file describes how the frequency converters have
construction file been constructed to comply with the directive and standard requirements.
Declaration With the declaration of conformity the manufacturer informs that device is
of conformity manufactured to fulfill required EMC standards.
CE-mark The CE marking is a declaration by a manufacturer or importer located in the
European Economic Area that a product complies with the safety and health
requirements of the directive in question. The manufacturer demonstrates for
the authorities that the product complies with the safety requirements within the
EU.
EMC Plan EMC Plan for inverters is intend to use as a guide in cases when disturbance
problems appears in crane installations, in the crane itself or in other device in
installation environment.
Environments Immunity and emission requirements are divided in two levels in the product
standard according to the environments.
First environment means environment that includes domestic premises and
also establishments directly connected to a low-voltage power supply network.
The first environment is divided in to categories C1 and C2.
DynACon is not intended to be used on a low-voltage public network, which
PDS supplies domestic premises. It may cause radio frequency interference to other
devices if used on such a network.
Second environment means environment that includes all establishments other
than those directly connected a low-voltage power supply network. The second
environment is divided in to categories C3 and C4.
If rated current of the crane supply is less than 400 A, the inverters belong to
the category C3, otherwise they belong to the category C4.
PDS Power drive system (PDS) means a system consisting of power and control
equipment, including DynACon.

1.6.1 Fulfilled EMC-standards

Immunity DynACon fulfills the immunity requirements defined in the EN/IEC 61800-3: 2004
for the second environment, EN/IEC 61000-6-1 (residential, commercial and light
industry) and EN/IEC 61000-6-2 (industrial environment).
Emissions DynACon is designed according to the EN/IEC 61800-3: 2004 to fulfill the EMC
requirements. However it doesn’t need to fulfill emission requirements for the
second environment because it belongs to the category C4. If there occurs
disturbance problems the EMC Plan can be used as the guide to solve those.

8/32
This document and the information contained herein, is the exclusive property of Konecranes Plc and represents a non-public, confidential and proprietary trade secret that may not
be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes Plc. Copyright © (2011)
Konecranes Plc. All rights reserved.
HU4.07.0095en / Rev. A / 01.07.2011 / Con3V040

2 INSTALLATION

2.1 Cooling
The need of cooling arrangements for the DynACon varies by application. The actual thermal loading of the
enclosure has to be estimated based on the loading conditions and duty cycles. The power losses are listed
in the below table.

Inverter Power losses [W]

Model ED40 ED60 ED100
022F 208 292 460
045F 308 435 688

2.2 Power cabling

Shielded cable There is no need to use shielded cables in DynACon power supply.
Cable selection Cabling for DynACon can be done using normal crane cables. All the cables
must be dimensioned according to local regulations. Ambient temperature,
cabling method (size of bunches etc.) and allowable current for the cable in use
must be taken into consideration. If there are no other regulations, following
values can be used (three phase 400V supply).
The table below is based on ED ≤ 60% and ambient temperature +40°C
(104°F). A higher ambient temperature may require increased cable sizes. The
continuous current (Icont) of DynACon is selected to be the dimensioning
current. If the actual load current is below DynACon continuous current, then
the AC fuses and the supply cable may be dimensioned according to the load
current.
Dimensioning of the DC-fuse should not be changed.

Power class 022F 045F

Continuous current In (A) ICONT A 48 90
DC-fuse A 125 250
AC-fuse A 50 100
Power cables 40°C mm² 10 35
104°F AWG 6 2

Cable protection To protect the AC-supply cables against short circuit there must be fuses or
motor circuit breakers (MCCBs) installed at the generator end of the AC-supply
cable. Dimensioning of the fuses or MCCBs depends on the cable used and on
the type of primary fuses or MCCBs. If there are no other regulations, the
values given in this section can be used to dimension fuses (three phase 400V
supply).
The fuses of the supply provide the short circuit protection.
DC-bus protection DC-bus is protected against short circuits by DC-fuses.
Each unit connected to the common DC-bus has its own DC-fuses.

All control cables must be placed as far from the power cables as possible.

9/32
This document and the information contained herein, is the exclusive property of Konecranes Plc and represents a non-public, confidential and proprietary trade secret that may not
be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes Plc. Copyright © (2011)
Konecranes Plc. All rights reserved.
HU4.07.0095en / Rev. A / 01.07.2011 / Con3V040

2.3 Sinus filter

A sinus filter needs to be used between DynACon and the auxiliary load. Cabling between DynACon and the
filter should be as short as possible.
Switching frequency of DynACon is 7.5 kHz. Operation point of the sinus filter must be selected accordingly.
The load should be connected to the capacitive side of the filter if LC-type filter is used.

2.4 EMC compatible grounding

Construction All metal construction parts of the cubicle must be electrically connected to
connections each other using largest possible surface area. Paint to paint connection must
not be used.
Cable connections Control cables and power cables should be separated and routed separately
for eliminating noise coupling. Cable lengths should be kept as short as
possible to minimize coupling capacitances and inductances.
Shielded control Shielded control cables should be grounded in both ends. The shield must be
cables connected to the ground using the largest possible surface area. Extra
intermediary terminators cutting the shield are not allowed, the shield should be
as integrity as possible. Spare conductors should be grounded in the both
ends. All shielded cable shields should be 360 degree grounded.

10/32
This document and the information contained herein, is the exclusive property of Konecranes Plc and represents a non-public, confidential and proprietary trade secret that may not
be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes Plc. Copyright © (2011)
Konecranes Plc. All rights reserved.
HU4.07.0095en / Rev. A / 01.07.2011 / Con3V040

3 START-UP PROCEDURE
If any problems or malfunctions occur during the start-up, refer to chapter “Troubleshooting”, to find out the
reason. All problems must be solved before continuing.

cm WARNING: High voltages inside the device. Wait for at least five minutes after the
supply voltage has been switched off before doing any service actions. The display in
the operating condition (lights on) indicates a dangerous voltage on the DC-bus. When
display turns off, the DC-bus voltage is approximately 100 Vdc. Note also that there is
always a dangerous voltage in the braking resistor when the DC-bus is charged.

Do not connect any AC voltage to the DC-bus terminals of DynACon (B+ and B-). Otherwise, the inverter
will be damaged.
Do not connect any DC voltage to the line terminals of DynACon (L1, L2, L3). Otherwise, the inverter will
be damaged.
The overload protection of DynACon protects the output cables. The fuses or motor circuit breaker of the
supply provide short circuit protection.
Fuses in DC-bus provide circuit protection when DC-supply is used.
CAUTION: Make sure that polarity of the DC-bus connections is correct. Otherwise, the inverter will
be damaged.

3.1 Visual checks

Record all checks and results.
Check condition of the cubicles.
Check that DynACon serial number is the same as in the delivery documents.
Check the cabling to sinus filter.
Check the supply cabling.

3.2 Test run

cm WARNING: High voltages inside the device.

The parameters are properly set after factory tests and no adjustments are needed except for the
parameters that depend on the application, the sinus filter or the load.
Check the power supply voltage (nominal voltage +/- 10%).
Turn on the power from the main switch.
Check that DC-bus is charged. (If DC-supply is used).
Check that DynACon comes in READY state (green status indicator turns on).
In a fault situation, the red FAULT status indicator blinks and the display shows a fault code.
Check that DynACon comes in RUN state (green status indicator turns on). This happens automatically if
P2.1.8 Control place is Auto and DC voltage is above P2.1.6 DC start limit. For other control alternatives
see chapter 1.5 Functional description.
Measure the AC voltage after the sinus filter. If necessary make adjustments with P2.1.5 Output Voltage.
Turn off the power from the main switch.

3.3 After the test run

Record possible parameter value changes in the parameter list.
Make sure all remarks and setting values are recorded.
Copy all parameters up to keypad memory by parameter S5.3.2 Up to keypad.
Save user parameters in Control Unit by parameter B1.7.2 Save User Par.

11/32
This document and the information contained herein, is the exclusive property of Konecranes Plc and represents a non-public, confidential and proprietary trade secret that may not
be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes Plc. Copyright © (2011)
Konecranes Plc. All rights reserved.
HU4.07.0095en / Rev. A / 01.07.2011 / Con3V040

4 PARAMETER ADJUSTMENTS

4.1 Control keypad operation

Drive status indications:

RUN DynACon is running
Always on
RUN STOP READY ALARM FAULT Not used in DynACon
V1.1 I/O term Keypad Bus/Comm Auto STOP DynACon is stopped
READY No faults present
Output Voltage ALARM Warning is on

400 V FAULT Fault is on

Control place indications:

I/O term Not used in DynACon.
ready run fault
Keypad Control keypad is the selected control place.
START Bus/Comm Control through Profibus is selected.
Auto
Automatic control.
reset

STOP Text lines:

Line 1 Location indication (parameter number).
Line 2 Description line (parameter name).
Line 3 Value line (parameter value).
select enter
Status LEDs:
ready green Illuminates when no faults are present.
run green Illuminates when DynACon is running.
fault red Illuminates when fault is on.

Button Description Button Description

RUN request if the keypad is the active control

reset Reset active faults START place

STOP request if the keypad is the active control

select Switch between two latest displays STOP place

enter Confirmation of selections

Move to previous menu level

Browse up the menus
Move cursor left
Increase values
Exit edit mode

Move to next menu level

Browse down the menus
Move cursor right
Decrease values
Enter edit mode

m WARNING: Do not change to keypad control during crane operation. This may cause
hazardous situation.

12/32
This document and the information contained herein, is the exclusive property of Konecranes Plc and represents a non-public, confidential and proprietary trade secret that may not
be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes Plc. Copyright © (2011)
Konecranes Plc. All rights reserved.
HU4.07.0095en / Rev. A / 01.07.2011 / Con3V040

4.1.1 Navigation on the control keypad

B = Button G = Group N = Multimonitor T = Trip Counter
C = Counter H = Fault History P = Parameter V = Value
D = Data I = Info R = Reference
E = Expander M = Menu Group S = System

STOP READY STOP READY

M5. Auto
S5.2. Auto

System Menu Application

S1 S11 Control
STOP READY STOP READY STOP READY

M4. Auto
H4.1. Auto
T4.1.1. Auto

Fault History 1 Overcurrent Operation days

H1 Hxx F T1 T16 0
STOP READY

M3. Auto

Active Faults
F0
STOP READY STOP READY STOP READY

G2. Auto
G2.1. Auto
P2.1.6. Auto

Parameters Basic Parameters DC Start Limit

G1 G5 P1 P10 600 V
STOP READY STOP READY

G1. Auto
V1.1. Auto

Monitoring Output Voltage

V1 G13 0.00 V

4.1.2 Value line editing

STOP READY Mode Edit Accept

P2.1.7. Auto change value value

DC Stop Limit
enter
400 V

m WARNING: Changing parameter settings during running may cause a hazardous situation.
Parameter settings must not be changed during running.

13/32
This document and the information contained herein, is the exclusive property of Konecranes Plc and represents a non-public, confidential and proprietary trade secret that may not
be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes Plc. Copyright © (2011)
Konecranes Plc. All rights reserved.
HU4.07.0095en / Rev. A / 01.07.2011 / Con3V040

4.1.3 Special button functions

In the following functions button must be held down for a specific time.

Button Time Description

delay

>3
Displays the software version.
seconds

>3
START Password level changes to Level 3 Engineering.
seconds

>0
select enter seconds
Switches start function between selected control place and keypad.

>1
enter seconds
Resets whole H4 Fault History when display in any level of H4 menu.

m WARNING: Do not change to keypad control during crane operation. This may cause
hazardous situation.

14/32
This document and the information contained herein, is the exclusive property of Konecranes Plc and represents a non-public, confidential and proprietary trade secret that may not
be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes Plc. Copyright © (2011)
Konecranes Plc. All rights reserved.
HU4.07.0095en / Rev. A / 01.07.2011 / Con3V040

4.2 Passwords

Parameter Name Description

P2.1.1 Password Following passwords release the parameter locks.
Level 1 Locked 0
Level 2 Start-up 26
Level 3 Engineering 768

4.3 Basic parameters adjustment

The basic setup of the drive is made with parameters that are listed below.
P2.1.4 Output frequency Set to 50 Hz or 60 Hz according to desired control voltage frequency.
P2.1.5 Output voltage Set to desired output voltage. Increasing of the value P2.1.5 can compensate possible voltage drop
in sinus filter or in transformer.
P2.1.7 DC Stop limit Set according to P2.1.5 output voltage and acceptable voltage drop in output voltage.
P2.1.8 Control place Choose the desired control place.
P2.1.9 Current limit Set to maximum acceptable current of the sinus filter (normally 1.5 … 2 x In) Note that the value
must be limited to drive maximum output current (1 minute value).

Drive cannot produce the desired output voltage if the DC link voltage is too low. To avoid undervoltage
situations in the output DC Stop Limit is defined. Drive stops driving if the DC link voltage drops below the
limit. Following table shows the minimum value for the limit according to output voltage and maximum
acceptable voltage drop.

Output voltage Max. voltage drop DC stop limit (P2.1.5)

260 V 0% 340 V
260 V 5% 320 V
260 V 10 % 305 V
400 V 0% 520 V
400 V 5% 495 V
400 V 10 % 470 V
415 V 0% 535 V
415 V 5% 508 V
415 V 10% 485 V
460 V 0% 595 V
460 V 5% 565 V
460 V 10% 535 V
480 V 0% 625 V
480 V 5% 590 V
480 V 10% 560 V

Notice that the voltage drops in sinus filter and transformers when adjusting the P2.1.7 DC Stop Limit.

4.3.1 Automatic mode

In automatic mode (P2.1.8 = Auto) the P2.1.6 DC Start Limit is used. Drive starts automatically when DC bus
voltage exceeds the DC Start Limit. DC bus voltage can be read from value V1.4 DC Link Volt. If DC Start
Limit is changed the restart is possible only after power off.

P2.1.6 DC start limit Set to 1.2 …1.3 x AC supply voltage. DC start limit should be at least 5 V higher than DC Stop
Limit (P2.1.7). Limit cannot be set lower than P2.1.7.

15/32
This document and the information contained herein, is the exclusive property of Konecranes Plc and represents a non-public, confidential and proprietary trade secret that may not
be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes Plc. Copyright © (2011)
Konecranes Plc. All rights reserved.
HU4.07.0095en / Rev. A / 01.07.2011 / Con3V040

5 PARAMETER DESCRIPTIONS
Below are listed the default values for parameters in DynACon. Also are listed the password lock levels for
parameter P2.1.1. This parameter list is based on the software version Con3V040.
022F 022F 045F 045F
G1 Monitoring 260V 50Hz 260V 60Hz 400V 50Hz 480V 60Hz Unit PW 1 Description
V1.1 Output Voltage V 1
V1.2 Output Current A 1
V1.3 Output Frequency Hz 1
V1.4 DC Link Volt V 1
V1.5 Unit Temperature °C 1
V1.6 Power kW 1
G1.7 Parameter Backup 260V 50Hz 260V 60Hz 400V 50Hz 480V 60Hz Unit PW 1 Description
B1.7.1 Load Default Par 1 Enter
Loading
B1.7.2 Save User Par 1 Enter
Saving
B1.7.3 Load User Par 1 Enter
Loading
B1.7.4 Save Default Par 260V 50Hz 260V 60Hz 400V 50Hz 480V 60Hz Unit PW 4 Description
B1.7.4.1 Save Default Par 4 Enter
Saving
G1.8 Relay Output 260V 50Hz 260V 60Hz 400V 50Hz 480V 60Hz Unit PW 1 Description
V1.8.1 ROB1 State 1
V1.8.2 ROB2 State 1
G1.9 Operate Counters 260V 50Hz 260V 60Hz 400V 50Hz 480V 60Hz Unit PW 1 Description
V1.9.1 Output MWh MWh 1
V1.9.2 Runtime (h) h 1
G1.10 Fault Counters 260V 50Hz 260V 60Hz 400V 50Hz 480V 60Hz Unit PW 1 Description
V1.10.1 F1 Overcurrent 1
V1.10.2 F2 Overvoltage 1
V1.10.3 F3 Earth Fault 1
V1.10.4 F7 Saturation 1
V1.10.5 F9 Undervoltage 1
V1.10.6 F10 Input Phase 1
V1.10.7 F11 Output Phase 1
V1.10.8 F13 Undertemp 1
V1.10.9 F14 Overtemp 1
V1.10.10 F25 Watchdog 1
V1.10.11 F31 IGBT Temp HW 1
V1.10.12 F41 IGBT Temp 1
V1.10.13 F53 Profibus 1
V1.10.14 F57 Thermistor 1
V1.10.15 Other faults 1
V1.10.16 Total Faults 1
G1.11 Bus Control 260V 50Hz 260V 60Hz 400V 50Hz 480V 60Hz Unit PW 1 Description
V1.11.1 Run Request 1
V1.11.2 Profibus status 1
G1.12 Service 260V 50Hz 260V 60Hz 400V 50Hz 480V 60Hz Unit PW 3 Description
V1.12.1 HeatSinkTempMax °C 3
V1.12.2 HeatSinkTempMin °C 3
V1.12.3 IGBT Temp Max °C 3
V1.12.4 IGBT Temperature °C 3
G1.12.5 Max Current 260V 50Hz 260V 60Hz 400V 50Hz 480V 60Hz Unit PW 3 Description
V1.12.5.1 Max Current A 3
V1.12.5.2 Max Current Freq Hz 3
G1.13 Multimonitor 260V 50Hz 260V 60Hz 400V 50Hz 480V 60Hz Unit PW 1 Description
N1.13.1 V/A/Hz 1
G2 Parameters
G2.1 Basic Parameters 260V 50Hz 260V 60Hz 400V 50Hz 480V 60Hz Unit PW 1 Description
P2.1.1 Password 0 0 0 0 1
V2.1.2 Supply Voltage 1 2 = J 200V - 240V
5 = F 380V - 500V
6 = K 525V - 690V
V2.1.3 Device 1 1 = Control
P2.1.4 Output Frequency 1 2 1 2 1 0 = None
1 = 50 Hz
2 = 60 Hz
P2.1.5 Output Voltage 260 260 400 480 V 1
P2.1.6 DC Start Limit 450 450 600 600 V 1
P2.1.7 DC Stop Limit 340 340 550 560 V 1
P2.1.8 Control Place 1 1 1 1 1 0 = Panel
1 = Auto
2 = Bus
P2.1.9 Current Limit 72.0 72.0 84.0 84.0 A 1
P2.1.10 Voltage Boost 0 0 0 0 % 1

16/32
This document and the information contained herein, is the exclusive property of Konecranes Plc and represents a non-public, confidential and proprietary trade secret that may not
be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes Plc. Copyright © (2011)
Konecranes Plc. All rights reserved.
HU4.07.0095en / Rev. A / 01.07.2011 / Con3V040

022F 022F 045F 045F

G2.2 Bus Parameters 260V 50Hz 260V 60Hz 400V 50Hz 480V 60Hz Unit PW 3 Description
P2.2.1 Slave Address 17 17 9 9 3
P2.2.2 Process Data 4 3 3 3 3 3 0 = Not Used
1 = Power
2 = Power Kw
3 = HeatSinkTemp
4 = FaultCode1+2
5 = FaultCode3+4
6 = D/A BoardCh1
7 = D/A BoardCh2
8 = D/A BoardCh3
9 = D/A BoardCh4
10 = DC Link Volt
11 = U PhaseCurr
12 = V PhaseCurr
13 = W PhaseCurr
P2.2.3 Process Data 5 10 10 10 10 3
P2.2.4 Process Data 6 2 2 2 2 3
P2.2.5 Process Data 7 5 5 5 5 3
P2.2.6 Process Data 8 4 4 4 4 3
G2.3 Protection 260V 50Hz 260V 60Hz 400V 50Hz 480V 60Hz Unit PW 3 Description
P2.3.1 Earth Fault 1 1 1 1 3 0 = Off
1 = On
P2.3.2 Line Supervision 0 0 0 0 3 0 = Off
1 = On
P2.3.3 Output Supervis 0 0 0 0 3 0 = Off
1 = On
P2.3.4 Thermistor Fault 0 0 0 0 3 0 = Off
1 = On
P2.3.5 Switching Freq 4 4 4 4 3 0 = Auto
1 = 1.5 kHz
2 = 2.5 kHz
3 = 3.6 kHz
4 = 7.5 kHz
P2.3.6 Unit Max Size 22 22 22 22 4
P2.3.7 Under Volt Limit 200 200 333 333 V 4
G2.4 Expert 260V 50Hz 260V 60Hz 400V 50Hz 480V 60Hz Unit PW 4 Description
P2.4.1 Accel Time 0.50 0.50 0.50 0.50 s 4
P2.4.2 U/f Mid Volt 20.00 20.00 20.00 20.00 % 4
P2.4.3 U/f Mid Freq 30.00 30.00 30.00 30.00 Hz 4
G2.5 Laboratory 260V 50Hz 260V 60Hz 400V 50Hz 480V 60Hz Unit PW 4 Description
P2.5.1 DAC1 Var Type 1 1 1 1 4 0 = System2
1 = Application2
2 = System3
3 = Application3
P2.5.2 DAC1 Address 560 560 560 560 4
P2.5.3 DAC1 Mask 65535 65535 65535 65535 4
V2.5.4 DAC1 Value
P2.5.5 DAC2 Var Type 1 1 1 1 4 0 = System2
1 = Application2
2 = System3
3 = Application3
P2.5.6 DAC2 Address 234 234 234 234 4 FreqOut (default)
P2.5.7 DAC2 Mask 65535 65535 65535 65535 4
V2.5.8 DAC2 Value
P2.5.9 DAC3 Var Type 1 1 1 1 4 0 = System2
1 = Application2
2 = System3
3 = Application3
P2.5.10 DAC3 Address 1050 1050 1050 1050 4 MotorVoltage (default)
P2.5.11 DAC3 Mask 65535 65535 65535 65535 4
V2.5.12 DAC3 Value
P2.5.13 DAC4 Var Type 1 1 1 1 4 0 = System2
1 = Application2
2 = System3
3 = Application3
P2.5.14 DAC4 Address 222 222 222 222 4 MotorTorque (default)
P2.5.15 DAC4 Mask 65535 65535 65535 65535 4
V2.5.16 DAC4 Value
P2.5.17 DAC Enable 1 1 1 1 4 0 = Off
1 = On
G2.5.18 DAC Write 260V 50Hz 260V 60Hz 400V 50Hz 480V 60Hz Unit PW 3 Description
P2.5.18.1 Index 1 0 0 0 0 4
P2.5.18.2 Value1 0 0 0 0 4
P2.5.18.3 Write Mode 1 0 0 0 0 4 0 = Not Written
1 = Power-up
2 = Cyclic
P2.5.18.4 Index 2 0 0 0 0 4
P2.5.18.5 Value 2 0 0 0 0 4
P2.5.18.6 Write Mode 2 0 0 0 0 4 0 = Not Written
1 = Power-up
2 = Cyclic
P2.5.18.7 Index 3 0 0 0 0 4
P 2.5.18.8 Value 3 0 0 0 0 4
P2.5.18.9 Write Mode 3 0 0 0 0 4 0 = Not Written
1 = Power-up
2 = Cyclic
P2.5.18.10 Index 4 0 0 0 0 4
P2.5.18.11 Value 4 0 0 0 0 4
P2.5.18.12 Write Mode 4 0 0 0 0 4 0 = Not Written
1 = Power-up
2 = Cyclic

17/32
This document and the information contained herein, is the exclusive property of Konecranes Plc and represents a non-public, confidential and proprietary trade secret that may not
be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes Plc. Copyright © (2011)
Konecranes Plc. All rights reserved.
HU4.07.0095en / Rev. A / 01.07.2011 / Con3V040

022F 022F 045F 045F

G 2.5.19 Datalogger 260V 50Hz 260V 60Hz 400V 50Hz 480V 60Hz Unit PW 3 Description
P2.5.19.1 Trigger Mode 2 2 2 2 4 0 = None
1 = First Four
2 = Last Four
P2.5.19.2 Logger Variable1 8 8 8 8 4 0 = None
1 = OutputVolt V
2 = OutputFreqHz
3 = OutputCurr%
4 = Power Kw
5 = Ready
6 = Ramp Gen Hz
7 = DClinkVolt V
8 = Fault Code
9 = IGBT Temp °C
10 = Run Req
11 = D/A BoardCh1
12 = D/A BoardCh2
P2.5.19.3 Condition 1 0 0 0 0 4 0=>
1 = >=
2=<
3 = <=
4==
5 = <>
P2.5.19.4 Limit 1 0 0 0 0 4
P2.5.19.5 Logic Operator 0 0 0 0 4 0 = None
1 = AND
2 = OR
P2.5.19.6 Logger Variable2 0 0 0 0 4 Same as P2.5.19.2
P2.5.19.7 Condition 2 0 0 0 0 4 Same as P2.5.19.3
P2.5.19.8 Limit 2 0 0 0 0 4
V2.5.19.9 Data Log Counter 4

18/32
This document and the information contained herein, is the exclusive property of Konecranes Plc and represents a non-public, confidential and proprietary trade secret that may not
be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes Plc. Copyright © (2011)
Konecranes Plc. All rights reserved.
HU4.07.0095en / Rev. A / 01.07.2011 / Con3V040

6 COMPONENTS

6.1 DynACon spare parts list

022
045
POS DESCRIPTION ID NAME REMARKS
INVERTER
Inverter D2V022RF00D6 1
D2V045RF00D6 1
D2V includes PSU ( power unit ) and CSU ( control unit )
A2 Power supply unit PSU* 1 1
PSU is not available separately
Fan 52371615 D2VSP-EPP01062 24VDC 1
Fan 52355592 D2VSP-EPP01063 24VDC 1
A1 Control unit CSUD6 1 1
Display keypad 52413337 D2VSP-ENXPAN_A 1 1
Relay / Thermistor Board 52335565 D2V-NXOPTA3L Slot B1 1 1
Profibus Board 52355625 D2V-NXOPTC5L Slot E1 1 1
F1, F2 Main fuse of DC-supply 52415975 170M1571 690VAC/250A 2

6.2 Inverter
Inverter (D2V) includes Power supply unit (PSU) and Control unit (CSU), which are separate parts. PSU
includes supply, brake resistor and output connections. IGBTs are placed to PSU. Microprocessors and
ASIC are placed to CSU. Same CSU can be used in every power class.
1min Frame Dimension Dimension Weight Weight
D2V PSU CSU In Imax size mm (WxHxD) in (WxHxD) kg lbs
D2V022RF00D6 PSU022NF002 CSU06 48 72 Fr6 195x558x237 7.68x21.97x9.33 20 44
D2V045RF00D6 PSU045NF002 CSU06 90 135 Fr7 237x630x257 9.33x24.80x10.12 34 82

6.2.1 Inverter main circuit diagram

D2V022F and D2V045F

BR B+ B-

DC+

UH_G VH_G WH_G

UH_D VH_D WH_D

L1 U/T1
L2 V/T2
L3 W/T3

BRK_G UL_G VL_G WL_G

BRK_D UL_D VL_D WL_D

DC-

19/32
This document and the information contained herein, is the exclusive property of Konecranes Plc and represents a non-public, confidential and proprietary trade secret that may not
be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes Plc. Copyright © (2011)
Konecranes Plc. All rights reserved.
HU4.07.0095en / Rev. A / 01.07.2011 / Con3V040

6.2.2 Power supply unit (PSU)

Power supply unit (PSU) includes the main circuit components. PSU
has connectors for supply cables, motor cables and braking resistor
cables. PSU also includes a D-connector for CSU-connection.

Main supply voltage

Terminal Description
L1 Phase L1
L2 Phase L2
L3 Phase L3
PE Protective earth

DC-bus voltage and braking resistor

Terminal Description
B- External DC-bus negative
B+ External DC-bus positive / Braking resistor positive
R- Brake resistor negative

Output voltage
Terminal Description
U/T1 Output phase U
V/T2 Output phase V
W/T3 Output phase W

6.2.3 Control unit (CSU)

Control unit (CSU) includes a control board with BOARD TYPE 761
five board slots for option boards and a control RED YELLOW KEYPAD

keypad for parameter adjustments. CSU is

GREEN
normally connected to PSU through a D-
connector. In special applications CSU is
connected to PSU with an optic fibre. CSU can be
powered with an external power supply (24 Vdc).
Control board LED indications:
Yellow Red Status
blinking blinking Everything is OK. IEC
0.5 Hz 0.5 Hz Application Scheduler is
running and Application is
running
blinking blinking IEC Application Scheduler
0.25 Hz 0.5 Hz is running and Application is
NOT running BOARD TYPE 661
RED YELLOW
OFF blinking IEC Application Scheduler
0.5 Hz and Application are NOT
running

Green Status
ON PSU ready
OFF PSU not ready

A B C D E

20/32
This document and the information contained herein, is the exclusive property of Konecranes Plc and represents a non-public, confidential and proprietary trade secret that may not
be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes Plc. Copyright © (2011)
Konecranes Plc. All rights reserved.
HU4.07.0095en / Rev. A / 01.07.2011 / Con3V040

6.2.4 Relay / Thermistor board (Slot B)

Relay / Thermistor board is always included in CSU slot B.

D2V-NXOPTA3
Terminal Signal name Description
21 ROB1
22 ROB1 Relay output, 250 V 8 A
23 ROB1

Relay output, 250 V 8 A,

25 ROB2
normal open
26 ROB2
28 T1
Thermistor input, double isolated, RTRIP=4.7 kΩ
29 T2

21 22 23 25 26 28 29

21/32
This document and the information contained herein, is the exclusive property of Konecranes Plc and represents a non-public, confidential and proprietary trade secret that may not
be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes Plc. Copyright © (2011)
Konecranes Plc. All rights reserved.
HU4.07.0095en / Rev. A / 01.07.2011 / Con3V040

6.2.5 Profibus board (Slot E)

Profibus board can be optionally included in CSU slot E. The board
has the 9-pin female D-connector for the Profibus cable. The
connector signals are presented in the following table.

D2V-NXOPTC5
Terminal Signal name Description
1 Shield Cable shield
3 RxD/TxD-P Receive/Transmit data – plus (B = red wire)
5 DGND Data Ground (reference potential for VP)
6 VP Supply voltage – plus (5 V)
8 RxD/TxD-N Receive/Transmit data – minus (A = green wire)

The shield of the Profibus cable can be grounded in two different

ways in the board: directly to the drive frame or to the frame of the
drive through a RC filter. The selection of grounding the bus cable
shield is done with the jumper X1. The default setting is the direct OFF/ON
OFF/ON
grounding. The default position of jumper X1 is shown beside. X4
X1

YELLOW
X6

GREEN
Jumpers X4 and X6 are for the bus termination. As default the bus

RED
termination setting is OFF. The default position for the jumpers is
shown beside.
The three LED indicators on the board are located next to the bus
connector. In the normal Profibus communication the red LED is
OFF, the yellow LED is blinking once a second and the green LED is
also blinking once a second.

Red LED Profibus status

OFF Profibus communicates normally
• normal data exchange between Master and Slave
ON Profibus communication is broken or not started
• Profibus cable broken or incorrectly connected
• incorrect configuration or programmed data of Profibus master
• Profibus master is offline or shut down

Yellow LED Status of Profibus option board

OFF Option board not activated
ON Option board in initialization state waiting for activation command from the drive control unit
Blinking fast 1 Hz Option board is activated and in RUN state, ready for external communication
Blinking slow 0.2 Hz Option board is activated and in FAULT state (an internal fault of option board)

Green LED Communication status

OFF Profibus board is waiting for the parameters from the drive control unit, no external communication
ON Profibus board is activated: the parameters received from the drive control unit and the board is waiting for
messages from the Profibus master
Blinking fast 1 Hz Profibus board is activated and receiving messages from the Profibus master
Blinking slow 0.2 Hz Profibus board is in a FAULT state
• no messages from Profibus master within the watchdog time
• Profibus cable broken, cable loose or Profibus master offline

22/32
This document and the information contained herein, is the exclusive property of Konecranes Plc and represents a non-public, confidential and proprietary trade secret that may not
be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes Plc. Copyright © (2011)
Konecranes Plc. All rights reserved.
HU4.07.0095en / Rev. A / 01.07.2011 / Con3V040

7 TROUBLESHOOTING

cm WARNING: High voltages inside the device. Wait for at least five minutes after the
supply voltage has been switched off before doing any service actions.

This chapter describes how to detect DynACon failures. The purpose is to find out which components are
damaged and how to replace them to restore proper operation. Advice is also given to find possible external
failures that affect DynACon function.

7.1 Field repair actions

The purpose of troubleshooting and field repair actions is primarily to determine whether DynACon or
external devices cause the problems. After that, the next step is to detect the possibly damaged components
inside the DynACon. If any damage inside the DynACon is caused by the environment it is very important to
repair/change all faulty items to prevent further damage.
The best way to repair a faulty inverter is to replace it with a new one. If the fault can be located, it is also
possible to replace some of the inverter components. Always, if any power component inside the inverter is
damaged, it is also recommended to change the component that controls the damaged component.
When replacing an inverter or a PC-board with a new one, the parameter list of the existing DynACon is
needed so that the parameter settings can be copied from the existing DynACon.
If parameters have been copied to the keypad before damage, it may be used for uploading the parameters
to the spare part inverter (requires same software versions).

7.2 Troubleshooting actions

Check external protection circuits, fuses and fault history.

Display is blank and DynACon does not function

faulty keypad
supply voltage is missing
DC-fuse is damaged (DC-supply)
DynACon does not go to RUN state
On the control keypad RUN indicator is off.
DynACon has been stopped from control keypad
run command missing from selected control place
supply voltage is not correct
DC start voltage parameter is in wrong value
one supply line phase is missing (AC-supply)

23/32
This document and the information contained herein, is the exclusive property of Konecranes Plc and represents a non-public, confidential and proprietary trade secret that may not
be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes Plc. Copyright © (2011)
Konecranes Plc. All rights reserved.
HU4.07.0095en / Rev. A / 01.07.2011 / Con3V040

7.3 Inverter fault codes

If any of the following failures are found, the inverter displays the fault code and stops. If several faults occur
one after another, the latest one is displayed, the others are stored to fault history page.
When inverter fault supervision trips, the FAULT indicator turns on and the blinking fault code “F xx“ (xx =
fault number) appears on the display.
All of the fault codes require to switch the power off before run is possible.
The faults are stored to the fault history, from there they can be seen if necessary. The fault history can store
last 30 fault codes. Repeated fault F55 is stored only once.

Fault code Possible cause Checking

F1 Inverter has measured too high current (over 4*In) Reset: switch power off and restart after the lamps of
Overcurrent in the motor output: keypad are off.
• sudden heavy load increase Check:
• short circuit in the load or cable • cable connection
• wrong parameters • cable insulation
• loading
• type of the load and power ratings
• parameters
F2 DC-bus voltage has exceeded 135% maximum Reset has an additional 5 s time delay.
Overvoltage level, 911 Vdc Check:
• supply voltage raised >1.35 x Un (high • measure main supply voltage level and wave form while
overvoltage spikes at mains or not sinusoidal not running
voltage wave form) • output cable insulation (phase-ground, phase-phase)

F3 Current measurement has sensed unbalance in Reset has an additional 5 s time delay.
Earth fault output phase currents. Supervision level is 5% of Check:
inverter nominal current • load insulation
• not symmetric load • cable insulation (phase-ground, phase-phase)
• insulation failure in the load or the cables
F5 Charging switch is open when START command Check:
Charging switch becomes active • control unit and power unit connections
• interference fault • charging resistors (external)
• component failure If the fault comes again, change the control unit.
F7 Very high overload or defective component Reset: switch power off and restart after the lamps of
Saturation trip keypad are off.
Check:
• load and cable insulation
• measure main circuit diodes and IGBT transistors
If the fault comes again, change the unit.

24/32
This document and the information contained herein, is the exclusive property of Konecranes Plc and represents a non-public, confidential and proprietary trade secret that may not
be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes Plc. Copyright © (2011)
Konecranes Plc. All rights reserved.
HU4.07.0095en / Rev. A / 01.07.2011 / Con3V040

Fault code Possible cause Checking

F8 System fault due to component failure or faulty Reset: switch power off and restart after the lamps of
System fault operation. keypad are off.
Subcodes: Check:
• read fault extension code and contact authorized service
If the fault comes again, change the unit.
S1 = Feedback of motor voltage Motor voltage feedback not received correctly from power
unit:
• measure main circuit diodes and IGBT transistors
• check all fibre optic connections and connectors
• replace the fibre adapter board
• replace the control unit
S2 = Microprocessor Watchdog Microprocessor watchdog failure in the ASIC circuit
• check that all groundings are done properly
• replace the control unit
S3 = Microprocessor Watchdog Microprocessor watchdog failure in units ≥ D2V055F
• check that all groundings are done properly
• replace the control unit
S4 = ASIC trip Subcode 4 does not exist in D2V. Contact factory.
S5 = Disturbance in optical bus Communication failure in the optical bus between Control
Unit and Power Unit in units ≥ D2V110F.
• check the fibre optic connection at power unit end
• check the fibre optic connection at control unit end
• check the condition of the fibre optics. Replace fibre
optics if necessary.
S6 = Feedback of charging switch External charging switch feedback fault in units
≥ D2V110F. External charging switch is not used in D2V.
• check jumpers between power unit terminals:
• X9: 25 – X15: 23
• X9: 26 – X15: 21
S7 = Charging switch External charging switch feedback fault in units
≥ D2V110F. External charging switch is not used in D2V.
• check jumpers between power unit terminals:
• X9: 25 – X15: 23
• X9: 26 – X15: 21
S8 = No power to driver board Driver board auxiliary voltage missing in units ≥ D2V110F
• check all fibre optic connections and connectors
S9 = Power unit communication Communication bus between control unit and power unit
S10 = Power unit communication faulty in units ≥ D2V110F
S11 = Power unit communication • check all fibre optic connections and connectors
• check that the fibre adapter board and control unit is
properly connected together.
• replace the fibre adapter board
S12 = Expander board failure Failure of board in slot D or E
• if there is a system bus board in the D2V, replace the
board
• replace other boards in Slots D or E
• replace the control unit
F9 DC-bus voltage has dropped below 333 Vdc In case of temporary supply voltage break, reset the fault
Undervoltage • mains supply voltage interrupted and start again. Check mains input.
• inverter fault can also cause an undervoltage trip • if mains supply is correct, an internal failure has
• external fault during run may cause an occurred
undervoltage trip • contact authorized service
F 10 One input line phase is missing or supply voltage is Check:
Input line wrong. AC-supplied model. • supply voltage
supervision • mains connection
F 11 Current supervision has sensed that one of the Check:
Output phase motor phases has no current • cable connections
supervision • measure output phase currents and compare to display
value

25/32
This document and the information contained herein, is the exclusive property of Konecranes Plc and represents a non-public, confidential and proprietary trade secret that may not
be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes Plc. Copyright © (2011)
Konecranes Plc. All rights reserved.
HU4.07.0095en / Rev. A / 01.07.2011 / Con3V040

Fault code Possible cause Checking

F 13 Temperature of heat sink is below acceptable
Check
Inverter operating level -10°C (14°F) • ambient temperature
undertemperature • cubicle heating
• inverter cooling fan activation (continuous / temperature
limit)
F 14 Temperature of heat sink is over acceptable Check:
Inverter operating level +90°C (194°F). • ambient temperature
overtemperature Overtemperature warning is issued when the heat • inverter cooling fan operation
sink temperature exceeds +85°C (185°F) • cooling air flow through heat sink
• heat sink is not dusty
F 22 Parameter save error After power off the inverter will automatically load factory
F 23 • interference fault default parameter settings. DynACon does not work
EEPROM checksum • component failure (control unit) properly nor enable running after this fault.
fault Check:
• all parameter settings
• +24 V voltage output loading
If the fault comes again, contact authorized service.
F 24 Changes may have occurred in the different counter No special actions required. Take a critical attitude to the
Counter fault data due to mains interruption counter data.
F 25 • interference fault If the fault comes again, read fault extension code and
Microprocessor • component failure (control unit) contact authorized service.
watchdog-fault
F 26 Faulty power unit Contact authorized service.
Power Unit Fault
F 31 Too high temperature in IGBT transistors. A Reset: switch power off and restart after the lamps of
IGBT temperature hardware temperature measurement has tripped. keypad are off.
Check:
• loading
• inverter heatsink
• inverter cooling fan operation
• environment temperature
F 32 Cooling fan of the frequency converter do not work, If the fault comes again, contact authorized service.
Fan cooling fault when ON command has been given
F 35 Run-time exception in the application program Contact authorized service.
Application fault
F 36 Faulty Control Unit Contact authorized service.
Control Unit
F 37 Option board or power unit has been changed to Reset the fault.
Device changed same type
F 38 Option board of same type or drive of same power Reset the fault.
Device added rating added
F 39 Option board removed. Drive removed. Reset the fault.
Device removed
F 40 Unknown option board or power unit. Check the type of option board or control unit and power
Device unknown unit.
F 41 Too high temperature in IGBT transistors. Reset: switch power off and restart after the lamps of
IGBT temperature • long duration overload keypad are off.
• lowered cooling Check:
• high environment temperature • loading
• inverter heatsink
• inverter cooling fan operation
• environment temperature
F 44 Option board or control unit has been changed to Reset the fault. Option board parameters or all parameters
Device changed different type or different power rating are set up to default values.

26/32
This document and the information contained herein, is the exclusive property of Konecranes Plc and represents a non-public, confidential and proprietary trade secret that may not
be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes Plc. Copyright © (2011)
Konecranes Plc. All rights reserved.
HU4.07.0095en / Rev. A / 01.07.2011 / Con3V040

Fault code Possible cause Checking

F 45 Option board of different type or drive of different Reset the fault. Option board parameters or all parameters
Device added power rating added are set up to default values.
F 53 Watchdog time out in Profibus communication. Reset: switch power off and restart after the lamps of
Profibus Effective only if control through Profibus is selected keypad are off.
communication error and DynACon is in RUN state. Poor Profibus cable Check:
connection or communication problems with • Profibus slave address
Profibus master. • Profibus cable connection
• Profibus termination resistor settings
F 55 Some of following board is missing: Reset: switch power off and restart after the lamps of
Board Fault • B = Thermistor board keypad are off.
Check:
• board slots B
• control mode
F 57 Thermistor input in relay / thermistor board has Check:
Thermistor fault detected overtemperature. Fault appears when • cooling and loading of the monitored component
thermistor input has been open over 1s. • thermistor connection. If expansion board thermistor
input is not used, it should be shorted
F 58 Wrong application, unit maximum size or input card • Contact authorized service.
Wrong application combination.

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This document and the information contained herein, is the exclusive property of Konecranes Plc and represents a non-public, confidential and proprietary trade secret that may not
be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes Plc. Copyright © (2011)
Konecranes Plc. All rights reserved.
HU4.07.0095en / Rev. A / 01.07.2011 / Con3V040

7.3.1 Fault time data record

When a fault occurs, the fault number is displayed. By pushing the cursor right button you will enter the Fault
time data record menu, indicated by T.1-T.16. In this menu, some selected important data valid at the time of
the fault are recorded. The data available are:
Data record Description Value
T.1 Counted operation days d
T.2 Counted operation hours hh:mm:ss
T.3 Output frequency Hz
T.4 Motor current A
T.5 Motor voltage V
T.6 Motor power %
T.7 Motor torque %
T.8 DC voltage V
T.9 Unit temperature °C
T.10 Ready 0=Not Ready 1=Ready
Run 0=Not Running 1=Run
T.11 Direction 0=Off 1=On
Fault 0=No 1=Yes
T.12 Warning 0=No 1=Yes
At reference 0=No 1=Yes
T.13 0-speed 0=Not Zero Speed 1=Zero Speed
T.14 Subcode
T.15 Module
T.16 Submodule

Values T.4-T.7 refers to the output values of the inverter.

7.3.2 Fault Counter

When a fault occurs, the fault is recorded in a counter.
Fault counter Fault code and name Description
V1.10.1 F1 Overcurrent Overcurrent fault counter
V1.10.2 F2 Overvoltage Overvoltage fault counter
V1.10.3 F3 Earth Fault Earth fault counter
V1.10.4 F7 Saturation Saturation trip fault counter
V1.10.5 F9 Undervoltage Undervoltage fault counter
V1.10.6 F10 Input Phase Input phase supervision fault counter
V1.10.7 F11 Output Phase Output phase supervision fault counter
V1.10.8 F13 Undertemp Inverter undertemperature fault counter
V1.10.9 F14 Overtemp Inverter overtemperature fault counter
V1.10.10 F25 Watchdog Watchdog fault counter
V1.10.11 F31 IGBT Temp HW IGBT temperature fault counter
V1.10.12 F41 IGBT Temp IGBT temperature fault counter
V1.10.13 F53 Profibus Profibus communication error fault counter
V1.10.14 F57 Thermistor Thermistor fault counter
V1.10.15 Other faults Sum counter of following faults: F4, F5, F8, F22, F23, F24, F25, F26, F32, F33,
F35, F36, F37, F38, F39, F40, F44, F45, F48, F54, F55, F58
V1.10.16 Total Faults Total number of all faults.

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This document and the information contained herein, is the exclusive property of Konecranes Plc and represents a non-public, confidential and proprietary trade secret that may not
be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes Plc. Copyright © (2011)
Konecranes Plc. All rights reserved.
HU4.07.0095en / Rev. A / 01.07.2011 / Con3V040

8 SERVICE
In the normal operation DynACon do not require regular maintenance. The following actions are
recommended:
Action Note
1. Check the fault history of the inverter • Find out reasons of possible faults
• Record faults and clear the fault history
2. Clean the heat sink of the inverter • Prevent the dust to spread inside cubicles
• Lock the fans before blowing compressed air
3. Check the operation of the main cooling fan. Pay attention
on extra noise and vibrations.
4. Tighten all screws and connectors • Avoid too high tightening torques
5. Clean dust from PC-boards

8.1 DC-bus electrolytic capacitors

Inverters have large aluminium electrolytic capacitors in DC-bus. In the normal operation the leakage current
of the capacitor is low based on dielectric aluminium oxide layer (forming) on the foil. If the inverters or
separate capacitors are stored a long period without applied voltage, the forming looses it’s homogeneous.
When a long stored inverter is connected straight to mains voltage, a high leakage current can exist and
damage the other inverter components.

8.1.1 Re-forming after a long storage period

Complete inverters regular maintenance
When the complete inverters are stored without voltage applied, the re-forming of the capacitors should be
done at least once in a year. Connect the mains voltage into inverter and keep power on at least 1 h
continuously.

Complete inverters re-forming after a long storage period

If much more than one year has elapsed since the inverter was energized last time, the re-forming of the
capacitors has to be done in a way that the possible high leakage current through the capacitors is limited.
Best alternative is to use a DC-power supply provided with an adjustable current limitation. Set current limit
to 300…500 mA and connect DC-power supply straight to the inverter DC-bus terminals B+ and B-. Then
adjust DC-voltage up to nominal DC-voltage level of the inverter (F-series: 675 Vdc) and keep power
supplied at least 1h.
If the DC-power supply is not available and the inverter has been stored much longer than 1 year de-
energized, consult authorized service before switching the power on.

Spare capacitors re-forming after a long storage period

When using over one year old spare part capacitors from the stock, the re-forming is recommended to
perform before capacitors are installed inside the inverter. For loose capacitors, set DC-power current limit to
50…100 mA. Then adjust DC-voltage up to the rated value of capacitors (F-series: 420 Vdc) and keep power
supplied at least 1h. The degree of re-forming process can be followed on the current meter of the DC-power
supply.
If the re-forming is not done for the loose capacitors, the re-forming has to be done for a complete inverter
according to above instruction of re-forming after a long storage period.

m WARNING: Due to high leakage resistance the dangerous voltage can remain in capacitor a
long time. If the DC-power supply is not able to dissipate the voltage after re-forming,
discharge the capacitor by using a resistor (minimum 100 kΩ 2 W). Discharging will take
several minutes and resistor will get hot. Measure the voltage before touching the capacitor
terminals.

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This document and the information contained herein, is the exclusive property of Konecranes Plc and represents a non-public, confidential and proprietary trade secret that may not
be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes Plc. Copyright © (2011)
Konecranes Plc. All rights reserved.
HU4.07.0095en / Rev. A / 01.07.2011 / Con3V040

9 DRAWINGS

9.1 Description of terminals

Control unit
Relay / Thermistor board (slot B)
No Name Description, signal level
21 ROB1 NC contact of ROB1
22 ROB1 NC contact of ROB1
23 ROB1 NO contact of ROB1
25 ROB2 NO contact of ROB2
26 ROB2 NO contact of ROB2
28 T1 Thermistor input
29 T2 Thermistor input

Profibus board (Slot E)

Name Description, signal level
Profibus connector Profibus D-connector (female)

Power unit
Name Description, signal level
L1 Generator, phase 1
L2 Generator, phase 2
L3 Generator, phase 3
B+ DC-output, positive
B- DC-output, negative
U Output, phase 1
V Output, phase 2
W Output, phase 3
PE Protective earth

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This document and the information contained herein, is the exclusive property of Konecranes Plc and represents a non-public, confidential and proprietary trade secret that may not
be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes Plc. Copyright © (2011)
Konecranes Plc. All rights reserved.
HU4.07.0095en / Rev. A / 01.07.2011 / Con3V040

9.2 Layouts, dimensions and weights

D2R022F
Weight 20 kg (44.1 lbs)

558 mm (21.97 in)

541 mm (21.30 in)

148 mm (5.83 in) 171 mm (6.73 in)

189 mm (7.44 in) 237 mm (9.33 in)

D2R045F
Weight 37 kg (81.6 lbs)
630 mm (24.80 in)
614 mm (24.17 in)

190 mm (7.48 in) 191 mm (7.52 in)

230 mm (9.05 in) 257 mm (10.12 in)

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This document and the information contained herein, is the exclusive property of Konecranes Plc and represents a non-public, confidential and proprietary trade secret that may not
be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes Plc. Copyright © (2011)
Konecranes Plc. All rights reserved.
HU4.07.0095en / Rev. A / 01.07.2011 / Con3V040

9.3 Circuit diagrams

D2R 022 F D2R 045 F

F1 A1
DC+ B+
L3
R- L2
F2 L1
DC- B-

U U1 U2 U
V V1 V2 V

W W1 W2 W

E1 B
PROFIBUS
T1 28

T2 29

21

23
ROB1
22

25

ROB2
26

32/32
This document and the information contained herein, is the exclusive property of Konecranes Plc and represents a non-public, confidential and proprietary trade secret that may not
be reproduced, disclosed to third parties, altered or otherwise employed in any manner whatsoever without the express written consent of Konecranes Plc. Copyright © (2011)
Konecranes Plc. All rights reserved.