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OWNERS MANUAL
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TABLE OF CONTENTS
GENERAL INFORMATION
SYSTEM SPECIFICATIONS INSTALLATION THEORY OF OPERATION OPERATOR'S INSTRUCTION MAINTENANCE
Page 1
SECTION I
GENERAL INFORMATION
INTRODUCTION
The MDR-8400 Radio Remote Control System is a microprocessor based control device which provides relay command outputs. In designing the MDR-8400, Control Chief's engineers have combined over 20 years of industrial radio remote control experience with the advanced technology of proprietary software techniques and VLSl (Very Large Scale Integrated Circuit) hardware. The result is a digital radio remote control system where the signal is highly secure and the system is reliable and easily maintained.
SYSTEM DESCRIPTION
The MDR-8400 consists of a hand held battery powered command transmitter and a Receiver/ Decoderllnterface unit. Peripheral support equipment include a battery charger, rechargeable batteries, surge suppressors and a transmitter carrying harness.
The MDR-8400 transmitter was designed to be comfortably carried and operated with one or two hands. Heavy duty "deadman" (spring return) motor control levers permits ease of operation for initiating crane motion commands to the crane mounted Receiver/Decoder/lnterface unit. Industrial grade toggle and pushbutton switches are used for activating transmitter "on" and for activating peripheral auxiliary functions. Within the transmitter the operator generated commands are converted to a digitally coded serial data stream and modulated onto a carrier frequency within the 72-76 Mhz range. A rechargeable 12 volt (.75 amp-hour) NlCAD battery supplies power to the standard transmitter. Each transmitter is custom designed. The variables which determine how a transmitter is manufactured are frequency, engraving and number of motions-auxiliaries. By matching the transmitter to the exact user criteria CONTROL CHIEF CORPORATION provides a control device which is not only technically superior but also oriented to the specific user.
RECEIVER/DECODER/INTERFACE UNIT
The standard Receiver/Decoder/lnterface unit is housed in a 24"Hx24"WxI 0"D Nema 12 rated enclosure and operates from 120 volts AC. The major components of the ReceiverlDecoder/lnterface unit are: 1. Power supplies (5 and 12 volt) 2. Card CagelMother Boardlnput-Output Terminal Strips A. 72-76 Mhz Receiver Card B. Processor Card C. I10 Relay Cards 3. Transfer Switch (ManualJRemote)
Page 2
MDR-8400 SPECIFICATIONS
GENERAL
Frequency: .................................. 72-76 MHz Operating Range: ........................ 1000 feet typical ("power our' adjustable) Temperature Range: .................. -20 degrees F to +I 40 degrees F (-30 degrees C to +60 degrees C) Battery Life: ................................ 8 hours typical (continuous operation) Nickel cadmium (.75 Amp Hour) rechargeable batteries. Environmental Conditioning:........ Transmitter and receiver both sealed against dust. System Diagnostics: .................... Built-in with LED and numerical indicators. System Address Capability: ........ 15 addresses EncodinglDecoding Method: ...... Microprocessor/softwarebased
TRANSMITTER
Dimensions: ................................ 9" or 10.5" x 7-314" x 4-112" Weight: ....................................... 6-8 pounds (including battery) Case: .......................................... Unit completely contained in a heavy gauge, aluminum housing. Carrying Method: ........................ Adjustable web beltlharness of strong, lightweight nylon fabric. Switches: .................................... Motor control switches are spring-return (deadman) lever type with five detented positions in each direction. Other switches are industrial grade and may be "lock-off" toggle, key operated, pushbutton or others as required. Supply Voltage: .......................... 12 volts DC Power Output: ............................ 50 milliwatts adjustable Frequency Stability: .................... .005% Modulation Bandwidth: ................ + 5 KHz Maximum Modulation Type: ........................ FM Digital CFSK Spurious Output: ........................ -50 dbc Duty Cycle: .................................. 100% RF Output Impedance: ................ 50 ohms
RECElVERlDECODER
Enclosure: .................................. Supply Voltage: .......................... Sensitivity: .................................. Squelch Threshold ...................... Frequency Stability: .................... l mage Rejection .......................... Spurious Response .................... Selectivity: .................................. Modulation: .................................. RF Input Impedance: .................. Output Relays: ............................ 24"Hx24"WxI 0"D Nema 12 cabinet (standard) Customer supplied 120 VAC, Single Phase 60 Hz at 500 VA .7 uV (20 db Quieting Method) 0.5 uV or less .001%
60db
70db 60 db (20 KHz Adjacent Channel) +/- 5 khz 50 ohms Contact rating 110 VAC 10 amps resistive, 7.5 amps inductive: 220 VAC 7.5 amps resistive 5 amps inductive Response Time: .......................... 68 milliseconds
Page 3
SECTION II INSTALLATION
INTRODUCTION
The installation of the MDR-8400 ReceiverlDecoderllnterface unit must be performed in a prescribed manner for proper operation and overall system satisfaction. The personnel needed to properly install a MDR-8400 Receiver/Decoderllnterface unit are an electrician and a welder.
RECEIVER/DECODER/INTERFACE MOUNTING
The ReceiverlDecoderllnterface unit is equipped with a mounting flange on both top and bottom. After a suitable location is found, the enclosure may be bolted or welded to the support structure. Care must be taken to ensure ample space is provided to open the door (not less than 18" in front) and to permit conduit entrances at the lower right area of the enclosure. The Receiver/Decoder/lnterface unit's mounting location depends on several factors:
1.
The receiver must be located at the same location as the crane's operating controls. If the crane controls are located on the bridge, then the Receiver/Decoder/lnterface unit must be mounted on the bridge. If the crane controls are located on the trolley, then the Receiver/ Decoderllnterface unit must be mounted on the trolley. A source of single phase 120 VAC, 500 VA power must be available. The unit should not be mounted where it will be subject to temperatures in excess of 140 degrees F.
2.
3.
All interconnection and power supply wiring must enter the enclosure in the lower right corner. Interconnection wiring between the MDR-8400 and the crane controller should be a minimum #I6 AWG and routed through rigid conduit or flexible conduit such as Sealtite. For interconnecting the MDR-8400 to the existing crane controller, refer to the Output Circuit Schematic and the Output Wiring Diagram included in the drawing package. These drawings show where to wire each output terminal.
CAUTION: Any device (magnet circuit) which will require power irrespective of the status of the ReceiverlDecoderllnterface unit must be wired on the line side of the main line contactor. This is necessary to prevent loss of power to the devices due to opening of the main line contactor (See Safety Features, Page 14).
2.
I
Page 4
SURGE SUPPRESSORS
Supplied with each system is a quantity of surge suppressors. These are used to protect the electronic equipment from electrical line surges and to increase the life of the electrical contacts. The surge suppressors must be connected in parallel across all relay contactor coils of the crane control circuits (at the coil location). In those cases where Control Chief has supplied an intermediate relay panel, the suppressors will already be installed on the coils of the relays.
ANTENNA PLACEMENT
Included with each system is the receiving Antenna, an Antenna Mount with 25 feet of cable and the Receiver/Enclosure Cable Assembly. In order to obtain optimum system performance, it is essential the receiving antenna be properly located. Ideally, the antenna should be mounted on a vertical axis below the bottom of the bridge structure and be visible from any operational point on the floor (See Figure 2.1, Page 26)
FINAL CHECKS
The following system checks and guidelines must be adhered to prior to operating the system for the first time: 1. Ensure separate 120 VAC, 500 VA control transformer has been installed to supply power to the Receiver/Decoder/lnterface unit. Check status of the AC power supplying collector shoes1 festooning. Ensure the transmitter battery is charged to full capacity. Ensure surge suppressors are installed across ALL relay coils. The surge suppressors must be installed at the location of the controlled relay coil. The failure to install surge suppressors will cause unsatisfactory crane operation. Ensure the person(s) operating the radio remote control have been properly trained and are qualified for both the safe operation of a radio remote control unit and the safe operation of a overhead industrial crane. Ensure a main line contactor is employed on the crane and controlled by the MDR-8400 Receiver/Decoder/lnterface units "Main On" (address) and "Warning Start" relay (See Safety Features Page 14). The main line contactor is vital for emergency crane shutdown. Ensure a fail safe braking mechanism is used on the bridge drive. OSHA rules and regulations Chapter 17, Para 1910.1 79, Section (f), (6)(iii) states "On all floor, remote and pulpit operated crane bridge drives, a brake or non-coasting mechanical drive shall be provided". The braking mechanism generally employed is an electronically operated, spring close type of brake. Ensure a log book is maintained b y the Maintenance Department. The log should include a list of assigned address codes and carrier frequencies cross referenced to the proper transmitter, Receiver/Decoder/lnterface unit and crane.
2.
3.
4.
5.
6.
7.
Page 5
The main circuitry of the transmitter unit consists of the Logic Card and the RFIRegulator Card. The Logic Card is pre-programmed to encode control switch information into a binary coded serial data stream. The RF/Regulator Card modulates the carrier with serial data by means of direct Carrier Frequency Shift Keying (CFSK).
Page 6
Page 7
- CRC PARITY
CRC (Cyclic Redundancy Code) parity is a sophisticated method of error detection for a block of data (Serial Data Stream). The transmitting microprocessor treats the block of data as a high order polynomial. This polynomial is divided by a generator function G(x) =XI5 + X5 + 1 which is known by both the transmitting and receiving microprocessor. The quotient of this division is discarded and the remainder is appended to the end of the block of data. The receiving computer divides its received data by the same generator function G(x). If the division has no remainder the stream is valid. The advantage to this type of parity is that it can detect bursts of serial data errors.
Page 8
TRANSMllTER
When the battery voltage is above 10V the battery cutoff circuit U3B and Q8 outputs a high (5 volts) to the NAND Gate of U2B of the Logic Card. If the battery voltage drops below 1OV, then a low (0volts) is applied to U2B producing an oscillator cutoff condition.
RECEIVER/DECODER/INTERFACE UNIT
The main circuitry of the Receiver/Decoder/lnterface unit consists of the Power Supply, Mother Board, Receiver Card, Processor Card, and Stepped 110 Relay Cards. The Receiver Card converts the w o incoming RF signal to a binary coded serial data stream. The Processor Card utilizing t microprocessors, decodes the serial data stream and outputs control information to the I10 Relay Cards. The If0 Relay Cards provide output contacts to be used for interfacing directly to the crane control circuits or to an auxiliary interface panel.
Page 9
Ir
1. 2. 3. 4. 5.
lnternaly, U1 contains a second mixerloscillator stage, a limiter, a quadrature detector, a noise amplifier and a squelch detector circuit. The 10.7 MHz signal from FLI and a 10.245 MHz signal provided by the oscillator of U1 and external crystal Y2, are presented to the mixer of U1. The mixer outputs the difference of these two frequencies (455 KHz) through an external filter FL2. From FL2 the 455 KHz signal re-enters U1 to the limiter and quadrature detector sections.
Page 10
The quadrature detector circuit outputs a desired demodulated signal containing the transmitted serial data and any internally generated noise. The strength of the demodulated signal versus that of the noise is proportional to the strength of the incoming carrier signal (72-76 MHz). The strongerthe carrier signal, the lower the amplitude of the noise. Amplifying then sensing one level of the noise are the Noise Amplifier and Squelch Detector sections of U1. If the rectified noise level exceeds the Squelch Threshold setting (R17), then the Squelch Detector will squelch or quiet the output of the quadrature detector. Providing the RF signal is of sufficient amplitude, the demodulated signal from the quadrature detector will be presented to the Low Pass Filter U2B. Filter U2B "cleans" the demodulated signal by removing the high frequency noise components. From U2B the signal travels to the Wave Shaper circuitry; Peak Detectors U6A and U6B, and Slicer U5A. This circuitry shapes the signal from a rounded waveform into a square waveform. The squared digital or serial data stream, which is now identical to the serial data stream generated by the transmitter Logic Card, passes through a feed-through capacitor to an inverting buffer and is sent to the Processor Card. In addition to the serial data stream, a signal from squelch circuitry (SquelchlCarrier Status] is sent to the Processor Card. A +5V signal indicates a satisfactory carrier strength level; OV indicates a squelched receiver. The signal is used by the Processor Card for diagnostic troubleshooting purposes and to key the two microprocessors as to the status of the squelch circuit. The three light emitting dies (LED'S) on the Receiver Card are for troubleshooting and will be covered in Section V.
5V Monitor Address Switch Serial Data Processor (SDP) InpuUOut~ut Processor (IOPI ohput ln'hibit Troubleshooting Diagnostics
A simplified block diagram of the Processor Card is shown in Figure 3.1 1, Page 37.
Decoding of the serial data stream and formatting of relay control information by the P r r Card is accomplished by two microprocessors; the Serial Data Processor (SOP) U1, and tha Inmmt Processor (IOP) U2. The serial data stream from the Receiver Card is fed to the SDP. Two conditions must be met before either microprocessor can process the data:
1. The +5V supply must be above 4.5V.
2. The SquelchlCarrier Status signal from the receiver Card must be high (5V), indicating a satisfactory carrier signal strength. Before explaining the processing of the serial data stream by the IOP and SOP,the p r o g m f peripheral hardware and its functional role will be covered.
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Comparator circuit U5 monitors the status of the 5V supply. If the supply voltage should fall below 4.5V,then U5 will provide a reset or low signal to both the SDP and the IOP. The system reset signal causes the microprocessor's internal program to reset to the beginning and prohibits the program from running as long as the low signal is preseni. A manual reset can be applied by activating switch S1. A four pole DIP Switch (S2) provides a preset address code to the SDP. The address code must beset to match the corresponding transmitter code. Monostable multivibrators USA and U9B each perform a watchdog function for the SDP and IOP, respectively. When the microprocessors' programs are running properly, a "watchdog" toggle pulse is sent to U9A and U9B. Providing these 'katchdog" circuits receive their respective toggle pulses on a timely basis, a 5V signal will be continually sent to one of the input ports of NAND Gate U15. Absence of this 5V watchdog signal results in an Output lnhibit signal or system shutdown generated by U15. For timing purposes oscillator crystal (XI) supplies a 6 MHz frequency to both the SDP and IOP. The SDP divides the 6 MHz clock frequency and outputs a 400 KHz clock frequency to a Divide-By-Four Counter (U6). The output of U6 provides a toggle signal of 100 KHz to the SDP (Ul) for program loop timing. For a troubleshooting aid, the Processor Card contains three seven-segment error display units and eiaht discrete error LED's. The error codes are covered under the Alianment and Troubleshootina sections. Error display D l is controlled by a BCD-to-7-segment ~ a t c i ~ e c o dDriver er (U8). he ~ D P (Ul) supplies error information to U8. Error displays D3 and D2 are considered one display unit with D3 indicating a'Yensn digit and D2 a "ones" digit. U10, an 8-Stage ShiWStore Register, receives error information from the IOP (2) and sends it to the appropriate BCD-to-7-Segment Latch Decoder Driver U12 or U13. Error Displays D3 and D2 are controlled by U12 and U13, respectively. The eight discrete LED's, three green and five red, are controlled by the microprocessors (U1 or U2), the Squelch Status signal, and the Output lnhibit signal from U15. For safety, an Eight Input NAND Gate, U15, generates an output signal (5V) when any of the inpu, gates recelve a low (OV). The input gates of U15 monitor the status of the IOP and SDP watchdog circuits, the IOP Data Error Signal, and the System Reset Signal from Switch S1 or Comparator U5. The Output lnhibit Signal cues the SDP and IOP to a safety fault condition and commands the Relay Cards to return all relays to the normally off mode. The serial data stream enters the Serial Data Processor (SDP, U1) on pin 38. The SOP examines the incoming data looking for the "String Synchronization" or "Message Start" word. (See Serial Data Message Format explanation, Page 8). Once recognized, the SDP will store, reformat, and output to the IOP (U2) in parallel form, the transmitter address, motor, auxiliary function and CRC parity information. The SDP also reads the Processor Card's address from S2 and sends it to the IOP. Upon receipt of the parallel data from the SDP, the IOP performs four basic functions with the information: 1. Compares the transmitted address with the processor address. 2. Calculates the CRC parity of the received data and checks the result against the transmitted CRC parity words. 3. Formats the parallel data into serial data containing 110 Relay control information as instructed by a pre-programmed routine, and outputs this information to the shift registers of the 110 Relay Cards.
4. Stores and compares outputed relay data with returning relay status informatior
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If the Address and CRC Parity evaluations are acceptable, the IOP will complete the information transfer by strobing the I/O Relay Cards' relay control registers. If data sent does not match the relay status information received back from the 110 Relay Cards, an Output lnhibit will be triggered by a data error signal from the IOP.
The relay control serial data from the Processor Card consists of sixteen (16) bits per motor and sixteen (16) bits total for the auxiliary functions. Each bit is capable of controlling one I10 relay. A "one" or "high" bit instructs a relay to turn on. A "zero" or "low" bit instructs a relay to turn off. Each motor card contains eight relays. Some motor logic sequences require more than eight relays. In these situations, two It0 Relay Cards are used. By means of the positive clock pulse transitions generated by the IOP of the Processor Card, the relay control serial data bits are shifted through the Serial-to-Parallel Registers (U1 and U2) of each 1 1 0 Relay Card, eventually filling all registers. The eight registers of the U1 tie directly to the relay latch1 driver circuits of U3 and U4. Once the registers are filled, a strobe pulse from the IOP simultaneously instructs the appropriated Latch Drivers of U3 and U4 on all cards to latch or unlatch. A latched driver circuit will result in turning "on" its respective relay. Also feeding the Relay Control Shift Registers U1 and U2 and the Latch1 Drivers U3 and U4 is an Output lnhibit input line from the Processor Card. In the event that an Output lnhibit signal is received, all relays are turned off. For safety reasons, a Relay Status Monitor Circuit has been incorporated into the MDR-8400. When an output relay is energized its output contacts change state. The Opto-Isolators U8 through U15 notify the Safety Monitor Registers (U6 and U7) as to the status of the contacts. Upon receipt of a strobe pulse, U6 and U7 sends the information back to the IOP of the Processor Card. The IOP compares the relay status information received against the relay control information sent. If the data does not agree, then an Output Inhibit Signal is generated. The output contacts of the I/O Relay Cards are connected via the Mother Board to the terminal strips. Direct interfacing to the crane magnetic motor controllers or to additional interfacing relays is accomplished through these terminals.
S A F t r Y FEATURES
In the development stage of the MDR-8400, safety was a design priority. The use of digital electronics and microprocessors has allowed sophisticated safety checks. Throughout the prior General Circuit Description, the various safety features have been described. A summary of several of these features are:
1. Narrow Band FM Receiver Allows only the passing of the desired frequency (See Receiver Card, Page 10). 2. Receiver Squelch Circuit Requires carrier signal strength to be of sufficient amplitude before receiver will output the serial data stream (See Receiver Card, Page 10). 3. Accurate String Synchronization String Synchronization pulses must appear at given positions throughout each serial data message (See Serial Data Message Format Page 8).
4. Correct Address Coding and CRC Parity Result Requires correct 4 bit address code and correct CRC parity result with each serial data message before the I/O Relays will respond to the message (See Logic Card Page 8).
5. Relay Status Monitoring IOP microprocessor stores and compares relay control data sent to I/O Relay Cards with returning relay status information. If the two do not match, then a data error is generated to the Output Inhibit Circuit (See lnput/Output Relay Cards Page 13).
6. Output lnhibit Signal Enacted by data error from IOP (Address fault, CRC Parity fault, relay status fault). Initiates a system shutdown by instructing the Relay Shift Registers and LatchIDrivers to return all relays to the normal "off" position (See Processor Card Page 1 1).
Page 14
OVERVIEW
The MDR-8400 consists of two basic components; the transmitter and the Receiver/Decoder/ Interface unit. Peripheral support equipment includes a battery charger, rechargeable batteries and a transmitter carrying harness. A battery charger for charging the Nicad batteries is also included. When a transmitter command switch is activated after turning on the transmitter "Power On" and "Main On" switches, a digitally coded radio signal containing the operator's commands is modulated and sent via RF to the Receiver/Decoder/lnterface unit. The spring loaded motion levers are designed to return to the "deadman" or "off' position upon release. The levers operate much in the same manner as crane master switches. With electrically operated brakes, the deadman position will set the associated brake. It is also possible to operate more than one crane motion lever concurrently; such as bridge and hoist.
TRANSMllTER OPERATION
The transmitter is powered by a rechargeable battery. For safety purposes and to conserve battery power, it is recommended the transmitter "Power On" switch be turned off whenever a lift is not being made. To command a crane function, the following steps are to be followed: 1. Turn keylock power switch "on".
2. Check battery power by depressing battery test switch. If the light glows, then battery is OK.
3. Engage "Main On" switch. This action sends system address information.
4. Depress "ReseWarning" pushbutton. This action activates the main line contactor
circuit which allowing power to the crane motors. Once mainline contactor is activated depressing "Reset/Warning" pushbutton will activate any warning devices utilized. 5. Select and operate desired motor lever(s).or auxiliary command switch(es).
page 15
In the event a condition exists requiring emergency shutdown, the operator can either turn off the "Power On" keylock switch or the "Main On" switch. Either procedure will immediately open the crane main line contactor, cutting power to the crane motors and setting all electrically operated brakes.
PREVENTIVE MAINTENANCE
The portable transmitter is housed in a heavy gauge aluminum enclosure. The unit is designed to survive in an industrial environment with moderate "banging around". However, the unit does consist of solid state electronic circuitry and should not be subject to careless abuse. It is your lifeline to the crane - so take good care of it. The battery charge should last a minimum of 8 hours of continuous use. Turning the key off between lifts will conserve battery power. Battery power can be checked by depressing the battery "Push-toTest" switch. If your battery is not lasting a full 8 hours, notify your Maintenance Department.
BAJTERY MAINTENANCE
When used properly, the 12 volt Nickel cadmium batteries used to power the transmitters will provide 8 hours of continuous use. Proper battery maintenance allows for 16-20 hours of charging between uses. Prior to charging, the batteries must be completely discharged. The battery is considered to be completely discharged when the battery will no longer operate the transmitter. If the batteries are repeatedly placed on the charger before they have been completely discharged the electrochemical cycle of the batteries will be compromised and the batteries will not provide 8 hours of continuous operation.
Page 16
SECTION V MAINTENANCE
INTRODUCTION
The intent of this section is to provide maintenance information to facilitate system troubleshooting to the "board" level. To aid in locating a system problem, the MDR-8400 features both built-in LED status indicators and microprocessor controlled Numerical Display units. Troubleshooting consultation is available by calling Control Chief Corporation. For troubleshooting to the first level, it is recommended a set of spare printed circuit cards for the Receiver/Decoder/lnterface Unit and a spare operating transmitter be stocked. Within the MDR-8400 there are seven unique printed wiring boards; the transmitter's Logic Card and RFlRegulator Card and the Receiver/Decoderllnterface unit's Receiver Card, Processor Card and Stepped 110 Relay Card. To order spare parts contact your local representative. Once the problem circuit card or transmitter has been identified, return it to Control Chief for repair. Normal card level repair is less than 48 hours. For servicing to the component level, it is possible to purchase a MDR-8400 Component Service Manual Part Number 8002-9000-01. Figure 5.1 provides a list of drawings, schematics and parts lists included.
FIGURE 5.1
MDR-8400 DRAWINGS, SCHEMATICS 8 PARTS LIST
Circult Card
A
Drawing Number
8002-1001-01 8002-1003
Rev. Level
-
Ejector Color
Transmitter Logic Card Transmitter RFIRegulator Card (72 MHz) Receiver Processor Card Receiver I/O Relay Card Receiver Mother Board Receiver Module (72 MHz)
Blue Red
E
A3
C
E
Yellow
NOTE: These drawings, schematics and parts list are included in the Component Service Manual which may be purchased and used for servicing to the component level.
Page 17
DIAGNOSTICS
To aid in locating the source of a system operating problem, LED Status Indicators and Numerical Display Units are incorporated into the crane mounted MDR-8400 equipment (See Figure 5.2 for location, Page 39). Utilization of the L.E.D. Status lndicators and Numerical Display Units in conjunction with the troubleshooting information contained in this section will result in rapid system problem solving. The seven-segment display units will indicate the first malfunction experienced. Only malfunctions which cause a sustained Output Inhibit will shut the system down until corrective action is taken. Temporary malfunctions or RF interference will cause a shutdown, but the system can be brought up again by depressing the transmitter Warning/Reset pushbutton. To clear the displays and reset the Processor Card depress the Reset switch located on the Processor Card. Receiver Card LED indicators are as follows:
LED
Green Yellow Red
With transmitter on, Green LED should flicker, Yellow LED will glow and Red LED should be off. If these conditions are not met, refer to Troubleshooting Chart Figure 5.4. With transmitter off, Red LED should glow and the Green and Yellow LEDs should be off. If these conditions are not met, locate source of external RF interference.
LED
Green #1 Green #2 Green #3 Red #1 Red #2 Red #3 Red #4 Red #5
Not used Output Inhibit has been activated SDP Fault (Check Single 7-Segment Display) IOP Fault (Check Double 7-Segment Display) Relay Fault (Check Double 7-Segment Display relay number and refer to system drawing ....3000 for location of this relay in your system.)
Page 18
Error Code
With SDP Fault LED (Red #3) on
1
Function
Corrective Action
Locate external RF interference and reset Processor Card Check transmitter RF power and frequency Check receiver antenna connection Check Receiver Card LED Replace Receiver Card Ensure surge suppressors are installed on all relay coils and all inductive and capacitive devices Replace Processor Card Turn system power off, wait a few seconds, turn system power on If error remains replace U1 of I10 Processor card
3
4
Fatal Hardware Fault (Output Inhibit will be active) SDPIIOP Communication Fault Ram Fault
Error Code
With IOP Fault LED (Red #4) On 01 02
Function
Corrective Action
SDP Fault (Refer to Code on Single -/-Segment Display Address Fault Check transmitter Main On switch. Ensure transmitter & Receiver/Decoder/lnterface unit address codes match Ensure surge suppressors are installed on all relay coils and all inductive and capacitive devices Replace Processor Card Locate external RF interference Starting with relay card 1 substitute a good relay card through each relay card position until error is corrected Retune Receiver card Retune Transmitter card Locate external RF interference Turn system power off wait a few seconds, turn system power on If error remains replace U2 of 110 processor card
&
03
04
Fatal Hardware Fault (Output Inhibit will be active) IOPISDP Communications Fault Parity Fault Unidentifiable Relay Fault
05 06
07
08
Ram Fault
With "Relay Fault" LED lighted, double 7-Segment display shows faulty relay number. A relay fault of less than two seconds will cause a temporary shutdown. A relay fault of greater than two seconds will cause a permanent shutdown until the fault is corrected and the reset switch on the Receiver1 Decoder/lnterface unit Processor Card is depressed.
Page 19
TROUBLESHOOTING
Through the use of microprocessor-based circuitry, system problems and troubleshooting time hBvB been minimized. Computer software greatly reduces hardware, the chance of hardware fault<, an$. . . .. provides self-diagnostics for rapid problem identification. . .I .
.':-
Before attempting to troubleshoot the MDR-8400, it is advised the assigned s e ~ i c e personnel become well acquainted with the information provided in Section Ill,Theory of Operation. problem; with any equipment can be classified into one of the three following areas:
1.
2.
Loss of one or more operating function but not total shutdown. A system shutdown that can be remedied with a transmitter or Receiver/Decoder/lnterface unit Processor Card reset. No Response.
3.
CAUTION: DO NOT REMOVE ANY CARDS IN THE RECElVEWDECODERnNTERFACE UNIT WHILE THE SYSTEM IS UNDER POWER. DISENGAGE FUSE SWITCH F1.
Proceed to step 4.
Check appropriate transmitter command switch and wiring for faulty switch or connection. Check serial data output of transmitter Logic Card at TP4 (yellow with volt meter on 10 VDC scale.
- With "Power On" (key) switch only engaged, meter will read approximately 4 VDC. - Engage faulty switch. Meter needle should move to lower reading. If not, replace
Logic Card. 4. Try manual mode of operation. If problem still exists, check crane magnetics and wiring.
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1
P I C : .
IN'rERMlTTENT SHUTDOWN
An Intermittent Shutdown is a condition whereby a momentary malfunction, loss of signal or outside noise interference results in an Output Inhibit causing a temporary crane shutdown. The situation can usual&Re remedied by activating transmitter ResetMlarning switch or the ReceiverIDecoderilnterface unit Processor Card Reset Switch. The following is a check for hardware malfunctions.
1. 2.
Try resetting Main Line Contactor by pressing the transmitter ResetMlarning switch. Check battery voltage by pressing "Battery Test" on transmitter. Try spare transmitter. If fault still exists, problem is with crane-mounted equipment. Move to Step 5. Check RF power and deviation (See RFIRegulator Card Alignment). Try manual mode. If fault remains, problem is with the crane. Check wiring and magnetics. Check diagnostics LED'S and Displays for abnormal indication (See Pages 18 EL 19). If a relay fault is indicated, replace faulty card. Press Processor Card reset switch, S1 Ensure all printed wiring cards are secure in connectors. Check all interconnection wiring and internal wiring to and from power supply. Check antenna, antenna cable and connections. Check coil arc suppressors.
3.
4.
5.
6.
7.
8.
9.
10. 11.
ALIGNMENT
Although system adjustment is not normally required, this section provides steps to determine if alignment is necessary and the procedures and equipment needed to perform the alignment. The transmitter's RFIRegulator Card and the Receidr Card located in the ReceiveriDecoderllnterfaceare the or& system d r d s which have adjustments.
b*
4
Wattmeter - Bird Thruline Model 43 or equivalent with 72-76 MHz, 100 mw elemem an& female UHF (SO-239) inputloutput connectors 50 ohm dummy load termination with UHF (PL-259) connector 80 MHz frequency counter 50 ohm coaxial cable (8 inches maximum length) with two male UHF (PL-259) connectors Hex alignment tool (GC Electronics No. 9300 or equivalent) Trimmer adjustment tool (Spectrol Model 8 or equivalent) Non-metallic tuning tool (GC Electronics No. 8987 or equivalent) Antenna stand (Control Chief Part No. 0082-0051-Stand) PRELIMINARY 1.
4
Ensure a fresh battery is installed in the transmitter. With power "OW', remove the transmitter case bottom and place the transmitter on a flai' .. surface with the switches facing down.
1
2 .
3. 4. 5.
Remove the transmitter antenna and connect the wattmeter to the antenna jack using ohm coaxial cable. Install a 50 ohm dummy load on the wattmeter and rotate the meter element to ir "Forwarcf' power.
fe~;,
Turn power "on". Wattmeter should indicate 50 milliwatts + 10 mw unless power has intentionally increased for greater range. If adjustment is required, refer to Alignment Procedure, Step 2. Turn transmitter power "OW'. Replace the 50 ohm load on the wattmeter with the transmar antenna. Rotate the wattmeter element to indicate reflected power and turn the transmitter poyer Using the nonrmetallic tuning tool, adjust the tuning slug for minimum reflected replace the plastic antenna cap. Reflected power must be less than 10% of antenna. Continue with preliminary step 12.
6.
7. 8.
rr.
+-
a9
9.
10.
Turn transmitter power "Off'. Replace the 50 ohm load on the wattmeter with the transmitter antenna mounted on the antenna stand. Rotate the wattmeter element to indicate reflected power and turn the transmitter power "on". Using the trimmer adjustment tool, adjust the trimming capacitor for minimum reflected power. Reflected power must be less than 10% of forward power into antenna. Turn power "Off' and reconnect the antenna to the transmitter. Turn power "On" and loose couple the frequency counter to the antenna using a coaxial cable with a pickup loop at the end. Locate spring-return toggle switch, S1, on the RFlRegulator Card and note the "H" and "L" markings above connector, J2. Hold S1 in the "H" (high) position and read the frequency counter. Deviation should be 2 KHz to 2.5 KHz above the assigned RF carrier frequency. Hold S1 in the "L" (low) position and read the frequency counter. Deviation should be 2 KHz to 2.5 KHz below the assigned RF carrier frequency. If adjustrr~ent is required, refer to Alignment ,Procedure, Steps 4 through 6.
11.
12.
13.
ALIGNMENT PROCEDURE
1.
2.
Perform Preliminary Steps 1 through 5 above. Adjust trimmer capacitor, C20, for a peak (maximum) wattmeter reading; then adjust C15 for 50mw. For transmitters with a whip antenna continue with preliminary step 6. For transmitters with a solid antenna continue with step 9. Hold toggle switch, S1, in the "L" (low) position and adjust coil, L3, for a frequency 2 KHz below the assigned RF carrier frequency. Hold S1 in the "H" (high) position and adjust potentiometer, R5, for a frequency 2 KHz above the assigned RF carrier frequency. Recheck the frequency with S1 in the low position. This completes the RF/Regulator Card alignment. Reinstall the transmitter case bottom, being careful not to pinch any wiring in the process.
3.
4.
5.
6.
7.
Page 23
PRELIMINARY
1.
Turn "OW' power to the Receiver/Decoder/lnterface unit, disconnect the antenna cable and remove the Receiver Card. Refer to Figure 5.5. Connect power supply "common" to the aluminum case and 12 volts to FL4. Set VOM to the 1 volt AC scale. Connect the positive (+) lead to FL9 and the common lead to the case power supply "common".
2.
3.
4.
r.
/'
Ensure power is "OW' on all associated transmitters. If necessary, adjust R17 counterclockwise until a noise-level reading is obtained on the VOM and continue 2 full turns counterclockwise past this point. Note the noise reference level. This should be (-)9 db minimum.
Set the RF generator to the receiver frequency at an unmodulated output of 2 uV and connect the generator to the receiver's BNC antenna jack. Set the VOM to the 0.1 volt AC scale. To check receiver sensitivity, decrease the generator output until the VOM reads 20 db lower than the reference level obtained in Step 4. This should occur when the output is 0.7 uV or less. If the generator output is greater than 0.7 uV, refer to Alignment Procedure, Steps 2 through 9. Set the RF generator output to 10 uV unmodulated and the VOM to the 10 volt DC scale. Connect the positive (+) lead to FL9. Adjust C27 several complete turns, noting the minimum and maximum VOM readings. Set C27 at the point midway between these readings. This will be approximately 3 volts DC. Connect the positive (+) lead of the oscilloscope to FL9 and the ground lead to the case. Set the generator for a 1 KHz modulating frequency at a deviation of 2 KHz. Adjust L5 and L6 for maximum audio amplitude with minimum distortion. Set the generator output for 0.5 uV with no modulation. Adjust R17 clockwise until there is no noise on the oscilloscope. Slowly increase the generator output and verify that the receiver unsquelches. This is indicated by the presence of noise and should occur before the generator output reaches 1 uV.
.
5.
6.
7.
This completes the alignment. Reinstall the Receiver Card and apply system power.
Page 24
ALIGNMENT PROCEDURE
1.
Perform Preliminary Steps 1 through 6 above. Set the VOM to the 3 volt DC scale and connect the positive (+) lead to FL5. Set the generator for minimum outpt~ tthen , increase the unmodulated output to where the VOM reading just starts to increase. (L1 and L2 may have to be adjusted to see this increase.) Adjust L1, L2, L3, L4, L5, L6 and L7 for a maximum VOM reading; decreasing the generator output, as necessary, to remain on the 3 volt DC scale. It may be necessary to first adjust L2, if no peak is obtained by adjusting L1. Set the generator output for 30 uV and the VOM for a mid-scale reading. Repeat Step 3. (Note: Tuning L7 will produce only a minor change.) Set the VOM to the 0.1 volt AC scale and connect the positive (+) lead to FL9. Adjust the generator output for a VOM reading of approximately (-)20 db. Slightly tune all coils for the minimum level on the VOM. Set the VOM to the 1 volt AC scale and disconnect the generator cable from the antenna jack. Note the noise reference level on the VOM. This should be 09 db minimum. Set the generator output for 2 uV and reconnect the cable to the antenna jack. Set the VOM to the 0.1 Volt AC scale. Decrease the generator output until the VOM reads 20 db lower than the reference level obtained in Step 6. This should occur when the generator output is 0.7 uV or less. Continue with Preliminary Steps 7 through 10 above.
1
Page 25
Receiver Enclosure
Page 26
._-_-----_____----_~---------~--------------------------------------------------------4I I
~ o d lator u
I I I
I 0
.________________------------------------STEPPED
I
Battery
LOGIC CARD
M a i n On (Address >
F I G U R E 3.1
n1
-" i
DL:
-I
U" i
Page 28
ADDRESS SWITCH
TOGGLE
GMHr
I CR YSTAL
4 0 0 KHz
X1
a
FROM CONTROL SWITCHES
T I
5
I -
0 8 SCAN L I N E S
V)
cn
W
SWITCH L I N E S
a
5
o
0
0 a
) S E R I A L DATA STREAM
CO CD
pl;'
81 COMMONS
a n
? a
8 READ L I N E S
U3
CARD)
<- I
LOGIC CARD BLOCK DIAGRAM F I G U R E 3.3
CODE:
1001
ADDRESS SWITCH
Figure 3.4
Page 30
NOTE
bode
A-
O~psw~tch, S2 Are Not Located on T h ~ sP W B And Are Shown For Reference Only
(1
-b
+
--Z
+ - ___C
+ 5v
A 4 1
- --
'>
R E A D LINES
(To M~croprocessur. P l r l , 2 7 thrci 3 4 )
.+
L
.-
-- -
J8-9
MOTOR 1
J6-9
. ; -S C A N
LINES )
(From M~~roprocess~r
Plns 12 Ihru 19
J4-9
4-BIT
ADDRESS
TRAM-
L Q Q C CARD DIODE M A T R I X
FIGURE 3,5
SERIAL DATA MESSAGE SYNC WLSE SYNC SYNC PULSE SYNC PULSE SYNC WLSE SYNC PUSE SYNC PULSE SYNC PUSE SYNC PUSE
WLSE
I
I I
I I
I
MOTOR 1 s m N G SYNC AUXIUARY 2 AUXILIARY 1 CRC PANTY
CRC PARTY
I
A___ _L_______I.__
"
I ,
&
..-
68 MSEC
DETAILED SERIAL DATA MESSAGE SYNC PUSE MZSSAGESTART STRING SYNC SYNC PULSE
ADDRESS
MOTOR 5
SYNC WLSE
i 1 1
0
(4 BITS)
(4 BITS)
1 1
l
ANTENNA
EXAMPLE:
FREQ. 72.60MHz
2n,
72.602MHz
LOGIC 0
72.598MHz
LOGIC 1
L1\
Buffer
v
Hi Adjust R 5 & UlA
Amplifier
U1B
#
v
Variable Capacitance Diodes CR1 & C R 2
ANTENNA
fl
1st Mixer
10.7 MHz Filter
FL2
,
Low Pass . Filter U2B
Amplifier
Oscillator, Mixer, Limiter. Quad Detector, Noise Amplif ier, & Squelch Detector
vv
-[-nr
SERIAL DATA
F M I F SECTION
Oscillator
SQUELCH
Error Display
Error Display
Relay Card
To Card <Safety Serial ~ata(0ut) Next Relay or Processor Card (~epending on Slot Position) From Processor Card or Next Relay Card (~epending on Slot Position)
* .E
.-
C,
e 2 - 3
2
0
Relay Status
$ ,
0
5
Q3
Relay Status
t n
z =
OUTPUT RELAYS TO CRANE MAGNETICS CONTROLLERS
.$
*
Relay Control
From Prpa$sor
Processor Card Processor Reset Switch Single 7-Segment Numerica S.D.l? Error Code
1 . 0 . Relay Cards
Receiver Card
Power Supply
Page 39
INPUT TO FUSE
CHECKCONNECTORS 8 WIRING.
REPAIR.
BATTERY TEST
iNOT OK
>
WIOHM METER NOT CHECK OUTPUT SIDE OF F1 . FOR SHORT CIRCUIT TO GROUND.
TO FUSE F2.
YES
TRANSMITTER.
TROUBLESHOOTING
P U A QT.
>
rJ)
FROM J I , LOGIC CARD. WIOHM METER CHECK OUTPUT SIDE OF F2 ON RFIREG. CARD FOR SHORT TO GROUND. NOT SHORTED
TROUBLESHOOT INOPERATIVE
w
TRANSMITTER REPAIR FAULTY CONNECTIONS. (SEE NOTES 1 8 2)
v
TP7 (VIOLET) FOR 0 VOLTS. OK
RFIREG.
REPLACE
\L
CHECK LOGIC CARD TP6 (BLUE) FOR 5 VOLTS. OK
\
NOT OK
OR COMPONENTS.
I
NO
v
CHECK LOGIC CARD TP5 (GRAY) FOR 5 VOLTS. OK NOTE: 1. WITH TRANSMllTER 'POWER O N (KEY) ON. USING A VOLT METER ON 10 VOLT SCALE, METER SHOULD READ APPROX. 4 VOLTS. MOVE LEVERS; VOLTAGE READING SHOULD CHANGE. IF METER READS 0 VOLTS OR 5 VOLTS, REPLACE LOGlC CARD. 2. IF VIEWING THE SERIAL DATA IS DESIRED, AN EXTERNAL TRIGGER FOR AN OSCILLOSCOPE IS AVAILABLE AT TP3 (ORANGE) ON THE LOGlC CARD.
F CABLE CONNECTIONS. i z
>a
Figure 5.3
*
RMSPECT STATUS ff DUO*OSTIC LE O DISPUVS
C W M WE. NOT REIeDND
I0 A m coy*-
NO
-
NO
TURNTRANYlTTW POWER S W R M
NO
WrnANYITTER
ER SUPPLY lS
OOESWEWmKH LUNUAL W E 1
NOT
~~~~~~~!~ VES R E C E N W U R D 10
O m YUEVH IRE4 N m N fff a
DATA AIESENT (OML
RIOCEEO
",W$zzE a
m
OI
FUCIW?
a
(BEEHOTE?)
-minEmcaNa w l
CCNNECTIMS *RE THW SECURE? WECU V U T A G E S M 5 L l2V WRES FRCUWRDEm CONNECT~J RE. MECK5V I 1 2 3
j M D
$ 1I T ~~ ! . R M S E R T S M E I T A M U M I L V ~ T ~ AICe4EdAPPEUIS
ANTENNA INPUT
FIGURE 5 . 5
Page 42
CHIEF
CORPORATION
h
INSTALLATION QUESTIONS?
Technical Assistance Via the Telephone is available from Control Chief. Please use either of our 800 telephone numbers, depending from which state you are calling.
NOTICE
This Control Chief remote control system is designed to be employed for many different applications (material handling equipment, machine tools, gates, furnace doors, lights and et cetera). In addition to this booklet, Control Chief offers supplementary product and/or application information assistance, if requested. However, we can accept no responsibility for the proper application of the remote control system. Further, Control Chief recommends all appropriate safety and operating manuals, relatingto the controlleddevice or machine, be reviewed prior to the installationof the remote control system.
If the remote control system is being employed on material handling equipment (e.g. hoists, trolleys, monorails or cranes), all applicable ASME standards must be reviewed and followed.
I
I
I
Control Chief Corporationshall not be liablefor technicalor editorial errors or omissions contained herein; nor for incidental or consequential damages resulting from the furnishing, performance, or use of this material. The information in this booklet is subject to change without notice.
Section 5
This smartorqueB Sjr control has been adjusted at the factory. However, it is strongly suggested that the entire Smartorque Sjr control system be commissioned by a qualified Harnischfeger service representative. Even though there are very few adjustments possible on the Smartorque control, proper and safe operation are dependent upon these adjustments. Readjustment of the control should only be performed by individuals that have been thoroughly trained, and who have read and understand this manual.
Verify that ,all adjustments discussed underithe topic, . preliminary Adjustments, have been completed.
1. With no load on the hoist, close the mainline
1 1
disconnect and energize the mainline contactor. Verify that the charge lamp o n the inverter illuminates. 2. Using the pushbutton operator, jog the motor in the first point raise direction and verify that rotation of the motor is correct. Using a volt meter verify that a signal is present at the FWD terminal of the SIF-3LC-2/4 board when the FWD pushbutton is depressed. This must be done to insure the upper limit switch circuit will operate properly.
If the forward run command is present and motor rotation is incorrect, do the following.
PRELIMINARY ADJUSTMENTS
/
3.
Before energizing the control, verify that all electrical connections are tight and terminated in accordance with the system wiring diagrams.
4.
NOTICE
Application of 460 VAC to a 230 VAC inverter will destroy the inverter. Check trapsformer wiring to insure the proper voltage is being applied.
NOTICE
Power source must be limited to 500 kVA to protect against premature rectifier assembly failure. If the source exceeds 500 kVA, the installation of appropriate reactors are required. If multiple inverters are installed, individual reactors are not required. One reactor that is capable of the combined amperage is acceptable. Consult with Harnischfeger technical representatives for the required reactors.
Electric current can cause injury or death. Disconnect, lock open and tag the power source which feeds the crane o r equipment to prevent power from being applied t o the machinery while repairs are being performed.
A. Disconnect, lock open, and tag the power source which feeds the equipment being worked upon.
D. Jog the motor in the first point lower direction and verify proper motor rotation.
Revised 4/5/95
Slowly run the hoist in the raise direction and verify operation of the upper limit switch. When the upper limit switch is actuated, the hoist motion should stop and the motor brake should set immediately.
6.
Check for clearance between the bottom block and the trolley frame. Continue to run the hoist up at increased speed, into the limit switch, to verify adequate clearance between the bottom block and the trolley frame when striking the limit switch at full speed. If necessary, adjust the geared limit switch and/or the height of the control circuit limit switch.
C.Jog the motor in the opposite first point direction and verify correct motor rotation.
4. Slowly run the motion and verify adequate operating clearances throughout the entire length of travel.
NOTICE
The bottom block must never strike the trolley deck or drum. Failure to observe this warning may result in damage to the hoist rope and bottom block.
7. Starting at floor level, run the hoist at maximum speed in the raise direction and allow the controller to quickly return to neutral.
8. Note the amount of drift that occurs and adjust the upper geared limit switch, if provided, accordingly. When running at maximum speed i n the raise direction, the geared limit switch should stop the bottom block before it contacts the weight-operated limit switch if it is provided. See notice above.
9.
Rapidly advance the controller to the "full on" position and observe the acceleration rate. If necessary, adjust the acceleration time constant to obtain the desired acceleration. If acceleration is too rapid, an over-current fault may occur in the inverter. If this happens, lengthen the acceleration time.
TRAVERSE ADJUSTMENTS
Verify that all adjustments described under the topic, Preliminary Adjustments, have been completed.
1. With n o load on the unit, close the mainline disconnect and energize the mainline contactor. Verify that the charge lamp on the inverter is illuminated.
7. Rapidly advance the controller from the "full on" position to the neutral position, and observe the deceleration rate, If necessary, adjust the deceleration control constant to obtain the desired deceleration time. If deceleration is too rapid, an over-voltage fault may occur in the inverter. If this happens, lengthen the deceleration time.
Two-speed multi-step Three-speed multi-step Two-step infinitely variable Three-step infinitely variable
2. Using the pushbutton operator, jog the motor in the first point direction and verify that motor rotation is correct.
3.
If motor rotation is incorrect, do the following.
Consultation with Harnischfeger technical representatives is recommended before attempting any programming changes to the speed control constants. Electric current can cause injury or death. Disconnect, lock open and tag the power source which feeds the crane o r equipment to prevent power from being applied to the The following braking methods are available: Base block at STOP command Decelerate at STOP command
Upon stop command, the drive blocks the main output transistors (to electrically disco nect the motor from the drive), and the brake interlo k relay sets the motor brake.
NOTICE
The initial factory setting is "Base Block at Stop" command. Use caution in selecting "Decelerate at Stop" command. A long deceleration time will cause driven equipment to require greater stopping distances. The situation may allow equipment to impact other cranes or end stops on the runway, which may result in damage to the machinery.
NOTICE
The initial factory setting is "Base Block at Stop" command. Use caution in selecting "Decelerate at Stop" command. A long deceleration time will cause driven equipment to require greater stopping distances. The situation may allow equipment to impact other cranes or end stops on the runway, which may result in damage to the machinery.
Brake Method Selectable
Time Frame 1
2
Description Run ForwardIReverse Command. Frequency output increases to hertz set by DS1-4, DSI -5 and DS1-6. Second DetentlSecond Speed Command. Frequency output increases to hertz set by DS1-7 and DS1-8. Removal of Second DetentfSecond Speed Command. Frequency output decreases to hertz set by DS1-4, DS1-5 and DS1-6. Absence of Commands. Removal of RUN Forward/Reverse. STOP. Operation depends on the setting of DS1-3.
3
i
4
Revised 4/5/95
c
Frequency butput (Hz) Fwd./Rev. Command 2nd Detent Frequency 3rd Detent Frequency
Time Frame 1 2 3
Description Run ForwardIReverse Command. Frequency output increases to hertz set by DS1-4 & DS1-5. Second DetentISecond Speed Command. Frequency output increases to hertz set by DS1-6 & DS1-7. Third Detentfrhlrd Speed Command. Frequency output increases to hertz set by DS1-8. Removal of Third DetenUThird Speed Command. Frequency output decreases to hertz set by DS1-6 & DS1-7. Removal of Second DetentISecond Speed Command. Frequency output decreases to hertz set by DS1-4 & DS1-5. Absence of Commands. Removal of RUN Forward/Reverse. STOP. Operation depends on the setting of DS1-3.
5
6
Time Frame 1
Description Run ForwardJReverse Command. Frequency output increases to hertz set by DS1-4
DS1-6.
2
3
Second DetenffFrequency Increase Command. Frequency output increases. The longer this contact is closed, the higher the frequency output becomes. Limited by the adjustable maximum speed (DS1-7 and DS1-8 or VR3). First DetentfFrequency Hold Command. Frequency output remains constant. Second DetenffFrequency lncrease Command. Frequency output increases. The longer this contact is closed,
the higher the frequency output becomes. Limited by the adjustable maximum speed (DS1-7 and DS1-8 or VR3).
5
6
First DetentJFrequency Hold Command. Frequency output remains constant. Second DetentIFrequency Increase Command. Frequency output increases. The longer this contact is closed, the higher the frequency output becomes. Limited by the adjustable maximum speed (DS1-7 and DS1-8 or VR3).
1
8
9
10
I Absence of Commands. Removal of RUN Forward/Reverse. STOP. Operation depends on the setting of DS1-3.
1
t hod Selectable
Time Frame
Description Run Forward/Reverse Command. Frequency output increases to hertz set by DS1-4 DS1-6. Second DetentIFrequency Hold Command. Frequency output remains constant. Third DetenUFrequency lncrease Command. Frequency output increases. The longer this contact is closed, the higher the output frequency becomes. Limited only by the adjustable maximum speed (DS1-7 and DS1-8 or VR3). Second DetentIFrequency Hold Command. Frequency output remains constant. Third DetenUFrequency lncrease Command. Frequency output increases. The longer this contact is closed, the higher the output frequency becomes. Limited only by the adjustable maximum speed (DS1-7 and DS1-8 or VR3). Second DetentIFrequency Hold Command. Frequency output remains constant. Third DetenVFrequency Increase Command. Frequency output increases. The longer this contact is closed, the higher the output frequency becomes. Limited only by the adjustable maximum speed (DS1-7 and DS1-8 or VR3). Second DetentJFrequency Hold Command. Frequency output remains constant.
1
2
4
5
7
8 9 10 11 12 13
Run ForwardJReverse at Lower Limit Command. Frequency output decreases. The longer this input signal condition exists, the lower the output frequency becomes. Limited only by DS1-4 DS1-6.
Second DetentiFrequency Hold Command. Frequency output remains constant. Run ForwardiReverse Command. Output frequency decreases. The longer this input signal condition exists, the lower the output frequency becomes. Limited only by DS1-4 DS1-6.
'
Second DetentIFrequency Hold Command. Frequency output remains constant. Absence of Commands. Removal of RUN ForwardfReverse. STOP. Operation depends on the setting of DS1-3. Table 5-4: Three-Step Infinitely Variable Speed C o n t r o l Timing
Revised 4/5/95
r Q U l C K PROGRAMMING
Two-Speed Multi-Step Speed Control
Settlng
45 Hz
DS1-7 = off DS1-8 = off DS1-7 = off DS1-8 = on DS1-7 = on DS1-8 = off DS1-7 = on DS1-8 = on
50 Hz
To set for two-speed multi-step control, begin with DS1, which is located on the TM2 board. (DS1-1 through DS1-10)
55 Hz 60 Hz
2.
5. Set your acceleration and deceleration times. Use RDS1 to set your acceleration time. Use RDS2 to set your deceleration time.
Setting
2 HZ
DS1-4 = on DS1-5 = off DS1-6 = off DS1-4 = on DS 1-5 = off DS1-6 = on DS1-4 = on DS1-5 = on DS1-6 = off DS1-4 = on DS1-5 = on DS1-6 = on DS1-4 = off DS1-5 =off DS1-6 =off DS1-4 = off DS1-5 = off DS1-6 = on DS1-4 = off DS1-5 = on DS1-6 = off DS1-4 = off DS1-5 = on DS1-6 = on
3 HZ
5 Hz
10 Hz
15 HZ
20 HZ
6. For information about voltage/frequency patterns see Settings and Adjustments following.
Your inverter is now set up for two-speed multi-step operation. DS1-9 and DS1-10 are used for an analog input. Their settings will not affect normal operation.
3rd Speed 60 Hz
Continue by setting RDS1 and RDS2, located on the TM2 board. To set for three-speed multi-step control, begin with DS1, which is located on the TM2 board. (DS1-1 through D S I - 1 0 )
6.
Set your acceleration and deceleration times. Use RDS1 to set your acceleration time. Use RDS2 to set your deceleration time.
2.
3.
Setting DS1-4 = off DS1-5 = off DSI-4 =off DS1-5 = on DS1-4 = on DS1-5 = off DS1-4 = on DSI-5 = on
3 Hz 5 Hz 10 Hz 15 Hz
2nd Speed
15 Hz 20 Hz 30 Hz 40 Hz
Setting
I
DS1-6 = off DS1-7 = off DS1-6 = off DS1-7 = on DS1-6 = on DS1-7 = off DS1-6 = on DS1-7 = on
7. For information about voltagelfrequency patterns see Settings and Adjustments following.
Your inverter is now set up for three-speed multi-step operation. DS1-9 and DS1-10 are used for an analog input. Their settings will not affect normal operation.
Setting
J
DS1-8 = on
Revised 4/5/95
,Two-Step
Setting DSI-7 = off DSI -8 = off DS1-7 = off DS1- $ = o n DS1-7 = on DS1-$=off DS1- 7 - on DS1- 8 = o n
To set for two-step infinitely variable speed control, begin with DS1, which is located on the TM2 board.
50 Hz 55 Hz 60 Hz
5. Set your acceleration and deceleration times. Use RDS1 to set your acceleration time. Use RDS2 to set your deceleration time.
Minimum Speed
2 HZ
Setting
DS1-4 = on DS1-5 = off DS1-6 = off DS1-4 = on DS1-5 = off DS1-6 = on DS1-4 = on DS1-5 = on DS1-6 = off DS1-4 = on DS1-5 = on DS1-6 = on DS1-4 = off DS1-5 = off DS1-6 = off DSI -4 = off DS1-5 = off DS1-6 = on DS1-4 = off DS1-5 = on DS1-6 = off DS1-4 = off DS1-5 = on DS1-6 = on
3 HZ
5 Hz
10 Hz
15 HZ
20 HZ
25 Hz
6.
30 HZ
For information about voltage/frequency patterns see Settings and Adjustments following.
Your inverter is now set up for three-speed infinitely variable operation. DS1-9 and D S I - 1 0 are used for an analog input. Their settings will not affect normal operation.
4.
Setting
To set for three-step infinitely variable speed control, begin with DS1, which is located on the TM2 board.
50 Hz
55 Hz
60 Hz
DS1-7 = off DS1-8 = off DS1-7 = off DS1- 8 = o n DS1-7 = on DS1- 8 = off DS1-7=on DS1- 8 = o n
DS1-1 = on DS1-2 = on 5. Set your acceleration and deceleration times. Use RDS1 to set your acceleration time. Use RDS2 to set your deceleration time.
2.
,a
3.
3 HZ
5 Hz
10 Hz
15 HZ
20 HZ
DS1-4 = on DS1-5 = off DS1-6 = off DS1-4 = on DS1-5 = off DS1-6 = on DS1-4 = on DS1-5 = on DSI-6 = off DS1-4 = on DS1-5 = on DS1-6 = on DS1-4 = off DS1-5 = off DS1-6 = off DS1-4 = off DS1-5 = off OS1-6 = on DS1-4 = off DS1-5 = on DS1-6 = off DS1-4 = off DS1-5 = on DS1-6 = on
6.
For information about voltagelfrequency patterns see Settings and Adjustments following.
Your inverter is now set up for three-speed infinitely variable operation. DS1-9 and DS1-10 are used for an analog input. Their settings will not affect normal operation.
Revised 4/5/95
S E T T I N G S AND ADJUSTMENTS
General Description
Smartorque @ Sjr inverter offers many specific adjustments and setting capabilities. These adjustments are accessed on both the interface card (SIF-3LC-2/4)and the logic card (TM2) of the inverter.
Fwd./Rev.
DS1 functions - speed control method selection I braking method selection I speed selections VR1, VR2, VR3 functions - special functions
Time =
' . ,
he acceleration time and the deceleration time can be independently set by rotary selector switches RDS1 and RDS2 located on the TM2 logic card. You may select a specific acceYdece1 time from one of sixteen preset independent ramps.
RDSI Accel.
ROS2 Decel.
(Both are shown in the initial setting position The time indicated by each notch setting in the table below is the time to accelerate (decelerate) from zero frequency to maximum frequency (f-max.). To determine acceleration to any intermediate frequency, follow the example below.
) r r
smartorquemsjr inverter offers sixteen Vlf patterns specially tailored for crane and hoist applications. Rotary selector switch RDS3 determines which pattern is applied. RDS3 serves to adjust low speed "torque boost".
RDS3 - Vlf pattern initial setting for traverse motions is
2. Initial setting for hoisting motions is 8.
"A"
1.7 3
60.0
120.0
Note: Actual output voltage depends on actual input voltage. Actual output voltage may be calculated as percentage of above numbers. All relationships will be linear. Voltage/frequency Pattern Selection Procedure. Application notes for choosing optimum V/f pattern: As a general rule, notch 2 is considered the traverse Vlf pattern. As a general rule, notches 5 to 8 are considered hoisting Vlf patterns.
As a general rule, notches 9 to F are for extremely high torque applications (not for general use).
To determine the appropriate Voltagelfrequency pattern, proceed as follows:
1. Set lowest notch appropriate for your application (traverse or hoisting).
2.
Run motor under "worst-case" conditions (fully loaded hoist, etc.) A. If 1250h load test is required, then load for this condition.
3.
If operation is successful, t h e n setting is acceptable. If operation is not successful, then try again at next higher notch value.
4.
Revised 4/5/95
,
Mode
Smartorque Sjr offers additional analog frequency reference selections for specific control voltage inputs other than 120V. Settings are shown below:
Frequency Reference Setting
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Set by frequency setting potenti- DS1-9 = Off DS1-10 = O f f ometer or 1 - 10 VDC signal Set by 1 5 VDC signal Set by 4 20 mA signal Analog frequency setting is not
used
Multi-Step First SpeedILower Limit Adjustment VR1. Certain applications require output frequencies that are unavailable from the menu of digital selections. Note that VR1 has a function in both infinitely variable and multi-step speed control modes. For example, the application requires 12 Hz as the first speed (multi-step mode) or the lower limit (infinitely variable mode). Note that 12 Hz is not available with digital selection by means of the appropriate DS1 switches. Under these circumstances, the VR1 potentiometer can be used to attain the desired speed. The adjustment range of VR1 is as below: VR1 Function Infinitely Variable Mode
Multi-Step Second Speed Adjustment VR2. Certain applications require output frequencies that are unavailable from the menu of digital selections. For example, an application requires 33 Hz as the second speed (multi-step mode). Note that 33 Hz is not available with digital selection by means of the appropriate DS1 switches. Under these circumstances, the VR2 potentiometercan be used to attain the desired speed. The adjustment range of VR2 is as below:
VR2 Function Multi-Step Speed Mode
CW
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Multi-Step Third SpeedlUpper Limit Adjustment. Certain applications require output frequencies that are unavailable from the menu of digital selections. Note that VR3 has a function in both infinitely variable and multi-step speed control modes. For example, an application requires 55 Hz as the third speed (multi-step mode) or the upper limit (infinitely variable mode). Note that 55 Hz is not available with digital selection by means of the appropriate DS1 switches. Under these circumstances, the VR3 potentiometer can be used to
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attain the desired speed. The adjustment range of VR3 is as below: VR3 Function Infinitely Variable Mode
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INSTRUCTION MAN'WA.L
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Software NSG618221-1
Adjustable Frequency Motor Control
Intelligent Drive for No Load Brake Hoists1 Load Brake Type Hoists & Horizontal Motions
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Table of Contents
Page Forward Section 1 GENERAL INFORMATION 1.1 General 1.2 Receiving & Inspection 1.3 Verify Model Number on Ratings Sticker 1.4 200V Class IMPULSE PH3 Specifications 400V Class IMPULSE PH3 Specifications 1.5 1.6 575V Class IMPULSE PH3 S~ecifications 1.7 CDBR Braking Module Specifications INSTALLATION 2.1 Location 2.2 Positioning 2.3 Overall Dimensions of IMPULSE PH3 2.4 Overall Dimensions of the CDBR Braking Units 1 2 3 4
5
6
7
8 8 9 11
Section 2
Section 3
WIRING 3.0 WIRING: Block Diagram 3.1 Main Power Wiring 3.1.1 Main Circuit Input/ Output Considerations 3.1.2 Power Wiring Diagram 3.1.3 Grounding Considerations
3.2
2
Line Voltage Selection for IMPULSE PH3 Logic Power Supply 3.1.5 Dynamic Braking Module (CDBR) 3.2.1 Dynamic Braking Module Wiring Precautions . DB Module Wiring as a Function of Drive Rating 3.2.2 3.2.3 Line Voltage Selection for CDBR Braking Modules , DC TAch Generator Wiring 3.3.1 Tach Generator Wiring Precautions 3.3.2 Tach Generator Connection Diagram (Bias Module Type) 3.3.3 Tach Generator Connection Diagram (AI-14B Type) Control Circuit Wiring 3.4.1 Control Circuit Wiring Precautions 3.4.2 Control Input Terminal Functions 3.4.3 TC-GIF-SH Interface Connections PH3 Logic Card Terminal Function Table 3.4.4 3.4.5 PH3 Logic Card Terminal Function Diagram Control Output Terminal Wiring 3.5.1 Control Output Terminal Wiring Precautions 19 20 20 21 23 24 24 25 26 27 27 28 29 30 31 32 32
13 14 14 15 15
3.3
3.4
3.5
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DIGITAL OPERATOR 4.1 Operator Layout & Keypad Functions 4.2 Programming Mode Key Functions 4.3 Changing Constant Data in Program Mode 4.4 Local Operator Control Mode Key Functions
CONSTANT DESCRIPTIONS 5.1 What is a "CONSTANT" 5.2 Access to Various Constant Modes 5.3 An-xx Constants: Mu lti-Step Speed Reference Constants 5.4 Bn-xx Constants: Active Mode Constants Sn-xx Constants: System Mode Constants 5.5 Sn- 10 Data1 Function Tables 5.5 Sn-xx Constants: System Mode Constants (continues) Sn- 11 Sn-14: Multi-Function Input Terminals Fault Input (External Terminal Function) Programming Sn- 15 Sn- 17: Multi-Function Output Terminals 5.6 Cn-xx Constants: Control Mode Constants 5.7 Un-xx Constants: Monitor Mode Constants
33 34 36 38
Section 5
4Q 40 40 41 42 43 47-54 55 56 56 57 58 59
63 63 63 63 64 65 66 67 69 70 71 72 73
Section 6
SPECIAL FUNCTIONS (Sequence) OF PH3 6.0 Special Functions Forward 6.1 Standard Safetv Functions of PH3 6.1.1 STOP Key (of Digital Operator) Operation 6.1.2 RUN button Operation 6.1.3 Phase Loss Detection 6.2 The Basic Hoisting Sequences 6.2.1 Hoisting Sequence SE Faults 6.3 Deviation Detction (Oversveed Detection) Function 6.4 Micro-Speed Gain Function 6.5 Quick STOP Function 6.6 Plug Reverse Simulation Function 6.7 Automatic Keypad Lockout Function (Sn-03 Functions) 6.8 Overspeed (Swift Lift) Operation PERIODIC INSPECTION/ TROUBLESHOOTING 7.1 periodic Ins~ection 7.2 Troubleshooting 7.2.1 Motor/ Drive Won't Run 7.2.2 Motor Stalls or Won't Accelerate Properly 7.2.3 Fault T r i ~ Condition 7.3 Power Section Check 7.4 Spare Parts
Appendix
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Section 7
76 76 77 79 80 82 83
87
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We at ELECTROMOTIVE SYSTEMS, INC., Inc. appreciate your purchase of this IMPULSE PH3 model adjustable frequency drive. When properly installed, operated and maintained, the IMPULSE PH3 will provide a lifetime of reliable, troublefree operation. It is MANDATORY that the person who operates, inspects, and maintains this equipment thoroughly read and understand this manual. This manual has been designed to serve as a comprehensive, self-contained guide covering all aspects of the installation and use of the IMPULSE PH3 unit. In it, you'll find step-by-step instructions covering topics ranging from installation to preventative maintenance and troubleshooting. In Appendix 8, you'll even find a complete listing of every programming parameter, with valid ranges, factory settings, and with space to record your particular settings. If you require additional information, please feel free to contact either your local supplier or contact ELECTROMOTIVE SYSTEMS, INC., Inc. directly at 414-783-3500 (24 hour service line).
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WARNING !
1.Do not touch any circuit components while the main, AC power is on. In addition, you must wait until the red "Charge" lamp is extinguished before performing any service on the unit. It may take as along as 10 minutes for the charge on the main DC bus capacitors to drop to a safe level. Failure to adhere to this warning could result in personnel injury.
2.Do not check signals during operation.
3.Be sure to ground the IMPULSE PH3 unit using the G (E) terminal. 4.Never connect the main output terminals (T,, T , TJ to the incoming three-phase AC source. This will damage the unit !
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.General Information
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The IMPULSE PH3 represents a new age in adjustable speed motor controls. The PH3 design is complimented by the use of Insulated Gate Bipolar Transistors (IGBT) and a 16 bit microprocessor to provide unsurpassed operability and safety to the Crane and Hoist drive application. The IMPULSE PH3 incorporates a high performance, Pulse Width Modulated (PWM) design generating the optimum current waveform to produce any desired speed from a conventional AC motor. The IMPULSE PH3 is a unique blend of hardware and software specifically designed to meet the severe demands of cranes and hoists. This product is the direct result of over 10 years experience in manufacturing and in applying adjustable frequency drives to hoisting machines. Following are a few of the key features: Easily configured for conventional pendant or joystick control Can be directly interfaced with 120VAC control signals * User selected speed control methods--multi-step(up to 9) or Infinitely Variable Speed (by analog joystick or pendant) * Brake Proving at Start and Stop * Swift Lift for high speed operation of lighter loads
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Upon receipt of this product you should first check the box for possible damage sustained in transit. If damage is noticed, you should notify the freight carrier within 15 days of receipt to file a damage claim. Next, verify the specifications sticker (on the side of the unit) corresponds with your application voltage and HP. Finally, remove the front cover of the unit and check for any visible signs of shipping damage. If the inverter is to be stored for a long period of time you should return it to its original packing carton and store it in a clean, dry place, away from direct exposure to sunlight or corrosive gases. Furthermore, you should ensure the ambient storage temperature is between -20 O C and +60 OC.
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The product will have two ratings labels on it. One is a metallic label found on the side of the unit (typically left-hand side). The other sticker will be found on the front cover of the unit, immediately below the keypad. Before you mount the unit you should first verify the voltage, current and HP ratings on these stickers match with your application requirements. The model numbering system is shown below:
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230 AFD
Rated Input Voltage (30,50/60Hz) Available in 230 or 460 or 5 7 N Models
T I T
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PH3
Meaning: "Inverter"
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Inverter Rating (kW) Rated Current (A)
Max. Continuous CurrW (A)
50
60
45
75
100 75
30 130 146
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160
55
224 252
183
300
337
180 205
Mar Voltage (Vac) Rated Frequency (Hz) Rated lnput Power Supply Voltage & Fresuencv . Allowable Input Voltage Fluctuation Allowable Input Frequency Fluctuation Control Method Output Freq. Control Range Output Frequency Stability Frequency Ref. Resolution Output Freq. Resolution
-
Up to 400 Hz maximum Sphase, 200,2C8,220, or 230 Vac; 50 or 60 Hz f 1OX of nominal f 5% of nominal Sinecded, Pulse Width Modulated (PWM), real-time generated 0.1 to 400 0.01% (with digital reference command, -10 to +40C); 0.1% (with analog reference command, 25 O C lPC) 0.01 Hz (digrtal operator S 99.99 Hz); 0.1 Hz (digital operator 1 100 Hz); 0.06 Hz (analog, 60 Hz); 0.1 Hz (analog 2 100 Hz) 0.01
Hz (11 30,000)
Ovwload Capacity Remote Freq. Ref. Sources AcceU Decel Times Braking Torque V F Patterns Motor Overload Protectlon Overcurrent Protectlon Level Blown Fuse Protection
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150%of rated for 1 minute; 130% of max. continuous for 1 minute 0- 10 Vdc (20 kn);4- 20 mA (250 Q); k 10 Vdc (optional); Serii (optional) 0.1 to 6,000 secs.; two sets; each parameter (4 total) is independentlyadjustable Approx. 20 % (if motor and inverter are sized 1:I); 150% or more is optional with Dynamic Braking 15 preset patterns (constant torque, variable toque, high starting torque); 1 field-programmablepattern Eledronic, !requency dependent, overload relay (field- programmable)
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Thermostat trips at 90 'C (in addition, model 2037 and above also have fan loss detezon) Separate functions for accel, decel, at speed, and constanl Hp region Yes
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5 5
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15 11 24
20
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25
185
30
40
30 64
72
50
37
60
45
75 55 128
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110 224 29
160
185 2aD
300
28
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9
12
135
40
48
54
80
90
96
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3-phase, 380,400,415,440, or 460 Vac; 50 or 60 Hz
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0.01 Hz (1130,000) 150%of rated for 1 minute; 130% of maw. continuous for 1 minute
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Remote Fnq. Ref. Sources
AccsVOecdTimes
BrakingTorque
VtF Patterns
Appmx. 20 % (if motor and Inverter are sized 1:l); 150% or more is optional with Dynamic Braking
15 preset patterns (constant torque, variable torque, high starting taque); 1 field-programnable pattern flectonic, frequency dependent, wetload relay (fieid- programmable)
200% of rated current
Motor Overload Protection Overcurrent ProtectJon Lsvd Blown Fuse PlOtCEtjon Ovwrottaga ProtectionLevel Undemthge Protectron Luvel PowecLwr Wdathru Heablnk Overbmparature Stall P m t i o n Ground Fault Protection
Yes
so0 vdc (700 Vdc)
420 Vdc M i m time i s 15 mS,mxinum time is 2 seconds Thermostat bips at 90 "C ( n i addition, model 4055 and above a!so hwe fan loss detection) Separate functions for accel, decel, at speed, and constant Up region
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Applicable Motor Output HP Max. Discharge Current (Peak A) Rated Discharge Current (A) Braking Start Voltage
30
150
60
300 250
50 40
60
250
60
20
80
18
80
15
8251950V k8V
=20V
607 to 1O O O V
VAC*" Fin Overheat Power Charge lndication Location Ambient Temperature Storage Temperature Humidity Vibration Protective Configuration
NIA
NIA
NIA
Thermostat Charge lamp stays ON until bus voltage drops below 50Vdc Indoor (protected from corrosive gases and dust)
+I 4 to 140F (-10 to 40C) (no freezing)
-4 to 140F (-20 to 60C)
"Note: Certain Units (large Capacity) require a Separate Power Supply as noted. See connec tion diagrams in Section 3 for details.
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The selection of the proper mounting location of the IMPULSE PH3 is imperative to achieve optimum performance and longevity. These units were designed and built to meet the harsh demands of industrial and commercial applications. Nevertheless, caution should always be exercised to ensure the selected location meets the following criteria: Ambient Temp.- +I4 to + 122 O F (open chassis) or +I4 to 104 O F (for NEMA 1). Protected from rain or moisture Protected from corrosive gases or liquids Sheltered from direct sunlight Free from mechanical vibration
Make sure there is sufficient clearance around the IMPULSE PH3 for cooling and maintenance purposes (see the figure below). To maximize effective air flow & cooling, the IMPULSE PH3 should be installed with its heatsink ribs oriented vertically. We also recommend removing the front cover (and the top and bottom covers on applicable units) whenever you mount the IMPULSE PH3 inside a larger enclosure. This will improve the air flow over the electronic components, and as a result, further improve the unit's reliability. Your installation should adhere to the following recommended minimum clearances.
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The wiring of the IMPULSEaPH3 can be separated into several categories- power, encoder, control inputs and control outputs. The block diagram shown below should serve as a "map" to the various subsections discussing the proper wiring of this unit. You will have no difficulty in making the proper connections if you simply follow these sections in order.
DYNAMIC . BRAKING
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The basic power wiring is illustrated in the figure given on the facing page. Please remember to follow NEC guidelines when selecting the wire and branch circuit protection devices.
The main input power on L1, L2, L3 is phase sequence insensitive (may be CW or CCW). Input sequence will not effect motor rotation direction. When the inverter output terminals (TI, T2, T3) are connected to motor terminalsT1, T2, T3, respectively,the motor must rotate counterclockwise (viewed from opposite the shaft end) when a Forward Run command is given (for hoisting applications, it is mandatory that "pH3 Forward" results in lifting (Up direction). To reverse the rotation of direction interchange any two motor leads (you may also need to change the Tach Generator wiring, refer to section 3.3). Note: switching the input wiring to the inverter will not change motor direction! Never connect the incoming three-phase AC power to the inverter output terminals T I , T2, T3. Care should be taken to prevent contact of wiring leads with the IMPULSE PH3 unit enclosure since a short- circuit may result. Never connect power factor correction capacitors on the inverter input or output. Never open or close inverter output contactors (between inverter and motor) unless the motor's inrushcurrent (typically 500- 600% motor'srated current) has been taken into consideration when the inverter model was selected.
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HPLB= Hoist Power Bypass HPLS= Hoist Power Limit Switch Note: if these are used you must also interlock the HPLS to the PH3 via a control circuit interlock. Please refer to section 3.4 for details.
Connect a positive ground using terminal "E" on the drive chassis or power terminal strip
Wire size should be selectedaccordingto the charts on the following pages. The lead length should also be kept as short as possible. Ground resistance should be 100 ! 2 or less. Never ground the IMPULSE PH3 along with welding machines, large current machines, etc. When several IMPULSE PH3 units are used together they should all be directly groundeddo a common ground pole. Alternatively, connecting all of the IMPULSE PH3 Earth (E) ground terminals together and running a single wire to the ground pole is also acceptable. Be careful to ensure that you do not form a loop with the ground wires.
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In order to comply with most safety standards you should have some disconnecting means and branch circuit protection between the incoming three-phase power supply and the IMPULSE PH3. This branch circuit protection can either be in the form of a thermal, magnetic, Molded Case Circuit Breaker (MCCB) or dual element "slow blow" type fuses. The table given below shows the recommended MCCB or fuse and wire size for each of the IMPULSEaPH3 models.
The following guidelines are only suggested values. You should always be sure to conform to your local electrical codes and wiring practices.
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The IMPULSE PH3 logic power supply of some units (460 V 2 15HP & all 575V)is derived-froma control transformer. This transformer has multiple taps on its primary to accommodate different incoming line voltages. You select among the different primary windings by moving a jumper plug on the small pc board as shown below. The factory setting is in the 460 V position (shaded in the figure below).
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The IMPULSEoPH3 model control unit was designed exclusively for crane and hoist applications. An integral component of a hoisting system will be the dynamic braking circuit. Dynamic braking is used to dissipate the regenerative energy from the motor while lowering the load. As a result, the ratings of the DB components have been selected to conform with the actual application requirements (HMIclassification). This section gives the necessary wiring information as a function of motod drive HP rating. When you are ready to wire the DB module. please refer to the respective diagram on the following pages.
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You must select the proper wire size in accordance with NEC requirements. Bring the wiring into the Dl3 module via the holes in the bottom of the enclosure. Make a "cross-cut" in the rubber bushings supplied with the unit then feed the wire through. This will provide an extra degree of protection of the CDBR module components from environmental contaminants. Separate the DB module power wiring from all control wiring. The wiring distance between the CDBR module and the IMPULSEoPH3 unit must be less than 16.4 feet (5 meters). The wiring distance betweenthe braking resistor and the CDBR module/ inverter must be less than 32.8 feet (10 meters). If your application demands exceed the capability of a single CDBR module these units can be paralleled(consult ELECTROMOTIVE SYSTEMS applications engineers for more information). You can connect up configuration. Any application to 10 of these units in a "master/slaveW can multiple slaves, but only have one master. You configure the individual CDBR modules as being either master or slave via a small jumper plug found on the pc board. Wire the master/slave outputs as shown below with a twisted-pair, shielded cable (Belden 8760 or equiv.). Finally, you should connect all of the thermal switches (terms. #3 & 4) in bull parallel and interlock them with your run circuitry. IYPIUeWa
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Note: co&g fans are only used on mode( 2110 and modeb 4080 end 4220
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The CDBR Braking Units supplied with the drive must be set to correspond with the incoming power supply. This is achieved by the changing position of the CP1 shunt to the desired value. You select among the different CP1 shunt values on the small pc board as shown below. The factory setting is in the 230/ 460/ 575 V position, depending upon the CDBR model no (shaded in the figure below).
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Note: the model CDBR4220 also has a separate voltage selector board used to power the cooling fan. You must also verify the jumper on this board is set to correspond with the three-phase, ac input voltage. See diagram on Page 19 (460VClass).
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Shield Sheath
Cable
Jacket
To chassis ground (terminal # 12 of the IMPULSEaPH3 unit. If a drain wire is used, connect both shield and drain to # 12 (or 32).
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IMPULSE^^ pH3
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Wiring
Section 3.4
~nsiiuktion ~anual
The control circuit wiring of the IMPULSE.PH3 unit must be connected to a number of pc boards (as shown in section 3.0). Section 3.4.1 will list the general wiring precautions. Section 3.4.2 provides a set of control input terminal tables, definging functions and signal levels. If you plan to deviate from the typical interconnect given in section 3.4.3 this section will be an invaluable reference.
Wiring Precautions:
Be sure to double check your control circuit interconnections before you apply power to the unit. Wiring distance should be 164 feet (50 meters) or less. Control wiring must be separated from the three-phasepower leads (L1, L2, L3, TI, T2, T3) to prevent capacitively coupled noise from entering the logic section. All 120 VAC control must be separated from the low level logic inputs. If wiring can not be separated, it should always intersect the other control wiring at right angles. Always use R-Ctype surge absorbers (not MOV) type across the coils of any contactors installed in the inverter enclosure. Use twisted shieldedor twisted- pair shieldedcable for control circuit interconnections. Be sure to only ground one end of the shield sheath as shown below:
To chassis ground (terminal # 12 or 32 of the IMPULSEoPH3 unit). If a drain wire is used, connect both shield and drain to # 12 or 32.
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ELECTROMOTIVESYSTEMS, INC.
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.The wiring diagram given below shows a typical interconnect for 5-speed control via our 120 Vac interface, the TC-GIF5H. For a complete listing of terminal functions and specifications, please refer to the tables on the following pages.
TO 2 1 ' OF 120 VAC SUPPLY
120 VAC SUPPLY
TO 'X2' OF
--
.,
L4 (Comectimto brverterT4)
q,
4
L8 (Connecb'onto Inverter T8)
--
I1
L11 ( C c r r m t o hverterTi 1)
Page 28
IMPULSE@^ pH3
Instruction Manual
.
These Function Descriptions Apply ONLY if Sn-10 = "06", and if Sn-I 1 = "01"
X2
F R
2
3
120 v Return Raise While 120 V signal is applied (Hz of An-01) Lower While 120 V signal is applied (Hz of An-01) Enables 2nd Speed (An-02) Enables 3rd Speed (An-03) Enables 4th Speed (An-06) Enables 5th Speed (An-05) Direct Connection to Inverter Logic Terminal 4 (Fault Reset) Direct Connection to Inverter Logic Terminal 7 (BE3 at Open) Direct Connection to lnverter Logic Terminal 8 (Brake Answerback at Closed) Direct Connection to lnverter Logic Terminal 11 (Logic Common)
(+) of 0
4 5
L4
L7 L8 L11
+ (Input)
- (Input)
+ (Output)
(-) of 0
- 10Vdc Speed
Command
- (Output)
page 29:'
I
Note: Except as noted below, the application of 120 Vac directly to the PH3 inverter terminal strip will cause board damage! These terminals are shown for reference purpose only. You should not need to terminate wiring directly on these terminals (except 9
- 10).
2
3
Multi-functionInput Terminal #I; factory set for 2nd step speed Multi-functionInput Terminal #2; factory set for 3rd step speed
6 7 8 9110 11 12 13 14 15
*eM
0- 10 VDC (20 kn)
4- 20 mA (250 R)
16
kQ)
0- 10 V D U 0- 100 % (20
Sn-10 = 6.8 or 9 then: Analog lnput: set for TO Feedback for Deviation Detection Function Analog Common (0 V)
Fixed by
o,Sn-10
m)
17 18 19 20
Sn-10 = 0.1.2,3 or 4 then: Multi-Function Analog Output; set for 0 1OVdc at 0 100% Frequency
-- - - -
Change by Sn-05.
-
21, 22
Sn-10 = 6. 8 or 9 AND Sn-06 Digit 4 = '0' then: Multi-Function Analog Output; set for 0 10Vdc at 0 100% Frequency
Output: 0- 10 VDC
Sn-10 = 6.8 or 9 AND Sn-06 Digit 4 = '1 ' then: Multi-Function Analog Output; Outpus SVdc at OL3 Fault 23 24 Not Used Multi-functionOutput W (PHC); factory set for Speed Increasing Multi-functionOutput #3 (PHC); factory set for Speed Increasing
25/ 27
26/ 27
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Page 30
Instruction Manual
7~ I 1 Control Com
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1 7 $1 Run Forward
2 Run Reverse 3 Fault Input by Sn-11 4 Fault Reset by Sn-12 5 Speed Control by Sn-10 6 Speed Control by Sn-10
7 Ext. BB at Open by Sn-10
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Neg Bus Pos Bus +/B1 Brake Res. 62
25 Multi-Function PHC
X 9 I
Bias Mod
13 0-1 OVdc Speed Ref 17 O V Analog Signal Corn 14 4-2Oma Sped Ref
0 16 TG 0 - 1OVdc Feedback
TI
T2
T3
TG Feedback to Logic Cardl AI- 146 TC1 Ch. # I (k1OVdc) TC4 Common (OV) AI-148
o 1994
P&
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It is vital the control ouputs be wired correctly because they control the action of the brake contactor(s). The wiring is, however, straightforward. All of the complex sequencing used to control the parking brake is contained within the IMPULSEoPH3 unit, but the output of this safety- based sequence is a contact between terminals #9-10 which is connected to the coil of the brake contactor.
More By P&H
Always separate 12-V wiring from DC control and power wiring. If the two must cross, they should do so at 90angles.
You must use R-C type surge suppressors across the coils of the brake contactors to prevent potential nuisance tripping of the PH3 unit due to excessive magnetic noise when the contactors are de-energized.
contactor coivmagnetic
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IMPULSEZPH~
Instruction Manual
The IMPULSEaPH3 is a completely digital controller that can be used to precisely control the motions of a standard three-phase induction motor to facilitate variable speed control. Being completely digital, there are no potentiometers or selector switches to be tampered with. Instead, the u n l is shipped with a digital keypad as standard. This device is very powerful, not only allowing convenient access to the programming parameters, but it also provides alpha-numeric indication of fault codes to simplify troubleshooting. This digital keypad will allow you to do the following:
* Program the various parameters (or constants)
Read alpha-numeric fault diagnostics Monitor the performance of the unit This digital keypad is shown below:
CIWI
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SM FBXm REF
11
(x) (r) 1I
DRNE
Page 33
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Some keys on the digital keypad have dual purposes, depending on whether the keypad is being used to program various parameters (or constants) or to operate the unit locally. The various keypad functions are listed below whenever the IMPULSEsPH3 is being used to program various parameters (or is in the program mode):
Depressing this key toggles operator mode between DRIVE and PROGRAM modes.
Used to increase or decrease the setting of the blinking digit of the keypad.
\
Depressing the DISPLAY key repeatedly changes the display mode. Refer to the following page for the details of the function of this key.
DATAIENTER key displays the contents of the selected programming parameter. ENTER key is used while in PROGRAM mode to permanently store program changes.
Moves the blinking digit (cursor) from left to right. RESET function is used to reset fault trips.
Page 34
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IMPULSE@@ pH3
Instruction Manual
Each time the DISPLAY key is pressed the display mode will be varied according to the diagram given below.
Power ON
l - l
DRIVE MODE
PROGRAM MODE
PRGM
DRIVE
b
DRIVE MODE
PROGRAMMING CONSTANTS (Please refer to the appropriate section of this manual for a detailed description of each) An (REFERENCE) mode constants are used to set the various speed settings for the multi-step speed mode of operation or the minimum speed in the infinitely variable speed modes. Bn (ACTIVE) mode constants are used to vary certain programming parameters while the inverter is running.
Sn (SYSTEM) mode constants are used to configure the broadest of inverter operating parameters.
Cn (CONTROL) mode constants are used to fine tune the inverter operating characteristics.
O n (ORDER) mode constants are used by the factory only. These constants should not be changed in any way.
Page 35
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Example of Changing Constant Data: Change Cn-18 (DC Injection Time at Stop) from data '0.5" to data '0.8" Change Cn-25 (Overtorque Detection Time) from data '0.1 ' to data '1 .l '
Note: the underlined digit in the keypad display column indicates .. Z . . on the dzsvluv) the cursor oosztronb ( .
K e n a d Dis~lay
An-01
press press
[eE)
to enter the program mode (you must first be stopped) three times to access the Cn family of parameters
[Dspc]
Cn-O1
[x)
) [
Cn- 18
Q.5
0.5
Press press
0 . 8
End
[ Z R ]
to Enter the new data into Cn-11. Display will show "End" for approx. 1 sec., then will show data again
4
0.8
Cn- 18 Cn-25
press
press press
[x)
B
Q. 1
Ll End
press
E [ d "End" enter the new data in Cn-25. Display will show for approx. sec., then will show the data again.
to
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Ll previous display mode
press
[EE)
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Page 36
IMPULSE?. pH3
Instrueition Manual
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The various keypad functions are listed below whenever the IMPULSE*PH3 is in the DRIVE Mode (or ready to run the motor, either locally or remotely via external input commands).
Red lamp lights in DRIVE mode and goes out in PROGRAM mode Depressing this key toggles operator mode between DRIVE and PROGRAM modes. Jog Key function is disabled.
Red lamp lights while commands supplying the TC-GIF card are enabled (this is normal operating mode, lights will only be out while troubleshooting the unit.) Seq= Run/Stop Ref= Speed Reference Depressing the DISPLAY key repeatedly changes the display mode. Refer to the following page for the details of the function of this key. Used to increase or decrease the setting of the blinking digit of the keypad. DATA1 ENTER key is used in DRIVE mode to store new An or Bn constants.
RNDIREV Key reverses motor direction of rotation while in keypad control mode. Red lamp lights while RUN Key is depressed.
While RUN key is pressed, the inverter output will ramp up to existing speed reference level. When STOP is released, the output will go to zero.
I
STOP key is pressed. When inverter is stopped, LED will remain on until inverter is re-started.
Moves the blinking digit (cursor) from left to right. RESET function is used to reset fault trips.
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PROGRAM MODE
c
DRNE MODE
0
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I
Display of fauns which had occurred before power supply was turned off
I
PROGRAMABLE CONSTANTS
(Please refer to the appropriate section of this manual for a detailed descrMtion of each)
Un (MONITOR) mode constants are used to observe the input and output characteristics of the inverter.
An (REFERENCE) mode constants are used to set the various speed settings for the multi-step speed mode of operation or minimum speed in the infinitely variable speed control mode (An-01). Bn (ACTIVE) mode constants are used to vary certain programming parameters while the inverter is running.
Display o f Faults wtrich had occurred before power supply was last turned d.If there are no faults, this mode is
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Un- xx Monitor Mode Display
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Multi-step Speed Settings Adive Constants
3.
Speed Reference ( X )Value Display 'P Prefix on K e m d
Page 39
--
* In this manual, the term "Constant" simply refers to one of many operating parameters which can be adjusted and/or monitored. These constants are organized according to function and grouped into several constant "modes". Each mode carries a two letter code as a designator (either An, Bn, Cn, Sn, or Un). Therefore, regardless of the existing display, it is very easy to navigate your way through the various programming constants by depressing the Display key at any time. (Please refer to Section 4 for details of the interrelationships between the constant modes.)
* There are four programming constant modes available and these are:
- Multi-step speed REFERENCE mode (An) Constants. - ACTIVE mode (Bn) Constants which can be "tuned" while the inverter
is operating.
- SYSTEM mode (Sn) Constants are available to set the inverter's broadest
operating characteristics (i.e. input1output characteristics, V/F pattern). - CONTROL mode (Cn) Constants are used to fine tune the inverter operation.
* In addition, there is one group of constants used specifically to monitor the input and output characteristics of the inverter. These are called the MONITOR mode (Un) Constants. These functions essentially eliminate the need for external test equipment or meters at the time of start-up. If a fault trip occurs, these constants can also be very useful in the troubleshooting process. See Section 5.8.
There are several levels of accessibility to the programming constant modes. As you-might expect, these options are controlled by yet another constant. This important constant is called Sn-03 and is located within the SYSTEM mode grouping. See page 44 for a detailed description of these various access levels.
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@ 1994 ELECTROMOTIVE SYSTEMS, INC2,INC. Milwaukee, Wisc: Soft NSG618221-1: 12119/94
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Following is a table illustrating the relationshipsbetween the An constant mode and the available, preset speeds.
AM1 An-02
An43
I I I
An44
An-05
---
Freq. Reference
An06
I Multi-Step Speed 6
Page 41
IMPULSE@.pH,$'
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'Bn-01 'Bn-02 'Bn-03 'Bn-04 Bn-05 Bn-06 Bn-07 Bn-08 Bn-09 Bn-I0 Bn-11
Acceleration time 1 Deceleration time 1 Alternate acceleration time Alternate deceleration time Automatic Deceleration Time Change Frequency Reference Gain Frequency Reference Bias Torque Compensation Gain Motor Rated Slip Not Used--Reservedfor Future Use Analog Monitor Channel 1 Gain Analog Monitor Channel 2
0.1 Sec 0.1 Sec 0.1 Sec 0.1 Sec 0.1 Sec 1% 1% 0.1 0.1%
0.0 0.0
- 25.5
- 25.5
3
1.6
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- 9.9
0.0 - 9.9%
0.01 0.01
0.00 0.00
- 2.55 - 2.55
1.OO 1.OO
Bn-01
Forward Direction Acceleration Time Forward Direction Deceleration Time Reverse Direction Acceleration Time Reverse Direction Deceleration Time When data of Sn-1I
0.1 Sec
0.1 Sec
0.0
0.0
- 25.5
- 25.5 - 25.5
Bn-02
Bn-03 Bn-04
0.0 0.0
- 25.5
- 2.55
Bn-12
Micro-Speed Gain
0.01
0.00
1.oo
Page 42
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Sn-01
KVA Selectkn
01
01
- 33
230AFDl-PH3 230AFD3-PH3 23OAFD5-pH3 230AFD7.5-pH3 230AFDIO-PH3 230AFD15-PH3 230AFD2GPH3 230AFD30-PH3 230-pH3 230AFD50-pH3 23OAFD60-pH3 230AFD75-PH3
22 23 24
25
26
45
46
28
460AFD2O-PH3 460AFD30-PH3
WAFD50-PH3 460AFD60-PH3 4D 4E
2E
31
WA WA
51 52
33 34 35 36
NIA WA
NfA
N/A
Page 43
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Sectioh 5.5
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Program Mode
Setting & O n l y Setting & Setting & O n l y Setting & Reading Reading Reading Reading Reading Reading is is is is is is Enabled Enabled Disabled Enabled Enabled Disabled Cn, Sn, On Cn, Sn, On An,Bn An, Bn, Cn,Sn An, Bn, Sn-03 An, Bn, Cn, Sn,
On
On
Cn, Sn
On
Un
Cn, Sn,
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IMPULSE@@ pH3
Instruction Manual
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Page 45
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Page 46
'1i
IMPULSE@^ pH3
Instruction Manual
IMPULSE PH3 software offers pre-defined control modes set by the data of Sn-10. These modes are separated into two (2) groups: Group 1: Hroizontal Motion (or Load-Brake type Hoist) Control defined by Sn-I0 = 00, 01, 02, 03, or 04 Group 2: Hoisting (No-Load Brake Type) Control defined by Sn-10 = 06, 08, or 09 As delineated by the Sn-10 description on the previous page, each Control Group is capable of a variety of data, and, hence, each Control Group is capable of a variety of Speed Control methods: Multi-Step (2 or more types), and Infinitely Variable (2 or more types). Below are tables for each data of Sn-10 that details the precise terminal functions and speed reference scheme thereby enabled:
sn-10 = 6@>(~t$riz@h$al ... . :..- . . --- - -l:-.,~.&4.+($! ~oti6&~5fStep Multi-Step $peedg~on!rol). ~6rmi,dd' ~uiictibn~%"~~peed~~eference Fwctions i
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When Sn-10 is programmed for data "OO", the terminals and speed reference scheme is defined per the below tables:
Terminal 5
0
1
1
Terminal 6 Terminal 7 0 0
1
Terminal 8 0
0
Applied Speed Reference HIGHER of the Analog Reference (TI 5) or An-01 An-02
0 0
0
An-03
An-04
1 1
1
0
1
An-05
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Page 47
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When Sn-10 is programmed for data "01",the terminals and speed reference scheme is defined per the below tables:
Fixed
Multi-Speed Input 1 Multi-Speed Input 2 No Function (Sn-13 = OF) No Function (Sn-14 = OF) Auxilliary Analog Input
6
7
8
Fixed
16
Fixed
Not Possible
Page 48
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IMPULSES PH3
Instruction Manual
When Sn-10 is programmed for data " 0 2 ' ,the terminals and speed reference scheme is defined per the below tables:
F i x e d
Fixed
Fixed
Multi-Speed Input 1 Multi-Speed Input 2 Multi-Speed Input 3 No Function (Sn-14 = OF) Auxilliary Analog Input
7
8
16
Fmed
Not Possible
Page 49
Instruction Manual
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When Sn-10 is programmed for data '03", the terminals and speed reference scheme is defined per the below tables:
Fixed
Multi-Speed Input 1 Multi-Speed Input 2 No Function (Sn-13 =OF) No Function (Sn- 14 = OF) Auxilliary Analog Input
6
7 8
Fixed
1 6
Fixed
Not Possible
Terminal 8
I
1
Not Used
Not Used
1 I
1
Page 50
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IMPULSE@.P P H ~
Instruction Manual
When Sn-10 is programmed for data '04', the terminals and speed reference scheme is defined per the below tables:
Fixed
Fied
Speed Increment Command Speed Decrement Command No Function (Sn-13 = OF) No Function (Sn-14 = OF) Auxilliary Analog Input
6 7
8
16
Fixed
Not Possible
Page 51
Constant Descriptions
Section 5.5
Instruction Manual
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When Sn-10 is programmed for data '06", the terminals and speed reference scheme is defined per the below tables: Note that the fifth (5th) step is provided by terminal 3 when Sn-11 is programmed to data "01
".
Terminal 1
2
Status Fmed
Initial Value Description Forward Run Command Reverse Run Command Jog Reference (5th Speed) When Sn- 11 = "01" External Fault Reset Multi-Speed Input 1 Multi-Speed Input 2 Base Block Command a t Open Brake Answerback at Closed
Fixed
3
4
Programmable Change by Sn-11 Programmable Change by Sn-12 Fmed Not Possible Not Possible Not Possible Not Possible
I
6
7
8
16
Fixed
Fixed Fixed
Fixed
Not Possible
Page 52
IMPULSE@.pH3
Instruction Manual
When Sn-10 is programmed for data "08", the terminals and speed reference scheme is defined per the below tables:
l*
Applied Speed Reference HIGHER of An-0 1 or the Analog Reference (T 1 3 T 14) Frequency Hold Command Frequency Increment Command (Upper Limit = Cn- 19)
Page 53
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When Sn-10 is programmed for data '09", the terminals and speed reference scheme is defined per the below tables:
Page 54
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Pulse Monitor
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Page 55
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Terminals 3, 4, 7 or 8 can be programmed for inputing an External Fault (EF). The operation of the PH3 at Fault Input can be programmed by the data of Sn-11 Sn-14 as below:
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Ex.
Data = -1
X
Convert to 4 digit Binary
-L---1
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Page 56
Q 1994 ELECTROMOTNE
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IMPULSE@* pH3
instruction Manual
Sn-15
06 07 08
09
OA
O B OC O D O F
Output is closed When PH3 is Ready for Operation Output is Closed When Undervoltage is Detected Output is Closed during Base Block Operation Output is Closed When Frequency Reference Control is from External Terminals (Open When Frequency Reference is from Keypad) Output is Closed When Start/ Stop Control is from External Terminals (Open When Start/ Stop is from Keypad) Output is Closed When Overtorque is Detected Not Used Output is Closed at Braking Resistor Fault (rr) Output is Closed at OL3 Fault
1%
0-100 0
50 0.5 100
0
0.1 s 1% 1%
- 25.5
0 - 109 0 - 109 0
- 39999
0
1.5 30
Cn-23
01-24
Cn-25
1
- 2.6
- 150
0
1-5
0
160 0.1
- 200 0 - 25.5
Page 58
IMPULSE". P H ~
Instruction Manual
I ref 1 for Load Check Cn-28 Cn-29 Cn-30 Cn-31 Cn-32 Cn-33 Cn-34 Cn-35 Cn-36 Cn-37 Cn-38 Cn-39 Cn40 Cn-41 Cn-42 Cn-43 Cn-44 Cn-45 Cn-46 Cn47 Cn-48 Cn-49 Cn-50 Cn-51 Cn-52 Cn-53 Motor no load current Slip Compensation delay time Carrier frequency upper limit Carrier frequency lower limit Carrier frequency gain Swift Lift current at Forward Swift Lift current at Reverse Swift Lift frequency Swift Lift acceVdece1time gain Swift Lift threshold frequency Swift Lift delay time Phase Loss frequency set level Phase Loss current detect level (Note: Data '0" disables the Phase Loss Function) Phase Loss Detection delay time
1%
1 Hz 1% 1 Hz 1% 0.1 s 0.1 s
1%
- 255 30 - 200
0 0 30
60 160 60
% of lnverter
- 255
Rated Current
1%
1%
- 200
50 160
- 200
Not Used
% of lnverter Rated Current
1%
1% 1 Hz 0.1 1 Hz 0.1 s 1% 1% .1 s
30 0 15 15 0
. .fi 160
S o 160
9 4 60
1 60 0.1
- 25.5
3
40
t3
25 -1
e
Page 59
No.
Name Freq. Refe.rence (Hz) Freq. Output Output Current Voltage Ref. DC Voltage Power Out (rt Kw) Input Term Status
Description Inverter Frequency Reference is Displayed Inverter Frequency Output is Displayed Inverter Output Current is Displayed in AMPS Inverter Output Voltage is Displayed in Volts (AC) DC Bus Voltage is Displayed in Volts (DC) Inverter Output Power is Displayed in Kilowatts Sequence Input Terminal Status is Displayed as Below:
I
Output Term Status
Un-09 Un-10
All LEDs on the Digital Operator are lit--Integrity Check Control Section EPROM Software Version is Display
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Page 62
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As discussed previously, the IMPULSE PH3 is a powerful combination of hardware and software specifically designed for Crane and Hoist applications. This section deals with the special software functions of IMPULSE PH3:
IMPULSE PH3 is a unique combination of hardware and software specifically tailored to the Craneand Hoist Industry. We offer a myriad of functions that uniquely apply to the special demands of performance and safety required when plant personnel operate under and around potentially deadly loads. Section 8.1 describes these simple yet vital functions:
Unlike more typical industrial applications, the Hoist or Crane drive must operate differently to provide a higher level of safety. The STOP key is just our first example of IMPULSE PH3 technolody:
= ALWAYS Enabled, Operation is programmed by Sn-05, Digit 1 = "0" DO NOT CHANGE THIS DATA!
The RUN button on the digital keypad operates differently than that typical of general purpose inverters. Safe operation of cranes and hoists in the local operation mode demands that operation only be possible when the RUN button is depressed. The absence of a RUN command demands STOP (according to the programmed stopping method, Sn-04 Digit 2). This reduces the possibility of a runaway crane.
11
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~ i d 63 e
Phase Loss Detection compares the output current of each of the three phases to a pre-set level. If the output current of any of the phases falls below that pre-set level, an LF fault will appear on the display. Unlikeconventionalinverters in case of a phase loss, the IMPULE PH3 will immediatelyset the brake, thus retaining control of the load.
Phase Loss is
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Page 64
As mentioned previously in this document, IMPULSE PH3 offers two basic sequences--Horizontal Mode and Hoisting Mode. The Hoisting Mode provides for a special start/ stop sequence designed especialty for No-Load Brake hoists. This sequence is enabled by Sn-10 = 6,8 or 9 and cannot be changed by any other constants. Great caution should be exercised in calculating the appropriate data for the constants pertaining to this sequence!
/C0///?//////C///##//#////#/#////#f#///~//#/////#0/~
Speed Ref. Input (TI 3 or An-xx) Run (Fwd/ Rev) Command (TI/2Closed)
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k \ \ \ \ \ \ \ \ \ \ \ \ \ \ \ \ \ \ \ \ \ \ \ \ \
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BT(Cn-58)
b HT(Cn-59)
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Answerback Signal
2. Make sure that ALL connections are appropriate and
despite the Brake Release Brake Answerback IS Open. During Stopping, the Brake Answerback remains Closed for more than 1 Second despite the Brake Release Command being Output.
1. Check the status of the Brake contactor--Contactor may be frozen (welded) closed.
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IMPULSE PH3 software offers a unique safety function that when programmed properly precludes the possibility of 'losing the load". The Deviation Detection circuit utilizes a direct coupled speed sensing device on the motor output shaft and compares this feedback to its own internal reference. Should the actual speed be significantly different that the commanded speed, the 'dd" fault is output and the machine is shut down. The feedback device must output a signal as below:
Where: Nfb = Actual Motor Shaft Speed TI6 Vdc: Input Vdc to Terminal 16 of PH3 Logic Card
1
109% (Higher of Cn-02 or Cn-47) 100% (Higher of Cn-02 or Cn-47)
Nfb
9.08V
T I 6 Vdc
0.92V
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Page 67
Special Functions
Section 6.3
IMPULSE~~,PH~
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0 ~ 9 %
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Page 68
IMPULSE@.pH3
- Instruction Manual
The IMPULSE PH3 offers the Micro-Speed Gain function for precision in hoisting. This function provides for extremely slow speed operation in addition to the normal running speeds programmed by the User. Enabled by an input to the PH3, this function multiplies the normal speed reference (any of An-01 An-06 or the Analog Reference) by the data of Bn-12. This will prove extremely useful when "spotting" the load. Please refer to the programming method, joystick operation and examples below:
ProgrammingMethod:
--
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0.00 2.55
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,411-04
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25 Hz
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30 Hz
0-50%
Analog
Analog
Page 69
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Section 6.5
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The IMPULSE PH3 offers the Quick STOP function that provides an alternate deceleration time upon STOP comand (absense of commands). Note that when decelerating from a higher speed to a lower speed the active deceleration time remains Bn-02. ONLY when the pH3 is provided a STOP command does the active deceleration time become BN-04. Please refer to the programming method and timing chart below: ProgrammingMethod:
00,01, 10, 11
25'5 Seconds
00
10.0Second
Speed Out
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The IMPULSE PH3 offers the Plug Reverse Simulation function toprovides an automatic alternate deceleration time1Acceleration time at a change direction command. Note that the Deceleration time and Acceleration time differ from the normal normal times. Please refer to the programming method and timing chart below: ProgrammingMethod:
Bn-01
Speed Out
B
Bn-02
I Time
t
-W
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The IMPULSE PH3 provides for programming security and enables an enhanced level of safety by the automatic keypad lock-out function. Enabled by the data of Sn-03, this function will automatically prohibit unauthorized personnel from making changes to the IMPULSE PH3 program data. See below programming method:
Program Mode
Setting & Setting & Only Setting & Only Setting & Reading Reading Reading Reading Reading Reading is is is is is is Enabled Enabled Disabled Enabled Enabled Disabled Cn, Sn,
An, Bn,
Cn, Sn,
An, Bn,
Cn,Sn
On
Page 72
IMPULSE PH3 provides the operator withthe ability to overspeed the motor1hoist when the load is less that 100% of rated capacity. The Swift Lift function determines the value of load and if the load is less than the data of Cn-45 (Forward operation) or Cn-46 (Reverse Operation), then the pH3 will automatically acclerate to the Swift Llft frequency. Please see the below programming method.
Programming Method:
Cn-45
30 200%
3Wo
User Choice
Swift Lift Enabliing Current at Forward: Swift Lift Operation (at Forward) begins if I-Out 5 the data of Cn-45 (and F-out = Cn-49). Swift Lift Enabliing Current at Reverse: Swift Lift Operation (at Reverse) begins if I-Out 5 the data of Cn-46 (and F-out = Cn-49). Swift Lift Frequency: If the enabling conditions of Cn45146 are assured, the PH3 will accelerate to the Hz of Cn-47 Swift Lift AcceV Decel Time Gain: The acceV decel times are multiplied by the data of Cn-48 during ramp up to/ ramp down from Swift Lift Frequency. Swift Lift Threshold Frequency: The detect frequency for Cn-45/ 46. When F-Out = Cn-49 the current is compared to Cn-45/46. Swift Lift Delay Time: The delay time beginning at the Threshold Frequency (Cn-49). Used to assure that the detection current is accurate (not* detection of slack cable)
Cn-46
30 200%
WO
User Choice
Cn-47
0 HZ 255
Hz
6QHz
User Choice
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0.0 9.9
0.1
User Choice
Cn-49
0 HZ 255 Hz
60 Hz
User Choice
Cn-50
2.0 Sec
User Choice
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InstructionjManual
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Page 74
Milwaukee. w&:
o 1 994
ELECTROMOTIVESYSTEMS, INC~,;INC.
Soft NSG618221-1: 12/19/94
IMPULSE@^ pH3
Instruction Manual
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WARNING !
Do not touch any circuit components while the main, AC power is on. In addition, you must wait until the red "CHARGE" lamp (located just left of the terminal strip) is extinguished before performing any service on the unit. It may take as long as 10 minutes for the charge on the main DC bus capacitors to drop to a safe level. Failure to adhere to this warning could result in personnel injury. Do not check signals during operation. Be sure to ground the IMPULSE PH3 using the G (E) terminal. Never connect the main circuit output terminals (TI, T2, T3) to the main, three-phase input power supply.
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The IMPULSE PH3 inverter is virtually maintenance free. Only a few simple items should be periodically checked and these are summarized below:
Loosened screws or
consider replacement.
Cooling Fan
Replace. If total operation exceeds 20,000 hours, also consider replacement. Blow with compressed air (from approx. 57 to 85 PSI) Replace all of the capacitors.
Power Elements
DC bus capacitor
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This section is presented as a series of simple instructions/ suggestions oriented to troubleshooting with the standard keypad and an analog VOM (Simpson 260 or equivalent). Accordingly, it has been divided into four sub-sections according to the nature of theproblem: 7.2.1: Motor1drive won't run 7.2.2: Motor won't accelerate smoothly 7.2.3: Fault Trip Condition and Definition
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Please refer directly to the appropriate sub-section and its respective table.
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Measure the three-phase, AC input voltage directly on the inverter terminals L1, L2, L3.
Voltage should be within tolerances given below and should be balanced within 2 %. * 200 V units: 180- 253 VAC 400 V units: 342- 506 VAC * 575 V units: 450- 633 VAC Replace fuses Or move jumper to correct location-
Check glass 1A fuses on small card. Make sure voltage selector jumper is in correct position (refer to sec. 3.1.5)
Make sure the incoming power has s not been removed beforeperforming Resistance should measure 100 Charge lamp i or less. If you detect an open illuminated this check ! circuit the pre-charge resistor is A damaged pre-charge Use an analog VOM (Simpson 260 or resistor is ~YP~C caused ~I~Y a equal) and measure the resistance shorted braking transistor (see from output terminal T I (positive section 9.3)lead) to main circuit terminal BO/P.
Make sure the inverter is programmed for terminal strip control (Sn-04= xxx0, remote seq LED should be lit). When shipped from the factory the inverter is programmed for keypad control, not terminal strip control. Use the monitor parameter Un-07 (see section 5.8 for details) to make sure you are getting the correct inputs to the inverter's control terminal strip. Make sure the inverter is programmed for keypad control of run/ stop (Sn-04= n i x , remote seq LED on keypad is'not lit).
YOU should get an input on terminal 1 (forward run) or terminal (reverse run)
2 wire control:
Inverter is receiving an external base- Correct external wiring to VGIF-5H block ("bbU) command at the terminal tet-minalL7(depending on which is strip. Check the programming/ wiring programmed for BB command). of the multi-functioninput terminals
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Page 77
IMPULSE?. P H ~
Instruction Manual
Use the keypad display with the N prefix to observe the level of the enabled reference. Terminal control is denoted by the illumination of the Remote Ref LED on the keypad.
Keypad control: make sure the speed reference command is present. Terminal control: make sure .the speed pot is wired correctly to terminals 15, 13, 17).
Use an analog voltmeter to measure the three-phase output voltage across terminals T I , T2, T3.
Voltages should be balanced within 3 %. If you use a digital meter the readings will be distorted due to the shape of the output waveform. See section 9.3 for test method. if the rectifier bridge is damaged you should add a three-phase, AC input reactor between the incoming source and the inverter power terminals L1, L2, L3.
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Extend the programmed acceleration time. Open the motor conduit box and confirm the motor leads are connected for the proper voltage (208, 230, 460, etc).
If extending the time doesn't improve the situation, uncouple the load from the motor and try again. Also make sure the motor doesn't have an opened phase.
Check the Tach Generator & Bias Tach Generator Connected Improp- Module wiring. erly?
Low impedance motor (Wound Rotor)?
Considering using an output reactor between the IMPULSE PH3 and the motor. Consider installing some level of resistance in the secondary circuit.
Inverter is too small Make sure the motor's rated current Inverter's rated current is on the is less than (or equal to) the inverter's nameplate of the unit and also for load. published in Sec. 3 of thismanual. rated current.
Stabilize source or extend accel and decel times (Bn-01, -02, -03, 04)
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If you should experience a fault t i p condition and then remove the main ac power supplying the inverter, the fault code (s) will be stored in memory. When you reapply power, the keypad will blink the alpha-numeric code corresponding to the original fault trip for 2 secs. then will return to the previous display mode. If you want to observe the trip condition more closely, simply depress the DSPL (Display) key until the fault trip display is accessed. This mode will carry a prefix of "U1"to indicate the first fault, "U2"to indicate the second fault, etc. A maximum of 4 sequential key until you faults can be stored in memory and you can access them by pressing the A observe all the faults (display will scroll through all registered faults, up to and including the fourth). See below table for Fault Code listinq and information:
I 1
Uul
Uu2
I 1
Undervoltage 1 Undervoltage 2
Undervoltage 2 Overcurrent
Overvoltage
Fu
OH
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Motor Overload
Inverter Overload
Overtorque Detection
Undervoltage status occurs for more than 2 seconds. Check the Main Power Supply for proper connections. The Control Circuit voltage becomes low during operation. Check the Main Power Supply for proper connections. Main Circuit DC contactor answerback is not present. Check the pre-charge resistor. Inverter output current exceeds 200% of transistor rated current. Check inverter wires for short, check the motor for shorted/ grounded winding. The DC Bus voltage is too high. Check the braking resistor. If Braking resistor is not present, intall Braking resistor. Check the Deceleration time. Call Electromotive Systems, Inc. immediately The main cooling heatsink of the inverter exceeds 90C. Inspect - fin for cleaniness. I - the cooling I RMS current of motor exceeds the Data of Cn-16. Check the data of Cn-16 for appropriateness. Check the mechanical system for bearing and other types of failure. Reduce the load. Output current of PH3 exceeds RMS rating of inverter. Check the mechanical system for bearing and other types of failure. Reduce the load. Output current of PH3 exceeds the data of Cn-24 for the time of Cn-25. Check the data of Cn-24 and Cn-25 for appropriateness. Inspect the mechanical system. Output current at the Load Check function exceeds the app;opriate level (one of Cn-Cn-27.29 or 3 1). Check the data of Cn-27,29 & 3 1 for appropriateness. Reduce the load. Applies to units: 200V Class: S 10HP; 400V Class: QOHP The built-in braking transistor is blown. Call Electromotive Systems immediately. EF3: External Fault is Input by Terminal 3 (Sn-11 = lx) EF4: External Fault is Input by Terminal 4 (Sn-12 = lx) EF7: External Fault is Input by Terminal 7 (Sn-13 = lx) EF8: External Fault is Input by Terminal 8 (Sn-14 = lx) Enabled only in when Sn-10 = 0, 1 , 2 , 3 or 4: Input sequence is not allowed. Check the pushbutton wires for proper connection.
Page 80
IMPULSE@# pH3
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IMPULSE:?, P H ~
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1) Use surge absorbers (R-C networks) on all relay and contactor coils.
2) Shielded cable shall be used for all low level D.C. speed reference signals (0-IOVDC, 4-20 mA). Shield should be grounded only at the AF drive side.
3) Use a minimum of #16 AWG for control wiring, and #12 AWG (or larger) for power wiring. Size according to N.E.C. table 310-16.
4) The following is required for all dual motor bridge cranes and suggested for center driven cranes, trolleys and hoists. Upsize the wiring one size for every 25 feet of distance between AF drive and motor to account for voltage drop (which becomes significant at low frequencies).
5) Use time delay fuses for AF drive input protection. They shall be sized at approximately 150% of AF drive continuous rated amperage.
6) Control and power wiring (including dynamic braking resistor wiring) shall be kept separate on terminal block strip.
7) Keep control (directional and speed command inputs to the AF drive) and power wiring from running together in parallel paths on the panel or in conduit runs. Keep control and power festoon wiring in different cables and separated.
8) If control and power wiring do meet on a panel, cross them perpendicularly. 9) Before applying power to the AF drive, check the output circuit (TI, T2, T3) for possible short circuits or ground faults.
10) Always mount the AF drive in its proper (vertical) orientation with at least 3" of clearance on all four sides. AF drives should be housed in appropriate NEMA rated enclosures for the environment in which they will be used. 11) Keep AF drive heatsink clear of any obstructions (components on panel) to ensure proper cooling air flow. 12) If using externally mounted interface boards, or remotely mounted speed reference signals, use shielded cable from the interface output or remote speed reference to the AF drive control input terminals. 13) On external input devices (control), hard contact inputs are preferred rather than solid state inputs into the control voltage input boards ( T C - G I F , TC-SIF-, TC-SLC-). 14) If the input device is a PLC triac output, a 5K ohm, 10 watt'resistor may have to be used between the signal and L2 (X2). 15) AF drives should always have the cover mounted on unit during normal operating conditions to protect the digital operator (Specific to Electromotive Systems IMPULSEaPH3 Series, 1MPULSE.G Series, IMPULSE.VG Series and IMPULSEaP series).
Page 87
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Appendix
Instruction Manual .. .
IMPULSE!$PH~, : .
16) All ground terminals or screws ("G" or "Ernmust be grounded back to earth ground.
17) If the power source is greater than 500 KVA, there should be at least 3% impedance in the line between the source and the input to the AF drive.
18) Incoming power supply voltage must be limited to 230 volts f 10% or 460 volts f 10%.
19) On existing wound rotor motor applications >25HP, a line reactor of 3% impedance shall be required on the load side of the AF drive. (Specific td Electromotive Systems IMPULSEaPH3
oversizing the drive or installing a load reactor is suggested to avoid over-current conditions upon starting a motor.
23) When supplying single phase input to the AF drive, the amperage of the drive must be derated
by approximately one-half. (Consult Electromotive Systems.) 24) All worm gear box hoist applications require dynamic braking resistors to avoid overvoltage conditions when lowering the hook. 25) Sliding collector bars are not to be used between the drive and the motor. It must be hard wired (i.e. festoon cable).
*'
If there are any questions, or a further explanation of the above recommendations is needed, please contact Electromotive Systems at 4141'783-3500 before proceeding. The above recommendations, if followed, will help to ensure trouble-free start-up and successful operation of the adjustable frequency drive when applied to overhead material handling equipment.
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Prices: Terms:
Electromotive Systems, Inc., hereafter referred to as Company, guarantees all items manufactured by it against any defects of material andlor workmanship for a period of two years from the date of shipment. Company makes NO OTHER WARRANTY, EXPRESSED OR IMPLIED, AS TO THE MERCHANTABILITY OR FITNESS OF THE ITEMS FOR THEIR INTENDED USE OR AS TO THEIR PERFORMANCE. Any statement, description or specification in Company's literature is for the sole purpose of identification of items sold by the Company and imparts no guarantee, warranty or undertaking by company of any kind. Components and accessories not manufactured by Electromotive Systems are not included in this warranty and are warranted separately by their respective manufacturers Company's sole liability shall be to repair at its factory, or replace any item returned to it within two years from date of shipment, which Company finds to contain defective material or workmanship. All items to be repaired or replaced shall be shipped to Company (Note: return authorization by Company is required) within said two year period, freight prepaid, as a condition to repair or replace defective material or workmanship. Company's herein assumed responsibility does not cover defects resulting from improper installation, maintenance, or improper use. Any corrective maintenance performed by anyone other than the Company during the warranty period shall void the warranty. Company shall not be liable for damages of any kind from any cause whatsoever beyond the price of the defective Company supplied items involved. Company shall not be liable for economic loss, property damage, or other consequential damages or physical injury sustained by the purchaser or by any third party a## result of the use of any Company supplied items or material. %<,.,# &\! Company neither assumes nor author~zb ny other person to assume for Company any other liability in connection with the sale or use of items sold by Company.
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List prices or discounts are subject to change without notice. Quoted prices will be honored for a period of 30 days from the date of the written quotation unless otherwise stated. Orders of $25,000 or more, and orders for special control panels are subject to special terms and conditions of sale. Refer to those specific sections within this document. Orders are not subject to alteration or cancellation except upon written consent of Company.and payment of proper cancellation charges, when deemed applicable by Company. Materials or items may not be returned for credit, without the prior written consent of the Company. Any authorized return of materials or items shall be subject to a restocking charge equal to 2O0I0of the net invoiced amount therefor after Company determines that the material or item is in good condition and may be resold without alteration or service. Terms of payment are NET 30 days. All materials and items are sold F.O.B. Company's shipping point. Company retains a security interest in all items sold by it so long as they remain in Company's possession to secure all obligations of purchaser to Company. A processing fee will be applied to all invoices for requested prepaid freight charges other than UPS. A service charge will be incurred on past due accounts extending beyond the terms of sale described above, at a rate of 1 112% per month of the net balance extending beyond 30 days. Any claim for material or item shortages must be received by Company within 30 days of shipment and must be accompanied by copies of the bill of lading and packing slip.
@ 1994 ELECTROMOTIVE SYSTEMS, INC.
Milwaukee, Wisc: Soft NSG618221-1: 12/19/94
Page 89