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11.9 MPC-200 / MPC-210 WINCH CONTROL ELECTRONICS, TECHNICAL

DESCRIPTION

11.9.1 General

The task of control electronics is to take care of starter controls and

measurings.

Base unit MPC-200 of control electronics is installed inside metallic protection

cover. The unit is provided with terminals for starter internal connections (5X),
equipment and sensors in winch and out going indication signals (0X), control
column 1 (1X) and control column 2 (2X). The base unit is always similar, but
the function can be selected with jumpers J1...J5 according winch
construction and type of motor to be controlled. Correct condition of jumpers is
told in starter circuit diagram.

Extension unit MPC-210 of control electronics is installed inside metallic

protection cover. The unit is provided with terminals for controlcolumn 3 (3X)
and control column 4 (4X). The extension unit can be connected to base unit
with multipole connector ready installed in the unit. Extension unit is needed
only in case, when more than two control columns are used.

Following functions controlled by electronics can cause alarm which is given

also with closing contact in terminals 0X21 and 0X22.
• when switching on voltage
• controller must be in 0-position
• push buttons must not be pressed
• in automatic winches automatic setting switch must be in 0-position
• motor overtemperature control with thermistors
• motor overcurrent control with thermal overcurrent relays
• electronic motor overcurrent control / winch overload control
• motor brake circuit control
• main contactor control (feedback).

11.9.2 Winch control and functions

Control places

Two control places can be connected to base unit and two more to extension
unit. Furthermore, two push buttons can be connected to base unit, these
push buttons are counted as one control place. If, due to winch construction,
more push buttons are needed, parallel connection is to be used to connect
necessary amount of push buttons.

Winch control can be done from only one control place at a time so, that
controls are accepted only from control place where signals were first given.

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Control place can be changed only after the controller (or push buttons) are
returned to 0-position.

In case, that voltage is on and there is no disturbance, "READY FOR

OPERATION"-signal light is on in control column. When possible automatic
will be connected, "READY FOR OPERATION"-signallight will be switched off
and "AUTOMATIC ON"-signallight will be switched on.

Controller

By using controller, motor can be driven with all (max 3) speeds to both
directions if, driving is permitted considering overcurrent, overload etc.
conditions. If controller is turned directly to high speed, lower speeds will be
driven first. Winch will stay in every lower speed step before changing to
higher speed step, until adjusted starting time has passed. Changing to lower
speed can be done withouit delay. However, if the controller is take from 3-
step to 0-position so quickly, that neither 2- nor 1-speed step are switched on,
a motor braking of adjusted lenght will be performed at 1-speed before closing
motor brake.

When turning controller directly to opposite direction, motor stopping and

restarting will be performed according above explaned procedure.

Push buttons

With push buttons, assembled next to winch claw clutch, motor can be driven
with slow speed in/out to make clutch operating easier.

If both push buttons are pressed simultaneously, motor will stop.

Anchor drive

Anchor drive will be switched on, when inductive sensor in anchor winch claw
clutch is activated (led 1 will be switched off). This will cause:
• possible automatic can not be switched on
• electronic current control will be switched off (thermal current control
remains in function)
• speedsteps higher than nominal, can not be switched on.

If necessary due to winch construction, motor rotation direction can be

changed in anchor drive, to keep logical function of controller.

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Mechanical high gear

When inductive sensor in mechanical high gear claw clutch is activated, led 2
will be switched off and possible automatic can not be switched on. This
function has no affect to base unit operation.

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11.10 MPC 220 MOORING AUTOMATIC, TECHNICAL DESCRIPTION

11.10.1 General

The task of mooring automatic is to keep tension in mooring line within pre-
adjusted limits.

Automatic unit is installed inside winch control electronics (MPC-200) metallic

protection cover and it is connected directly to base unit with 2x16 pin
multipole connector. External connections to automatic unit are coming
through base unit terminals.

11.10.2 Function

Automatic is switched on by pulling desired tension to rope with manual

control. After this, automatic switch is setted to position nearest to true value.
Automatic will switch on when setting switch position is within tension
hysteresis range. When automatic is on, "AUTOMATIC ON"-signal light in
control column is switched on, "READY FOR OPERATION"-signal light is
switched off, further more a closing contact signal is available in terminals
0X17 and 0X18 of base unit. Manual operation of winch is not possible before
automatic is switched off by taking automatic switch to 0-position.

The automatic keeps rope tension within hysteresis range. If rope tension is
changing outside hysteresis range, automatic will start winch and tension is
driven back to hysteresis range. While automatic is on, rope tension can be
changed with automatic setting switch.

Normally automatic is operating with 1-speed, but if the tension is deviating a

lot from setting value and quickly enough correction can not be achieved by
using 1-speed, automatic will change to 2-speed. Automatic is able to use 3-
speed only for paying out the rope in case that tension is higher than set max.
tension.

If desired, alarm can be received when too much rope has been payed out,
e.g. in case that external load is higher than automatic setting value and
automatic is continuously paying out. For pay out control, a sensor is to be
installed to winch to measure drum rotation. A closing contact signal is
available in base unit terminals 0X19 and 0X20 when alarm is activated.

An overload control to prevent manual in-hauling while rope tension is higher

than set max. tension, it is also included in automatic unit.

3-speed can not be connected, if set 3-speed prevention limit has been
exeeded in manual drive. Automatic unit is provided with separate limits for
nominal gear and mechanical high gear.

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Automatic can not be connected when:

• anchor drive is connected
• mechanical high gear is connected
• load sensor is missing or broken
• disturbance is on.

Led's H1...H8 are installed to automatic unit for disturbance indication. Further
more, a closing contact disturbance signal is available in base unit terminals
0X21 and 0X22.

DISTURBANCE LED: DISTURBANCE:

H1 high starting frequency
H2 load sensor failure
H3 rope break
H4 electronic failure
H5 protection device failure
H6 supply failure
H7 feedback failure
H8 overload

11.10.3 Connections

Load sensor

A load sensor, installed in gearbox, is giving mV signal proportional to rope

tension. This signal is used for winch control and tension display.

It is to be noticed, that tension measuring can operate correctly only, when

rope drum is directly connected to power transmission line. In winches with
many drums, only one drum at a time can be connected to automatic
operation.

Automatic setting switch

Tension setting is done by 8-step control switch installed in control column.

Control switch is provided with positions: 0%, 40%, 50%, 60%, 70%, 80%,
90%, 100%. When switch is in 0-position, automatic is switched off. Other
positions are indicating setting value in percents of winch nominal load.

Two automatic setting switch can be connected to base unit (MPC-200) and
two more to extension unit (MPC-210).

Tension meter

Rope tension can be seen from tension meter installed in control column.

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Drum rotation sensor

Drum rotation sensor is installed to winch, when needed for rope pay out
control.

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11.11 MPC-200 /MPC-210 WINCH CONTROL ELECTRONICS, COMMISSIONING,

ADJUSTING AND DISTURBANCES

11.11.1 Commissioning

Before switching voltage on, all connections according starter circuit diagram
must be connected to the unit. Also possible expansion unit and automatic
unit must be connected when voltage is off. When re-assembling base unit
MPC-200 (e.g. spare part), ensure before switching voltage, that jumpers
J1...J5 are according starter circuit diagram (1 = jumper unbroken, 0 = jumper
broken). When taking unit in to operation, the cover must be closed to ensure
undisturbed operation.

To enable control electronics to start operation when switching on voltage, it is

to be checked that all controllers and push buttons are in 0-position.

Furthermore, in automatic winch it is to be checked that automatic setting

switch is in 0-position.

11.11.2 Connections

Connections and functions of control electronics are listed according

maximum equipment and functions. Used connections and functions can be
seen in starter circuit diagram.

*) Marked functions are possible only in automatic winch. MPC-

200 TERMINAL GROUP 0X

Z1,Z2 Motor thermistors.

B1,B2 Motor brake.
1-4(* Load sensor.
5-7(* Drum rotation sensor. If sensor is not used, connect link
between terminals 6 and 7.
8-10 Anchor drive sensor. If sensor is not used, connect link
between terminals 9 and 10.
11-13 Mechanical gear sensor. If sensor is not used, connect link
between terminals 12 and 13.
14-16 Push button control.
17-18(* Contact output "automatic on".
19-20(* Contact output "pay-out limit".
21-22 Contact output "disturbance".

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MPC-200 TERMINAL GROUPS 1X AND 2X MPC-

210 TERMINAL GROUPS 3X AND 4X

1 Common 0 for meters.

2 (* Tensionmeter.
3 Ammeter.
4 "Ready for operation" signal light.
5 "Automatic on" signal light.
6 Common 0 for signal lights, controller and automatic setting
switch.
7-10 Controller.
11-13(* Automatic setting switch.

MPC-200 TERMINAL GROUP 5X

1,2 Motor brake voltage supply.

3,4 Control electronics voltage supply.

5 Control voltage supply for contactors.

6 1-speed contactor K1.
7 2-speed contactor K2.
8 3-speed contactor K3.
9 "in" direction contactor K4.
10 "out" direction contactor K5.
11 "dahlander" contactor K6.
12 motor brake contactor K7.

13 Common 0 for feedback contacts and "run" signal light.

14 Ammeter 0.
15 Thermal relay feedback. If thermal relays are not assembled,
connect link between terminals 13 and 15.
16 K1 contact feedback.
17 K2 "
18 K3 "
19 K4 "
20 K5 "
21 K6 "
22 "run" signal light.
23 Ammeter.

24,25 Current sensor supply.

26,27 Current sensor signal.

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11.11.3 Adjusting

Jumpers J1...J5

Starter operations are defined by jumpers J1...J5 according winch

construction and used motor. Demanded condition of jumpers is shown in
starter circuit diagram. Jumper 1 is located closest to code switches.

J1 J2 J3 J4 J5 Jumper
1 No direction change in anchor drive
0 Direction change in anchor drive
1 0 Nominal speed 1
1 1 Nominal speed 2
0 1 Nominal speed 3
1 0 Dahlander with 1-speed
1 1 Dahlander with 2-speed
0 1 Dahlander with 3-speed

1 = jumper unbroken
0 = jumper broken

As a factory setting, all jumpers are unbroken.

Motor brake current, trimmer P1

Before motor starting, control electronics check motor brake circuit by

measuring current. When brake circuit current is higher than adjusted limit,
motor can start. Green led next to trimmer P1 is on, when acceptable current
is measured.

Trimmer P1 adjusting range is 0 mA ... 500 mA.

• Max. clockwise = 0 mA
• Center = 250 mA
• Max. counter-clockwise = 500 mA

Current limit adjusting is 0.14 x brake nominal current.

Brake current = Brake power / voltage (110 VDC)

Brake power is told in brakes rating plate.

Setting values under 100 mA are to be avoided.

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Electric motor current control, trimmers P2, P3 and P4

A separate current limit is provided for motors every speed steps. Electronic
current control is acting also as an over load protection for winch.

1-speed = P2
2-speed = P3
3-speed = P4

Red leds located next to trimmers are indicating when adjusted current limit
has been exeeded. Current limits are not used during starting. As there is a
common current sensor, several current limits can be activated
simultaneously, but only limit for speed which is in use is checked by control
electronics.

Adjusting range of trimmers P2, P3 and P4 is 0 A ... current sensors nominal

value.
• max clockwise = sensors nominal value
• max counter-clockwise = 0 A.

Recommended setting value is normally about 1.1 x speed steps nominal

current. If necessary, setting may deviate from recommendation.

Starting time, switches S1, S2 and S3

Starting time for every speed steps can be adjusted with 10-step code switch.
Electronical current control is not working during adjusted starting time and
changing to higher speed step is possible only after starting time of lower
speed stap has gone.

Starting time of speed step is to be adjusted long enough to enable proper

starting of motor at nominal load. Anyhow, too long starting time settings are
to be avoided to prevent unnecessary delay before switching higher speed
steps.

1-step = S1
2-step = S2
3-step = S3

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Switch starting
position time (s)
0 0.5
1 1 <- S1,S2 factory setting
2 1.5
3 2 <- S3 factory setting
4 3
5 4
6 5
7 6
8 7
9 8

Setting value between numbers or otherwise undefined value is interpreted to

be setted to value 5 (4 s).

Motor braking time, switch S4

When turning controller directly from 3-speed to 0, motor braking in 1-speed

will be performed before closing motor brake. Braking time can be adjusted
with 10-step code switch. Time is to be adjusted long enough to let motor
speed slow down before closing motor brake. The meaning of motor braking
is to reduce the wear in motor brake.

switch braking
position time (s)
10 0.5 <- factory setting
1 1
2 1.5
3 2
4 3
5 4
6 5
7 6
8 7
9 8

Setting value between numbers or otherwise undefined value is interpreted to

be setted to value 5 (4 s).

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11.11.4 Disturbances

Disturbances at starting

Disturbance will occur when switching on voltage if:

• all controllers are not in 0-position.
• push button is pressed.
• over temperature in motor(thermistor protection)
• thermal over current relay tripped.

In these cases disturbance relay is energized. Disturbance situation will

disappear only when the reason causing disturbance has been removed, after
this the operation will be continued normally. Disturbance relay will be de-
energized and "READY FOR OPERATION"-signal light will be switched on.

When disturbance relay is energized, a red light "DISTURBANCE" is switched

on in control electronics.

Thermistor disturbance (motor over temperature)

If motor temperature will rise too high while motor is running, it will cause
thermistor disturbance. The motor will stop immediately, and disturbance relay
will be energized. Disturbance situation will disappear after motor temperature
has decreased under allowed value.

Thermal relay disturbance

If thermal over-current relay is tripping while motor is running, it will cause

thermal relay disturbance. The motor will stop immediately and disturbance
relay will be energized. Disturbance situation will disappear after thermal relay
has been resetted. During thermal relay disturbance the green led next to
terminal 5X15 will be switched off.

Brake current disturbance

If acceptable brake current will not occur after switching on brake contactor or
if brake current will not disappear after switching off brake contactor,
disturbance relay will be energized for a short moment. After this, control
electronics will start operation from beginning and starting conditions
according item 4.1 will be checked.

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Over current disturbance

If the current limit adjusted for speed step is exeeded after adjusted starting
time:
• disturbance situation will occur if motor was running on nominal speed or
slower than nominal speed or if possible automatic was switched on.
• if a speed step higher than nominal was used, control electronics will
automatically change to nominal speed. To switch back to high speed, the
controller must be taken to nominal speed and then back to high speed.

Disturbance relay will be energized for a short moment. After this, control
electronics will start operation from beginning and starting conditions
according item 4.1 will be checked.

Feedback disturbance

Feed back disturbance occur if incorrect feedback contact will be received

from cintactors K1...K6 compared with control signals given from control
electronics.

Disturbance relay will be energized for a short moment. After this, control
electronics will start operation from beginning and starting conditions
according item 4.1 will be checked.

Unknown disturbance

Unknown control electronics disturbance can be removed by pushing

"EMERGENCY STOP" down and releasing again. control electronics will start
from beginning.

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