Owner manual

ManualsBrandsR&M Materials Handling ManualsEquipmentHOIST MONITORS

English

16.9.2008

SERVICE MANUAL FOR HOIST CONTROL DEVICE

Summary of content (105 pages)

PAGE 1
English 16.9.
PAGE 2
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 Read the instructions supplied with the product before installation and commissioning. Keep the instructions in a safe place for future reference. Table of content 5.6.1 Starting and stopping through slow speed instructions .............................................................. 28 1 General.......................................................... 5 1.1 Description..............
PAGE 3
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 8.2 8.2.1 8.2.2 8.2.3 8.3 8.3.1 8.3.2 Multi-hoisting instructions......................... 42 Multi-hoisting parameters............................. 42 Cabling........................................................ 43 Menus through CAN bus.............................. 44 CAN-bus topology.................................... 45 Termination resistors ...................................
PAGE 4
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 Appendix 4 - Motor temperature NTC charts 97 Appendix 5 - Example connections ............... 98 Appendix 6 - External power supply for ESD 143.................................................................. 101 Appendix 7 - Replacing the condition monitoring unit.............................................. 103 4/105 R&M Materials Handling, Inc.
PAGE 5
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 1 General 1.1 Description The hoist-monitoring unit is an electronic device designed to supervise and protect the hoist. The hoistmonitoring unit measures the use of the hoists and prevents hoisting or lowering in case a situation is detected which can cause a potential dangerous situation.
PAGE 6
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 1.2.3 Patent Pending • • US09/940,514 EP01000406,7 US09/940,464 EP01000405,9 1.2.4 Certificate of compliance • 1334676 (LR025623) 6/105 R&M Materials Handling, Inc. reserves the right to alter or amend the above information without notice.
PAGE 7
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 120.3 2 Technical characteristics 10 8.
PAGE 8
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 2.1 Description of terminals c_cid1a 1. Connector X1: Terminals 1-19 for “power signals” (high voltage) 2. Display unit with pushbuttons and three indication LEDs (optional) 3. Connector X2: Terminals 20 -38 for the measurement signals (low voltages). 4. Green LED (OK and run state indication) 5. Red LED (warning and fault indication) 6.
PAGE 9
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 Connector X2: Terminal 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 Signal PE TP11 TP12 TP21 TP22 10V AIN1 AIN2 AIN3 IB 0V CL-A CL-B AN AN0 CAN-H CAN-L CAN-GD Description Protective earth Thermistor input 1 Thermistor input 2 Load sensor supply, 10...
PAGE 10
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 2.2 Product description sticker 1.Supply voltage / Control Voltage 2.Unit type 3.Tested (year, week, tester) 4.Serial number 5.Product specific code Unit types Unit type CID-48V CID-115V Serial number Hxxxxx Txxxxx Product specific code ID: 52292509 ID: 52292510 Control voltage 42-48 VAC 110-230 VAC 10/105 R&M Materials Handling, Inc.
PAGE 11
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 3 Display unit t 1 2 3 1. Red LED (Fault and Warning indication) 2. Orange LED (Tare load active) 3. Green LED (OK and Run indication) The display unit shows in the large text field the actual or tared load. Also warning and fault messages are shown in the display. Parameter values can be read and set via display unit after a correct password has been given.
PAGE 12
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 Service-state means that a limit value set for the next service has been expired. This is indicated to the crane user, but the hoist can still be run normally. Fault-state means that a serious problem has been detected. Running the hoist is restricted. 3.3 Display information 3.3.
PAGE 13
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 3.3.2 Menu Mode Pushing the ENT button in the tare or actual load display mode, shifts the display into the menu mode. A password is required in order to proceed. Pushing the ESC button returns to the actual load display. 3.3.3 Status mode Status mode indicates all active faults, warnings and service warnings when applicable.
PAGE 14
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 3.4 Menus Monitoring items and parameters are presented in menus. The menus are accessible with passwords. The right to read and/or modify parameters within a menu depends on the selected password. 3.4.1 Moving in menus Toggling between the menus is done with the up and down arrow buttons. When the desired menu has been selected, it is entered with the ENT-button.
PAGE 15
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 3.5 Parameters 3.5.1 Read-only parameters Menu 1 (Monitor 1) and menu 2 (Monitor 2) contain read-only parameters. These menus will show the calculated and measured values of the solo hoist, connected to the selected unit. 3.5.
PAGE 16
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 Example: selecting the MFI1 input to intermediate load function, with a load of 8.5 Tons. 3.6 Remote Display 3.6.1 General The display can be also located at a remote location, for example in the push button station, in the cubicle-door or in a crane driver cabin. In this way the crane operator can read load information directly from the display.
PAGE 17
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 Connections and Display Selection Switch A. Current loop to remote display B. Display selection switch in down position for remote selection If the display is in a remote location, the display is connected via a current loop with the hoist-monitoring unit. The current loop is between terminals 32 (CL-A) and 33 (CL-B).
PAGE 18
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 4 Parameters 1 Monitor 1 1-1 1-1-1 Cond mon SWP% 1-1-2 1-1-3 1-1-4 1-1-5 1-1-6 Starts Run time Cycles Mean load Br SWP% 1-1-7 1-1-8 MFI1 RT MFI1 ST Read only menu for condition monitoring values and measured values. Condition monitoring menu Remaining Safe Working Period of the hoist in percentage, starting from 100%.
PAGE 19
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 4-3 4-3-1 ROUT ROUT oper. 4-3-2 4-3-3 ROUT logic The operation logic of the relay: ROUT LoadX The load limit to switch the relay is entered here 6 6-1 4-3-4 4-3-5 TempX meas The temperature measurement operation TempX lim The temperature limit 6-2 6-3 4-4 4-4-1 4-5 4-5-1 4-6 T1 T1 operat. T2 T2 operat. AOUT Temperature measurement channel 1 parameters Selects the function channel 1.
PAGE 20
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 4.1 Passwords The table below indicates the access to the menus with different password levels. The display asks for the password when the ENT button is pushed in the main load display mode. If the given password does not match to any of the levels, the display returns to the main load display mode.
PAGE 21
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 5 Basic Functions 5.1 General The basic functions assure the safe functioning of the hoist. The hoist-monitoring unit constantly performs a number of checks to determine if all conditions are safe in order to proceed the motion. In case the hoist-monitoring unit detects a potentially unsafe situation, the motion will be stopped.
PAGE 22
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 Fault means that one (or more) of the supervised safety features values exceeds the limit. Running the hoist is restricted. lamp For Run or Fault supervision, it is possible to connect an external indication device like a horn or to the relay output. Relay output must be programmed to the desired function “OK” or “Ready” 5.
PAGE 23
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 5.3 Hoist motor overheating supervision To prevent the hoisting motor from burning up, the hoist-monitoring unit will constantly measure the internal temperature of the motor. The motor is therefore equipped with temperature sensors; PTCthermistors, NTC-thermistors or Bi-metal switches (Klixons).
PAGE 24
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 Thermistors operating curve NTC PTC Bi-metal 40 35 30 kohm 25 20 15 10 5 0 Motor Temperature Over temperature and PTC: The temperature sensor’s cable must NTC be shielded if the cable between the unit and the temperature sensors is longer than 10m. The cable shield is connected to the ground of the hoist.
PAGE 25
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 5.3.1 Hoist motor overheating supervision instructions Param. Name Description 4-4 T1 Temperature measurement channel 1 parameters 4-4-1 T1 operat. Selects the function of temperature measurement channel 1: Motor without thermistors or only one sensor that is connected to the NU Not used temperature input 2.
PAGE 26
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 5.4 Supply voltage phase supervision The supply voltage phase supervision consists of two functions: - Missing supply phase detection Incorrect supply phase order The three supply voltage phases are wired to the hoist-monitoring unit. Each time the unit is powered up, the phase order is checked. The unit will continuously measure the existing of all three phases.
PAGE 27
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 5.5 RUN and fault supervision The hoisting and lowering request from the control station will come as an input to the hoist-monitoring unit. Before the hoist can start the requested motion, the hoist-monitoring unit checks if it is safe to proceed. If no limitations are detected, the hoist-monitoring unit will activate the requested output and movement will start.
PAGE 28
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 5.6 Starting and stopping through slow speed (2 speed application only) Starting the motor directly in high speed will cause a high starting current that heats up the motor quite rapidly. To prevent the motor from overheating, the hoist-monitoring unit will always start the motion in slow speed.
PAGE 29
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 5.7 Sudden load increase supervision In case the hoist-monitoring unit measures a sudden load increase when driving upwards in high speed, the unit will control the hoist to low speed. A sudden load increase is considered when the load exceeds 30% of the rated load of the hoist within 200ms.
PAGE 30
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 6 Monitoring Items 6.1 General In order to read the monitoring items and to program the unit, the hoist-monitoring unit is equipped with a display. The monitoring items of the hoist-monitoring unit consist of variable read-only values. These monitoring items are of great advantage when efficiently planning maintenance, preventive repairs, troubleshooting and general overhauls.
PAGE 31
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 Relation between the hoist duty class and the primary monitoring items: Class code 3 4 5 6 7 8 Hoist duty class ISO FEM M3 1Bm M4 1Am M5 2m M6 3m M7 4m M8 5m Starts [n] Par. 1-1-2 Run time [hr.] Par. 1-1-3 SWP / SRT3 [hr.] Par. 2-13 SWP / SL3 [n] Par. 2-17 480.000 1.134.000 3.000.000 7.500.000 18.000.000 42.000.000 3.200 6.300 12.500 25.000 50.000 100.000 400 800 1.600 3.200 6.300 12.
PAGE 32
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 SRT3 I ∆tfi ∆tsi SR loadi nom.load SL3 loadk k SWPRT% D_SRT3 SWPHC% D_SL3 SWP% Load sum with hoist running time, third power. The parameter 2-13 Time period number (Time period is 0,1s) Run time in fast speed with loadi Run time in slow speed with loadi Speed ratio. Two-speed systems: slow-fast (i.e. 6); Inverter drives: always 1 Actual load in period i. Hoist’s nominal load.
PAGE 33
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 6.3 Measured values The measured values allows maintenance analysis. A dot will appear on the correct spot to indicate the decimals Param. 1-2 1-2-1 Name Measure Act. Load Value 1-2-2 Temp 1 “nnn” C 1-2-3 Temp 2 “nnn” C 1-2-4 1-2-5 1-2-6 1-2-7 1-2-8 1-2-9 1-2-10 1-2-11 Supply L1 Supply L2 Supply L3 Motor I1 Motor I2 Motor I3 Ain1 value Ain2 value “nnn” V “nnn” V “nnn” V “nn.
PAGE 34
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 7 Optional functions 7.1 General The hoist-monitoring unit can be equipped with a number of additional features. Each one of the features can, under certain restrictions, be chosen during the ordering process of the hoist, or added in afterwards. Contact a service agent authorised by the manufacturer for further details.
PAGE 35
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 7.2.2 Slack rope protection connections Only if by-bass function is needed for Slack rope-function. A “normally open” contact should be connected to either one of the multi-functional inputs. The slack: MFI1 or MFI2 ON OFF 7.
PAGE 36
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 7.3.2 Intermediate load limits connections One or two “normally closed” contact should be connected to the multi-functional inputs. The contacts can either be manual switches, or automatically actuated according to the position of the crane. The intermediate load function operates according to the following logic: MFI1 oper.
PAGE 37
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 7.4.1 Run time and start counter for trolley and bridge parameters Parameter 4-1 MFI1 4-1-1 MFI1 oper. Parameter 4-2 MFI2 4-2-1 MFI2 oper.
PAGE 38
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 7.5.2 Analogue output connections The load display (or other device) is connected to the analogue output terminals AN and ANO (terminals 33 and 34). The connected device must have an input resistance of at least 1kΩ in order to prevent the analogue output being overloaded. analogue output has a filtering delay of 1000ms before SW The 2.100. In the SW 2.
PAGE 39
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 Parameter Value 4-3-2 Norm ROUT logic 4-3-3 “n” t ROUT loadX 4-3-4 TempX meas T1 T2 T1+2 4-3-5 TempX lim “n” C 7.7 Description Selects the operation logic of the relay. Normal operation is as described above Sets the load limit “X” in tons, when the option “LoadX” is selected. Setting range: 0.0t…rated load of the hoist Selects the temperature measurement.
PAGE 40
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 7.8 Load tare With an additional switch, the monitored load on the display can be tared (tared load value is set to zero). This option is most useful when the hoist is equipped with the display in the push-button station, or when the crane is equipped with an additional load display. 7.8.
PAGE 41
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 7.9.2 Levelling Function Connections MFI1: For the levelling function MFI1 (or MFI2) can be used. For the desired function the parameter setting must be 4-1-1 MFI1 oper. (or 4-2-1 MFI2 oper.) = Level Single hoist selection: The switch must be closed if only one of the hoist is run without the levelling function.
PAGE 42
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 8 Multi-hoisting 8.1 General Up to five units can be connected together with a CAN bus. The communication is tailored for the hoist applications and is restricted for the hoist monitoring units only. It is not possible to add any other CAN units to this bus. Several functions are realised via CAN bus.
PAGE 43
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.
PAGE 44
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 8.2.3 Menus through CAN bus With CAN bus the load display with large digits indicates the sum load of all units working in the CAN bus. Even if the sum overload protection is not selected, the large digits show the sum load of all units. The actual load values of single units are shown with small digits.
PAGE 45
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 8.3 CAN-bus topology Generally it is recommended that a CAN network should be as close as possible to a single line structure. Thus the bus cable should be one long line into which the stations are connected with short drop cables. Resistors must terminate both ends of the bus line. Also other topology options are possible.
PAGE 46
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 8.3.2 Recommended topologies The table below provides the general recommendations for the CAN bus topology for different numbers of units connected together. When three units are connected the CAN bus can be a line type or a star type. The termination must be done at both ends but it seems to be no problem if also the middle unit connects the termination resistors in a line type topology.
PAGE 47
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 9 Commissioning 9.1 • • • • • Start-up Check that the supply control voltage complies with the rated control voltage of the unit. Check that all electrical connections are done according to the delivered electrical diagrams. Switch the power on. Check that the hoists control method complies with the application (inverter control or two-speed control) with parameter 4-8.
PAGE 48
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 9.3 Functional checks 9.3.1 Multi hoisting • • • • Set parameter 4-11-1 to “1” and carry out the start-up procedure for the single hoist as described above in “Start-up” Set parameter 4-1-1 back to “n” (where “n” is the number of unit connected to the CAN-bus). Check that all parameter values in the parameter group 4-11 “Comm hoist”, are equal in all units.
PAGE 49
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 9.3.2.5 Second overload limit ”2OLL” • • When MFI1 input is activated then the hoist can lift over the nominal load (1.00 – 1.30 x nom.). Check by parameter 1-2-14, that MFI1 status bit is 1 when lifted in the area where need lift more than nominal load. 9.3.2.
PAGE 50
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 9.3.3.
PAGE 51
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 • • • 9.4 Check, from el.drawings if any by-pass function is designed. If yes, continue. (Designer might have activated slack ropes by-pass function parameter but the connections in el.drawings are done only when ordered.) Activate the input and lower the hook. The motion should run.
PAGE 52
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 10Overload protection – Load sensor 10.1 Load sensor-system The load sensor-system uses the analogue signal coming from a load sensor. The sensor can be either a Strain-gauge type, or a Hall-sensor type. The Strain-gauge type of sensor is the default solution in hoists. The Strain-gauge type will give out a signal in the range of 0…40mVDC.
PAGE 53
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 10.3 Load calibration sequence with load sensor Before carrying out the calibration procedure, make sure that the load sensor amplifier (if present) is correctly installed and calibrated. Refer to the chapter “Load sensor adjustment” of this manual for instructions. Power On Enter password 0732. Display will jump to menu 3 parameters when one hoist is being calibrated.
PAGE 54
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 10.4 Manual load calibration Before starting the calibration, make sure you have a known test-load available of at least 80% and maximum 130% of the nominal lifting capacity of the hoist It is advisable to by-pass the overload protection during this calibration routine by setting the parameter 3-5 “OL protect” = OFF The overload protection will automatically reset after 30 min.
PAGE 55
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 11Overload protection – Motor torque 11.1 Overload protection instructions 11.1.1 Motor torque calculation-system The parameters as described in the table “Motor torque calculation parameters” must be checked and if needed adjusted, before the calibration sequence is carried out. The unit used these values in order to calculate the actual load.
PAGE 56
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 Parameter 4-7-13 Acc-t slow 4-7-14 Acc-t fast Value 0.20s Parameter 6 Design 6-4 Nom. Load Value 0.30s 0.00- 999t Description Acceleration time from stop to slow speed 0.00s – 1.00s Acceleration time from slow speed to fast speed 0.00s – 1.
PAGE 57
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 11.2 Connections 57/105 R&M Materials Handling, Inc. reserves the right to alter or amend the above information without notice.
PAGE 58
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 11.3 Load calibration sequence with motor torque Power On Enter password 0732. Display will jump to menu 3 parameters when one hoist is being calibrated. If there is more than one Hoist (Multi hoisting mode) then the hoist must be selected by a “Letter” Name. . Go to menu 3-1-1.
PAGE 59
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 11.4 Zero load calibration sequence with motor toque Power On Enter password 0732. Select the hoist. Go to menu 3-1-1. Move to the next section with the arrow up button. Hang a test-load of less than 30% of the rated load of the hoist in the hook. Typically this is an empty hook. Make sure the load hangs freely and steady. Enter the value of the test load (in tons, empty hook = “0.00t”).
PAGE 60
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 A. The display shows more than the lifted test load: • Increase (more positive) the value of parameter 3-2-2 “Mhs1” • Select parameter 1-2-1 “Act. Load”. • Drive the hoist in slow speed up and check the load from the display. • Repeat step 1…3 until the display shows the correct load. • Increase (more positive) the value of parameter 3-2-3 “Mhf1” • Select parameter 1-2-1 “Act. Load”.
PAGE 61
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 12Load sensor adjustment 12.1 KAE400 + Strain Gauge 12.1.1 General KAE400 is a amplifier which is used to amplify the strain gauge load sensor signal (mV) to higher level (V). Both full bridge and half bridge sensors can be connected. Amplifier has zero adjustment with led indication and two-fixed gain (160/400). 12.1.
PAGE 62
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 A. Shield is grounded with 360 degree connector B. Amplifier KAE400 12.1.4 Adjustment Tools needed for adjustment: • A small screwdriver for trimmers • Test load Adjustment can be done with a known load in the range of 80…130% of the rated lifting capacity. Following procedure can be used to perform the setup of the amplifier: • Connect the sensor and monitoring unit.
PAGE 63
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 12.1.5 Dimensions 27 2 3 4 -IN +IN 0V OUT 6 7 Rail Mounting 1/1 160 +S 1 -S 400 1/2 ZERO 10V KAE400 GAIN 5 97 43 12.2 ESD142 amplifier + Strain Gauge 12.2.1 ESD142 Description The ESD142 is a load sensor amplifier, which is used to amplify the load signal coming from a straingauge type of load sensor to a suitable voltage level for the hoist-monitoring unit.
PAGE 64
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 12.2.2 Adjustment Tools needed for adjustment: • A small screwdriver for trimmers • Test load Adjustment can be done with either a test load of exactly 100% of the rated load of the hoist, or with a known load in the range of 80…130% of the rated lifting capacity. The adjustment is carried out in two steps: • Zero load adjustment • “Known load” adjustment 12.2.
PAGE 65
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 12.2.5 Connections Long cables A. Shield is grounded with 360 degree connector B. Full bridge amplifier ESD142 C. Shield end connection in Strain gauge load sensor cable in floating 65/105 R&M Materials Handling, Inc. reserves the right to alter or amend the above information without notice.
PAGE 66
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 13Faults and warnings 13.1 Faults Fault means that the hoist control unit has detected a situation that prevents the hoist from running. The hoist control unit stops the motion, indicates the fault text on the display and illuminates the red LED continuously on both the unit and display.
PAGE 67
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 13.2 Warnings 13.2.1 General warnings The warning state means that at least one calculated condition monitoring value has exceeded the corresponding design value of the hoist. Any active warnings are indicated with the corresponding text on the display.
PAGE 68
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 14Troubleshooting In the fault logger (5-2 Fault log) each fault is identified with a fault code and the values of the start counter that corresponds to the detection time of the fault. The first fault in the logger (5-2-1) is the latest one. In the table below, the column “Code” (e.g. F_OL) indicates the abbreviation for each fault as shown in the fault logger. 14.1 Fault descriptions 14.1.
PAGE 69
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 The parameter 4-7-1 value is “Motor” • Check parameters 1-2-2 and 1-2-3. - • Check that temperature sensor 1 (slow speed) is connected to terminals 21 - 22, and sensor 2 (fast speed) is connected to terminal 23 - 24. - • - • • Drive the hoist in slow speed and check that reading of parameter 1-2-2 Temp 1 increase.
PAGE 70
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 14.1.2 Fault Motor OT F_OT Hoist motor overtemperature • Check that 4-4-1 T1 operat. corresponds to the actual sensor of the hoist motor • Check that 4-5-1 T2 operat.
PAGE 71
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 - • • Limit switches • Bimetal switch • Mechanical overload switch Check the operation of the current transformer - • Drive the hoist in slow speed and measure voltage between the terminal 27 and the terminal 29 See appendix: Current Transformer Table Check connection to the hoist motor - • If the contactor isn’t energized then problem is the control connections.
PAGE 72
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 14.1.8 Fault Sensor ch. F_SCh Measurement signal out of acceptable range • Measure the voltage across terminals 26 (I1-A) and 30 (0V). Voltage should be between 0.5...9.5VDC (low at zero-load; high when load attached to the hook) • Check the parameter 1-2-10 value - The parameter 1-2-10 value should be nearly the same as measured, ±1 VDC.
PAGE 73
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 14.1.10 Fault Supply vol F_SPh Main supply fault, one phase missing • Check that the main voltage connects simultaneous to the control voltage • Check the connections of the terminals 19 (U1-1), 17 (U1-2) and 15 (U1-3) Intheinsulated or high impedance grounded networks, the zero level floats, causing errors in detecting actual supply voltage. Set parameter 4-10-3 to NO 14.1.
PAGE 74
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 14.1.14 Fault CAN bus F_CAN CAN bus communication fault Check the CAN bus wiring Check that the value of parameter 4-11-1 “Hoist cnt” in each unit corresponds to the number of units connected with the CAN-bus Check that each connected unit has an unique address, parameter 6-1 “Hoist name” Check with parameter 2-1 “SW version” that each connected unit has the same software version.
PAGE 75
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 14.3 Blank display • • • If display shows “blank”, check that display location selection switch position is right, logal (LOC) or remote (REM), in the monitoring unit. Check the connections from the unit to the display Change the remote display cables connections for terminals 32 and 33 14.
PAGE 76
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 Correct wiring Wrong wiring 3 1 2 2 1 3 c_curtr2a c_curtr1a 1. Terminal block 2. Current transformer 3. Contactor 14.6 There is no fault, but hoist doesn’t work 14.6.
PAGE 77
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 14.6.2 Hoisting and lowering prevented Check the input status from parameter 1-2-14 HIN 1 • • LIN 0 FIN 1 MFI1 0 MFI2 0 If the unit does not receive any input commands, check the control voltage and the commanding inputs Check the terminal Itmore is normal that a Voltmeter shows a disturbance value.
PAGE 78
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 15Replacement Instructions WARNING! Wrong Parameter settings can lead to a fatal malfunction of Monitoring Unit. Only authorized Service Technicians with a proper know-how about Monitoring Unit are allowed to make a replacement! 15.1 General The Hoist-Monitoring-Unit is a multifunctional device.
PAGE 79
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.
PAGE 80
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 Description 7-18 SL1 7-19 SL3 Calculated value from Load and Cycles, ^1 Calculated value from Load and Cycles, ^3 Read old values Set value from old unit Set to 0 1-1-1 SWP% SL3 = 7-20 SL8 7-21 Power on 7-22 Temp index 7-23 Max Load 7-24 Br.Count Desing values from parameter Calculated value from Load and Cycles, ^8 Total hours when the unit was powered on.
PAGE 81
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 15.5 Flow chart 81/105 R&M Materials Handling, Inc. reserves the right to alter or amend the above information without notice.
PAGE 82
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 16Menu structure 16.1 Monitor 1 (Menu 1) Read only menu for condition monitoring values and measured values. Accessible with the customer’s password. 1 Monitor 1 Param. 1-1 Name Cond mon Value 1-1-1 SWP% “n” % 1-1-2 1-1-3 Starts Run time “n” “n” h 1-1-4 Cycles “n” 1-1-5 Mean load “n.
PAGE 83
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 Param. 1-2 Name Measure 1-2-13 Int. temp 1-2-14 Input 1-2-15 Output 1-2-16 Supply f Param. 1-3 1-3-1 1-3-1 1-3-2 1-3-2 1-3-3 1-3-3 1-3-4 1-3-4 Name Min/Max Min supply Reset ? Max supply Reset ? Min Int. T Reset ? Max Int. T Reset ? Value Description Measurement menu used for measurement purposes only “n” C Internal temperature of the unit.
PAGE 84
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 16.3 Load calibration menu (Menu 3) 3 Load setup Load calibration menu. Accessible password level 2 Param. Name 3-1 Cal. Motor 3-1-1 Set>80% 3-1-2 “nn.n”t OK ? 3-1-3 3-1-4 3-1-5 3-1-6 3-1-7 Up, slow Up, fast Down, slow Down, fast Set<30% 3-1-8 “nn.n” t OK ? 3-1-9 3-1-10 3-1-11 3-1-12 Up, slow Up, fast Down, slow Down, fast Param.
PAGE 85
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 16.4 Start-up menu (Menu 4) 4 Start-up Start- menu. Accessible password level 4 Param. 4-1 Name MFI1 Value 4-1-1 MFI1 oper. NU 4-1-2 MFI1 IntL ”nn.n” t 4-1-3 MFI1 2OLL ”n.nn” 4-1-4 MFI1 CintL “nn.n” t Param. 4-2 Name MFI2 Value 4-2-1 MFI2 oper. NU 4-2-2 MFI2 IntL ”nn.n” t 4-2-3 1+2 IntL “nn.n” t 4-2-4 MFI2 2OLL ”n.nn” 4-2-5 MFI2 CintL “nn.
PAGE 86
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 Param. 4-3 Name ROUT Value Description Relay output parameters When “LoadX” is chosen with parameter 4-3-1, the load limit to switch the relay is entered here (in tons). Range: 0…hoist rated load.
PAGE 87
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 Param. 4-7 Name Load param Value 4-7-7 Temp_fast T2 4-7-8 4-7-9 4-7-10 4-7-11 4-7-12 C2F C2S C1F C1S ki nnnn nnnn nnnn nnnn nnnn 4-7-13 Acc-t slow 0.20s 4-7-14 Acc-t fast 0.30s Param. Name Value 4-8 Hoist ctrl Description The selection for the hoist control method 2-SP Two step control INV Stepless control (i.e. Inverter drives) Param.
PAGE 88
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 16.5 Service menu (Menu 5) 5 Service Start- menu. Accessible password level 5 Param. Name 5-1 S limits 5-1-1 5-1-2 5-1-3 5-1-4 S Run time S starts S SWP% S Br SWP% “nnnn” h “nnnnn” “nn” % “nn” % Param. Name Value 5-2 Fault log “n” 5-2-1 F_”XXX” “nnnnn” 5-2-2 F_”XXX” “nnnnn” 5-2-“n” F_”XXX” “nnnnn” Param.
PAGE 89
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 16.7 GO –settings menu (Menu 7) Values are equal to the ones in Menu 1 and/or Menu 2 (monitoring items). After a General Overhaul has been performed, these parameter have to be reset to the original value (zero) unless otherwise indicated 7 GO-setup GO-settings menu. Accessible with password level 7 Param.
PAGE 90
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 Appendix 1 - Default parameters All values are default values and can alter from application to application.
PAGE 91
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 Appendix 2 - Version History Software version history Version Changes SW 1.9 • • • • • SW 1.98 SW 2.000 First production SW Only one hoist operation Two hoists operation Corrections to AOUT Serial number - H00678 - H01660 - T00187 - T00730 SW 2.004 • • Multihoisting operation Serial number - H01661- H05697 - T00731- T01945 SW 2.
PAGE 92
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 Hardware version history Version HW C Changes • • First production HW Serial number - H00677 - T00263 HW D • Serial number - H00678 – H01287 - T00264 – T00496 HW E • • • • • Layout (Diode, ferrite) AC-inputs layout Current loop to RJ terminal CAN-bus speed (25 kB => 50 kB) Serial number - H01288 – H02324 - T00497 – T01087 HW H • • • • • • • Layout (Leds and display’s switch) El.
PAGE 93
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 Appendix 3 - Current Transformer’s information Current transformer connections Current transformers are connected between the incoming terminal block and hoisting contactor. Phase lines are coming from terminal block and going through the current transformer(s) and then going to the contactor.
PAGE 94
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 Phase line goes two times through the current transformer. (2 ROUNDS) Phase line goes three times through the current transformers. (3 ROUNDS) 10 Peak value Voltage The current transformer’s grey wire is connected to the terminal 29. The terminal 29 is neutral level for current transformers.
PAGE 95
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 Appendix 3.
PAGE 96
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.
PAGE 97
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 Appendix 4 - Motor temperature NTC charts A NTC Bccomponents NTC 23226338.303 R25 = 30 k T/C -40 -35 -30 -25 -20 -15 -10 -5 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 105 110 115 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 RT / R25 33.060000 23.900000 17.470000 12.900000 9.621000 7.242000 5.501000 4.214000 3.255000 2.534000 1.987000 1.570000 1.
PAGE 98
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 Appendix 5 - Example connections 98/105 R&M Materials Handling, Inc. reserves the right to alter or amend the above information without notice.
PAGE 99
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 99/105 R&M Materials Handling, Inc. reserves the right to alter or amend the above information without notice.
PAGE 100
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 100/105 R&M Materials Handling, Inc. reserves the right to alter or amend the above information without notice.
PAGE 101
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 Appendix 6 - External power supply for ESD 143 General The current of 10VDC of the Control Pro is limited to 50mA. When KAE400 (ESD142), strain-gauge sensor and EDS143 or KAE400 (ESD142) and two strain-gauge sensor is used simultaneously the needed current is much over 50mA. Furthermore, the current of relay card ESD143 alternates depending on the state of the relays.
PAGE 102
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 Example drawing OL00 OL00 6 A-T10 FG 7 AC L 5 N.C. 8 4 AC N 4 OL WRM-22FWX-U+ G2 12 RIN A-A1 1 12 VDC 3 24 VDC 2 0 VDC ANALOG INPUT @ANALOG INPUT V1 A-A1 10VDC AIN1 AIN2 AIN3 V2 25 26 27 28 IB 29 0VDC 30 G1 GND 11 14. K3 13. 12. K2 11. 10. 9 8 N 18VAC 7 6 4 2 0V 15.
PAGE 103
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 Appendix 7 - Replacing the condition monitoring unit continuing! Read through all steps of these instructions and make yourself familiar with the procedure before Write down the following information: Hoist’s order Number: Hoist’s serial number: Old unit serial number: New unit serial number: Fill in the requested fields of this document.
PAGE 104
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 4-7-1 Load meas = Motor 3-2-1 Load 1 3-2-2 Mhs 1 3-2-3 Mhf 1 3-2-4 MIs 1 3-2-5 MIf 1 3-2-6 Load 2 3-2-7 Mhs 2 3-2-8 Mhf 2 3-2-9 MIs 2 3-2-10 MIf 2 - 4-7-1 Load meas = Sens. 3-4-1 Load 1 3-4-2 Input 1 3-4-3 Load 2 3-4-4 Input 2 Push ESC-button 2 timen => Menu 3 Push 4 times Up-button => Menu 7 Push ENT-button => Menu 7-1 Read parameters’ values.
PAGE 105
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 • Hang the test load in the hook and check the actual load in both slow speed and in fast speed with parameter 2-1-1. The display should show the value of the test load, ±5% of nominal load. - • • • If the load values are within the given range, the work is finished. Return the old unit to the manufacturer.