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service manual for hoist control device

1. b _ Md osvo WIH eta Wid OISIAR OSHA OISHA S VAVWENES NAIS SNASANT peu SNASANT OUNSOVTLL i is IESI 13S Dav HEN SNINYAO HN HHO wad 2 p E 5 Ee pire pon ONTLSIOH WALWSANI Fin an 113 EY pam kd Y AW1dSI0 L V YOSNAS 0Y07 N0I193100d WWHSHL g SE 1X by Ev Db Eb EN TWNIWWAL 3394 3OVITOA TOHINOD 1X3 40 TWHLNGN INO 30VLT0A OHINOD 1X3 370 IWY HLIM dOS ACH A CWNIWAL 334s dO1S WNE S3 Sh v El zi th at 7 Jug wao 10 svio wyo evia 2s IS v sa AU aE LX T T ad JMO AI ENIV NIV INI 30AOI zdl bdl ebdl bidl aj ANANI SOTYNY INANI HOLSTHUSHL O L O Pan gt 09O 5 ow oO J cs LO Me RRS SRE CS SS ae oot S isp cm o gt o Se Lo lO HOLIMS OVOTH3AO WOINVHIH G T FODD M rN DOONL a vooo e t FD o SE ee d cat gt 557x nl Hare FOAL SSHOLIMS LIWII E dOLS MOTS ISY4 NMO a OL 6 8 9 G V I E Cc L MATERIALS o Z Z Z T R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice 100 105 R amp M Materials Handling Inc R amp M 4501 Gateway Boulevard me Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC Appendix 6 External power supply for ESD 143 General The current of 10VDC of the Control Pro is limited to 50mA When KAE400 ESD142 s
2. 6 Design Design values menu Accessible password level 6 Param Name Value Description 6 1 Hoist name wy Identifying letter of the hoist monitoring unit A B C D or E Each connected unit in a multi hoist application connected via the CAN bus must have a unique letter 6 2 Unit No nnnnn The serial number of the hoist Setting is informative only there is no function behind the value Mechanical class for the hoist according to the FEM ISO duty classes See chapter 6 3 Class n Primary monitoring items of this manual for details Setting is informative only there is no function behind the value 6 4 Nom Load nn n t Rated load of the single hoist connected to the unit 6 5 Nominal ED nn Rated ED value of the hoist 6 6 Sp ratio n Speed ratio Two speed systems slow fast i e 6 inverter drives always 1 6 7 Max ST nnnnn Maximum allowed number of starts 6 8 Max E stop nnnnn Maximum allowed number of interrupted hoists emergency stops 6 9 Max RT nnnn h Maximum allowed run time in hours 7 Designed running hours power three Equals the safe working period in hours as described in chapter 6710 D SRT3 nanan Primary monitoring items of this manual F 5 Designed running hours power eight Equals the safe working period in hours as described in chapter om cones nanan Primary monitoring items of this
3. Parameter Value Description Note 4 9 Accessible with password 4 8124 Slack rope 4 9 1 Yes Selects the slack rope function SR select 4 9 2 n t Sets the slack rope limit When the measured In practice the minimum value is about 10 of the rated load of the Load limit load is less than the limit lowering is prevented hoist or higher Range 0 rated load of the hoist e A right Slack Rope level must be adjusted during the commissioning of the hoist 34 105 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc REY ME 4501 Gateway Boulevard Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 MATERIALS HANDLING INC 7 2 2 Slack rope protection connections eo Only if by bass function is needed for Slack rope function A normally open contact should be connected to either one of the multi functional inputs The slack MFI1 or MFI2 Active load limit rope by pass function operates according to the following logic ON Slack rope by pass function active lowering allowed OFF Slack rope function active lowering prevented when the load is below the set limit OL10 ee MFI1 MFI2 MULTIFUNCTION INPUTS 7 3 Intermediate load limits In addition to the normal overload protection function one two or three intermediate load limits can be selected An int
4. 49 9 3 4 Analog output AOUT 50 9 3 5 Slak TOPE were werent 50 9 4 Commissioning table ccceeee 51 10 Overload protection Load sensor 52 10 1 Load sensor syStem ccscccsceececiees 52 10 1 1 Load sensor Set UP 0 eceeeeeeeeeeeeeeeeee 52 10 2 Load sensor parameters 0cceeee 52 10 3 Load calibration sequence with load sensor 53 10 4 Manual load calibration cccee 54 11 Overload protection Motor torque 55 11 1 Overload protection instructions 55 11 1 1 Motor torque calculation system 55 11 1 2 Motor torque calculation parameters 55 11 2 COnnectiONn Sna 57 11 3 Load calibration sequence with motor torque 58 11 4 Zero load calibration sequence with motor toque59 11 5 Manual load calibration ccee 59 12 Load sensor adjustment eeeeeeeees 61 12 1 KAE400 Strain Gauge 61 121 1 Generalhiereciaai a 61 12 1 2 Technical data sesscsssssssisssiusnsnnisnnnnnnnn 61 121 3 WINN ineei e a 61 12 1 4 Adjustment eeooeenneeeeeeoesenenneseeesennnneae 62 12 1 9 DIMCNSIONS sisiiisisiiisisisiiiiirisiacainaiininiiiniaiiia 63 12 2 ESD142 amplifier Strain Gauge 63 12 2 1 ESD142 Description n 63 12 2 2 AdjUStMeNt 00 eee cece e eect eeeeetteeeeeeeeeeeeeee 64 12 2 3 Zero load adjustment 64 12 2 4 Adjustment with higher load 64 12 2 5 CONMECUONS ie ncsnana
5. 1 2 13 Int temp Internal temperature of the unit 3 4 SC values Load calibration values for the load sensor method 1 2 14 Input Indicates the status of the inputs HIN LIN FIN MFI1 amp 3 4 1 Load 1 The higher test load value MFI2 1 2 15 Output Indicates the status of the outputs HOUT LOUT 3 4 2 Input 1 The load measurement voltage in the analogue input FOUT RS amp ROUT Ain1 corresponding to the higher test load 1 2 16 Supply f Supply voltage frequency 50 or 60Hz 3 4 3 Load 2 The lower test load value 1 3 Min Max Minimum maximum value menu 3 4 4 Input 2 The load measurement voltage in the analogue input Ain1 corresponding to the lower load 1 3 1 Min supply Minimum measured value of the supply line voltage 3 5 OL protect Set to OFF to temporarily by pass of the overload RMS protection 1 3 2 Max supply Maximum measured value of the supply line voltage 4 Start up Start menu Accessible password level 4 RMS 1 3 3 Min Int T Minimum measured value of the internal temperature of 4 1 MFI1 Multi Functional Input 1 parameters the unit 1 3 4 MaxInt T Maximum measured value of the internal temperature of 4 1 1 MFI1 oper Selects the function of MFI1 the unit 2 Monitor 2 Read only menu for advanced condition monitoring 4 1 2 MFI1 IntL Intermediate load limit value values and measured values Accessible password level 3 2 1 SW version Software version of the unit 4 1 3 MFIl1 2OLL The second load 2 2 RT slow Tot
6. R amp M R amp M Materials Handling Inc 4501 Gateway Boulevard Springfield Ohio 45502 MATERIALS sommes P 937 328 5100 eee FAX 937 325 5319 INC Parameter Value Description Note 4 7 13 0 20s Acceleration time from stop to slow speed 0 00s See also chapter Starting and stopping through slow Acc t slow 1 00s speed of this manual 4 7 14 0 30s Acceleration time from slow speed to fast speed 0 00s See also chapter Starting and stopping through slow Acc t fast 1 00s speed of this manual Parameter Value Description Note 6 In this menu are the mechanical design values of Accessible with password 6 9822 Design the hoist determined 6 4 0 00 999t Rated load of the hoist Setting according to the data label of the hoist Nom Load In case the automatic load calibration sequence does not give the required result i e the difference between the actual load and the calculated displayed load is more than 10 the unit can be calibrated manually with the following parameters Refer to paragraph Manual load calibration of this chapter for further instructions Parameter Value Description Note 3 2 Load calibration value for the motor torque method Accessible with password 2 0732 MC values 3 2 1 0 00 999t The higher test load value 80 130 x Hoist Load 1 nominal Load tons 3 2 2 nn nn Mo
7. Setted to 0 in the new unit e Switch OFF the power supply remove the orange plug termination X1 and X2 and remove the unit e Confirm that the control voltage of the replacement unit either 48V or 115V matches the control voltages of the old unit Insert the new unit e Insert the plug termination X1 and X2 e Insert the display from the old unit into the new unit if the new unit is delivered without display in case the hoist is equipped with a display in the pendant station this is not needed e Switch ON the power supply e Set parameters 3 4 1 3 4 4 and 7 1 7 24 equal to the values written in the above table Give the password 2180 Push Up button 2 times gt Menu 3 Push ENT button gt Menu 3 1 Select menu 3 2 or 3 4 whit Up button and push ENT button Set the down written values into the new unit er When a parameter has to be adjusted first select the desired parameter Pushing the ENT button opens the parameter and the value can be adjusted The free adjustable parameters will ask to adjust the digits one at the time e Go into menu 7 and set parameters 7 1 7 24 Set next parameters 7 21 Power on and 7 22 Temp Index to 0 on the new unit e Make sure there is no load in the hook and check the actual load in slow speed and in fast speed with parameter 2 1 1 The display should show 0 0t 5 for nominal load Push ESC button Push Up button twice 104 105 R amp M Materials Handling Inc
8. 4 3 1 ROUT oper Selects the function of the relay output 5 3 Reset log The reset action must be confirmed by pushing the ENT button once more 4 3 2 ROUT logic The operation logic of the relay 6 Design Design values menu Accessible password level 6 4 3 3 ROUT LoadX The load limit to switch the relay is entered here 6 1 Hoist name ldentifying letter of the hoist monitoring unit A B C D or E 4 3 4 TempX meas The temperature measurement operation 6 2 Unit No The serial number of the hoist 4 3 5 TempXlim The temperature limit 6 3 Class Mechanical class for the hoist according to the FEM ISO duty classes 4 4 T1 Temperature measurement channel 1 parameters 6 4 Nom Load Rated load of the single hoist connected to the unit 4 4 1 T1 operat Selects the function channel 1 6 5 Nominal ED Rated ED value of the hoist 4 5 T2 Temperature measurement channel 2 parameters 6 6 Sp ratio Speed ratio 4 5 1 T2 operat Selects the function channel 1 6 7 Max ST Maximum allowed number of starts 4 6 AOUT Analogue output parameters 6 8 Max E stop Maximum allowed number of interrupted hoists emergency stops 4 6 1 AOUT oper Selects the function of the analogue output 6 9 Max RT Maximum allowed run time in hours 4 6 2 Zero load Sets the voltage level with zero load Range 0 10V 6 10 DSRT3 Designed running hours power three 4 6 3 Nom Load Sets the voltage level with rated load Range 0 10V 6 11 D SRT8 Designed running hours power eight
9. R amp M Materials Handling Inc R amp M 4501 Gateway Boulevard me Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC 14 1 10 Fault Supply vol F_SPh Main supply fault one phase missing e Check that the main voltage connects simultaneous to the control voltage e Check the connections of the terminals 19 U1 1 17 U1 2 and 15 U1 3 e In insulated or high impedance grounded networks the zero level floats causing errors in detecting the actual supply voltage Set parameter 4 10 3 to NO 14 1 11 Fault Phaseorder F_Sor Main supply fault incorrect phase order supervision is carried out only once after each power Check the connections of the terminals 19 U1 1 17 U1 2 and 15 U1 3 Check the phase order Check the phase order of the wires through the current transformers Check the connections of the current transformer e In insulated or high impedance grounded networks the zero level floats causing errors in detecting the actual supply voltage Set parameter 4 10 3 to NO 14 1 12 Fault CParameter F_CP Internal parameter read or write fault e Incorrect check sum in reading the memory or internal hardware fault in the unit 14 1 13 Fault MParameter F_MP Internal parameter read or write fault e Incorrect check sum in reading the memory or internal hardware fault in the unit 73 105 R amp M Materials Handling Inc reserves the right to alter or amend the above information wi
10. The control unit must have a button or a switch for this function Hang a load in the hook Check the display in tare load mode yellow LED is illuminated Push the tare load switch on the control station The value on the display should change to 0 0t 9 3 2 3 Slack rope by pass function Srope e The right action of Slack rope by bass function checked at same as the slack rope function is tested 9 3 2 4 Start and run time counter ST RT This function is start and run time counter for trolley and bridge Select the parameter 1 1 10 or 1 1 8 Drive trolley or bridge several times Check that the value shown with the parameter increases by one after each start 48 105 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc REY ME 4501 Gateway Boulevard Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 MATERIALS HANDLING INC 9 3 2 5 Second overload limit 2OLL When MFI1 input is activated then the hoist can lift over the nominal load 1 00 1 30 x nom Check by parameter 1 2 14 that MFI1 status bit is 1 when lifted in the area where need lift more than nominal load 9 3 2 6 Levelling function Level Drive one of the hooks higher upwards than the other s Select common hoisting with the selector switch on the control station Drive all hooks upwards to the upper limit When the hi
11. e Lower the hook carefully in slow speed onto a stable platform e The motion should stop er Pay attention to the rope coming from the drum Make sure the rope does not jump out of the drum grooves e Drive carefully in slow speed upwards while guiding the rope coming from the drum by hand e f aslack rope by pass switch is installed check the function of it from the parameter 4 1 1 or the parameter 4 2 1 If either ones parameter value is Srope then do the following checks 50 105 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc R amp M 4501 Gateway Boulevard mem Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC e Check from el drawings if any by pass function is designed If yes continue Designer might have activated slack ropes by pass function parameter but the connections in el drawings are done only when ordered e Activate the input and lower the hook e The motion should run 9 4 Commissioning table Read the below parameters from the display and write them down in the table e Keep this sheet in a safe place for future reference Hoist serial number Date ee unit serial Name Param Name Value Param Name Value 0 2 Hoist
12. In case the hoist monitoring unit detects a potentially unsafe situation the motion will be stopped Depending on the kind of fault both hoisting and lowering is prevented or in other cases driving in the opposite direction is allowed In addition to the basic functions a wide scale of optional functions can be installed Refer to the section Optional functions or contact a manufacturer s representative for further details The basic functions of the hoist monitoring unit are Overload protection Hoist motor overtemperature supervision Supply phase supervision Run and fault supervision Starting and stopping through slow speed Sudden load increase supervision The basic functions are factory set according to specific hoist and customer s demand It is possible that few basic functions can t be used in every hoist e g Insulated network inverter drive The additional optional functions of the hoist monitoring unit are Lifetime counters Remote display Multicare Multi function input Options Potentional Free Relay Options Analog Output When during run one of the supervised safety features value exceeds the limit the unit will stop the motion Re starting is only possible after the reason for the fault is terminated Note that some faults are direction dependent and running in the opposite direction will terminate the fault Refer to the sections that describe the supervisions for details The hoist monitoring uni
13. Selects the load calculation method 47A Mead aadd NU Not used the display show all time to 0 0t Motor Motor torque calculation Refer to chapter Overload protection Motor torque of this manual Sens Load sensor measurement Refer to chapter Overload protection Load sensor of this manual Load measurement tolerance is 10 of nominal load by use motor torque calculation system and load measurement tolerance is 5 of nominal load by use load sensor 22 105 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc R amp M 4501 Gateway Boulevard me Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC 5 3 Hoist motor overheating supervision To prevent the hoisting motor from burning up the hoist monitoring unit will constantly measure the internal temperature of the motor The motor is therefore equipped with temperature sensors PTC thermistors NTC thermistors or Bi metal switches Klixons The hoist monitoring unit can be programmed to either prevent both hoisting and lowering default or only the hoisting motion PTC thermistor connections PTC thermistors are commonly used in most of the motors in the past PTC thermistors will rapidly increase their THERMISTOR INPUT resistance when the measured temperature exceeds the limit The maximum allowed tempe
14. can either be manual switches or automatically actuated according to the position of the crane The intermediate load function operates according to the following logic MFI1 MFI2 MFI1 MFI2 z a OL10 oper Oper status status Pete long limit NU NU Normal Overload limit Intl NU ON Normal Overload limit IntL NU OFF gt MFI1 load limit The parameter 4 1 2 NU IntL ON Normal Overload limit NU IntL OFF MFI2 load limit The parameter 4 2 2 MFIA MFI2 MULTIFUNCTION INPUTS IntL IntL ON ON Normal Overload limit IntL IntL ON OFF MFI1 load limit The parameter 4 1 2 IntL IntL OFF ON MFI2 load limit The parameter 4 2 2 IntL IntL OFF OFF MFI 1 2 load limit The parameter 4 2 3 eo The hoist monitoring unit will prevent the hoisting motion when the measured load exceeds 110 of the intermediate load for a period of time The overload protection is reset when the measured load decreases to 80 of the intermediate load Connections if this function is used to do a load limited area OL10 a i RIN Limit switch H T ROUT MFI NFI MULTIFUNCTION INPUTS Travel inverter T 7 4 Run time and start counter for trolley and bridge In addition to the hoist run time and starts counter the hoist monitoring unit can be programmed to count the total run time and starts of either the trolley and or bridge travel motion When this option is activated
15. difference between zero load voltage and rated load voltage and upper and lower limits 7 6 Free relay output The hoist monitoring unit has one free relay output connected between terminals 11 and 12 which can be programmed to operate under the following conditions OL10 Overload A Load limit soak hs OK Warning Fault aoe Ready Fault h Motor over temperature D 2 Connected to the relay output can be any signalling device optical or a acoustic or an additional control circuit to react on any of the above be situations Th Note that only one of the options can be chosen at a time Relay s switch s technical data 230VAC 3A Free relay output parameters Parameter Value Description Note 4 3 ROUT Relay output parameters Accessible with password 4 8124 4 3 1 NU Not used Relay output does not operate Rout oper OL Overload Operates simultaneously with the overload protection Contact closed when overload is detected Bridge overload activates also the overload function in the relay output from software 2 100 LoadX Load limit Operates only according to the measured load of the solo Contact closed when the load exceeds the limit X where hoist connected to the unit the limit is determined by parameter 4 3 3 OK Fault and warming state supervision Operates simultaneously with the red LED on the unit Contact closed in normal operation Contact blinks when the units sh
16. 3 8 00V Analogue output voltage with rated load Refer to Adjustable according to the needed voltage of the connected device Nom Load parameter 6 4 for the rated load in single hoist when required 2 operation Refer to parameter 4 11 4 for the rated load in multi hoist applications 1 The zero load voltage should be higher than 0 00V in order to achieve broken wire protection 2 The rated load voltage should be less than 10 0V in order to allow overload indication er Reliable ranges are from 2V to 8V with large display and from 1V to 9V with other devices e g PLC equipments 37 105 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M MATERIALS HANDLING INC R amp M Materials Handling Inc 4501 Gateway Boulevard Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 7 5 2 Analogue output connections The load display or other device is connected to the analogue output terminals AN and ANO terminals 33 and 34 The connected device must have an input resistance of at least 1kQ in order to prevent the analogue output being overloaded e The analogue output has a filtering delay of 1000ms before SW 2 100 In the SW 2 100 and the later SW the filtering delay is 200ms to enable faster update of load information Consult on the specifications of the connected device for the minimum and maximum required voltage range
17. 4 1 1 NU gt 4 1 1 NU Start up MFI1 4A MFI1 oper 4 MFI oper am a A eae DD P a amp 4 1 41 Intl MFI1 oper e 4 1 1 IntL KA MFI1 oper 4 1 2 10 0t 4 1 2 10 0t P MFI1 IntL lt MF11 Intl 4 e 41 2 000 MFI1 Intl i xP 4 1 2 08 0t MF11 IntL 4 1 2 08 0t xA MFI11 IntL 4 1 2 8 50t MFI1 IntL 3 6 Remote Display 3 6 1 General The display can be also located at a remote location for example in the push button station in the cubicle door or in a crane driver cabin In this way the crane operator can read load information directly from the display All features as well as the parameter structure are the same as when the display would be located at the unit The display in the remote location is a very effective tool for applications where the crane operator needs to have a load indication when handling loads se Please note that the hoist monitoring unit is designed for overload protection The displayed load has an accuracy of approx 5 of the rated load and is thus not suitable to be used as a calibrated weighing scale 16 105 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc R amp M 4501 Gateway Boulevard MATERIALS Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC Connections and Disp
18. 50mA Potential free relay output Programmable 230VAC 3A Current loop 12 V 1 50 70mA CAN 0 Ucan H 2 5VDC Ucan L 2 5VDC 1 Ucan H 3 5VDC Ucan L 1 5VDC respect to CAN GD Height including 15mm assembly rail 120 3mm 4 73in Length 123 8mm 4 87in Width 108 5mm 4 27in Tightening torque of connector terminal screw 0 4 Nm 0 6 Nm 7 105 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc R amp M 4501 Gateway Boulevard MINANE Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC 2 1 Description of terminals Connector X1 Terminals 1 19 for power signals high voltage Display unit with pushbuttons and three indication LEDs optional Connector X2 Terminals 20 38 for the measurement signals low voltages Green LED OK and run state indication Red LED warning and fault indication Selection switch for display location inside the unit or remote RS232 serial link e g for PC software optional or PLC system NOOR OND Connector X1 Terminal Signal Description 1 LOUT Provides the control voltage to lower down contactor two step control or lower down request inverter drive 2 HOUT Provides the control voltage to hoist
19. GIS PIAY cecocscctescsovcerceecdeawacsberseccedeaes 75 14 4 The temperature sensors NTC wiring 75 14 5 Current transformersS 0 eee 75 14 6 There is no fault but hoist doesn t work 76 14 6 1 Hoisting works but lowering is prevented 76 14 6 2 Hoisting and lowering prevented 77 15 Replacement Instructions 0000 78 15 1 Gomeral 0 5 ccc0cescccsescsescseceseceseseseseseceses 78 15 2 Ordering a new Monitoring unit 78 15 3 FRE DIAGING scxiecceccactaxacsenencacorkaceeesiensetestiaes 78 15 4 Parameters and Valu sS sseeeeee 78 15 5 Flow Chall aia ste 81 16 Menu Structure eteeeeeeeeeeeeeeeeeeeeee 82 16 1 Monitor 1 Menu 1 eee 82 16 2 Monitor 2 Menu 2 cccceeeeeeeeeeeeeeeees 83 16 3 Load calibration menu Menu 98 84 16 4 Start up menu Menu 4 eee 85 16 5 Service menu Menu 5 eee 88 16 6 Design values menu Menu 6 0 88 16 7 GO settings menu Menu 7 00 89 Appendix 1 Default parameters 06 90 Appendix 2 Version History cccccccccceee 91 Appendix 3 Current Transformer s information cca cesnccnnactacacacssacnenactacccaccaaccnaansaccsaas 93 Appendix 3 1 Current transformer table 95 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M MATERI
20. Inc R amp M 4501 Gateway Boulevard me Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC 3 5 Parameters 3 5 1 Read only parameters Menu 1 Monitor 1 and menu 2 Monitor 2 contain read only parameters These menus will show the calculated and measured values of the solo hoist connected to the selected unit 0 2 A Hoist name 6 1 gt 1 1 gt 1 1 1 97 6 Monitor 1 Cond mon SwP 2 gt 2 gt 2 1 2 000 Monitor 2 Monitor 2 SW version iyi Ta Vv 3 5 2 Adjustable parameters There are two sorts of adjustable parameters e Free adjustable within the given limits e Choice from option list When a parameter has to be adjusted first select the desired parameter Pushing the ENT button opens the parameter and the value can be adjusted The free adjustable parameters will ask to adjust the digits One at the time whereas other parameters will give the choice between a number of options 15 105 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc R amp M 4501 Gateway Boulevard MNANE Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC Example selecting the MFI1 input to intermediate load function with a load of 8 5 Tons 4 A ARNEE N val pe 4 gt 44 gt
21. Load calibration sequence with motor torque 1 2 1 Act Load The measured actual load value 3 2 MC values Load calibration values for the motor torque method 1 2 2 Temp 1 Temperature measured at thermistor input 1 3 2 1 Load 1 The higher test load s value 1 2 3 Temp 2 Temperature measured at thermistor input 2 3 2 2 Mhs1 Motor torque for hoisting in slow speed with load 1 2 4 SupplyL1 Line voltage of phase L1 3 2 3 Mhf1 Motor torque for hoisting in fast speed with load 1 1 2 5 SupplyL2 Line voltage of phase L2 3 2 4 Mis1 Motor torque for lowering in slow speed with load 1 1 2 6 Supply L3 Line voltage of phase L3 3 2 5 MIf Motor torque for lowering in fast speed with load 1 1 2 7 Motor l1 Motor current of phase L1 3 2 6 Load 2 The lower test load s value 1 2 8 Motor 12 Motor current of phase L2 3 2 7 Mhs2 Motor torque for hoisting in slow speed with load 2 1 2 9 Motor I3 Motor current of phase L3 3 2 8 Mhf2 Motor torque for hoisting in fast speed with load 2 1 2 10 Ain1 value Measured voltage at analogue input AIN1 3 2 9 MIs2 Motor torque for lowering in slow speed with load 2 1 2 11 Ain2 value Measured voltage at analogue input AIN2 3 2 10 MIf2 Motor torque for lowering in fast speed with load 2 1 2 12 Ain3 value Measured voltage at analogue input AIN3 3 3 Cal Sens Load calibration when the sensor based load measurement is selected See chapter Load calibration sequence with the load sensor
22. R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice HANDLING INC R amp M Materials Handling Inc R amp M 4501 Gateway Boulevard MINANE Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 If the contactor isn t energized then problem is the control connections Check connections between the contactors and the unit terminal 1 e Limit switches e Bimetal switch e Mechanical overload switch Check the operation of the current transformer Drive the hoist in slow speed and measure voltage between the terminal 27 and the terminal 29 See appendix Current Transformer Table Check connection to the hoist motor If the power line is broken then current can t go to the motor If the hoist is stopped by any external reason for example stop limit switch breaker fault the unit always indicates this fault The situation is resetted when the requests HIN and LIN are deactivated Stepless control Check that the brake contactor switch is connected to the terminal 8 FIN Check that there are not faults of the inverters If the hoist is stopped by any external reason for example stop limit switch breaker fault inverter fault the unit always indicates this fault The situation is resetted when the requests HIN and LIN are deactivated 14 1 6 Fault Brake F_Br Hoist brake does not open only in motor torque based load calculation The parameter 4 7 1 Loa
23. Starts ST _ down Starts 0 5 7 13 ST fast Counter value for FAST requests 1 1 2 Starts ST _ fast Starts 0 15 7 14 Max ED Max value of calculated ED percentage Set to 0 7 15 Over ED Minutes when the ED value has exceeded the Set to 0 designed values 7 16 SRT3 Calculated value from Load and Runtime 3 1 1 1 SWP SWP 6 10 SRT3 D_ SRT3 D_SRT3 00 7 17 SRT8 Calculated value from Load and Run time 8 Set to 0 79 105 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc R amp M 4501 Gateway Boulevard MINANE Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC Description Read old values Set value Desing from old unit values from parameter 7 18 SL1 Calculated value from Load and Cycles 1 Set to 0 7 19 SL3 Calculated value from Load and Cycles 3 1 1 1 SWP SWP 6 12 SL3 D_ SL3 D_SL3 0 7 20 SL8 Calculated value from Load and Cycles 8 Set to 0 7 21 Power on Total hours when the unit was powered on Set to 0 7 22 Temp index Power on time weighted with unit s temperature Set to 0 7 23 Max Load The highest measured load Set to 0 7 24 Br Count Brake operation counter 1 1 6 Br SWP Br SWP 6 18 Br _ Count Max _ Br Max Br 100 80 105 R amp M Materials Handling Inc reserves the right to alter or amend the abov
24. When the feedback signal drops during running the motion will stop immediately During the starting sequence the feedback signal must be on within 200ms in contactor control and within 800ms in inverter control 2 Speed Hoisting Unit monitors a feedback signal from a current transformer to analog input 2 The current transformer measures the input current to the motor in 2 speed hoisting During the starting sequence the feedback signal must be on within 200ms in contactor control When the feedback signal drops during running the motion will stop immediately 2 Speed load measurement by motor 2 Speed load measurement by sensor PHASE ORDER CHANGE MUST BE DONE BY REVERSING THESE WIRES IN THIS LOCATION ANALOGIA SISAANTULD ANALOG INPUT When the unit supervises a hoist inverter application a brake contact from AK7 is connected to the FIN input terminal 8 to be a brake open feedback signal If the brake contactor does not energize during start or de energizes during hoisting initiated by a fault or due to brake failure the unit will disconnect control voltage from the FOUT signal output terminal 3 feeding the ES and RDY inputs of the inverter During the starting sequence in inverter control the feedback signal at FIN must be on within 800ms BRAKE CONTACTOR 27 105 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling In
25. a complete overview of the usage of the crane is recorded 36 105 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc R amp M 4501 Gateway Boulevard MINANE Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC 7 4 1 Run time and start counter for trolley and bridge parameters Parameter Value Description Note 4 1 MFI1 Accessible with password 4 8124 4 1 1 ST RT Start counter and run time counter Counts the amount of times the MFI1 input becomes active starts MFI1 oper and the total time the MFI1 input is active run time Parameter Value Description Note 4 2 MFI2 Accessible with password 4 8124 4 2 1 ST RT Start counter and run time counter Counts the amount of times the MFI2 input becomes active starts MFI2 oper and the total time the MFI2 input is active run time Parameter Value Description Note 1 Monitor 1 Accessible with password 1 1 1 7 n h Displays the total time MFI1 has been active Read only value MFI1 RT run time counter 1 1 8 n Displays the amount of times MFI1 has been Read only value MFI1 ST activated starts counter 1 1 9 n h Displays the total time MFI2 has been active Read only value MFI2 RT run time counter 1 1 10 n Displays the amount of times MFI1 has been Read only value MFI2 ST activated starts counte
26. basic model is the ESD 142 which is used with full bridge load sensors The ESD 142 1 is the modified version which is suitable for half bridge load sensors The units are adjusted by means of two trimmers named ZERO and GAIN With the ZERO trimmer the 0 load adjustment is biased The GAIN trimmer is used to adjust the amplification factor in order to reach the required output voltage at full load There are two LED s marked as 0 and 100 indicating the status of the load O om Terminal Signal Device O 100 1 0 VDC Terminal 30 2 0 VDC Sensor 3 Signal Terminal 26 4 Signal free 5 10 VDC Terminal 25 6 10 VDC Sensor 7 IN Sensor 8 IN Sensor OV SIGN 10V IN N 2 SHLD screen 10 4 VDC free 63 105 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc R amp M 4501 Gateway Boulevard MATERIALS Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC eerie CEnina e 12 2 2 Adjustment Tools needed for adjustment e A small screwdriver for trimmers e Test load Adjustment can be done with either a test load of exactly 100 of the rated load of the hoist or with a known load in the range of 80 130 of the rated lifting capacity The adjustment is carried out in two steps e Zero load adjustment e Known loa
27. e Bridge nominal load parameters doesn t influence the load display for single hoists e More information to the serial port e Load signal filtering serial port 60ms AOUT amp ROUT 200ms Slack rope and units load display 1000ms 91 105 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc R amp M 4501 Gateway Boulevard mem Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC Hardware version history Version Changes HW C e First production HW e Serial number H00677 700263 HW D e Serial number H00678 H01287 T00264 T00496 e Layout Diode ferrite e AC inputs layout e Current loop to RJ terminal e CAN bus speed 25 kB gt 50 kB HWE e Serial number H01288 H02324 700497 T01087 e Layout Leds and display s switch e El capacitors with improved lifetime e Butterworth filter e AC input resistors e AC input FET 600V gt 800V 115VAC e AC input diode 600V gt 2000V HW H e Serial number H02325 H03308 T01088 T01310 e AC input Layout e AC input diode 2000V gt 4000V e AC input varistor e AC input FET 600V gt 800V e Transformer HW K e Serial number H03309 H07182 T01311 T02376 e Few resistors type e HW K1 Green sticker e Since 8 12 03 a diode has been added to the clock rate circuit HW L
28. e Serial number H07183 102377 e The clock rate circuit s layout e Few soldering seams have been enlarged 92 105 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc REY ME 4501 Gateway Boulevard Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 MATERIALS HANDLING INC Appendix 3 Current Transformer s information Current transformer connections Current transformers are connected between the incoming terminal block and hoisting contactor Phase lines are coming from terminal block and going through the current transformer s and then going to the contactor PHASE OADER CHANGE MUST BE DONE BY REVERSING THESE WIRES IN THIS LOCATION ANALOGIA SISAANTULO ANALOG INPUT Current transformer A T20 s black wire is connected to the terminal 26 and current transformer A T30 s black wire is connected to the terminal 27 The grey wires of both current transformers are connected to the terminal 29 5 VDC If there is only one current transformer it is connected between terminals 27 and 29 There are two current transformers in motor torque calculation and one current transformer in load sensor based system An arrow and text IN is printed on one side of MI20 Put the coming phase line through the current transforms from that side In both pictures the phase lin
29. function connect the switch to the MFI2 input and set parameter 4 2 1 to Tare 7 9 Levelling function The levelling function is a feature especially designed for multi hoist applications where the positions of the hooks are balanced in the upper position This function is most useful when the crane is handling fixed or similar known loads such as containers or long objects In normal operation both hoist will stop the motion when either one of the hoist monitoring units detects a fault or is stopped by a limit switch This prevents the load from tilting The levelling function allows each hoist individually to continue hoisting close to the upper limit switch until the hooks are balanced 7 9 1 Levelling function instructions To activate the levelling function an additional levelling limit switch has to be connected to either one of the MFl inputs Levelling function parameters Parameter Value Description Note 4 1 MFI1 MFI1 parameters Accessible with password 4 8124 4 1 1 Level Activates the levelling function in multi hoist MFI1 oper applications a In case the MFI1 input is in use for another function connect the switch to the MFI2 input and set parameter 4 2 1 to Level 40 105 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc R amp M 4501 Gateway Boulevard MINANE Springfield Ohio 4
30. in tons Range 0 hoist rated load 4 2 4 MFl2 20LL n nn When 2OLL is chosen with parameter 4 2 1 the coefficient for the second load limit is entered here Range 1 00 1 30 4 2 5 MFl2 CintL an n t When CintL is chosen with parameter 4 2 1 the second bridge intermediate load limit value is entered here in tons Range 0 bridge rated load 4 2 6 1 2 CintL nn n t When CintL is chosen with both parameter 4 1 1 and 4 2 1 the third bridge intermediate load limit value is entered here in tons Range 0 bridge rated load Param Name Value Description ROUT Relay output parameters 4 3 1 ROUT oper NU Selects the function of the relay output NU Not used OL Overload Hoist in overload contact closed Bridge in overload contact closed since SW 2 100 LoadX Load limit Load greater than limit set by parameter 4 3 3 contact closed Normal contact closed OK Warning contact blinks Fault contact open Normal contact closed R eady Fault contact open TempX Temperature limit Temperature greater than limit set by parameter 4 3 4 contact closed 4 3 2 ROUT logic Norm The operation logic of the relay Norm Normal operation as described above 4 3 1 Inv Operation inverted compared to the description above 4 3 1 85 105 R amp M Materials Handling Inc reserves the right t
31. is connected to star A A2 1 CAN BUS CANH CANL CANG Te x x 46 105 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc R amp M 4501 Gateway Boulevard me Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC 9 Commissioning 9 1 Start up e Check that the supply control voltage complies with the rated control voltage of the unit e Check that all electrical connections are done according to the delivered electrical diagrams e Switch the power on e Check that the hoists control method complies with the application inverter control or two speed control with parameter 4 8 e Make sure there is no load in the hook Run the hoist both directions slow speed and full speed for at least five seconds Check that no messages appear on the display 9 2 Load measure S Check that hoists Load Measure type complies with the application Motor or Load sensor in two speed control with parameter 4 7 1 9 2 1 Load measure type by Motor see the parameter 4 7 1 e Check that the actual load value parameter 1 2 1 shows 0 00t 10 from nominal load when lifted only empty hook up and down also slow and fast speed e Check that the actual load value parameter 1 2 1 shows x xxt 10 from nominal load when lifted test load up and down also slow and fast speed 9 2 2 Lo
32. keep the jumpers available when needed 1 Default setting termination resistors connected 45 105 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc R amp M 4501 Gateway Boulevard me Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC 8 3 2 Recommended topologies The table below provides the general recommendations for the CAN bus topology for different numbers of units connected together When three units are connected the CAN bus can be a line type or a star type The termination must be done at both ends but it seems to be no problem if also the middle unit connects the termination resistors in a line type topology When 4 or 5 units are connected then termination resistors must be removed from the middle units If the CAN bus has 4 or 5 termination resistors the total bus termination resistance decreases too much for the CAN transceiver No units Bus topology Termination resistors 2 Line Termination at both ends 3 Star Termination at all 3 ends Line Termination at all 3 nodes 4 Line Termination at the ends not in the middle 5 Line Termination at the ends not in the middle Three units CAN bus is connected to line A A2 482A BEAN BUS Er BCAN BUS CAN BUS CAN BUS H CANL CANG LH CANL CANG jz a jz a Three units CAN bus
33. manual 6 12 D SL3 nnnnn Design constraint for hoisting cycles power three 6 13 D SL8 nnnnn Design constraint for hoisting cycles power eight 6 14 MaxST MEI nannnn ie ea of MFI1 starts See chapter Run time and start counter for trolley and bridge for 6 15 MaxRT MFI nnnn h ee time for MFI1 See chapter Run time and start counter for trolley and bridge for 6 16 MaxST MFI2 nnnnn oe of MFI2 starts See chapter Run time and start counter for trolley and bridge for 6 17 MaxRT MFI2 nnnn h re aa time for MFI2 See chapter Run time and start counter for trolley and bridge for 6 18 Max Br nnnnn Max number of braking actions for calculating the brake s life time 6 19 Max Control nnnnn Max number of Control for calculating the contactors life time 6 20 Password nnnn Set password level 1 4digits Customer password or device related password 88 105 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M MATERIALS HANDLING R amp M Materials Handling Inc 4501 Gateway Boulevard Springfield Ohio 45502 P 937 328 5100 INC FAX 937 325 5319 16 7 GO settings menu Menu 7 WY Values are equal to the ones in Menu 1 and or Menu 2 monitoring items After a General Overhaul has been performed these parameter have to be reset to the original value zero unless otherwise indicate
34. name 4 Start up 1 Monitor 1 4 1 1 MFI1 oper 1 2 4 Supply L1 4 1 2 MFI Intl 1 2 5 Supply L2 4 1 3 MFI1 2OLL 1 2 6 Supply L3 4 1 4 MFI1 CintL 1 2 16 Supply f 4 2 1 MFI2 oper 2 Monitor 2 4 2 2 MFI2 IntL 2 1 SW version 4 2 3 1 2 IntL 3 Load setup 4 2 4 MFI2 20LL 3 2 1 Load 1 4 2 5 MFI2 CintL 3 2 2 Mhs1 4 2 6 1 2 CintL 3 2 3 Mhf1 4 3 1 ROUT oper 3 2 4 Mis1 4 3 2 ROUT logic 3 2 5 MIf1 4 3 3 ROUT LoadX 3 2 6 Load 2 4 3 4 TempX meas 3 2 7 Mhs2 4 3 5 TempX lim 3 2 8 Mhf2 4 4 1 T1 operat 3 2 9 Mls2 4 5 1 T2 operat 3 2 10 Mif2 4 6 1 AOUT oper 3 4 1 Load 1 4 6 2 Zero load 3 4 2 Input 1 4 6 3 Nom Load 3 4 3 Load 2 4 7 1 Load meas 3 4 4 Input 2 4 7 2 Load rate 4 7 13 Acc t slow 4 7 14 Acc t fast 4 8 Hoist ctrl 4 9 1 SR select 4 9 2 Load limit 4 10 1 OT run 4 10 2 OT limit 4 10 3 Supply sup 4 11 1 Hoist cnt 4 11 2 Run sup 4 11 3 BOL 4 11 4 B nom load a The hoist monitoring unit has been tested and proven fully functional 51 105 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc R amp M 4501 Gateway Boulevard MINANE Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC 100verload protection Load sensor 10 1 Load sensor system The load sensor system uses the analogue signal coming from a load sensor The sensor can be either a Strain gauge type or a Hall sensor type The Strain gauge type of s
35. not Running stopped new start possible simultaneous Slack Rope Slack rope function is active Lowering prevented No Signal Communication fault between unit and display or Running possible Internal processor fault Running prevented ee These faults are not collected into the fault logger parameter 5 2 66 105 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc R amp M 4501 Gateway Boulevard MINANE Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC 13 2 Warnings 13 2 1 General warnings The warning state means that at least one calculated condition monitoring value has exceeded the corresponding design value of the hoist Any active warnings are indicated with the corresponding text on the display The warning text appears on the display directly when the value exceeds the design value and each time after switching the power on to the hoist control unit until the warning is cleared Moving to the load status display is carried out with the arrow buttons of the display In addition the LEDs in the unit and display are blinking Warning name Description SWP The calculated relative safe working period SWP is less than zero Starts The actual number of hoist starts has exceeded the design limit Run time The actual value for the hoist run time has exceede
36. of Starts and E stops Total hours of running time when MFI1 input is closed Can be used to monitor the total running time of 1 1 7 MFI1 RT n h another machinery i e the trolley drive Active only if parameter 4 1 1 is set to S T RT and the MFI1 input is connected 2 Total amount of starts when MFI1 input is closed Can be used to monitor the total amount of starts of 1 1 8 MFI1 ST n another machinery i e the trolley drive Active only if parameter 4 1 1 is set to S7 RT and the MFI 1 input is connected 1 Total hours of running time when MFI2 input is closed Can be used to monitor the total running time of 1 1 9 MFI2 RT n h another machinery i e the bridge drive Active only if parameter 4 2 1 is set to ST RT and the MFI2 input is connected 2 Total amount of starts when MFI2 input is closed Can be used to monitor the total amount of starts of 1 1 10 MFI2 ST n another machinery i e the bridge drive Active only if parameter 4 2 1 is set to ST RT and the MFI2 input is connected 1 The values on the display are present with five digits 1 there is no unit name all five digits are used to show the value The letter k appears when the value is greater than 99 999 indicating the full thousands The letter M appears when the value is greater than 1 000 000 indicating the full millions 2 a unit name is used i e hours h there are only four digits available t
37. protect OFF The overload protection will automatically reset after 30 min or after power off e Lift the test load up until it hangs freely and steady e Select parameter 3 4 1 Load 1 and enter here the value of the test load in tons e Select parameter 1 2 10 Ain1 value and read the value e Select parameter 3 4 2 Input 1 and enter here the value of parameter 1 2 10 e Select parameter 1 2 1 Act Load The display should show nnn t where nnn is the value of your test load 5 Repeat steps 1 to 4 until the value is within the desired range e Lower the load and ensure the hook is empty e Select parameter 3 4 3 Load 2 and enter here 0 00t e Select parameter 1 2 10 Ain1 value and read the value e Select parameter 3 4 4 Input 2 and enter here the value of parameter 1 2 10 e Select parameter 1 2 1 Act Load The display should show 0 00t 5 Repeat steps 5 to 8 until the value is within the desired range 54 105 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc 4501 Gateway Boulevard Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 R amp M MATERIALS HANDLING INC 110verload protection Motor torque 11 1 Overload protection instructions 11 1 1 Motor torque calculation system The parameters as described in the table Motor torque calculation
38. selection only multi hoists 14 3 5 Parameters 00cceceeeeeeeeeeeeeeeeeeeeeeees 15 3 5 1 Read only parameters ccceeeeeeeees 15 3 5 2 Adjustable parameters cccccccccceeeees 15 3 6 Remote Display secceccccctsccccctceteccncierenescc 16 SiG Gnora annn nnan 16 4 ParametersS nnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn 18 Ml Passwords ocene 20 5 Basic Functions seeeeeeeeeeeeeeeeeees 21 BA GONG al esis cciciavectxtsntsterdiarvcietsetedmeneces 21 5 2 Overload protection ccccceeeeeeeeees 22 5 3 Hoist motor overheating supervision 23 5 3 1 Hoist motor overheating supervision INSUPUCH ONS A E A 25 5 4 Supply voltage phase supervision 26 5 4 1 Supply phase supervision instructions 26 5 5 RUN and fault supervision 000 27 5 6 Starting and stopping through slow speed 2 speed application only eeeeeeeeeeeeeeeeeeeeeeeee 28 2 104 Keep the instructions in a safe place for future reference 5 6 1 Starting and stopping through slow speed INSUPUCH ONS E E S 28 5 7 Sudden load increase supervision 29 5 7 1 Sudden load increase supervision instructions 29 6 Monitoring IteMs cccceeesseeeeeeeeeeeees 30 61 Generaler ehe 30 6 2 Primary monitoring items ceee 30 6 2 1 Staris COUNtEL 2 ccc cccceceeeeeeeeeeeeeeeeees 31 6 2 2 Run Time COUnter cccccccccccceeeeeeeeeee
39. switch function in common hoisting CintL Intermediate load limit in common hoisting CAN CAN bus by pass MFI1 IntL nn n t When IntL is chosen with parameter 4 1 1 the first intermediate load limit value is entered here in tons Range 0 hoist rated load MFI1 2OLL n nn When 2OLL is chosen with parameter 4 1 1 the coefficient for the second load limit is entered here Range 1 00 1 30 4 1 4 MFI1 CintL an n t When CintL is chosen with parameter 4 1 1 the first bridge intermediate load limit value is entered here in tons Range 0 bridge rated load Param Name Value Description 4 2 MFI2 Multi Functional Input 2 parameters 4 2 1 MFI2 oper NU Selects the function of MFI2 NU Not used Intl Intermediate load limit Tare Load tare SRope Slack rope by pass ST RT Start and run time counter 2OLL Second overload limit Level Levelling limit switch function in common hoisting CintL Intermediate load limit in common hoisting CAN CAN bus by pass 4 2 2 MFI2 IntL nn n t When IntL is chosen with parameter 4 2 1 the second intermediate load limit value is entered here in tons Range 0 hoist rated load 4 2 3 1 2 IntL nn n t When IntL is chosen with both parameters 4 1 1 and 4 2 1 the third intermediate load limit value is entered here
40. termination exceptions etc limits the maximum bus length 43 105 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc R amp M 4501 Gateway Boulevard MINANE Springfield Ohio 45502 HANDLING INC P 937 328 5100 FAX 937 325 5319 8 2 3 Menus through CAN bus With CAN bus the load display with large digits indicates the sum load of all units working in the CAN bus Even if the sum overload protection is not selected the large digits show the sum load of all units The actual load values of single units are shown with small digits The figure below gives an example of the menu structure in the case of two units A and B communicating through the CAN bus Power ON Warning O Control 0 1 0000 0 2 A Password Hoist name When the power of the unit is switched on the display indicates with the text if there exist an active warning as in this example figure or an active service warning or an active fault If no warning service warning or fault is active the display indicates the tared sum load after the power on display number 4 From the text display pushing the up arrow key the display moves to the load value of one unit in this example unit B If there are several warnings service warnings or faults those are displayed one by one after pushing the arrow key Single unit loads are indicated fo
41. than large displays value e f load value differs with empty hook the correct value is achieved by adjusting parameters 4 6 2 If the large display load value is bigger than unit s load value then decrease parameter 4 6 2 value If the large display load value is lower than unit s load value then increase parameter 4 6 2 value e f load value differs with test load on the hook the correct value is achieved by adjusting parameter 4 6 3 If the large display load value is bigger than unit s load value then decrease parameter 4 6 3 value If the large display load value is lower than unit s load value then increase parameter 4 6 3 value 9 3 5 Slack rope S Slack rope feature only functions properly when a load handling device is attached to the hook It is not recommended to activate the Slack rope function if no load handling device is present The slack rope protection prevents lowering the hook when the measured load descends under a pre set limit When slack rope occurs during lowering the motion will be stopped according to the normal stopping sequence Movement in upward direction is allowed and will reset the slack rope protection The slack rope protection can be by passed by programming either one of the multi functional inputs MFI1 or MFI2 e Check the parameter 4 9 1 SR select if Yes e Check the load limit value by parameter 4 9 2 In practice the minimum value is about 10 of the rated load of the hoist or higher
42. the motor temperature has descended 30 C under the given limit value Selects the supply voltage supervision YES Supply voltage supervision is active NO Supply voltage supervision is not applied aie SURRY SUP YES The supply voltage supervision checks the phase order and the presence of all phases L1 L2 amp L3 In insulated or high impedance grounded networks selection must be NO When the control method is stepless speed control parameter 4 8 is INV selection must be NO Param Name Value Description 4 11 Comm hoist The settings for common hoisting multi hoist applications 4 11 1 Hoist cnt n The number of units connected with CAN bus Range 1 5 Common hoisting supervision 4 11 2 Run sup YES Run supervisions between hoists are active NO No run supervision between hoists Bridge overload protection 4 11 33 BOL YES active NO not active 4 11 4 B nom load nn n t Rated load of the bridge 87 105 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M MATERIALS HANDLING INC R amp M Materials Handling Inc 4501 Gateway Boulevard Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 16 5 Service menu Menu 5 5 Service Start menu Accessible password level 5 Param Name Value Description 5 1 S limits The limit values to indicate the need for service A
43. to Motor 1 2 9 Motor 13 nn n A RMS motor current of phase W Only functional when par 4 7 1 is set to Motor 1 2 10 Ain1 value n nn V Measured voltage at analogue input AIN1 Voltage across terminals X2 26 30 VDC 1 2 11 Ain2 value n nn V Measured voltage at analogue input AIN2 Voltage across terminals X2 27 30 VDC 1 2 12 Ain3 value n nn V Measured voltage at analogue input AIN3 Note that there is no function behind AIN3 This input can be 82 105 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M MATERIALS HANDLING INC R amp M Materials Handling Inc 4501 Gateway Boulevard Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 Param Name Value Description 1 2 Measure Measurement menu used for measurement purposes only 1 2 13 Int temp n C Internal temperature of the unit 1 2 44 input ie 10101 Indicates the status of the inputs HIN LIN FIN MFI1 amp MFI2 1 means active 0 means inactive Note that the leftmost zeros before the first appearing 1 are not displayed 1 2 15 Output i e 10100 Indicates the status of the outputs HOUT LOUT FOUT RS amp ROUT 1 means active 0 means inactive Note that the left
44. 0 of the nominal lifting capacity of the hoist It is advisable to by pass the overload protection during this calibration routine by setting the parameter 3 5 OL protect OFF The overload protection will automatically reset after 30 min or after power off If the display shows more than the lifted load continue with A If the display shows less than the lifted load continue with B 59 105 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc R amp M 4501 Gateway Boulevard meme Springfield Ohio 45502 HANDLING INC P 937 328 5100 FAX 937 325 5319 The display shows more than the lifted test load Increase more positive the value of parameter 3 2 2 Mhs1 Select parameter 1 2 1 Act Load Drive the hoist in slow speed up and check the load from the display Repeat step 1 3 until the display shows the correct load Increase more positive the value of parameter 3 2 3 Mhf1 Select parameter 1 2 1 Act Load Drive the hoist in fast soeed up and check the load from the display Repeat step 5 7 until the display shows the correct load Decrease more negative the value of parameter 3 2 4 Mis1 Select parameter 1 2 1 Act Load Drive the hoist in slow speed down and check the load from the display Repeat step 9 11 until the display shows the correct load Decrease more ne
45. 1 1 30 0 53 35 36 400 50 38 16 MI100 2 2 15 0 91 17 68 460 60 38 0 16 0 MI100 2 2 15 0 91 17 68 500 50 30 4 12 8 MI100 2 1 72 0 72 17 68 575 60 30 0 13 0 MI100 2 1 70 0 74 17 68 660 50 23 9 7 MI100 3 1 95 0 82 11 79 MF13XA 208 60 98 0 47 0 MI100 1 2 77 1 33 35 36 230 50 85 0 40 0 MI100 1 2 40 1 13 35 36 230 60 88 0 42 5 MI100 1 2 49 1 20 35 36 380 60 57 0 27 0 MI100 1 1 61 0 76 35 36 400 50 49 0 23 0 MI100 1 1 39 0 65 35 36 460 60 47 0 22 0 MI100 1 1 33 0 62 35 36 500 50 39 0 18 0 MI100 2 2 21 1 02 17 68 575 60 38 0 18 0 MI100 2 2 15 1 02 17 68 660 50 30 0 14 0 MI100 2 1 70 0 79 17 68 Two 208 60 143 0 54 0 MI500 1 0 81 0 30 176 78 MF13Z 230 50 112 0 54 0 MI500 1 0 63 0 31 176 78 230 60 129 2 45 0 MI500 1 0 73 0 25 176 78 380 60 75 1 36 3 MI100 1 2 12 1 02 35 36 400 50 57 0 30 0 MI100 1 1 61 0 85 35 36 460 60 62 0 30 0 MI100 1 1 75 0 85 35 36 500 50 52 0 22 0 MI100 1 1 47 0 62 35 36 575 60 52 0 20 0 MI100 1 1 47 0 57 35 36 660 50 43 2 39 0 MI100 1 1 22 1 10 35 36 Two 208 60 161 6 64 6 MI500 1 1 29 0 52 0 91 0 37 176 78 MF13X 230 50 132 0 56 0 MI500 1 1 06 0 45 0 75 0 32 176 78 230 60 146 0 58 0 MI500 1 1 69 0 46 0 83 0 33 176 78 380 60 92 0 38 0 MI100 1 3 68 1 52 2 60 1 07 35 36 400 50 76 0 32 0 MI100 1 3 04 1 28 2 15 0 91 35 36 460 60 76 0 32 0 MI100 1 3 04 1 28 2 15 0 91 35 36 500 50 60 8 25 6 MI100 1 2 43 1 02 172 0 72 35 36 575 60 60 0 26 0 MI100 1 2 40 1 04 1 70 0
46. 15 7 7 6 MI20 1 3 14 1 52 2 22 1 07 7 071 575 60 15 2 7 0 MI20 1 3 04 1 40 2 15 0 99 7 071 660 50 11 9 5 8 MI20 1 2 38 1 16 1 68 0 82 7 071 95 105 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc R amp M 4501 Gateway Boulevard VINTAR Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC Motor Un f In A In A Current Turn of In V In V In V In V Ik type WHz high low transformer winding the high low high low Hoist control type primary device col whit secondary whit secondary whit secondary whit secondary Parameters Peek value Peek value Effective value Effective value 4 7 12 MF13Z 208 60 71 5 27 0 MI100 1 2 02 0 76 35 36 230 50 56 0 27 0 MI100 1 1 58 0 76 35 36 230 60 64 6 22 8 MI100 1 1 82 0 64 35 36 380 60 37 5 18 2 MI100 2 2 12 1 03 17 68 400 50 31 0 15 0 MI100 2 1 75 0 85 17 68 460 60 31 0 15 0 MI100 2 1 75 0 85 17 68 500 50 26 0 11 0 MI100 2 1 47 0 62 17 68 575 60 26 0 10 0 MI100 2 1 47 0 57 17 68 660 50 21 6 19 5 MI100 3 1 83 1 66 11 79 MF13X 208 60 80 8 32 3 MI100 1 2 29 0 91 35 36 230 50 66 28 MI100 1 1 87 0 79 35 36 230 60 73 0 29 0 MI100 1 2 06 0 82 35 36 380 60 46 0 19 0 MI100
47. 19 HANDLING INC Thermistors operating curve R amp M Materials Handling Inc NTC PTC Bi metal i ae E Motor Temperature ee carry out the grounding eo NTC and PTC The temperature sensor s cable must be shielded if the cable between the unit and the temperature sensors is longer than 10m The cable shield is connected to the ground of the hoist It is recommended to use 360 degrees shield clamps to Bi metal It is recommended to use a supplementary oL10 relay between the unit and the thermistor In that case there is no need for a shielded cable and THERMISTOR ea possible disturbance is limited to the minimum Se In case third party motors are used please consult TP44 TP42 P21 _TP22 with the manufacturer of the motor for thermistor details w Motors without thermistors must be protected against overheating by other means e g a motor protection switch 24 105 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M MATERIALS HANDLING INC R amp M Materials Handling Inc 4501 Gateway Boulevard Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 5 3 1 Hoist motor overheating supervision instructions Param Name De
48. 2 32 1 22 3 536 460 60 8 0 3 8 MI20 2 3 20 1 52 2 26 1 07 3 536 500 50 6 6 3 1 MI20 2 2 64 1 24 1 87 0 88 3 536 575 60 6 4 3 MI20 2 2 56 1 20 1 81 0 85 3 536 660 50 5 2 4 MI20 3 3 00 1 44 2 12 1 02 2 357 MF10X 208 60 21 9 10 4 MI100 3 2 63 1 25 1 86 0 88 11 79 230 50 17 2 9 6 MI100 3 2 06 1 15 1 46 0 81 11 79 230 60 19 8 9 4 MI100 3 2 38 1 13 1 68 0 80 11 79 380 60 12 5 7 MI20 1 2 40 1 14 1 70 0 81 7 071 400 50 9 9 5 5 MI20 1 1 98 1 10 1 40 0 78 7 071 460 60 9 9 4 7 MI20 1 1 98 0 94 1 40 0 66 7 071 500 50 7 9 4 4 MI20 2 3 16 1 76 2 23 1 24 3 536 575 60 7 9 3 8 MI20 2 3 16 1 52 2 23 1 07 3 536 660 50 6 3 3 MI20 2 2 40 1 32 1 70 0 93 3 536 MF11XA 208 60 36 0 19 0 MI100 2 2 88 1 52 2 04 1 07 17 68 230 50 27 8 14 8 MI100 2 2 22 1 18 1 57 0 84 17 68 230 60 32 5 17 2 MI100 2 2 60 1 38 1 84 0 98 17 68 380 60 21 0 11 0 MI20 1 1 68 0 88 1 19 0 62 7 071 400 50 16 8 5 MI20 1 3 20 1 70 2 26 1 20 7 071 460 60 17 0 9 1 MI20 1 3 40 1 82 2 40 1 29 7 071 500 50 12 8 6 8 MI20 1 2 56 1 36 1 81 0 96 7 071 575 60 14 0 7 3 MI20 1 2 80 1 46 1 98 1 03 7 071 660 50 9 7 5 2 MI20 1 1 94 1 04 1 37 0 74 7 071 MF11X 208 60 42 0 21 0 MI100 2 3 36 1 68 2 38 1 18 17 68 230 50 34 1 16 5 MI100 2 2 73 1 32 1 93 0 93 17 68 230 60 38 0 17 4 MI100 2 3 04 1 39 2 15 0 98 17 68 380 60 23 0 10 5 MI100 3 2 76 1 26 1 95 0 89 11 79 400 50 19 6 9 5 MI100 3 2 35 1 14 1 66 0 81 11 79 460 60 19 0 8 7 MI100 3 2 28 1 04 1 61 0 74 11 79 500 50
49. 3 Load sum with hoist cycles the third power The parameter 2 17 load The load difference between maximum load and initial load within the hoist cycles k k Hoist cycles number SWPRT SWP value calculated with hoist running time The parameter 2 12 D_SRT3 Designed running hours power three The parameter 6 10 SWPHC SWP value calculated with hoist cycles The parameter 2 15 D_SL3 Designed constraint for hoisting cycles power three The parameter 6 12 SWP Remaining Safe Working Period of the hoist in percentage starting from 100 The parameter 1 1 1 SWP is calculated when the parameter 2 13 SRT3 and the parameter 2 17 SL3 are known Example The parameters 2 13 SRT3 is 163h the parameter 2 17 SL3 is 3780 and hoist duty class is M4 SWPRT 800 163 oo 79 6 SWPHC 3780 100 84 25 4000 SWP min SWPRT SWPHC 79 6 When SWP is known the parameter 2 13 SRT3 and the parameter 2 17 SL3 can be calculated See section Replacement instructions of this manual 6 2 4 Hoist cycles counter Total number of hoisting cycles The number increases by one when the hoist is started to down direction if a load difference was bigger than 20 of the rated load between a maximum load and a initial load within the last hoisting motion 6 2 5 Run time and start counter for trolley and bridge In addition to the hoist run time and starts counter the hoist monitoring unit can be programmed to count the
50. 4 7 Load param Load calculation parameters 6 12 D SL3 Design constraint for hoisting cycles power three 4 7 1 Load meas Selects the load calculation method 6 13 DSL8 Design constraint for hoisting cycles power eight 4 7 2 Load rate Load increase rate for controlling the hoisting in two step 6 14 MaxST MFI1 Max number of MFI1 starts control 4 7 3 RO_F Resistance of fast speed windings at temperature TO 6 15 MaxRT MFI1 Max running time for MFI1 4 7 4 RO_S Resistance of slow speed windings at temperature TO 6 16 MaxST MFI2 Max number of MFI2 starts 4 7 5 TO Resistance measuring temperature TO 6 17 MaxRT MFI2 Max running time for MFI2 4 7 6 Temp_slow Temperature measurement channel for the motor slow 6 18 Max Br Max number of braking actions speed windings 4 7 7 Temp_fast Temperature measurement channel for the motor fast 6 19 Max Control Max number of Control starts speed windings 4 7 8 C2F Coefficient 2 for fast speed 6 20 Password Set password level 1 4digits 4 7 9 C2S Coefficient 2 for slow speed 7 GO setup GO settings menu Accessible password level 7 4 7 10 C1F Coefficient 1 for fast speed 7 1 Cycles Number of hoisting cycles 4 7 11 C1S Coefficient 1 for slow speed 7 2 MFI1 RT MFI1 running time 4 7 12 ki Reduction factor for current transformer A V 7 3 MFI1 ST MFI1 starts 4 7 13 Acc t slow Acceleration time from stop to slow speed 7 4 MFI2 RT MFI2 running time 4 7 14 Acc t fast Acceleration time from s
51. 48900 7 4670 60 0 223700 7 328859 65 0 208400 6 2520 65 0 184590 6 047538 70 0 175300 5 2590 70 0 153050 5 014224 75 0 148100 4 4430 75 0 127550 4 178793 80 0 125600 3 7680 80 0 106770 3 497999 85 0 107000 3 2100 85 0 089928 2 946221 90 0 091560 2 7468 90 0 076068 2 492140 95 0 078620 2 3586 95 0 064524 2 113935 100 0 067770 2 0331 100 0 054941 1 799977 105 0 058630 1 7589 105 0 047003 1 539912 110 0 050890 1 5267 110 0 040358 1 322209 115 0 044330 1 3299 115 0 034743 1 138250 120 0 038730 1 1619 120 0 030007 0 983089 125 0 033950 1 0185 125 0 026006 0 852009 130 0 029850 0 8955 130 0 022609 0 740716 135 0 026330 0 7899 135 0 019720 0 646067 140 0 023280 0 6984 140 0 017251 0 565177 145 0 020650 0 6195 145 0 015139 0 495984 150 0 018360 0 5508 150 0 013321 0 436423 155 0 016360 0 4908 155 0 011754 0 385085 160 0 014550 0 4365 165 0 013030 0 3909 170 0 011690 0 3507 175 0 010520 0 3156 180 0 009480 0 2844 185 0 008570 0 2571 190 0 007760 0 2328 195 0 007040 0 2112 200 0 006400 0 1920 97 105 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice YOLONdS HOLOWdS OWN SAUSI OWN IDANOHd HEN SNTRVEO UN OHO SNILSIOH itt SWISY AVTdSIO HOLON SNTISTOH c 2 pm D c c OMINYYSIS HUSL INANI HOLSIHESHL 2 ig WPOATWAGHIVA G HOSN3S 3SVHd X lt az aan Lu I LIO O Z x l
52. 5 5319 A YOL V4 ANID a3033N 391A30 JOYLNOO LSIOH MAN 937 328 5100 FAX R amp M Materials Handling Inc 4501 Gateway Boulevard Springfield Ohio 45502 P MATERIALS o Z m Z Z T 15 5 Flow chart 81 105 R amp M MATERIALS HANDLING INC 16Menu structure 16 1 Monitor 1 Menu 1 R amp M Materials Handling Inc 4501 Gateway Boulevard Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 g Read only menu for condition monitoring values and measured values 1 Monitor 1 s Accessible with the customer s password Param Name Value Description 1 1 Cond mon Condition monitoring menu 1 1 1 SWP n Remaining Safe Working Period of the hoist in percentage starting from 100 When the SWP counter descends to 0 or even negative a General Overhaul must be carried out 1 1 2 Starts n Total number of starts of the hoist in either up or down direction 1 1 1 3 Run time n h Total running time of the hoist in hours 2 4 1 4 Cycles n Total number of hoisting cycles 1 The number increases by one when a load value increase more than 20 of the rated load is lifted 1 1 5 Mean load n n t Average of the handled load during the recorded cycles 1 1 6 Br SWP n Remaining Safe Working Period of the brake in percentage The SWP for the brake is calculated according to the number
53. 5502 P 937 328 5100 FAX 937 325 5319 HANDLING INC 7 9 2 Levelling Function Connections MFI1 For the levelling function MFI1 or MFI2 can be used For the desired function the parameter setting must be 4 1 1 MFI1 oper or 4 2 1 MFI2 oper Level Single hoist selection The switch must be closed if only one of the hoist is run without the levelling function If the switch is open as in the drawing the hoist request is forwarded directly to the MFI1 and through the levelling limit switch to HIN Limit switch When the hoist reaches the levelling limit the switch cuts off the HIN line resulting the hoist to stop in the normal way MFI1 however still has the hoist up request and it forwards this information to all other units through the CAN bus so that they can continue hoisting until they also reach their levelling limit or the hoist up request goes off ji ii Hoist A selection Hoist up request Levelling limit switch Hoist B selection K14 K411 T T Levelling function selection SIVA optional 41 105 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc R amp M 4501 Gateway Boulevard me Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC 8 Multi hoisting 8 1 General Up to five units can be connected together with a CAN bus The communication is tailored
54. 74 35 36 660 50 46 0 19 4 MI100 1 1 84 0 78 1 30 0 55 35 36 96 105 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc R amp M 4501 Gateway Boulevard MINANE Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC Appendix 4 Motor temperature NTC charts A NTC B NTC Bccomponents NTC 23226338 303 Siemens NTC B57227 K 227 Ros 30 k Ros 32 762 k T C Rr Ros R kO T C Rr Ros R kQ 40 33 060000 991 8000 40 41 938000 1373 972756 35 23 900000 717 0000 35 29 947000 981 123614 30 17 470000 524 1000 30 21 567000 706 578054 25 12 900000 387 0000 25 15 641000 512 430442 20 9 621000 288 6300 20 11 466000 375 649092 15 7 242000 217 2600 15 8 451000 276 871662 10 5 501000 165 0300 10 6 292700 206 161437 5 4 214000 126 4200 5 4 707700 154 233667 0 3 255000 97 6500 0 3 556300 116 511501 5 2 534000 76 0200 5 2 711900 88 8472668 10 1 987000 59 6100 10 2 086000 68 341532 15 1 570000 47 1000 15 1 620400 53 087545 20 1 249000 37 4700 20 1 268300 41 552045 25 1 000000 30 0000 25 1 000000 32 762000 30 0 805900 24 1770 30 0 794200 26 019580 35 0 653400 19 6020 35 0 632680 20 727862 40 0 532900 15 9870 40 0 507400 16 623439 45 0 437100 13 1130 45 0 410260 13 440938 50 0 360400 10 8120 50 0 333630 10 930386 55 0 298800 8 9640 55 0 272430 8 925352 60 0 2
55. 9 is connected together Voltage output V1 12 VDC replaces the 10 VDC output of the Control Pro 25 Zero volt G1 of the power supply and Control Pro 30 is connected together 101 105 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc REY ME 4501 Gateway Boulevard Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 MATERIALS HANDLING INC 0100 0100 ATIO js 7 aj L oac 5 nc la gt ACN e ANALOG INPUT 3 o _L12we ANALOG INPUT v bs 2 i lls AAI 24 VDC oL AN g ve OVC ANT AN2 ANS IB ODC A A 2 owe s p 7 3 ajo aD L o_a Tw Get a s n titr te n F z i eac eR K2 Ki AAS V LOAD INDICATOR UNIT ESD143 z a 4 10 w AAS wv N 0v N SH Si aso eas YE N ON lour Bu RD ws Te 5 ca GN ABI LOAD SENSOR Settings of the external power supply Voltage output V1 can be adjusted with a trimmer In our applications voltage must be set to 11 00 11 50 VDC V1 voltage adjust trimmer set to 11 00 11 50 VDC Power supply with cover plate Power supply without cover plate 102 105 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Hand
56. ALS HANDLING INC Appendix 4 Appendix 5 Appendix 6 4 105 R amp M Materials Handling Inc 4501 Gateway Boulevard Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 Motor temperature NTC charts 97 Appendix 7 Replacing the condition Example connections 98 monitoring WINE cc scicecienccndcccicecicissesnsctetecnicnece 103 External power supply for ESD siied swine ndadhevedanasinaasisnaneiatsntseanisnines 101 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc R amp M 4501 Gateway Boulevard MINANE Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC 1 General 1 1 Description The hoist monitoring unit is an electronic device designed to supervise and protect the hoist The hoist monitoring unit measures the use of the hoists and prevents hoisting or lowering in case a situation is detected which can cause a potential dangerous situation The hoist monitoring unit records the use of the hoist and calculates the remaining Safe Working Period SWP according to the FEM and ISO standards The hoist monitoring unit is designed to fit a wide variety of hoists and motor drives It can be used with variable speed control drives as well as two speed drives The hoist monitoring unit contains tailored hardware and software especially designed for crane use With t
57. EY ME 4501 Gateway Boulevard Tene Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC 8 3 CAN bus topology Generally it is recommended that a CAN network should be as close as possible to a single line structure Thus the bus cable should be one long line into which the stations are connected with short drop cables Resistors must terminate both ends of the bus line Also other topology options are possible A star topology with three branches is suitable for a crane with three separate trolleys and hoists The end of each branch must be terminated with a resistor 8 3 1 Termination resistors The unit includes the termination resistors So called split termination concept with two resistors and one capacitor is employed This means that one termination resistor is slip into two resistors of equal value 100 ohm The centre tap is grounded via a capacitor 100nF The termination resistors are connected through the jumpers X5 Ll lMlMIMIMIiIMIiIiIiMIiMIMiIMIM r N3 CAN Transceive R110 1000hm C115 100nF As factory setting the termination resistors are connected This means that two termination jumpers of the pin header X5 located on the CPU board of the unit are connected to the upper position according to the figure below If the termination is not desired the jumpers are set to the lower position This setting does not connect anything The lower pins are only to
58. English 16 9 2008 SERVICE MANUAL FOR HOIST CONTROL DEVICE R amp M MATERIALS HANDLING INC R amp M Materials Handling Inc R amp M 4501 Gateway Boulevard me Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC w Read the instructions supplied with the product before installation and commissioning e Table of content 1 CROTON AL siiscacsenssciesisnessncacncnencsewstenssewcnsncsenssvncien 5 Vel Descriptions 5 1 2 Directives Standards and Patents 5 1 2 1 DIFCCIVES s ccicfeccccscken cts nanata tatanan eanna aranan aa 5 1 2 2 Standard s sssssssssnssnnsninranapniananananniniananaiata iiaa 5 1 2 3 Patent Pending eeeeeeeeeeseeeerreesesrrrenn 6 1 2 4 Certificate of compliance cccceeeeee 6 2 Technical characteristics 000000 7 2 1 Description of terminals eeeee 8 2 2 Product description sticker 10 3 Display UNM tiiiccpteecieeecteen eas 11 Scab JPUSH DUMOMS osica 11 32 EEDS eer eee Pee eee eee ee A err eee 11 3 3 Display information ccceeeeeeeeee 12 3 3 1 Tare load actual load mode 0006 12 3 3 2 Menu Mode tecchencont woud 13 3 3 3 Status Mode essnee nnn 13 3 3 4 Sum load solo hoist load mode 0 13 34t MEn S ssrt reiini ets 14 3 4 1 Moving in Menus ssseeeeeeeeeeeeerne 14 B42 Password wiceccactecsnceatacedacsnscedecansdaredaaadvaadadaas 14 3 4 3 Hoist
59. No 4 11 4 n t Rated load of the crane Overload detection has similar filtering as in the overload B nom load detection of an individual unit This parameter scales the load information transferred in the CAN bus Each unit connected into the CAN bus must have the same value 8 2 2 Cabling CAN bus is connected by three wires between the terminals as follows 36 CAN H Differential high signal et er 37 CAN L Differential low signal eT 38 CAN GD Zero level for high and low signals jy The connection is made one to one i e terminals 36 CAN H of each unit are directly connected 37 CAN L and 38 CAN GD similarly It is highly recommended to use shielded cable for the CAN bus The cable shield is connected to the ground of the hoist It is recommended to use 360 degrees shield clamps to carry out the grounding Especially the shield should NOT be connected to the terminal 20 PE How to connect the or 38 CAN GD shielded cables If the CAN bus is very short and the hoist monitoring devices are located close to each other also twisted cables can be used It is recommended to separate the bus cable from power cables There should be enough free space or other type of isolation between the bus cable and power cables Theoretically the bus line can be over 1000 meters 3000 ft with the speed of 50 kbit s In practice however external disturbances reflection waves bus topology
60. Parameters and Values For a safe operation it is necessary to set the parameters in groups 3 4 6 and 7 To change the GO setup General Overhaul values group 7 has to be accessed Access is possible with password Level 7 If there is a record or the hoist relevant safety data from Menu 1 and Menu2 it is possible to copy this information to parameter group 7 GO setup In that way the SWP value is also reliable with a new Monitoring unit Check table on the next page The brake wear in Value 1 1 6 Br wear is calculated from the given brake design values in 6 19 and the brake counts in parameter 7 24 Each E stop is counted as 50 normal stops WY Monitoring Unit can t save parameters and values in the keypad like inverter drives Copying following values from Menu 1 and 2 to Menu 7 when replacing an unit makes it possible to keep the SWP values up to date 78 105 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M MATERIALS HANDLING INC R amp M Materials Handling Inc 4501 Gateway Boulevard Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 Read old values Description Last recording Estimated increase Copy value to Set Value from old unit Value since last record 1 1 4 Cycles Counter how often a load bigger than 20 of 7 1 Cycles hoist n
61. QUA er In case wrong direction of hoisting occurs reversed phase condition note that the two input power wires are reversed at terminal X2A lt E wi x31414 At Ae A3 SAPE mati Fo f3 TPE 3A 22 3 E 2 A3 APE X31A2 2 43 Fre V2 R6 AWGEAO PHASE ORDER CHANGE MUST BE DONE BY REVERSING THESE WIRES IN THIS LOCATION 5 4 1 Supply phase supervision instructions Supply phase supervision parameters Param Value Description Note 4 10 Accessible with password 4 8124 Single sup 4 10 3 Yes Switches the supply phase supervision on When the hoist monitoring unit is connected in insulated or high impedance grounded network or when the supply mains are not connected i e inverter use the setting must be No 26 105 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc R amp M 4501 Gateway Boulevard meme Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC 5 5 RUN and fault supervision The hoisting and lowering request from the control station will come as an input to the hoist monitoring unit Before the hoist can start the requested motion the hoist monitoring unit checks if it is safe to proceed If no limitations are detected the hoist monitoring unit will activate the requested output and movement will start The unit monitors a feedback signal
62. SENSOR A Shield is grounded with 360 degree connector B Full bridge amplifier ESD142 C Shield end connection in Strain gauge load sensor cable in floating 65 105 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc R amp M 4501 Gateway Boulevard MINANE Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC 13Faults and warnings 13 1 Faults Fault means that the hoist control unit has detected a situation that prevents the hoist from running The hoist control unit stops the motion indicates the fault text on the display and illuminates the red LED continuously on both the unit and display Depending on the detected situation and parameter settings only hoisting or only lowering is allowed or running the hoist is totally prevented by the hoist monitoring unit The fault messages shown on the display are given in the table below The messages appear when the corresponding fault is detected The message disappears automatically when the corresponding fault situation is cleared Also it is possible to clear the message and return to the original display by pushing the ENT button However as long as the fault is active the red LEDs are illuminated and the fault message can be read from the status mode 13 1 1 Fault codes and description Fau
63. ack rope protection prevents lowering the hook when the measured load descends under a pre set load limit When slack rope occurs during lowering the motion will be stopped according to the normal stopping sequence Movement in upward directions is allowed and will reset the slack rope protection The slack rope protection can by by passed by programming either one of the multi functional inputs MFI1 or MFI2 e SW 2 100 or later When slack rope function is activated the unit shows Fault Srope on the display If unit s software is SW 2 004 or earlier the unit doesn t show anything when slack rope is activated and lowering is prevented er The slack rope by pass function requires an additional selector switch or by pass button e g on the pendant station 7 2 1 Slack rope protection instructions Slack rope protection parameters Parameter Value Description Note 4 1 Accessible with password 4 8124 MFI1 4 1 1 Srope Slack rope by pass It is recommended to connect a switch to the multi functional input in MFI1 oper order to temporarily by pass the slack rope function in order to be able to perform repairing actions replacing hoisting ropes etc and to swap load handling device when applicable If the by pass function is not required set this parameter to NU oe If the MFI1 input is already in use for another function use the MFI2 for the by pass switch and set parameter 4 2 1 to Srope
64. ad 5 Service Start menu Accessible password level 5 7 19 SL3 Load sum with hoist cycles the third power 5 1 S limits The limit values to indicate the need for service 7 20 SL8 Load sum with hoist cycles the eight power 5 1 1 S Runtime Run time service limit 7 21 Power on The total power on time for hoist control unit 5 1 2 S starts Service limit for the number of starts 7 22 Temp Index The power on time weighted with the hoist control unit temperature 5 1 3 S SWP Service limit for SWP 7 23 Max load The maximum value of the measured load 5 1 4 S Br SWP Service limit for the hoist brake service life 7 24 Br Count The brake wear counter 5 2 Fault log The logger for the latest fault situations the number n indicates the number of faults in the logger 5 2 1 F_ XX The latest fault 5 2 2 F_ XXX The second latest fault 5 2 n F_ XXX The n latest fault highest number is 30 19 105 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc R amp M 4501 Gateway Boulevard MINANE Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC 4 1 Passwords The table below indicates the access to the menus with different password levels The display asks for the password when the ENT button is pushed in the main load display mode If the given password does not match to any of the levels th
65. ad measure type by Sens see the parameter 4 7 1 e Check that the actual load value parameter 1 2 1 shows 0 00t 5 from nominal load when lifted only empty hook e Check that the actual load value parameter 1 2 1 shows x xxt 5 from nominal load when lifted test load When either of the measurements done under step 1 or 2 does not result in the required outcome the load calibration procedure has to be carried out Refer to chapters Overload protection Motor torque or Overload protection for load sensor of this manual for instructions When local regulations require a dynamic true overload test follow the procedure as described by the local legislation WY When local regulations require a static overload test 110 140 of rated load of the hoist temporarily by pass the overload function with parameter 3 5 OFF Be aware of mechanical restrictions and additional mechanical overload switches When rated load is over 110 then hoisting is only possible with slow speed Check the function of the installed features 47 105 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc R amp M 4501 Gateway Boulevard me Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC 9 3 Functional checks 9 3 1 Multi hoisting e Set parameter 4 11 1 to 1 and carry out the start up procedu
66. al run time in slow speed 4 1 4 MFI1 CintL Bridge intermediate load limit value 2 3 RT fast Total run time in fast speed 4 2 MFI2 Multi Functional Input 2 parameters 2 4 No OT Total number of hoist motor overtemperature incidents 4 2 1 MFI2 oper Selects the function of MFI2 2 5 No OL Total number of overload incidents 4 2 2 MFI2 IntL The second intermediate load limit value 2 6 E stops Total number of emergency stops incidents 4 2 3 1 2 IntL The third intermediate load limit value 2 7 ST up Total number of starts in up direction 4 2 4 MFl2 2OLL The second load limit 2 8 ST down Total number of starts in down direction 4 2 5 MFI2 CintL The second bridge intermediate load limit value 2 9 ST fast Total number of starts to fast speed counts in two 4 2 6 1 2 CintL The third bridge intermediate load limit value speed control only 2 10 Max ED Maximum value of the calculated ED percentage 18 105 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc R amp M 4501 Gateway Boulevard meme Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC 4 3 ROUT Relay output parameters 5 3 Reset log Resets the fault log by pushing the ENT button
67. ally means tare command is not transferred to other units via CAN bus 12 105 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc R amp M 4501 Gateway Boulevard mem Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC 3 3 2 Menu Mode Pushing the ENT button in the tare or actual load display mode shifts the display into the menu mode A password is required in order to proceed Pushing the ESC button returns to the actual load display Power O Tared load A Actual load 2 7t fe 0 1 0000 Password 3 3 3 Status mode Status mode indicates all active faults warnings and service warnings when applicable The display shifts automatically into the status mode when a fault or warning occurs during power ON If more than one fault or warning are active all of them can be seen with arrow keys active faults first then warnings and service warnings The active fault message remains visible until the fault disappears or the message is removed by pushing the ENT button Power ON Status mode Tared load Actual load Fault ok Loaf 27t o fe 0 1 0000 Password Display Description Fault Peer Fault name Status display indicating active faults status Warning i aes F Warning name Status display indicating active warnings status Service Status display indica
68. alue by pushing the ENT button make sure the test load is attached to the 3 1 3 Up slow Drive the hoist upward in slow speed as long as the message appears 3 1 4 Up fast Drive the hoist upward in fast speed as long as the message appears 3 1 5 Down slow Drive the hoist downward in slow speed as long as the message appears 3 1 6 Down fast Drive the hoist downward in fast speed as long as the message appears 3 1 7 Set lt 30 nn n t Set the lower test load value in tons lt 30 of hoist rated load typically empty hook 0 00t 3 1 8 nn n tOK 2 Confirm the set second test load value by pushing the ENT button make sure the hook is empty when 0 00t is given in parameter 3 1 7 or that the set second test load is attached to the hook 3 1 9 Up slow Drive the hoist upward in slow speed as long as the message appears 3 1 10 Up fast Drive the hoist upward in fast speed as long as the message appears 3 1 11 Down slow Drive the hoist downward in slow speed as long as the message appears 3 1 12 Down fast Drive the hoist downward in fast speed as long as the message appears Param Name Value Description 3 2 MC values Load calibration values for the motor torque method 3 2 1 Load 1 nn n t The higher test load value set with parameter 3 1 1 3 2 2 Mhs1 nn nn Motor torque for hoisting in slow speed with load set by parameter 3 1 1 3 2 3 Mhf1 nn nn Motor torque for hoisting in fast speed with load set by para
69. ame Go to menu 3 3 1 Hang a higher test load of 80 1380 of the rated load of the hoist in the hook and make sure the load hangs freely and steady Enter the value of the test load in tons Confirm the correct value with the ENT button and wait until the next text appears Hang a lower test load of less than 30 of the rated load of the hoist in the hook Typically this is an empty hook Make sure the load hangs freely and steady Enter the value of the test load in tons empty hook O 00t Confirm the correct value with the ENT button The display shifts automatically back to Cal Sens when the values are accepted Run the calibration sequence according to the display instruction w When the calibration is done write down the load setup values of parameters 3 4 1 3 4 2 3 4 3 and 3 4 4 in the commissioning table 53 105 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc R amp M 4501 Gateway Boulevard me Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC 10 4 Manual load calibration Before starting the calibration make sure you have a known test load available of at least 80 and maximum 130 of the nominal lifting capacity of the hoist It is advisable to by pass the overload protection during this calibration routine by setting the parameter 3 5 OL
70. anges of the parameters in the group 4 11 Comm hoist take effect only after power off power on reset After switching the power on the bus configuration is set and it must be fixed all the time This means that it is not allowed to add any new stations or leave away any of the present stations Parameter Value Description Note 6 Design values menu Accessible with password level 6 Design 6 1 A E The identifying character for the hoist The address used in the CAN bus communication each unit must Hoist name monitoring unit have a unique address a good practice is to name the units in the alphabetic order 42 105 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc R amp M 4501 Gateway Boulevard mem Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC Parameter Value Description Note 4 11 The settings for common hoisting Accessible with password level 4 Comm hoist 4 11 1 2 5 The amount of units connected into the CAN Each unit connected into the CAN bus must have the same Hoist cnt bus number 4 11 2 Yes Activates the multi hoist supervision If multi hoist supervision is not required set this parameter to Run sup No 4 11 3 Yes Activates the bridge overload supervision If bridge overload supervision is not required set this parameter BOL to
71. ax designed brake operations 7 24 Brake operation 1 1 6 Br SWP Counter of Stops and E Stops counter er to calculate to menu 7 If only Monitor 1 Condition monitoring menu s values are read some parameter values are possible Description Read old values Set value Desing from old unit values from parameter 7 1 Cycles Counter how often a load bigger then 30 of 1 1 4 Cycles Set the parameter s 1 1 4 Cycles value hoist nominal load was lifted 7 2 MFI1 RT Run time in hours from Multi Function Input 1 1 1 7 MFI1 RT Set the parameter s 1 1 7 MFI1 RT value 7 3 MFI1 ST Start counter from Multi Function Input 1 1 1 8 MFI1 ST Set the parameter s 1 1 8 MFI1 ST value 7 4 MFI2 RT Run time in hours from Multi Function Input 2 1 1 9 MFI2 RT Set the parameter s 1 1 9 MFI2 RT value 7 5 MFI2 ST Start counter from Multi Function Input 2 1 1 10 MFI2 ST _ Set the parameter s 1 1 10 MFI2 ST value 7 6 RT slow Hoist run time in hours with slow speed 1 1 3 Run time RT _ slow Run _ time 0 25 7 7 RT fast Hoist run time in hours with slow speed 1 1 3 Run time RT fast Run _ time 0 75 7 8 No OT Counter for hoisting motor over temperatures Set to 0 7 9 No OL Counter value for overload situations Set to 0 7 10 E stops Counter for emergency stops Set to 0 7 11 ST up Counter value for UP requests 1 1 2 Starts ST _ up Starts 0 5 7 12 ST down Counter value for DOWN requests 1 1 2
72. ay is built in to assure trouble free lifting of a rated load The overload protection is reset when the measured load decreases to 80 of the rated load E The overload protection reacts faster than the display updates the measured values Therefore it may happen that the movement is stopped although the display indicates a load less than 110 of the rated load Overload level Filtering time Run down time 140 60 ms 100 ms 125 200 ms 250 ms 110 1000 ms 1050 ms The motor torque calculation system uses the motor voltage current and temperature to calculate the motor torque and converts this into load information This system cannot be used in combination with frequency converters and can only measure the load when the motor is running In addition to the overload protection the hoist monitoring unit also supervises the brake When the calculated load value descends under 50 of the rated load during lowering it indicates that the brake did not open Lowering the hook is prevented but lifting is still allowed Motors driven by a frequency converter are always equipped with a load sensor for load measurement Systems using a strain gauge type of sensor are also equipped with a load sensor amplifier to amplify the signal coming from the sensor In case a Hall type of sensor is used the load sensor amplifier is not needed Param Name 4 7 Load param Value Description Load calculation parameters
73. c REY ME 4501 Gateway Boulevard Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 MATERIALS HANDLING INC 5 6 Starting and stopping through slow speed 2 speed application only Starting the motor directly in high speed will cause a high starting current that heats up the motor quite rapidly To prevent the motor from overheating the hoist monitoring unit will always start the motion in slow speed After a short period of time the hoist monitoring unit allows driving in fast speed when requested Stopping the motion directly from high speed will cause excessive brake wear To protect the brake lining material the hoist monitoring unit will initiate slow speed for a brief moment before the mechanical brake is closed eo This function can only be activated in two speed systems A Speed B Position of pushbutton 0 1 2 5 6 1 Starting and stopping through slow speed instructions Starting and stopping through slow speed parameters Param Value Description Note 4 7Load param Load calculation menu Accessible with password 4 8124 4 7 13 0 20s Acceleration time from stop to slow speed 0 00s 1 00s See description below 4 7 14 0 30s Acceleration time from slow speed to fast speed 0 00s 1 00s See description below The parameters 4 7 13 and 4 7 14 have the following functions e During acceleration from zero to slow speed and deceleration from slow speed to zero the un
74. ccount when new values are calculated The condition monitoring items can only be read after a correct password has been given The manufacturer will provide a personal password with each delivery that has been acquired with this option Read only menu for condition monitoring values and measured values 1 Monitor 1 H 2 Accessible with the customer s password Param Name Value Description 1 1 Cond mon Condition monitoring menu 1 1 1 SWP n o Remaining Safe Working Period of the hoist in percentage starting from 100 When the SWP i 7 counter descends to 0 or even negative a General Overhaul must be carried out 1 1 2 Starts n Total number of starts of the hoist in either up or down direction 1 1 1 3 Run time n h Total running time of the hoist in hours 2 1 1 4 Cycles n Total number of hoisting cycles 1 The number increases by one when a load value increase y more than 20 of the rated load is lifted 1 1 5 Mean load n n t Average of the handled load during the recorded cycles 1 1 6 Br SWP n o Remaining Safe Working Period of the brake in percentage The SWP for the brake is calculated 7 according to the number of Starts and E stops also stops at limit switch 6 2 Primary monitoring items The primary monitoring items are according to the ISO and FEM regulation Depending on the hoist duty class the hoist is given an initial Safe Work
75. ce R amp M Materials Handling Inc R amp M 4501 Gateway Boulevard me Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC 5 7 Sudden load increase supervision In case the hoist monitoring unit measures a sudden load increase when driving upwards in high speed the unit will control the hoist to low speed A sudden load increase is considered when the load exceeds 30 of the rated load of the hoist within 200ms High speed hoisting is allowed again when the load increase in the last 200ms is less than the preset value determined by parameter 4 7 2 The function is completely reset when the measured load is less than 10 of the rated load of the hoist The function has no effect when the load is bigger than 30 of the rated load of the hoist Sudden load increase may occur e g due to jerky movements or starts in high speed L Load T Time 1 First speed 2 Second speed 3 Load increase stops er This function can only be activated in two speed application and hoist has no effect when hoisting in low speed Sudden load increase supervision is only activate with loads below 30 of rated load and is activated only once 5 7 1 Sudden load increase supervision instructions Sudden load increase supervision parameters Param Value Description Note 4 7 Load calculation menu Accessible with password 4 8124 Load param 4 7 2 10 Load increase rate for controlling the hoisting in two step con
76. ce of fast speed windings at temperature TO 4 7 4 RO_S n nnn Resistance of slow speed windings at temperature TO 4 7 5 TO nn C Resistance measuring temperature TO Temperature measurement channel for the motor slow speed windings used in motor torque calculation 4 7 6 Temp_slow T4 Ti Temperature measurement channel T1 terminals X2 21 22 T2 Temperature measurement channelT2 terminals X2 23 24 NU Temperature measurement not used 86 105 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M MATERIALS R amp M Materials Handling Inc 4501 Gateway Boulevard Springfield Ohio 45502 ANDING P 937 328 5100 nnn FAX 937 325 5319 INC Param Name Value Description 4 7 Load param Load calculation parameters Temperature measurement channel for the motor fast speed windings used in motor torque calculation T1 Temperature measurement channel T1 terminals X2 21 22 tzr Temp fast Je T2 Temperature measurement channelT2 terminals X2 23 24 NU Temperature measurement not used 4 7 8 C2F nnnn Coefficient 2 for fast speed 4 7 9 C2S nnnn Coefficient 2 for slow speed 4 7 10 C1F nnnn Coefficient 1 for fast speed 4 7 11 C1S nnnn Coefficient 1 for slow speed 4 7 12 ki nnnn Reduction factor for curre
77. cians with a proper know how about Monitoring Unit are allowed to make a replacement 15 1 General The Hoist Monitoring Unit is a multifunctional device Different hoist types applications and functions can be assigned by different parameter settings Monitoring Unit is capable to gather many safety relevant data from the hoisting machinery Based on the assigned design values Monitoring Unit is calculating the remaining Safe Working Period SWP according FEM 9 755 If a Monitoring Unit has to be replaced with a new unit it is absolute necessary to put the correct parameters and latest data to the new unit 15 2 Ordering a new Monitoring unit Factories have backups of the parameter files how Monitoring Unit left production To order a new Monitoring Unit the factory needs following information e Order number e g 276541 or work number e g CA0815 e Hoist number e g A B C e Unit control voltage 48V or 115 V e if possible Serial No e g H047110r T01234 If old parameters are send to the factory factory can make a complete new pre programming of the new unit If factory doesn t get a correct parameter file it will download the application parameter groups 4 5 and 6 to the new device Parameters from group 3 and 7 must be set at the field 15 3 Replacing The flow diagram in chapter Flow Chart shows how to make a Monitoring Unit replacement See also Appendix 7 Replacing the condition monitoring unit 15 4
78. d 7 GO setup GO settings menu Accessible with password level 7 Param Name Value Description 7 1 Cycles nnnnn Number of hoisting cycles 7 2 MFI1 RT nnnn h MFI1 running time 7 3 MFI1 ST nnnnn MFI1 starts 7 4 MFI2 RT nnnn h MFI2 running time 7 5 MFI2 ST nnnnn MFI2 starts 7 6 RT slow nnnn h Run time in slow speed 7 7 RT fast nnnn h Run time in fast speed 7 8 No OT nnnnn Number of hoist motor overtemperature incidents Reset when the hoisting motor has been replaced 7 9 No OL nnnnn Number of hoist overload incidents 7 10 E stops nnnnn Number of emergency stops 7 11 ST up nnnnn Number of starts in up direction 7 12 ST down nnnnn Number of starts in down direction 7 13 ST fast nnnnn Number of starts to fast speed two step control only 7 14 Max ED nn Maximum ED value 7 15 Over ED nnnnn Number of cases where ED value has exceeded the rated ED value 7 16 SRT3 nnnnn Load sum with hoist running time third power 7 17 SRT8 nnannn Load sum with hoist running time eight power 7 18 SL1 nnnnn Load sum with hoist cycles the first power mean load 7 19 SL3 nnnnn Load sum with hoist cycles the third power 7 20 SL8 nnannn Load sum with hoist cycles the eight power 7 21 Power on nnnn h The total power on time for hoist c
79. d adjustment 12 2 3 Zero load adjustment Adjustment is done with trimmer ZERO e Verify that there is no load in the hook e Check the LED 0 e If the LED 0 is ON turn the trimmer counter clockwise until the LED just goes off e If the LED 0 is OFF turn the trimmer clockwise until the LED lights up then counter clockwise until the LED just goes off e The output voltage measured between terminal 1 and 3 should be about 4 VDC 0 5 VDC 12 2 4 Adjustment with higher load Adjustment is done with trimmer GAIN e Lift the higher load and wait until the load hangs steady and does not swing e Check the LED 100 e If the LED 100 is ON turn the trimmer clockwise until the LED just goes off e If the LED is OFF turn the trimmer counter clockwise until the LED lights up then clockwise until the LED just goes off The output voltage measured between terminal 1 and 3 should be about 6 VDC 0 5 VDC e Lower the load and verify that the 0 LED remains OFF e Lift the load again and verify that the 100 LED remains OFF 64 105 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc R amp M 4501 Gateway Boulevard MINTIN Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC 12 2 5 Connections Long cables ANALOG INPUT 10VDC AIN1 AIN2 AIN3 IB OVDC LOAD
80. d meas Motor Check that the hoist brake opens properly Check the brake connections Check parameters 1 2 2 and 1 2 3 If the temperature sensors are not connected the values for parameters 1 2 2 Temp 1 and or 1 2 3 Temp 2 is lt 20 C lt 0 F Check that temperature sensor 1 slow speed is connected to terminals 21 22 and sensor 2 fast speed is connected to terminal 23 24 Drive the hoist in slow speed and check that reading of parameter 1 2 2 Temp 1 increase Drive the hoist in fast speed and check that reading of parameter 1 2 3 Temp 2 increase Check the parameters 3 2 2 Mhs1 and 3 2 7 Mhs2 If the values are equal to each other the calibration is done with only one load Confirm by checking the following parameters 3 2 343 2 8 3 2 443 2 9 3 2 543 2 10 Perform the calibration procedure as described in this manual If the parameters 3 2 7 3 2 10 values have the negative check the current transformers and their connections and or the voltage measurement connections Pay special attention to the correct phase order If supply voltage frequency is 60Hz check that parameter 1 2 16 is set to 60 Hz The hoist monitoring unit must identify the supply voltage frequency 14 1 7 Fault Br wear F_Brw Hoist brake is worn out only when the brake wear sensor is installed Check the brake wear sensor e If the sensor is connected to the terminals 21 22 check that 4 4 1 T1
81. d the design value Br SWP The calculated value for the brake SWP is less than zero E stops The number of interrupted hoists has exceeded the design limit Control The number of actual control actions has exceeded the design limit ST MFI1 1 The starts counter for MFI1 has exceeded the given maximum value RT MFI1 1 The run time counter for MFI1 has exceeded the given maximum value ST MFI2 1 The starts counter for MFI2 has exceeded the given maximum value RT MFI2 1 The run time counter for MFI2 has exceeded the given maximum value er If any warning is active the hoist will still run normal but safe using is not guaranteed er 1 When the programmable inputs MFI1 and MFI2 are used as start and run time counters the corresponding operation must be selected with the parameters Otherwise the starts and the run time values are not counted and the warnings related to MFI1 and MFI2 do not activate eo When warning has activated check actions from the Hoists GO manual or ask from crane factory 13 2 2 Service warnings Service warning state is activated when at least one of the monitored items has exceeded the limit set by parameter group 5 Service warning status is indicated with the corresponding text on the display The service warning text appears on the display directly when the service warning state becomes active and each time after switching the power on to the hoist control unit until the warning is cleared Moving to the
82. e cable of a half bridge sensor there is three wires and a in the cable of a full bridge sensor is four wires Terminal Signal Device 1 S Sensor 2 IN Sensor Free 3 IN Sensor 4 S Sensor 5 10 VDC Terminal 25 6 SIGN Terminal 26 7 0 VDC Terminal 30 In the half bridge sensor 61 105 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice HANDLING R amp M Materials Handling Inc R amp M 4501 Gateway Boulevard mee Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 INC LOAD SENSOR A Shield is grounded with 360 degree connector B Amplifier KAE400 12 1 4 Adjustment Tools needed for adjustment A small screwdriver for trimmers Test load Adjustment can be done with a known load in the range of 80 130 of the rated lifting capacity Following procedure can be used to perform the setup of the amplifier Connect the sensor and monitoring unit In a case of half bridge sensor the signal is connected to IN terminal Connect the cable shields outside of the amplifier to 360 terminals Select the sensor type full bridge 1 1 or half bridge 1 2 by the dipswitch Set the gain to 400 by the dipswitch Switch the power on If amplifier and monitoring unit are near each other go to the monitoring unit parameter 1 2 10 Ain 1 The parameter 1 2 10 shows amplifiers output signal level If the monit
83. e display returns to the main load display mode If the given password matches to one of the levels the user has access to the corresponding menus according to the table below Main menus Level 1 Level 2 Level 3 Level 4 Level 5 Level 6 Level 7 1 Monitor 1 X X X X X X 2 Monitor 2 X X X X X 3 Load Setup X X X X X 4 Start up X X X X 5 Service X X X 6 Design X X 7 GO setup X Passwords for different levels Level Password Note Level 1 Parameter Given with the parameter 6 20 Password Level 2 0732 Fixed value can only calibrate the load measurement Level 3 5201 Fixed value used to read the monitoring values Level 4 8124 Fixed value all menus up to input output settings and calibration Level 5 5029 Fixed value all menus up to service menu Level 6 9822 Fixed value all menus up to design limit values Level 7 2180 Fixed value access to all parameters 20 105 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc R amp M 4501 Gateway Boulevard me Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC 5 Basic Functions 5 1 General The basic functions assure the safe functioning of the hoist The hoist monitoring unit constantly performs a number of checks to determine if all conditions are safe in order to proceed the motion
84. e goes one time through the current transformers 1 ROUND Current transformer MI100 has a sticker on the side that phase line is put trough the current transformers On the sticker is a arrow and text IN 93 105 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc R amp M 4501 Gateway Boulevard VINTRAR Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC Phase line goes two times through the current transformer 2 ROUNDS Phase line goes three times through the current transformers 3 ROUNDS The current transformer s grey wire is connected to the terminal 29 The terminal 29 is neutral level for current it transformers The current transformer s neutral level point is 5 VDC so the unit can measure positive and negative values from current Maximum peak value is 3 5V and maximum effective value L222 J a is 2 5 VAC It is possible that start current gives bigger LHL AEA A t t ta output value from current transformers than what are 4 777 CIA AAA A maximum values therefore supervisions are by passed Wh time of start TET nla Start time parameters are 4 7 13 Start time to slow speed PI RA DA GARAR ARA and 4 7 14 Start time to fast speed as S o ey 94 105 R amp M Materials Handling Inc reserves
85. e information without notice LSS1 IWNOILONN Y SVN OHZ OL ZZ 2 ANY LZ SYSLAW Vad LAS t t t TIIN 09 Z dNOX9 NOS Sv NNA 3OINAC TOMLNOO LSIOH MIN 391A30 TOMLNOD LSIOH 391430 TOYLNO9 LSIOH OSH IIAIAN SI dMS dl WNOILIGGY SHL JLYNILSE IHL OL ATIYNNYN SINIYA SSSHL AdOO MAN SHL OL Nid Yala M N JHL OL S14 SIHL AYOT SSMIVA Z dnOwS SIVILSS ANY 319v NI GaaiNoSsa ZL GNV9 Sb dnOwO YILINVAYd G0 IHL SHVMLdOS JOINS TOULNOO LSIOH 3014438 LINSNOO SV SAMTWA SSSHL AdO WOY SAN TWA NMOG ALIAM Od JHL HLIM AdOO WOus S14 LN3034 GVO INMOG A A A A TEIN ZONYL TIVIN lt 4NOYS Y LINYYYd WO4 gt SaH00a Hadvd NL lt EREVAN angissod x Sy Pa ex oe Ss a a ma Ra a a aga E dNOUO NALAINVed lt lt SUaISINVVd Peano en aae bm lt SOINSC TOH LNO ISIOH MAN OL gt IOA TOULNOD ISIOH gt a TIEN lt lt oud SuaLSWWuVd VALOV gt S SANWA BTV AdO fe N SNIGVOINMOG we 7 i Pa sid slash aN ae r Tg Din NOLLWEENVO dyol a STSVTIWAV SIMYA Sii gavi lt 1 MAN SW go ION A NOLLWuavo er SNDISOM aao Nosia LON as rire aa ONIMYOM LON lt XILINYHYd SWINWeDOud Pa Tee _ _ 9 0NY SP SdNONO Sy AMOLOVA a YIAWNN AYOM JHL R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice 937 32
86. e load in the equation The hoist monitoring unit displays the SWP in percentage of the initial value A new hoist is given a SWP value of 100 which is in respect to the initial SWP hours value according to the hoist duty class When the SWP counter reaches zero a general overhaul must be performed after which the hoist shall be given a new SWP See the specific actions from the hoist GO manual The hoist monitoring unit will not prevent running the hoist when the SWP reaches zero but it will give a warning signal indicating that safe usage of the hoist is no longer guaranteed SRT3 S At Ats load 513 3 load oe a SR nomload mo nomload SWPRT D_SRT3 SRT3 100 SWPHC D _SL3 SL3 100 D_SRT3 D_SL3 SWP min SWPRT SWPHC 31 105 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc R amp M 4501 Gateway Boulevard MINANE Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC SRT3 Load sum with hoist running time third power The parameter 2 13 l Time period number Time period is 0 1s Atfi Run time in fast speed with load Ats Run time in slow speed with load SR Speed ratio Two speed systems slow fast i e 6 Inverter drives always 1 load Actual load in period i nom load Hoists nominal load The parameter 6 4 SL
87. edeieccrtecres 40 7 9 1 Levelling function instructions 0 40 7 9 2 Levelling Function Connections 41 8 Multi hoisting eeeeeeeeeeeeeeeeeeeeeeeeeees 42 BM Generalserrrsi inserire ee 42 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc 4501 Gateway Boulevard Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 R amp M MATERIALS HANDLING INC 8 2 Multi hoisting instructions c0 42 8 2 1 Multi hoisting parameters 42 822 CablinOseccccvecdsecesedercteruvtintsts a etatets seats 43 8 2 3 Menus through CAN bUS 0 ceeeeceeeeeees 44 8 3 CAN DUS lOpOlOOY sciences 45 8 3 1 Termination resistors ccccccccceeeeeeeeees 45 8 3 2 Recommended topologies cee 46 9 COMMISSIONING ccccceeeeeeeeeeeeteeeeeeeeeees 47 91 Stan UPort eee eects 47 9 2 Load M ASUIMEC cceeeeeeeeeeeeeeeeeeeees 47 9 2 1 Load measure type by Motor see the parameter 4 7 1 cceceeccsseeeeeeeeeeeeeeeeeeeeeeeeteeeeeaaaees 47 9 2 2 Load measure type by Sens See the parameter 4 7 1 cececccssceeeeeeeeeeeeenaeeeeeeeeeteeeeeaaaees 47 9 3 Functional Checks ceeeeeeeeees 48 93A Mult NOSUN wissiieisseenchinnnnds Scnoatiiencnetetehed 48 9 3 2 Multifunction inputs 48 9 3 3 Functional free relay output ROUT
88. eeees 31 6 2 3 Safe Working Period counter SWP h 31 6 2 4 Hoist cycles Counter ccceeeeeteeeeetees 32 6 2 5 Run time and start counter for trolley and bridge 32 6 3 Measured Values cccccceceeeeeeeeeeeeeeeeees 33 7 Optional fUNCtIONS cc ceceeeeeeeeeeeeeeteees 34 Pel Generalean eene e 34 7 2 Slack rope protection cceeeeeees 34 7 2 1 Slack rope protection instructions 34 7 2 2 Slack rope protection connections 35 7 3 Intermediate load limits ceee 35 7 3 1 Intermediate load limits parameters 35 7 3 2 Intermediate load limits connections 36 7 4 Runtime and start counter for trolley and Pridgen ea eee E 36 7 4 1 Runtime and start counter for trolley and bridge ParamelerS cccccceeeeeeeeeeeeeeeeeeeeeeeeeeeenaeees 37 7 4 2 Runtime and start counter for trolley and bridge CONNECTIONS cccceeeeeeeeeeteeeeeeeeeeteeeeeaaees 37 7 5 Analogue Output eeeeeeeeeeeeees 37 7 5 1 Analogue output parameters 00 37 7 5 2 Analogue output connections 0 38 7 6 Free relay Output eeeeeeeeeeeeeeeeees 38 7 7 Hoist brake wear supervision 0 39 7 7 1 Hoist brake wear supervision instructions 39 7 8 MOA TAGs catexiracsieirsinliccnateutedate aan 40 7 8 1 Load tare instructions cccccccceeeeeeeeees 40 7 9 Levelling function scsccecerccnzeseecccct
89. en the run command output either hoisting or lowering is activated and the run feedback becomes active If only run command input is activated then a start is not counted The maximum allowed number of starts is directly related to the theoretical lifetime of the hoist When the Starts counter reaches the design limit value an adequate overhaul must be performed See the specific actions from the hoist GO manual The hoist monitoring unit will not prevent running the hoist when the Starts counter reaches the design limit value but it will give a warning signal indicating that safe usage of the hoist is no longer guaranteed 6 2 2 Run Time counter The Run Time counter records the total amount of hours the hoist has been running either upwards or downwards The Run Time counter is not load dependent The maximum allowed run time is directly related to the theoretical lifetime of the hoist When the Run Time counter reaches the design limit value an adequate overhaul must be performed See the specific actions from the hoist GO manual The hoist monitoring unit will not prevent operating the hoist when the Run Time counter reaches the design limit value but it will give a warning signal indicating that safe usage of the hoist is no longer guaranteed 6 2 3 Safe Working Period counter SWP h The theoretical lifetime of the hoist is presented as Safe Working Period SWP The SWP is based on a calculation including the running hours and th
90. ensor Param Name Value Description 4 5 T2 Temperature measurement channel 2 parameters Selects the function of temperature measurement channel 1 NU Not used PTC Motor thermistor or Bimetal thermal switch 4 5 1 T2 operat Bwear Brake wear sensor A NTC Type A NTC sensor B NTC Type B NTC sensor C NTC Type C NTC sensor Param Name Value Description 4 6 AOUT Analogue output parameters Selects the function of the analogue output NU Not used 4 6 1 AOUT oper NU Act Actual load actual bridge load in multi hoist applications Tare Tared load tared bridge load in multi hoist applications Solo Actual load for single hoist connected to the unit 4 6 2 Zero load n nn V Sets the voltage level with zero load Range 0 10V 4 6 3 Nom Load ann V Sets the voltage level with rated load Range 0 10V The single hoist the rated load is determined by parameter 6 4 the rated bridge load is determined by parameter 4 1 1 4 Param Name Value Description 4 7 Load param Load calculation parameters Selects the load calculation method NU Not used oe Load meas Motor Motor torque calculation Sens Load sensor measurement Load increase rate for controlling the hoisting in two step control speed change to fast speed is allowed 4 7 2 Load rate 10 when actual load change within 200ms lt parameter 4 7 2 Value 0 means that the function is not applied See also chapter Sudden load increase supervision of this manual 4 7 3 RO_F n nnn Resistan
91. ensor is the default solution in hoists The Strain gauge type will give out a signal in the range of 0 40mVDC To amplify this signal a load sensor amplifier must be connected between the sensor and the hoist monitoring unit The instructions on how to set up the amplifier are included in chapter Load sensor adjustment of this manual The Hall sensor type was commonly used in XL hoists The Hall sensor gives out a signal in the range of 4 6VDC which can be fed directly into the hoist monitoring unit er Other sensor types are possible to use if the load sensor gives out a signal in the range of OV to 8V 10 1 1 Load sensor set up Follow the instructions given in the section Load sensor adjustment of this manual 10 2 Load sensor parameters Parameter Value Description Note 4 7 Load calculation menu Accessible with password 4 8124 Load param 4 7 1 Sens Selects the load sensor measurement method Load meas Parameter Value Description Note 6 In this menu are the mechanical design values of the Accessible with password 6 9822 Design hoist determined 6 4 0 00 999t Rated load of the hoist Setting according to the data label of the hoist Nom Load In case the automatic load calibration sequence does not give the required results i e the difference between the actual load and the calculated displayed load is more than 10 the unit can be calibrated manually with the followin
92. ent of phase U Only functional when par 4 7 1 is set to Motor 1 2 8 Motor 12 nn n A RMS motor current of phase V Only functional when par 4 7 1 is set to Motor 1 2 9 Motor 13 nn n A RMS motor current of phase W Only functional when par 4 7 1 is set to Motor 1 2 10 Ain1 value n nn V Measured voltage at analogue input AIN1 Voltage across terminals X2 26 30 VDC 1 2 11 Ain2 value n nn V Measured voltage at analogue input AIN2 Voltage across terminals X2 27 30 VDC 1 2 42 Ai A P Measured voltage at analogue input AIN3 Note that there is no function behind AIN3 This input 2 in3 value n nn V can be used for measurement purposes only 1 2 13 Int temp n C Internal temperature of the unit 1 2 44 input i e 10101 Indicates the status of the inputs HIN LIN FIN MFI1 amp MFI2 1 means active 0 means inactive Note that the leftmost zeros before the first appearing 1 are not displayed 1 2 15 Output i e 10100 Indicates the status of the outputs HOUT LOUT FOUT RS amp ROUT I means active 0 means inactive Note that the leftmost zeros before the first appearing 1 are not displayed 1 2 16 Supply f 50 Supply voltage frequency 50 or 60Hz Param Name Value Description 1 3 Min Max Minimum maximum value menu 1 3 1 Min supply nnn V Minimum measured value of the supply line voltage RMS 1 3 1 Reset nnn V Resets t
93. er or amend the above information without notice R amp M Materials Handling Inc R amp M 4501 Gateway Boulevard me Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC 12Load sensor adjustment 12 1 KAE400 Strain Gauge 12 1 1 General KAE400 is a amplifier which is used to amplify the strain gauge load sensor signal mV to higher level V Both full bridge and half bridge sensors can be connected Amplifier has zero adjustment with led indication and two fixed gain 160 400 12 1 2 Technical data Operation voltage Vsup 9 5 12 VDC maximum ratings Sensor supply voltage Vssup Vsup 0 5 VDC Gain set by a switch 160 400 Zero adjustment 10 10 mV 350R measuring elements 30 30 mV 1k measuring elements Output voltage at 0 mV input 2 048 VDC Minimum output load 10 kohm Operation temperature 25 85 C Wire brakage monitoring OUT lt 0 5VDC or gt 8 0 VDC EMC standards EN61000 6 2 EN61000 6 3 12 1 3 Wiring oN S EA Ss 10V i 5 10V l TAN i IN 2 O 1 our l I O oo IN 3 l lAN OV C 7 OV tog 48 8 4 Q r IR 40 8 s1il io abs loy 5 10V Ty a S S our D 6 uNa O L Nm ov Q 70V s 1 y 1 8608 4 Q 5 In th
94. ermediate load limit will prevent the hoisting motion when the measured load exceeds the pre set limit The intermediate load limit operation is selected by assigning this function to one or both multi functional inputs 7 3 1 Intermediate load limits parameters Parameter Value Description Note 4 1 MFI1 Accessible with password 4 8124 4 1 1 Intl Selects the intermediate load function for MFI1 MFI1 oper 4 1 2 n t Sets the intermediate load level in tons MFI1 Intl Range 0 0t hoist rated load Parameter Value Description Note 4 2 MFI2 Accessible with password 4 8124 4 2 1 IntL Selects the intermediate load function for MFI2 MEFI2 oper 4 2 2 n t Sets the intermediate load level in tons MFI2 IntL Range 0 0t hoist rated load 4 2 3 n t Sets the intermediate load level in tons The third intermediate load can only be activated when both MFI1 1 2 IntL Range 0 0t hoist rated load and MFI2 are selected for the intermediate load function 35 105 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc R amp M 4501 Gateway Boulevard me Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC 7 3 2 Intermediate load limits connections One or two normally closed contact should be connected to the multi functional inputs The contacts
95. ero load 6 10 D SRT3 D D D 4 6 3 Nom Load 6 11 D SRT8 D D D 4 7 1 Load Meas Motor Sensor Sensor 6 12 D SL3 D D D 4 7 2 Load rate 10 00 10 6 13 D SL8 D D D 4 7 3 RO_F D 6 14 MaxST MFI1 D D D 4 7 4 RO_S D 6 15 MaxRT MFI1 D D D 4 7 5 TO D 6 16 MaxST MFI2 D D D 4 7 6 TEMP_SLOW D 6 17 MaxRT MFI2 D D D 4 7 7 TEMP_FAST D 6 18 Max Br 1M000 1M000 D 4 7 8 C2F D 6 19 MaxControl 640k0 640k0 640k0 4 7 9 C2S D 6 20 Password D D D 90 105 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc R amp M 4501 Gateway Boulevard MINANE Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC Appendix 2 Version History Software version history Version Changes SW 1 9 e First production SW e Only one hoist operation SW 1 98 e Two hoists operation e Corrections to AOUT SW 2 000 e Serial number H00678 HO1660 T00187 T00730 e Multihoisting operation SW 2 004 e Serial number H01661 HO5697 T00731 T01945 e Motor torque calculation works better in IT network e Tare function ESC button must be pressed for three seconds to tare the load e Improved AOUT resolution e Fault Brake limit 50 SW 2 100 e Serial number H05698 T01946 e Multi hoisting supervision works better e Continous load update in Sensor application e Fault Srope
96. for the hoist applications and is restricted for the hoist monitoring units only It is not possible to add any other CAN units to this bus Several functions are realised via CAN bus Each unit indicates the status information and the load of the hoist for all other units connected with the CAN bus With this data two type of supervisions are done run supervision and sum overload protection The run supervision makes sure that if several hoists are running and one makes an uncontrolled stop all other hoists are stopped as well The sum overload protection is mainly used for the bridge overload protection in such cases where the total sum load of the individual hoists is bigger than the nominal load of the bridge There is no CAN bus master to collect all the information and make the needed supervisions Instead all units see the status and load information of every other units and each unit carries out the similar supervisions Thus there are as many supervision units as stations connected to the CAN bus In addition to the status and load information parameter values are transferred in the CAN bus Every unit is able to ask parameter values from any other unit This makes it possible to read with the display unit the parameter values of any other connected unit 1 Maximum 5 units 2 CAN bus 8 2 Multi hoisting instructions 8 2 1 Multi hoisting parameters The CAN bus related parameters are presented in the table below Note that the ch
97. g Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc R amp M 4501 Gateway Boulevard MINANE Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC 14 6 2 Hoisting and lowering prevented Check the input status from parameter 1 2 14 HIN LIN FIN MFI MFI2 1 0 1 0 0 e f the unit does not receive any input commands check the control voltage and the commanding inputs e Check the terminal S It is normal that a Voltmeter shows a disturbance value The measured voltage may appear to be more than twice the rated control voltage on non active inputs This voltage has however no power and can not activate the input Check the output status from parameter 1 2 15 HOUT LOUT FOUT RS ROUT 1 0 1 1 1 e If the outputs are to be active but the controlled device not check the terminals wiring and controlled device Usually the fault Run_FB appears on the display 77 105 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc R amp M 4501 Gateway Boulevard me Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC 15Replacement Instructions w WARNING Wrong Parameter settings can lead to a fatal malfunction of Monitoring Unit Only authorized Service Techni
98. g parameters Refer to paragraph Manual load calibration of this chapter for further instructions Parameter Value Description Note 3 4 Load calibration values for the load sensor method Accessible with password 2 0732 SC values 3 4 1 25 0t The higher test load value 80 130 x Hoist Load 1 nominal Load tons 3 4 2 7 23V The load measurement voltage in the analogue input Input 1 Ain1 corresponding to the test load 3 4 3 0 00t The lower test load value usually the empty hook 0 00t Load 2 0 30 x Hoist nominal Load tons 3 4 4 2 07V The load measurement voltage in the analogue input Input 3 Ain1 corresponding to the load 2 52 105 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc R amp M 4501 Gateway Boulevard me Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC 10 3 Load calibration sequence with load sensor w Before carrying out the calibration procedure make sure that the load sensor amplifier if present is correctly installed and calibrated Refer to the chapter Load sensor adjustment of this manual for instructions Power On Enter password 0732 Display will jump to menu 3 parameters when one hoist is being calibrated If there is more than one Hoist Multi hoisting mode then the hoist must be selected by a Letter N
99. gative the value of parameter 3 2 5 MIf1 Select parameter 1 2 1 Act Load Drive the hoist in fast soeed down and check the load from the display Repeat step 13 15 until the display shows the correct load The display shows less than the lifted test load Decrease less positive the value of parameter 3 2 2 Mhs1 Select parameter 1 2 1 Act Load Drive the hoist in slow speed up and check the load from the display Repeat step 1 3 until the display shows the correct load Decrease less positive the value of parameter 3 2 3 Mhf1 Select parameter 1 2 1 Act Load Drive the hoist in fast soeed up and check the load from the display Repeat step 5 7 until the display shows the correct load Increase less negative the value of parameter 3 2 4 Mls1 Select parameter 1 2 1 Act Load Drive the hoist in slow speed down and check the load from the display Repeat step 9 11 until the display shows the correct load Increase less negative the value of parameter 3 2 5 MIf1 Select parameter 1 2 1 Act Load Drive the hoist in fast soeed down and check the load from the display Repeat step 13 15 until the display shows the correct load It is difficult to predict how much one should increase or decrease the values The best way to do this is just by trying out say steps of 10 of the original value 60 105 R amp M Materials Handling Inc reserves the right to alt
100. ghest hook stops the other s should continue until the hooks are balanced 9 3 2 7 Bridge intermediate load limit CintL Bridge intermediate load limit is activated when input is not active e When actual load value exceeds a limit and the input is not active the unit works similarly as in overload situation e Check bridge intermediate load limit value by parameter 4 2 5 e Check that the hoist control device sees then the input status by parameter 1 2 14 MFI1 input s status bit is second bit from the right XXX1X 9 3 2 8 By pass CAN bus CAN e The control unit must have a button or a switch for this functions e CAN bus by pass function is activated when input is active e Test that the hoist control device sees the input status by parameter 1 2 14 9 3 3 Functional free relay output ROUT Check the relay operation by parameter 4 3 1 Check the operation logic of the relay by parameter 4 3 2 Normal operation is as described below 9 3 3 1 Overload OL Contact closed when overload is detected Check that the relay works 9 3 3 2 Load limit function LoadX Contact closed when the load exceeds the limit X where the limit is determined by parameter 4 3 3 Check the limit value from the parameter 4 3 3 Check that the relay works 9 3 3 3 Fault and warning state supervision OK Contact closed in normal operation Contact blinks when the unit shifts to warning state Contact opens when the uni
101. he display the unit can be programmed and calibrated and stored values can be read The hoist monitoring unit can be equipped and installed with many different options and additional features such as continuous load display tandem operation up to five units service warning information hook levelling intermediate overload options A service agent authorised by the manufacturer can provide detailed information and professional advice on a tailored solution for each application w The hoist monitoring unit is a safety device installed by the manufacturer Only service personnel authorised by the manufacturer are allowed to program and calibrate the unit Faulty programmed or calibrated unit may cause malfunctions that results in dangerous situations w Under no circumstances it is allowed to by pass or remove the hoist monitoring unit as that would disable all supervision and safety features 1 2 Directives Standards and Patents 1 2 1 Directives The product conforms to the relevant safety provisions of the e EMC Directive 2004 108 EC e Low Voltage Directive 2006 95 EC 1 2 2 Standards The product complies with the following standards e EN 50081 1 1992 Generic emission standard Residential commercial and light industry e EN 61000 6 2 1999 Generic immunity standard Industrial environment e EN 50178 1997 Electronic equipment for use in power installations e EN 60204 32 1998 Safety of machinery Electrical e
102. he value shown in parameter 1 3 1 by pushing the ENT button twice 1 3 2 Max supply nnn V Maximum measured value of the supply line voltage RMS 1 3 2 Reset nnn V Resets the value shown in parameter 1 3 2 by pushing the ENT button twice 1 3 3 Min Int T n C Minimum measured value of the internal temperature of the unit 1 3 3 Reset n C Resets the value shown in parameter 1 3 3 by pushing the ENT button twice 1 3 4 Max Int T n C Maximum measured value of the internal temperature of the unit 1 3 4 Reset n C Resets the value shown in parameter 1 3 4 by pushing the ENT button twice 33 105 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc R amp M 4501 Gateway Boulevard me Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC 7 Optional functions 7 1 General The hoist monitoring unit can be equipped with a number of additional features Each one of the features can under certain restrictions be chosen during the ordering process of the hoist or added in afterwards Contact a service agent authorised by the manufacturer for further details Slack rope feature only functions properly when a load handling device is attached to the hook It is not recommended to activate the Slack rope function if no load handling device is present 7 2 Slack rope protection The sl
103. hen ED value has exceed the measured values nominal ED value 1 1 Cond mon Condition monitoring menu 2 12 SWPRT SWP value calculated with hoist running time 1 1 1 SWP Remaining Safe Working Period of the hoist in 2 13 SRT3 Load sum with hoist running time third power percentage starting from 100 1 1 2 Starts Total number of starts 2 14 SRT8 Load sum with hoist running time eight power 1 1 3 Run time Total running time 2 15 SWPHC SWP value calculated with hoist cycles 1 1 4 Cycles Total number of hoisting cycles 2 16 SL1 Load sum with hoist cycles the first power mean load 1 1 5 Meanload Average of the handled load 2 17 SL3 Load sum with hoist cycles the third 1 1 6 Br SWP Remaining Safe Working Period of the brake in 2 18 SL8 Load sum with hoist cycles the eight power percentage 1 1 7 MFI1 RT Total hours of running time when MFI1 input is closed 2 19 Power on The total power on time of the unit 1 1 8 MFI1 ST Total amount of starts when MFI1 input is closed 2 20 Temp Index Power on time of the unit weighted with the unit s temperature 1 1 9 MFI2 RT Total hours of running time when MFI2 input is closed 2 21 Max load Maximum measured value of the load 1 1 10 MFI2 ST Total amount of starts when MFI2 input is closed 3 Load setup Load calibration menu Accessible password level 2 1 2 Measure Measurement menu 3 1 Cal Motor Load calibration when the motor torque based load measurement is selecte See chapter
104. ically the low speed windings T2 temperature measurement T2 determines the operation of the relay typically the high speed windings T1 2 both T1 and T2 are used When either one reach the limit the relay operates 4 3 5 n C Sets the motor temperature limit in Centigrade In practice the limit should be less than the temperature set TempX lim by parameter 4 10 2 7 7 Hoist brake wear supervision The unit can be programmed to supervise the brake wear This option requires a type of brake with a built in brake wear sensor and can only be used when the load measurement system is sensor based thus not with motor torque calculation systems When the unit measures excessive break wear the motion will be stopped 7 7 1 Hoist brake wear supervision instructions This option requires a brake wear sensor like commonly used in XL hoisting brakes or an additional micro switch that supervises the airgap of the brake The sensor is connected to the temperature measurement input T1 TP11 amp TP12 or T2 TP21 amp TP22 OL10 THERMISTOR INPUT TP41 P42 TP24 TPee Hoist brake wear supervision parameters Parameter Value Description Note 4 4T1 T1 parameters Accessible with password 4 8124 4 4 1 Bwear Activates the brake wear supervision when Worn brake thus open contact will stop the motion and Fault Br T1 operat connected to the T1 input wear indication appears on the dis
105. ifts to warning state Contact open when the unit shifts to fault state Ready Fault supervision Operates simultaneously with the red LED on the unit Contact closed in normal operation Contact open when the unit shifts to fault state TempX Motor overtemperature Can only be selected when the motor is equipped with Contact closed when the motor temperature exceeds the NTC type of temperature sensors see parameter 4 5 1 limit X where the limit is determined by parameter 4 3 5 38 105 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M MATERIALS HANDLING INC R amp M Materials Handling Inc 4501 Gateway Boulevard Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 Parameter Value Description Note 4 3 2 Norm Selects the operation logic of the relay Normal operation is When the operation logic has to be inverted set this ROUT logic as described above parameter to Inv 4 3 3 n t Sets the load limit X in tons when the option LoadX is The upper limit is the rated load of the solo hoist connected ROUT loadX selected to the unit Setting range 0 0t rated load of the hoist 4 3 4 T1 Selects the temperature measurement See also the settings of parameters 4 4 1 4 5 1 4 7 6 and TempX T2 T1 temperature measurement T1 determines the 4 7 7 meas T1 2 operation of the relay typ
106. ing Period SWP The SWP counts down according to a calculation which includes the running time with a certain load Also the total run time independent on the load and the amount of starts are directly related to the hoist s duty class and theoretical lifetime The primary monitoring items related to the FEM and ISO regulations are Hoist Safe Working Period counter SWP Starts counter Run Time counter er Monitoring items can only be read if the hoist monitoring unit is equipped with a display either mounted on the unit or in the pushbutton station 30 105 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc R amp M 4501 Gateway Boulevard me Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC Relation between the hoist duty class and the primary monitoring items Ci s5 code Hoist duty class Starts n Run time hr SWP SRT3 hr SWP SL3 n ISO FEM Par 1 1 2 Par 1 1 3 Par 2 13 Par 2 17 3 M3 1Bm 480 000 3 200 400 10 000 4 M4 1Am 1 134 000 6 300 800 24 000 5 M5 2m 3 000 000 12 500 1 600 64 000 6 M6 3m 7 500 000 25 000 3 200 160 000 7 M7 4m 18 000 000 50 000 6 300 378 000 8 M8 5m 42 000 000 100 000 12 500 750 000 6 2 1 Starts counter The Starts counter counts the number of instants the hoist is started A start is counted wh
107. it will not calculate or supervise the overload protection and current measurement for a period of time determined by parameter 4 7 13 e During acceleration from slow speed to fast speed and deceleration from fast speed to slow speed the unit will not calculate or supervise the overload protection and current measurement for a period of time determined by parameter 4 7 14 e The above function prevents the overload from tripping during the acceleration and deceleration moment especially in two step systems with motor torque calculation based overload protection since the starting currents are momentarily quite high e When accelerating from zero directly to fast speed the motion starts in slow speed for a period determined by par 4 7 13 e When decelerating from fast speed to slow speed the unit will keep the fast speed active for a period determined by par 4 7 14 e When decelerating from fast speed directly to zero the unit will activate the slow speed for a fixed period of 250ms not adjustable by parameters The above function prevents the use called as inching jogging or tipping operation Once the slow speed output is activated it remains active for 250ms even if the input command drops off within this time This prevents the directional contactors to drop off during the high starting currents 28 105 R amp M Materials Handling Inc reserves the right to alter or amend the above information without noti
108. l hardware fault in the unit internal safety relay contact closed all the time e Contact the manufacturer 14 1 4 Fault RUN act F_Run A fault detected in controlling the direction outputs only two step control e Feedback is ON already before the direction control HOUT LOUT is activated e Check the connections and wiring of terminals 1 to 19 Especially for short circuits between HIN HOUT and LIN LOUT e f external connections are correct and the fault occurs only in starts upwards the internal upwards control relay may be malfunctioning e f external connections are correct and the fault occurs only in starts downwards the internal downwards control relay may be malfunctioning e Make sure that the current transformer is correctly connected to the terminal 27 12 A e Check that the current transformer operates correctly w Make sure that any other electrical loads e g fans inverters haven t been connected behind the current transformer 14 1 5 Fault Run FB 2 The hoist stops although the unit controls it to run e Check AIN 2 values by parameter 1 2 11 Normal values 5V If 9 8V check current transformer connection e Check function of contactors If the contactor is energized the problem is in the power line connections or the current transformer connections probably e Check the current transformer connection to the terminal 27 12 A e Check the power line connections to the hoisting motor 70 105
109. lay Selection Switch Y e o n e DOO00000000000000000 fil_ 2345678 910111213141516171819 _ O A A Current loop to remote display B Display selection switch in down position for remote selection If the display is in a remote location the display is connected via a current loop with the hoist monitoring unit The current loop is between terminals 32 CL A and 33 CL B Because a current loop is not sensitive for electrical disturbances it is not needed to use shielded cables for the display connection With the red display selection switch on top of the hoist monitoring unit it is possible to switch between the display locations The display selection switch must be in the down position to select the remote location active Remote display and display in the unit cannot work simultaneously X32A2 M 14 15 CLA CLB PENDANT DISPLAY OUTPUT 17 105 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M MATERIALS HANDLING INC R amp M Materials Handling Inc 4501 Gateway Boulevard Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 4 Parameters 1 Monitor 1 Read only menu for condition monitoring values and 2 11 Over ED Counts the minutes w
110. ling Inc R amp M 4501 Gateway Boulevard me Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC Appendix 7 Replacing the condition monitoring unit ce Read through all steps of these instructions and make yourself familiar with the procedure before continuing Write down the following information Hoist s order Number Hoist s serial number Old unit serial number New unit serial number Fill in the requested fields of this document Follow the next steps to replace the Control Monitoring unit On the display are four pushbuttons for navigating and programming 1 Zeroing of tare load Press ESC button for three seconds 2 Moving from submenu to main menu and reject parameter changes e Enter password 2180 Actual load e e SE ee Password Password Password Password 4 Monitor 1 AN AN x D Toggle between actual load orange LED off and tare load orange LED on Scrolling down N Toggle between actual load orange LED off and tare load orange LED on Scrolling up Po Entering the password level Selecting a menu and accept parameter changes N e Read the parameter 4 7 1 value Push 3 times Up button gt Menu 4 Push Ent button gt Menu 4 1 Push 6 times Up button gt Menu 4 7 Push Ent button gt Parameter 4 7 1 Check whether parameter shows Motor
111. ling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc R amp M 4501 Gateway Boulevard MONTANE Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC LOAD SENSOR ANALOGIA SISAANTULO ANALOG INPUT The parameter 4 7 1 value is Motor e Check parameters 1 2 2 and 1 2 3 lf the temperature sensors are not connected the values for parameters 1 2 2 Temp 1 and or 1 2 3 Temp 2 is lt 20 C lt 0 F e Check that temperature sensor 1 slow speed is connected to terminals 21 22 and sensor 2 fast speed is connected to terminal 23 24 Drive the hoist in slow speed and check that reading of parameter 1 2 2 Temp 1 increase Drive the hoist in fast speed and check that reading of parameter 1 2 3 Temp 2 increase e Check the parameters 3 2 2 Mhs1 and 3 2 7 Mhs2 If the values are equal to each other the calibration is done with only one load Confirm by checking the following parameters 3 2 343 2 8 3 2 4 3 2 9 3 2 543 2 10 Perform the calibration procedure as described in this manual e If the parameters 3 2 7 3 2 10 values are negative check the current transformers and their connections and or the voltage measurement connections Pay special attention to the correct phase order e f supply voltage frequency is 60Hz check that parameter 1 2 16 is set to 60 Hz The hoist monitoring unit m
112. load status display is carried out with the arrow buttons of the display In addition the LEDs in the unit and display are blinking If any service warning is active the hoist can still be run normally Name Description Run time The actual value for run time has exceeded the set service limit value Starts The actual value for the start counter has exceeded the set service limit value SWP The actual value of SWP is less that the set service limit for SWP Br SWP The calculated brake SWP value is less than the set service limit value er When service warning has activated ask actions from crane service company 67 105 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc R amp M 4501 Gateway Boulevard MINANE Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC 14Troubleshooting In the fault logger 5 2 Fault log each fault is identified with a fault code and the values of the start counter that corresponds to the detection time of the fault The first fault in the logger 5 2 1 is the latest one In the table below the column Code e g F_OL indicates the abbreviation for each fault as shown in the fault logger 14 1 Fault descriptions 14 1 1 Fault Hoist OL F_OL Hoist overload Confirm that the value on load display is the actual load not tared load Confirm tha
113. low speed to fast speed 7 5 MFI2 ST MFI2 starts 4 8 Hoist ctrl The selection for the hoist control method 7 6 RT slow Run time in slow speed 4 9 Slack rope Slack rope function parameters 7 7 RT fast Run time in fast speed 4 9 1 SR select Selects the slack rope function 7 8 No OT Number of hoist motor overtemperature incidents 4 9 2 Load limit The slack rope limit 7 9 No OL Number of hoist overload incidents 4 10 Single sup 7 10 E stops Number of emergency stops 4 10 1 JOT run Selects the action when the motor temperature exceeds 7 11 ST up Number of starts in up direction the limit or when Fault Br wear occurs 4 10 2 OT limit When NTC type sensor is applied the limit value for the 7 12 ST down Number of starts in down direction hoist motor overtemperature 4 10 3 Supply sup _ Selects the supply voltage supervision 7 13 ST fast Number of starts to fast speed two step control only 4 11 Comm hoist The settings for common hoisting multi hoist 7 14 Max ED Maximum ED value applications 4 11 1 Hoist cnt The number of units connected with CAN bus Range 7 15 Over ED Number of cases where ED value has exceeded the a0 rated ED value 4 11 2 Run sup Common hoisting supervision 7 16 SRT3 Load sum with hoist running time third power 4 11 3 B OL Bridge overload protection 7 17 SRT8 Load sum with hoist running time eight power 4 11 4 B nom load Rated load of the bridge 7 18 SL1 Load sum with hoist cycles the first power mean lo
114. ls 32 and 33 14 4 The temperature sensors NTC wiring If the NTC sensor is selected and the temperature sensor is not connected the values for parameters 1 2 2 Temp 1 and or parameter 1 2 3 T2 are about 50 C Check that temperature sensor 1 slow speed is connected across terminal 21 and 22 and that the slow speed temperature is measured with channel T1 parameter 4 7 6 is set to T1 When driving in slow speed the value of parameters 1 2 2 Temp 1 should increase Check that temperature sensor 2 fast speed is connected across terminal 23 and 24 and that the fast speed temperature is measured with channel T2 parameter 4 7 7 is set to T2 When driving in fast speed the value of parameters 1 2 3 Temp 2 should increase Reverse the connections of terminals 21 22 and 23 24 when needed and carry out the calibration procedure again 14 5 Current transformers e Check that the current transformer AT 20 is connected across terminals 26 and 29 e Check that the current transformer AT 30 is connected across terminals 27 and 29 e The grey wires of both transformers must be connected to terminal 29 If one of current transformers is connected wrong it can be checked with parameters 1 2 9 Motor 13 In that case parameter 1 2 9 has a different value than parameters 1 2 7 Motor 11 and parameter 1 2 8 Motor 12 whereas all three should have the same value The most common fault is
115. lt name Code Description Running Fault Logger Hoist OL F_OL Hoist overload Hoisting prevented lowering allowed Motor OT F_OT Hoist motor overtemperature Hoisting and lowering prevented Int relay F_SR A fault detected in the internal safety relay Running prevented RUN act F_Run A fault detected in controlling the direction outputs only in two step Running prevented control Run FB The hoist stops although the unit controls it to run Controls to stop new start possible Brake F_Br Hoist brake does not open only in motor based load calculation Lowering prevented Br wear F_Brw Hoist brake worn out only when the sensor applied Hoisting and lowering prevented Sensor ch F_SCh Measurement signal out of acceptable range Hoisting prevented Curr meas F_Ain Measurement signal out of acceptable range Hoisting prevented Supply vol F_SPh Main supply fault one phase missing only when main supply Running prevented measured Phaseorder F_Sor Main supply fault incorrect phase order only when main supply Running prevented measured Mparameter F_MP Internal parameter reading or writing fault Running prevented Cparameter F_CP Internal parameter reading or writing fault Running prevented CAN bus F_CAN CAN bus communication fault only in multi hoisting Running prevented Bridge OL F_BOL Overload in calculated bridge load only in multi hoisting Hoisting prevented lowering allowed Bridge RS F_BRS Fault in multi hoisting requests for running or stopping
116. mergency stops incidents control voltage switched off during run 2 7 ST up nnnn Total number of starts in up direction 1 2 8 ST down nnnn Total number of starts in down direction 1 2 9 ST fast nnnn Total number of starts to fast speed counts in two speed control only 1 2 10 Max ED nn Maximum value of the calculated ED percentage 2 10 Reset nn Resets the value shown in parameter 2 10 by pushing the ENT button twice 2 11 Over ED nn Counts the minutes when ED value has exceed the nominal ED value 2 12 SWPRT nn SWP value calculated with hoist running time 2 13 SRT3 nnnn Load sum with hoist running time third power 1 2 14 SRT8 nnnn Load sum with hoist running time eight power 1 2 15 SWPHC nn SWP value calculated with hoist cycles 2 16 SL1 nnnn Load sum with hoist cycles the first power mean load 1 2 17 SL3 nnnn Load sum with hoist cycles the third 1 2 18 SL8 nnnn Load sum with hoist cycles the eight power 1 2 19 Power on nnnn h The total power on time of the unit 2 2 20 Temp Index nnnn h Power on time of the unit weighted with the unit s temperature 2 2 21 Max load nnn Maximum measured value of the load 2 21 Reset nnn Resets the value shown in parameter 2 21 by pushing the ENT button twice The values on the display are present with five digits 1 there is no unit name all five digit
117. meter 3 1 1 3 2 4 Mis1 nn n Motor torque for lowering in slow speed with load set by parameter 3 1 1 3 2 5 MIf1 nn n Motor torque for lowering in fast speed with load set by parameter 3 1 1 3 2 6 Load 2 nn n t The lower test load value set with parameter 3 1 7 3 2 7 Mhs2 nn nn Motor torque for hoisting in slow speed with load set by parameter 3 1 7 3 2 8 Mhf2 nn nn Motor torque for hoisting in fast speed with load set by parameter 3 1 7 3 2 9 Mls2 nn n Motor torque for lowering in slow speed with load set by parameter 3 1 7 3 2 10 MIf2 nn n Motor torque for lowering in fast speed with load set by parameter 3 1 7 Param Name Value Description 3 3 Cal Sans Load calibration when the sensor based load measurement is selected See chapter Load calibration sequence load sensor 3 3 1 Set gt 80 nn n t Set the higher test load value in tons 80 130 x hoist rated load 3 3 2 nn n t OK 2 real ae set higher test load value by pushing the ENT button make sure the test load is attached to 3 3 3 Set lt 30 nn n t Set the lower test load value in tons lt 30 of hoist rated load typically empty hook 0 00t 3 3 4 nn n tOK 2 Confirm the set lower test load value by pushing the ENT button make sure the hook is empty when 0 00t is given in parameter 3 3 3 or that the set second test load is attached to the hook Param Name Value Description 3 4 SC values Load calibra
118. most zeros before the first appearing 1 are not displayed 1 2 16 Supply f 50 Supply voltage frequency 50 or 60Hz Param Name Value Description 1 3 Min Max Minimum maximum value menu 1 3 1 Min supply nnn V Minimum measured value of the supply line voltage RMS 1 3 1 Reset nnn V Resets the value shown in parameter 1 3 1 by pushing the ENT button twice 1 3 2 Max supply nnn V Maximum measured value of the supply line voltage RMS 1 3 2 Reset nnn V Resets the value shown in parameter 1 3 2 by pushing the ENT button twice 1 3 3 Min Int T n C Minimum measured value of the internal temperature of the unit 1 3 3 Reset n C Resets the value shown in parameter 1 3 3 by pushing the ENT button twice 1 3 4 Max Int T n C Maximum measured value of the internal temperature of the unit 1 3 4 Reset n C Resets the value shown in parameter 1 3 4 by pushing the ENT button twice 16 2 Monitor 2 Menu 2 2 Monitor 2 Read only menu for advanced condition monitoring values and measured values Accessible with password level 3 Param Name Value Description 2 1 SW version 2 000 Software version of the unit 2 2 RT slow nnn h Total run time in slow speed 2 2 3 RT fast nnn h Total run time in fast speed 2 2 4 No OT nnn Total number of hoist motor over temperature incidents 2 5 No OL nnn Total number of overload incidents 2 6 E stops nnn Total number of e
119. nc reserves the right to alter or amend the above information without notice R amp M MATERIALS HANDLING INC 6 3 Measured values The measured values allows maintenance analysis e R amp M Materials Handling Inc 4501 Gateway Boulevard Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 A dot will appear on the correct spot to indicate the decimals Param Name Value Description 1 2 Measure Measurement menu 1 2 1 Act Load n n t The measured actual load value of the solo hoist connected to the unit Temperature measured at thermistor input 1 Only functional when par 4 4 1 is set to x NTC 1 2 2 Temp 1 nnn C and a NTC type of thermistor is connected across terminals X2 21 22 Otherwise the display shows NA Not Available Temperature measured at thermistor input 2 Only functional when par 4 5 1 is set to x NTC 1 2 3 Temp 2 nnn C and a NTC type of thermistor is connected across terminals X2 23 24 Otherwise the display shows NA Not Available 1 2 4 Supply L1 nnn V RMS line voltage of phase L1 measured at terminal X1 19 VAC 1 2 5 Supply L2 nnn V RMS line voltage of phase L2 measured at terminal X1 17 VAC 1 2 6 Supply L3 nnn V RMS line voltage of phase L3 measured at terminal X1 15 VAC 1 2 7 Motor l1 nn n A RMS motor curr
120. ng Inc 4501 Gateway Boulevard Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 R amp M MATERIALS HANDLING INC 3 Display unit a o 1 02 3 SOG 09 _ 1 Red LED Fault and Warning indication 2 Orange LED Tare load active 3 Green LED OK and Run indication The display unit shows in the large text field the actual or tared load Also warning and fault messages are shown in the display Parameter values can be read and set via display unit after a correct password has been given Load information are displayed in a single row other information are displayed in two rows If display is inside the hoist monitoring unit the red display selection switch must be on the local position up position eo Please note that the hoist monitoring unit is designed for overload protection The displayed load has an accuracy of approx 5 of the rated load and is thus not suitable to be used as a calibrated weighing scale 3 1 Push buttons On the display are four pushbuttons for navigating and programming Zeroing of tare load Press ESC button for three seconds Moving from submenu to main menu and reject parameter changes 3 2 LEDs There are three LEDs inside the display unit The left red LED is for fault or warning indication The orange or yellow LED in the centre is active when the tare load is selected The right green LED is on when the hoist monitoring
121. ngs at temperature If accurate measurements can not be performed one has to RO_F 1000 TO rely on the information given in the motor data files 4 7 4 0 00 Resistance of the slow speed windings at temperature If accurate measurements can not be performed one has to RO_S 1000 TO rely on the information given in the motor data files 4 7 5 nn C Temperature TO nn at the time when measurement is If accurate measurements can not be performed one has to TO carried out in degrees Celsius rely on the information given in the motor data files 4 7 6 T1 Temperature measurement channel for the motor slow Temp_slow speed windings 4 7 7 T2 Temperature measurement channel for the motor fast Temp fast speed windings 4 7 8 143 Coefficient 2 for fast speed Additional motor losses in fast speed windings Setting is C2F motor dependent 4 7 9 236 Coefficient 2 for slow speed Additional motor losses in slow speed windings Setting is C2S motor dependent 4 7 10 165 Coefficient 1 for fast speed lron losses in fast speed windings Setting is motor C1F dependent 4 7 11 255 Coefficient 1 for slow speed Iron losses in slow speed windings Setting is motor C1S dependent 4 7 12 0 0 300 0 Reduction factor for current transformer A V See appendix 3 Current Transformer Table of this ki manual for the correct setting 55 105 R amp M Materials Handi ing Inc reserves the right to alter or amend the above information without notice
122. nning the hoist is restricted 3 3 Display information 3 3 1 Tare load actual load mode Tare load can be used when the crane is operated with a load handling device such as a grab or spreader When no load handling device is used the tare load must be set to zero with empty hook Considering a grab crane as example the table explains the differences between tare load and actual load Press UP or DOWN button to toggle between tare and actual load Display information Hoist application Description Orange LED ON Orange LED OFF TARE LOAD ACTUAL LOAD Displayed value depends on last 10t grab without grab Only empty ropes or empty 0 2 t ee No load in the or zeroing press ESC for three sec 02t Display shows now 0 0 t 5 0t 10 t grab crane A grab is attached to the ropes Grab weight is 5 tons Press ESC button for three sec 5 D t The grab is empty and not Display shows loaded 0 0 t Display shows 5 0 t The payload grap weight The grab is loaded with 5 tons payload This is the payload of the load 10 2t 10 t grab crane without grab attached Display shows Only empty ropes or empty 0 2 t hook block No load in the crane S S er When the display is in the load mode the load can be tared value set to zero by pushing the ESC button about three seconds and after that display shifts into the tare load mode Tare function is made for each hoist individu
123. nsiiananiiadadnamannaadtinamnandiasannas 65 3 104 13 Faults and WarningS sssssseeeeeeeeeeeeeeeees 66 Taal Falser aes 66 13 1 1 Fault codes and description 66 13 2 Warming S sosser 67 13 2 1 General warnings eeeeeeeeseeeeeeeeeeereeeeee 67 13 2 2 Service Warnings eeeeeeeeseeeereeeeerereene 67 14 Troubleshooting ssssnnnnnnnnnnnnnnnnnnnnnnnnnnnn 68 14 1 Fault descriptions cece 68 14 1 1 Fault Hoist OL F_OL eee 68 14 1 2 Fault Motor OT F_OT cc eeeeeccceeeeeees 70 14 1 3 Fault Int relay FSR eee 70 14 1 4 Fault RUN act F_Run ee eeeeceeeeeeees 70 14 1 5 Fault Run FB 2 cceeeeeceeeeeeeeeeeeeeeeeees 70 14 1 6 Fault Brake F Br ccceeeeeeeeeeeeeeeees 71 14 1 7 Fault Br wear F_Brw cceeeeeceeeeeeeeees 71 14 1 8 Fault Sensor ch F_SCH ceecceccceeeeeees 72 14 1 9 Fault Curr meas F_Ajin cc ceececccceeeeeees 72 14 1 10 Fault Supply vol F_SPN cceeeeeeeee 73 14 1 11 Fault Phaseorder F_Sof ccccececeeeeeeeees 73 14 1 12 Fault CParameter F_CP eeeeccceeeeeees 73 14 1 13 Fault MParameter F_MP ccccccceeeeees 73 14 1 14 Fault CAN bus F_CAN ceeeeeeeteeeeees 74 14 1 15 Fault Bridge OL F_BOL 00 cceeeteeeeees 74 14 1 16 Fault Bridge RS F_BrS cceeeeeeeeeeees 74 14 1 17 Fault Slack Rope 2 74 14 2 No Signal 2 eeeeeeeeceeeeeeeeeeeeeeeeeees 74 14 3 Blank
124. nt transformer A V 47 49 Acc t slow 0 205 Acceleration time from stop to slow speed Range 0 00 1 00 sec See also chapter Starting and stopping through slow speed of this manual Acceleration time from slow speed to fast speed Range 0 00 1 00 sec See also chapter Startin NT ACCA TASI JSDS and stopping through en eee of thie manual j i lt Param Name Value Description The selection for the hoist control method 4 8 Hoist ctrl 2 SP Two step control INV Stepless control i e Inverter drives Param Name Value Description 4 9 Slack rope Slack rope function parameters Selects the slack rope function 4 9 1 SR select Yes Selected No Not selected 4 9 2 Load limit nn n t When YES is chosen with parameter 4 9 1 the slack rope limit is entered here in tons Range 0 hoist rated load Recommended value 10 50 of rated load of the hoist Param Name Value Description 4 10 Single sup Selects the action when the motor temperature exceeds the limit or when Fault Br wear occurs ANOA mO rng No No Both hoisting and lowering is prevented Down Hoisting is prevented lowering is allowed When NTC type sensor is applied P4 4 1 and P4 5 1 the limit value for the hoist motor 4 10 2 OT limit nnn C overtemperature supervision in given here in degrees Celsius with the resolution of one degree When the given limit is exceeded the overtemperature supervision is triggered Once activated the supervision remains active until
125. o alter or amend the above information without notice R amp M MATERIALS R amp M Materials Handling Inc 4501 Gateway Boulevard Springfield Ohio 45502 ANDING P 937 328 5100 nnn FAX 937 325 5319 INC Param Name Value Description 4 3 ROUT Relay output parameters When LoadxX is chosen with parameter 4 3 1 the load limit to switch the relay is entered here in tons 4 3 3 ROUT LoadX j nn n t Range 0 hoist rated load Note Functions only for the hoist connected to the unit When Temp is chosen with parameter 4 3 1 the temperature measurement operation is chosen here 4 3 4 TempX meas T1 T1 Temperature measurement channel T1 determines the limit T2 Temperature measurement channel T2 determines the limit T1 2 Both temperature measurement channels are used the first one to reach the limit will trip the relay 4 3 5 TempX lim nnn C When TempX is chosen with parameter 4 3 1 the temperature limit is entered here Param Name Value Description 4 4 T1 Temperature measurement channel 1 parameters Selects the function of temperature measurement channel 1 NU Not used PTC Motor thermistor or Bimetal thermal switch 4 4 1 T1 operat Bwear Brake wear sensor A NTC Type A NTC sensor B NTC Type B NTC sensor C NTC Type C NTC s
126. o present the value The letter k appears when the value is greater than 9 999 indicating the full thousands The letter M appears when the value is greater than 1 000 000 indicating the full millions A dot will appear on the correct spot to indicate the decimals Param Name Value Description 1 2 Measure Measurement menu 1 2 1 Act Load n n t The measured actual load value of the solo hoist connected to the unit Temperature measured at thermistor input 1 Only functional when par 4 4 1 is set to x NTC and a 1 2 2 Temp 1 nnn C NTC type of thermistor is connected across terminals X2 21 22 Otherwise the display shows NA Not Available Temperature measured at thermistor input 2 Only functional when par 4 5 1 is set to x NTC and a 1 2 3 Temp 2 nnn C NTC type of thermistor is connected across terminals X2 23 24 Otherwise the display shows NA Not Available 1 2 4 Supply L1 nnn V RMS line voltage of phase L1 measured at terminal X1 19 VAC 1 2 5 Supply L2 nnn V RMS line voltage of phase L2 measured at terminal X1 17 VAC 1 2 6 Supply L3 nnn V RMS line voltage of phase L3 measured at terminal X1 15 VAC 1 2 7 Motor l1 nn n A RMS motor current of phase U Only functional when par 4 7 1 is set to Motor 1 2 8 Motor 12 nn n A RMS motor current of phase V Only functional when par 4 7 1 is set
127. ominal load was lifted 1 1 7 MFI1 RT Run time in hours from Multi Function Input 1 7 2 MFI1 RT 1 1 8 MFI1 ST Start counter from Multi Function Input 1 7 3 MFI1 ST 1 1 9 MFI2 RT Run time in hours from Multi Function Input 2 7 4 MFI2 RT 1 1 10 MFI2 ST Start counter from Multi Function Input 2 7 5 MFI2 ST 2 2 RT slow Hoist run time in hours with slow speed 7 6 RT slow 2 3 RT fast Hoist run time in hours with slow speed 7 7 RT fast 2 4 No OT Counter for hoisting motor over temperatures 7 8 No OT 2 5 No OL Counter value for overload situations 7 9 No OL 2 6 E stops Counter for emergency stops 7 10 E stops 2 7 ST up Counter value for UP requests 7 11 ST up 2 8 ST down Counter value for DOWN requests 7 12 ST down 2 9 ST fast Counter value for FAST requests 7 13 ST fast 2 10 Max ED Max value of calculated ED percentage 7 14 Max ED 2 11 Over ED Minutes when the ED value has exceeded the 7 15 Over ED designed values 2 13 SRT3 Calculated value from Load and Run time 3 7 16 SRT3 2 14 SRT8 Calculated value from Load and Run time 8 7 17 SRT8 2 16 SL1 Calculated value from Load and Cycles 1 7 18 SL1 2 17 SL3 Calculated value from Load and Cycles 3 7 19 SL3 2 18 SL8 Calculated value from Load and Cycles 8 7 20 SL8 2 19 Power on Total hours when the unit was powered on 7 21 Power on must be 0 2 20 Temp index Power on time weighted with unit s temperature 7 22 Temp index must be 0 2 21 Max Load The highest measured load 7 23 Max Load 6 18 Max Br M
128. on overload C NTC Type C NTC sensor systems are as a standard equipped with type B NTC thermistors Param Value Description Note 4 10 Accessible with password 4 8124 Single sup 4 10 1 No Down Hoisting and lowering is prevented when the If for safety reasons local legislation or customer demands OT run overtemperature supervision trips lowering the load is required when the temperature supervision has tripped set this parameter to Down 4 10 2 150C Sets the tripping level of the overtemperature Consult with the motor data sheets for the maximum allowed OT limit supervision in degrees Celsius steps of one temperature for the motor Default for manufacturer s squirrel degree Only with NTC thermistor cage motors 150 C 25 105 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc R amp M 4501 Gateway Boulevard me Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC 5 4 Supply voltage phase supervision The supply voltage phase supervision consists of two functions Missing supply phase detection Incorrect supply phase order The three supply voltage phases are wired to the hoist monitoring unit Each time the unit is powered up the phase order is checked The unit will continuously measure the existing of all three phases A K1 5 44 i AMG 10 Li L2 L3 PHASE SENSOR VATHEVALY
129. ontrol unit 7 22 Temp Index nnnn h The power on time weighted with the hoist control unit temperature 7 23 Max load nnnn The maximum value of the measured load i is The brake wear counter Counts the number of stop actions to calculate the BrSWP Reset when the cen Br Count nnman hoisting brake has been replaced i 89 105 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc R amp M 4501 Gateway Boulevard Tone Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC Appendix 1 Default parameters All values are default values and can alter from application to application Abbreviations no effect because NU l only for Info C Calibration value D Design Value Hoist Control 2 Speeds 2 Speeds Inverter Hoist Control 2 Speeds 2 Speeds Inverter Load Measurement Motor Sensor Sensor Load Measurement Motor Sensor Sensor 3 Load Setup 4 Start up continue 3 2 1 Load 1 C 4 7 10 C1F D 3 2 2 Mhs1 C 4 7 11 C1S D 3 2 3 Mhf1 C 4 7 12 ki D 3 2 4 Mis1 C 4 7 13 Acc t
130. operat is set to Bwear e If the sensor is connected to the terminals 23 24 check that 4 5 1 T2 operat is set to Bwear e f a brake wear sensor is NOT installed make sure the function is disabled with parameters 4 4 1 and 4 5 1 71 105 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc R amp M 4501 Gateway Boulevard me Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC 14 1 8 Fault Sensor ch F_SCh Measurement signal out of acceptable range e Measure the voltage across terminals 26 11 A and 30 OV Voltage should be between 0 5 9 5VDC low at zero load high when load attached to the hook e Check the parameter 1 2 10 value The parameter 1 2 10 value should be nearly the same as measured 1 VDC If the parameter s value is different than measured value then it is possible that input is broken Ifthe parameter 1 2 10 value is 9 8V e The signal wire hasn t been connected to the Analog input 1 the terminal 26 e The neutral wire is broken between the unit and the sensor e Check the connections between the amplifier and strain gauge sensor e If the parameter 1 2 10 value is less than 1V Measure the voltage across terminal 25 10V and 30 OV Voltage should be about 10 12VDC The power signal wire 10V is broken between the terminal 25 and the sensor The strain gauge sensor is no
131. or Sens e Write down the following parameters Push ESC button 2 times gt Menu 4 Push Down button ones gt Menu 3 Push ENT button gt Menu 3 1 Select menu 3 2 or 3 4 whit Up button and push ENT button Read parameters values Select parameter by Up or Down button 103 105 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc R amp M 4501 Gateway Boulevard MINANE Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC 4 7 1 Load meas Motor 4 7 1 Load meas Sens 3 2 1 Load 1 3 4 1 Load 1 3 2 2 Mhs 1 3 4 2 Input 1 3 2 3 Mhf 1 3 4 3 Load 2 3 2 4 Mis 1 3 4 4 Input 2 3 2 5 Mif 1 3 2 6 Load 2 3 2 7 Mhs 2 3 2 8 Mhf 2 3 2 9 Mis 2 3 2 10 Mif 2 Push ESC button 2 timen gt Menu 3 Push 4 times Up button gt Menu 7 Push ENT button gt Menu 7 1 Read parameters values Select parameter by Up or Down button 7 1 Cycles 7 13 ST fast 7 2 MFI1 RT 7 14 Max ED 7 3 MFI1 ST 7 15 Over ED 7 4 MFI2 RT 7 16 SRT 3 7 5 MFI1 ST 7 17 SRT 8 7 6 RT slow 7 18 SL1 7 7 RT fast 7 19 SL3 7 8 No OT 7 20 SL8 7 9 No OL 7 21 Power on 7 10 E Stops 7 22 Temp index 7 11 ST up 7 23 Max Load 7 12 ST down 7 24 Br Count
132. oring units display can t be read a multimeter is needed Measure voltage level between KAE400 s terminal 6 and 7 Set the zero at no load by turning the trimmer until the led lits and then slightly back that the led does not lit anymore Led lits when the output is below 2 1VDC Check the gain at higher nominal load If the output is over 6 5VDC set the gain to 160 by the dipswitch If the output is under 2 0VDC exchange the wires S and S and return back to section 5 Perform the calibration of the monitoring unit at nominal load and at no load 62 105 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc REY ME 4501 Gateway Boulevard Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 MATERIALS HANDLING INC 12 1 5 Dimensions K gt A NJO NO Tt 7 Aag g sAN g on Ta E gs 2 97 3 e Ss Ee a j gt S52 MW Oo SSS Y 12 2 ESD142 amplifier Strain Gauge 12 2 1 ESD142 Description The ESD142 is a load sensor amplifier which is used to amplify the load signal coming from a strain gauge type of load sensor to a suitable voltage level for the hoist monitoring unit At the moment there are two versions the ESD 142 and the ESD142 1 The
133. parameters must be checked and if needed adjusted before the calibration sequence is carried out The unit used these values in order to calculate the actual load After the calibration has been done it is recommended to write down the values of the parameters of group 3 2 MC values and 4 7 Load param 11 1 2 Motor torque calculation parameters Load rate step control speed change to fast speed is allowed when actual load change within 200ms lt parameter 4 7 2 Parameter Value Description Note 4 Start up menu Accessible with password 4 8124 Start up 4 4 T1 parameters T1 4 4 1 BNTC Determines the type of thermistors in the low speed Type B is presently used as standard T1 operat windings connected to the temperature 1 input 4 5 T2 parameters Accessible with password 4 8124 T2 4 5 1 BNTC Determines the type of thermistors in the fast speed Type B is presently used as standard T2 operat windings connected to the temperature 2 input Parameter Value Description Note 4 7 Load calculation menu Accessible with password 4 8124 Load param 4 7 1 Motor Selects the motor torque calculation method Load meas 4 7 2 10 Load increase rate for controlling the hoisting in two See also description in chapter Sudden load increase supervision of this manual for further details 4 7 3 0 00 Resistance of the fast speed windi
134. password is given the display shifts back to the load display The first display of the password select menu shows four zeros with the leftmost underlined Pushing the up and down button will change the digit The desired digit is selected with the ENT button after which the next digit will be underlined Repeat this procedure until the correct password is given The display will now show the first menu 1 Monitor 1 Example Level 2 password 0732 Actual load 0 1 0000 0 1 0700 0 1 0730 9 0 1 0732 9 1 Password Password Password Password 4 Monitor 1 P AA AA 3 4 3 Hoist selection only multi hoists In multi hoist applications where more then one unit are connected with the CAN bus the display will ask to select the desired unit A B C D or E before the display shows the first menu This way each unit can be accessed via another unit For example all parameters and values of unit C can be displayed and modified via unit A 0 1 0732 0 2 A 0 2 B gt 0 2 E Password Hoist name Hoist name Hoist name 1 When reading data from the display in multi hoist application verify that you are reading the data from the correct device The selected hoist is shown in the 0 2 display 14 105 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling
135. play In case the T1 input is in use for another function connect the sensor to the T2 input and set parameter 4 5 1 to Bwear er It is recommended to set parameter 4 10 1 to Down in order to allow lowering the load when the brake wear supervision is activated Note that this will also allow lowering when the overtemperature is activated because parameter 4 10 1 determines the operation of both the T1 and T2 inputs 39 105 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc R amp M 4501 Gateway Boulevard MINANE Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC 7 8 Load tare With an additional switch the monitored load on the display can be tared tared load value is set to zero This option is most useful when the hoist is equipped with the display in the push button station or when the crane is equipped with an additional load display 7 8 1 Load tare instructions An additional switch or pushbutton must be connected to either one of the MFl inputs Closing the switch will set the tared load value to zero Load tare instructions parameters Parameter Value Description Note 4 1 MFI1 Accessible with password 4 8124 4 1 1 Tare Activates the load tare function Closed contact will set the tared load to zero MFI1 oper In case the MFI1 input is in use for another
136. que for lowering with fast speed load 2 The value n depends on the motor type The calibration Mif2 procedure will automatically write the correct value 56 105 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc REY 4501 Gateway Boulevard Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 MATERIALS HANDLING 11 2 Connections PHASE ORDER CHANGE MUST BE DONE BY REVERSING THESE WIRES IN THIS LOACATION 3 ROUNDS HIGH HOISTING MOTOR 57 105 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc 4501 Gateway Boulevard Springfield Ohio 45502 R amp M MATERIALS P 937 328 5100 FAX 937 325 5319 HANDLING INC 11 3 Load calibration sequence with motor torque iS a We 0 1 0000 Password ete Hoist name 1 10 J aine J 1 3 1 ES woe _ 3 1 1 5 00t H Set gt 80 PETA 3 1 2 ooo j OK a i Up slow EEO Up fast ee i Down slow aa i Down fast i Sodani 3 1 7 0 00t Set lt 30 Opa i OK c i Up slow i 3 1 10 i Up fast Power On Enter password 0732 Display will jump to menu 3 parameters when one hoist is being calibrated If there is more than one Hoist Multi hoisting mode then the hoist must be selected b
137. quipment of machines Part 32 Requirements for hoisting machines e EN 12077 2 1998 Cranes safety Requirements for health and safety Part 2 Limiting and indicating devices 5 105 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc R amp M 4501 Gateway Boulevard MINANE Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING 1 2 3 Patent Pending e US09 940 514 EP01000406 7 e US09 940 464 EP01000405 9 1 2 4 Certificate of compliance e 1334676 LRO25623 6 105 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc R amp M 4501 Gateway Boulevard MINANE Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC 2 Technical characteristics 120 3 Signal name Technical data Maximum supply voltage 690 VAC 10 Nominal supply frequency 50 60 Hz Control voltage range 42 48 VAC 10 or 115 230 VAC 10 Maximum power consumption Imax 4 5A peak value Power consumption 6W 8W Ambient temperature 20 C 65 C 0 F 150 F Storage temperature 40 C 85 C 40 F 185 F Humidity 0 100 RH no condensation Analogue output 0 10V Rmin 1kQ 10VDC output 10 12 VDC Imax
138. r 7 4 2 Runtime and start counter for trolley and bridge connections A normally open contact of the trolley and or bridge travel brake contactor is connected to the MFI1 and or MFI2 input Without a brake contactor the control command can be duplicated to the MFI1 and or MEFI2 input 7 5 Analogue output The hoist monitoring unit has one analogue output which can be used for e g a load display or a relay board that provides certain relay operations according to the load value The analogue output has a voltage range of 0 10 VDC The analogue output can be programmed to represent either the actual load or sum load in multi hoisting the tared load or summed tare load in multi hoisting or the actual load of the connected hoist 7 5 1 Analogue output parameters Parameter Value Description Note 4 6 AOUT Analogue output parameters Accessible with password 4 8124 4 6 1 Act Actual load s values in the output Actual sum load in multi hoisting application AOUT oper Tare Tared Load s values in the output Tared sum load in multi hoisting application Solo Solo hoist s load values in the output Tare function is made for each hoist individual means tare Parameter 1 2 1 command is not transferred to other units via CAN bus Same function as in the display 4 6 2 2 00V Analogue output voltage with zero load Adjustable according to the needed voltage of the connected device Zero load when required 1 4 6
139. r every unit working in the CAN bus Change from one single load display to the next one is done with the arrow keys The sum load of the units is shown with large digits When the yellow LED is illuminated the display shows the tared sum load Each unit makes the tare individually and thus each unit can have different tared sum load values When the yellow LED is not illuminated the large digits indicate the actual sum load of all units The menu structure makes a circle and so with up key button it is possible to go back to the text mode display amp ji Ot jf amp Ji GO jf N jC If the ENT key is pushed in one of the load display modes display numbers 2 3 4 or 5 the display changes to the password request menu With the ESC key or incorrect password the display return to the load display When the correct password is given in menu 0 1 the next menu is for the unit selection As default the actual unit where the display is connected is given Here it is possible to select some other unit connected with the CAN bus unit B in this example After selecting the unit the menu structure works similarly independently of the unit selection The display makes no difference if the value comes from the actual unit or through the CAN bus from another unit 44 105 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc R
140. rature depends on the motor and is determined by the used thermistors The TP44 TPt2 TP21 TP22 hoist monitoring unit will detect over temperature when the resistance of the PTC exceeds 4 0kOhm Bi metal switches are mounted on the motor stator windings Bi metal switches operate as thermal switches and will open up the contact when the measured temperature exceeds the limit The maximum allowed temperature depends on the motor and is determined by the used Bi metal switches The hoist monitoring unit will detect overtemperature when the resistance exceeds 4 0kOhm thus open contact In practice PTC thermistors and Bi metal switches operate in the same way The hoist monitoring unit stops the motion when the resistance of the temperature measuring device exceeds 4 0kOhm NTC thermistors are used when motor torque calculation is the load measurement method NTC thermistors will TEE STSRANTULD decrease their resistance in an almost linear relation to temperature increase The actual motor temperature is Tet IP14 IP12 TP22 accurately measured with NTC thermistors and the hoist monitoring unit will stop the motion in case the resistance of the temperature measuring device drops below the preset value HOISTING MOTOR 23 105 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M 4501 Gateway Boulevard VITRINE Springfield Ohio 45502 P 937 328 5100 FAX 937 325 53
141. re for the single hoist as described above in Start up e Set parameter 4 1 1 back to n where n is the number of unit connected to the CAN bus e Check that all parameter values in the parameter group 4 11 Comm hoist are equal in all units e Check the load display of all connected hoists via one unit Refer to chapter Sum load solo hoist load mode of this manual for instructions 9 3 2 Multifunction inputs Check the Multifunction Input 1 operation from the parameter 4 1 1 MFI1 oper and the Multi Function Input 2 operation from the parameter 4 2 1 MF2 oper NU Not used IntL Intermediate load limit Tare Load tare SRope Slack rope by pass ST RT Start and run time counter 2OLL Second overload limit Level Levelling limit switch function in common hoisting CintL Intermediate load limit in common hoisting CAN CAN bus by pass 9 3 2 1 Intermediate load limit IntL e Intermediate load limit is activated when input is not activated e When actual load values exceed a limit and the input is not activated then unit work similarly than the overload situation e Check by parameter 4 2 2 the intermediate load limit value e Check by parameter 1 2 14 that unit reads the input status oe oe MFI1 input s status bit is second bit from the right XXX1X MEFI2 input s status bit is first bit from the right XXXX1 9 3 2 2 Tare function Tare
142. reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc R amp M 4501 Gateway Boulevard mem Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC e Hang the test load in the hook and check the actual load in both slow speed and in fast speed with parameter 2 1 1 The display should show the value of the test load 5 of nominal load If the load values are within the given range the work is finished Return the old unit to the manufacturer If the displayed load values differ too much more than 10 from the actual test load carry out the calibration procedure as described in Service Manual e After the calibration procedure check the display values again If the load values are within the given range the work is finished Return the old unit to the manufacturer e If the new unit shows any fault code carry out the troubleshooting as described in Service Manual e Return the old unit to the manufacturer 105 105 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice
143. s are used to show the value The letter k appears when the value is greater than 99 999 indicating the full thousands The letter M appears when the value is greater than 1 000 000 indicating the full millions 2 a unit name is used i e hours h there are only four digits available to present the value The letter k appears when the value is greater than 9 999 indicating the full thousands The letter M appears when the value is greater than 1 000 000 indicating the full millions A dot will appear on the correct spot to indicate the decimals 83 105 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M MATERIALS HANDLING INC R amp M Materials Handling Inc 4501 Gateway Boulevard Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 16 3 Load calibration menu Menu 3 3 Load setup Load calibration menu Accessible password level 2 Param Name Value Description Load calibration when the motor torque based load measurement is selected See chapter Load 3 1 Cal Motor a n 3 s calibration sequence with motor torque 3 1 1 Set gt 80 nn n t Set the higher test load value in tons 80 130 x hoist rated load 3 1 2 nn n t OK et the set test load v
144. scription 4 4 T1 Temperature measurement channel 1 parameters 4 4 1 T1 operat Selects the function of temperature measurement channel 1 NU Kokused Motor without thermistors or only one sensor that is connected to the temperature input 2 Motor thermistor or Two speed motors typically only have one set of thermistors for both low speed PTC A cee Bimetal thermal switch and high speed windings Bwear Brake wear sensor See section Hoist Brake Wear supervision ANTC Type A NTC sensor Determines the type of thermistors in the low speed windings connected to the BNTC Type B NTC sensor temperature input 1 Manufacturer s hoisting motors used in motor torque calculation overload C NTC Type C NTC sensor systems are as a standard equipped with type B NTC thermistors Param Name Description 4 5 T2 Temperature measurement channel 2 parameters 4 5 1 T2 operat Selects the function of temperature measurement channel 2 NU Not sed Motor without thermistors or only one sensor that is connected to the temperature input 1 Motor thermistor or Two speed motors typically only have one set of thermistors for both low speed PTC A rt Bimetal thermal switch and high speed windings Bwear Brake wear sensor See section Hoist Brake Wear supervision ANTC Type A NTC sensor Determines the type of thermistors in the low speed windings connected to the BNTC Type BNTC sensor temperature input 1 Manufacturer s hoisting motors used in motor torque calculati
145. service warning is displayed in case one of the values exceeds the given limit 5 1 1 S Run time nnnn h Run time service limit 5 1 2 S starts nnnnn Service limit for the number of starts 5 1 3 S SWP nn Service limit for SWP 5 1 4 S Br SWP nn Service limit for the hoist brake service life Param Name Value Description ee The logger for the latest fault situations the number n indicates the number of faults in the 5 2 Fault log n logger 5 2 4 F XXX annnn The latest fault The fault code XXX and the actual number of starts nnnnn at the moment when the fault was detected Refer to chapter Faults for the fault descriptions 5 2 2 F XXX annnn The second latest fault The fault code XXX and the actual number of starts nnnnn at the moment E when the fault was detected Refer to chapter Faults for the fault descriptions 5 2 n F XXX annnn The n latest fault highest number is 30 The fault code XXX and the actual number of starts nnnnn at the moment when the fault was detected Refer to chapter Faults for the fault descriptions Param Name Value Description 5 3 Reset log n Resets the fault log by pushing the ENT button The number n indicates the amount of faults presently in the logger 5 3 Reset log The reset action must be confirmed by pushing the ENT button once more 16 6 Design values menu Menu 6
146. slow 0 2 0 2 3 2 5 MIf1 Cc 4 7 14 Acc t fast 0 3 0 3 3 2 6 Load 2 Cc 4 8 Hoist ctrl 2 SP 2 SP INV 3 2 7 Mhs2 Cc 4 9 1 SR select NU NU NU 3 2 8 Mhf2 Cc 4 9 2 Load limit 3 2 9 Mls2 C 4 10 1 OT run No No No 3 2 10 MIf2 C 4 10 2 OT limit 3 4 1 Load 1 C Cc 4 10 3 Supply sup No No No 3 4 2 Input 1 C 2 C 2 4 11 1 Hoist cnt 1 1 1 3 4 3 Load 2 Cc Cc 4 11 2 Run sup No No No 3 4 4 Input 2 C 5 C 5 4 11 3 BOL No No No 3 5 OL protect On On On 4 11 4 B nom load Single hoist use value from 6 4 4 Start up 5 Service 4 1 1 MFI1 oper NU NU NU 5 1 1 S run time For Service If not used use value 6 9 4 1 2 MFI1 IntL 5 1 2 S starts For Service If not used use value 6 7 4 1 3 MFI 2OLL 5 1 3 S SWP For Service If not used use value 0 4 1 4 MFI1 Cintl 5 1 4 S Br SWP For Service If not used use value 0 4 2 1 MFI2 oper NU NU NU 5 2 Fault log 4 2 2 MFI2 IntL 5 2 1 FAULT1 l l 4 2 3 142 Intl 5 2 2 ST1 l l l 4 2 4 MFI2 2OLL 4 2 5 MFI2 CintL 6 Design 4 2 6 142 ClintL 6 1 Hoist name A A A 4 3 1 ROUT oper OL OL OL 6 2 Unit No l l l 4 3 2 ROUT Logic Norm Norm Norm 6 3 Class l l l 4 3 3 ROUT LoadX 6 4 Nom Load D D D 4 3 4 TempX meas 6 5 Nominal ED D D D 4 3 5 TempxX lim 6 6 Sp ratio 6 6 1 4 4 1 T1 operat B NTC NU NU 6 7 Max ST D D D 4 5 1 T2 operat BNTC NU NU 6 8 Max E stop 5000 5000 5000 4 6 1 AOUT oper NU NU NU 6 9 Max RT D D D 4 6 2 Z
147. sly to each unit and remain active 14 1 17 Fault Slack Rope 2 Slack rope function is activated e Check parameter 4 9 1 SR select e Check parameter 4 1 1 MFI1 oper e See the chapter Slack rope protection of this manual 14 2 No Signal 2 Communication fault If the display shows the text No Signal it means that the current loop from the unit to the display provides the supply for the display but the serial data is distorted in such a way that the display is not able to read the data Two reasons e Communication fault between unit and display Running possible Remote display or fault is typical in first hardware revision on the monitoring unit all units are produced in year 2001 The unit s processor doesn t start e Running prevented Voltage between the terminal 25 to the terminal 30 is 0 VDC should be 10 12 VDC Unit has to be changed 74 105 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc R amp M 4501 Gateway Boulevard mem Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC 14 3 Blank display e f display shows blank check that display location selection switch position is right logal LOC or remote REM in the monitoring unit e Check the connections from the unit to the display e Change the remote display cables connections for termina
148. t 5 ot xe Ec a 5 OW fo O i s Cov S isp Q noraa Wea Q ite ZMOTO Q HOLIMS GVOTHSAO WOINVHIIN G 225E T gO A lt ii ii NOTLV3OT SIHL NI P oN ED SHIM ISHL ONISHIAZ Ad 2222 R 3NO0 39 ISMH 3ONVHO H30HO ASVHd S2 NOTLW1S INVONd gt Q Zah O D g CO oo gt 55x oTo i o S C NAL I3 NKO d TOUINOD Veg KiddnS Y3MOd I I I I I I MATERIALS Oo Z zZ lt T R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice 98 105 SNaSdS SNaSdSe y aen OWN SNLSMHIId HEN SNINY iii NOTLVOO7 SIH NI ONILSTOH AI E E a S3HIN 3S3HL SNISHSAZH AG 3NO0 38 1SNW 3ONVHO H3040 ISVHd bd V AVISIO v HOLON SNILSTOH apie We T EDE vie eal Er OWUNYYSIS WHIL ANGNI HOLSTWUSHL YOATWASHIVA HOSN3S SSVHd aoa n ev e V 88 417 ro a WH amp e amp ANANI SOTWNY OTNINYYSIS VISOTVNY NOLLOaLOUd WHHL Q HOLIMS QVOTHBAO TWOINVHIIN G NOTLVLS LNYON3d agnaneas 3svHd KV R amp M Materials Handling Inc 4501 Gateway Boulevard Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 isv4 NMOd dn TOHLNOD 3V4 AiddNS Y3MOd MATERIALS oO Z zZ lt T R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice 99 105
149. t connected to the amplifier Check the connections between the amplifier and strain gauge sensor w When the load sensor calibration is done in way that the zero load voltage is less than 1 0VDC the fault only occurs when the signal becomes greater than 9 5VDC 14 1 9 Fault Curr meas F_Ain Measurement signal out of acceptable range only two step control e Measure the voltage across terminals 29 IB and 30 OV Voltage should be about 5VDC e Measure the voltage across terminals 27 12 A and 29 during hoisting and lowering low and fast speed Voltage should be between 0 5 3 VAC peak values 4 5 4 5V You can see a voltage level for all hoist motors with the nominal current from the Appendix 3 1 Current Transformer Table of this manual e Measure the voltage across terminals 26 11 A and 29 during hoisting and lowering low and fast speed Voltage should be in between 0 5 3 VAC peak values 4 5 4 5VAC You can see a voltage level for all hoist motors with the nominal current from the Appendix 3 1 Current Transformer Table of this manual e Check parameter 4 7 13 Value should not be less than 0 20s e Check parameter 4 7 14 Value should not be less than 0 30s w Make sure that any other electrical loads e g fans inverters haven t been connected behind the current transformer 72 105 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice
150. t is equipped with two LEDs that provide operational information as follows Action LED Green LED Red LED Illuminated continuously OK not running Fault Blinking OK running Warning Not illuminated Fault OK OK state means that the hoist control unit is working normally and no fault or error has been detected Running the hoist is possible Warning means that a condition monitoring value has exceeded the design value Running the hoist is possible but safe operation can not be guaranteed 21 105 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc 4501 Gateway Boulevard Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 R amp M MATERIALS HANDLING INC Fault means that one or more of the supervised safety features values exceeds the limit Running the hoist is restricted For Run or Fault supervision it is possible to connect an external indication device like a horn or lamp to the relay output Relay output must be programmed to the desired function OK or Ready 5 2 Overload protection The overload protection can be done in two ways either with motor torque calculation or by using a load sensor Regardless which system is used the hoist monitoring unit will prevent the hoisting motion when the measured load exceeds 110 of the rated load for a period of time A filtering del
151. t shifts to fault state Check that the relay works 9 3 3 4 Fault supervision Ready Contact closed in normal operation Contact opens when the unit shifts to fault state Check that the relay works 49 105 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc R amp M 4501 Gateway Boulevard MINANE Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC 9 3 3 5 Motor temperature limit TempX Contact closed when the motor temperature exceeds the limit X Check the limit value by parameter 4 3 5 Check the input selection by parameter 4 3 4 T1 temperature measurement T1 determines the operation of the relay typically the low speed windings e T2 temperature measurement T2 determines the operation of the relay typically the high speed windings e T14 2 both T1 and T2 are used When either one reach the limit the relay operates e Check that the relay works 9 3 4 Analog output AOUT e Check the output operation by parameter 4 6 1 e Check that load value is same on the unit s display as on the and large display 4 6 1 Oper is Act then Actual load mode value should be same than large displays value 4 6 1 Oper is Tare then Tare load mode value should be same than large displays value 4 6 1 Oper is Solo then parameters 1 2 1 value should be same
152. t the lifted load is not more than 110 of the rated load of the hoist Load display updates the values slower than overload protection trips Check the parameter 6 4 must be equal to the rated load of the hoist Check if intermediate load limits are in use Parameters 4 1 1 and 4 2 1 Perform the calibration procedure when required as described in this manual Check the parameter 4 7 1 value The parameter 4 7 1 value is Sens e Check the parameters 3 4 2 Input 1 and 3 4 4 Input 2 When the values are equal to each other the calibration is done with only one load Perform the calibration procedure as described in this manual e Check that the parameter 1 2 10 Ain1 value is between the parameters 3 4 2 and 3 4 4 value Ifthe parameter 1 2 10 value is 9 8V e The signal wire hasn t been connected to the Analog input 1 the terminal 26 e The neutral wire is broken between the unit and the sensor e Check the connections between the amplifier and strain gauge Ifthe parameter 1 2 10 value is less than 1V e The power signal wire 10V is broken between the unit and the sensor e The strain gauge sensor is not connected to the amplifier e Check the connections between the amplifier and strain gauge Ifthe parameter 1 2 10 value is OK but the load measure don t work then is possible that wires have been connected crosswise e Check the connections from the unit to the load sensor 68 105 R amp M Materials Hand
153. that the input wire goes trough the transformers in the wrong direction 75 105 X32A2 F 14 15 32 33 CLA CLB PENDANT DISPLAY OUTPUT THERMISTOR INPUT TERM SISAANTULO TPei_ TP44 TP12 TPee HOISTING MOTOR PHASE ORDER CHANGE MUST BE DONE BY REVERSING THESE WIRES IN THIS LOCATION MOVOC AINI AIN2 AIN3 IB OVOC ANALOGIA SISAANTULO ANALOG INPUT R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc R amp M 4501 Gateway Boulevard eel Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING Correct wiring Wrong wiring 1 Terminal block 2 Current transformer 3 Contactor 14 6 There is no fault but hoist doesn t work 14 6 1 Hoisting works but lowering is prevented Check the Slack Rope function with parameter 4 9 1 Slack Rope is detected during normal operation Decrease the Slack Rope detection level If the slack rope function is not needed set to No If the slack rope function is needed in some cases but not always consider installing a slack rope by pass switch with either one of the MFl inputs oe SW 2 100 or later When slack rope function is activated the unit shows Fault Srope on the display If unit s software is SW 2 004 or earlier the unit doesn t show anything when slack rope is activated and lowering is prevented 76 105 R amp M Materials Handlin
154. the above information without notice R amp M Materials Handling Inc R amp M 4501 Gateway Boulevard me Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC 11 4 Zero load calibration sequence with motor toque Power On Enter password 0732 Select the hoist Go to menu 3 1 1 Move to the next section with the arrow up button Hang a test load of less than 30 of the rated load of the hoist in the hook Typically this is an empty hook Make sure the load Set gt 80 hangs freely and steady Enter the value of the test load in tons empty hook 0 00t Confirm the correct value with the ENT button 3 1 7 0 00t Set lt 30 imitate nee The text Up Slow appears on the display Drive the hoist in slow speed upwards until the next text appears Drive the hoist in fast soeed upwards until the next text appears i aa aca el et area es Drive the hoist in slow speed downwards until the next text OE A appears i Drive the hoist in fast speed downwards until the next text E 3 appears Meee A 3 1 12 Down fast lt Run the calibration sequence according to the display instruction w When the calibration is done write down the load setup values of parameter group 3 2 in the commissioning table 11 5 Manual load calibration Before starting the calibration make sure you have a known test load available of at least 80 and maximum 13
155. the right to alter or amend the above information without notice R amp M Materials Handling Inc R amp M 4501 Gateway Boulevard Tone Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC Appendix 3 1 Current transformer table Current transformer choosing Motor Un f In A In A Current Turn of In V In V In V In V Ik type V Hz high low transformer winding the high low high low Hoist control type primary device goll whit secondary whit secondary whit secondary whit secondary Parameters Peek value Peek value Effective value Effective value 4 7 12 MF10M 208 60 9 8 5 9 MI20 1 1 96 1 18 1 39 0 83 7 071 230 50 8 2 4 2 MI20 1 1 64 0 84 1 16 0 59 7 071 230 60 9 0 4 6 MI20 1 1 80 0 92 1 27 0 65 7 071 380 60 5 0 2 8 MI20 3 3 00 1 68 2 12 1 19 2 357 400 50 4 7 2 4 MI20 3 2 82 1 44 1 99 1 02 2 357 460 60 4 5 2 3 MI20 3 2 70 1 38 1 91 0 98 2 357 500 50 3 8 1 9 MI20 4 3 04 1 52 2 15 1 07 1 768 575 60 3 6 1 8 MI20 4 2 88 1 44 2 04 1 02 1 768 660 50 2 8 1 5 MI20 4 2 24 1 20 1 58 0 85 1 768 MF10Z 208 60 10 0 5 1 MI20 1 1 99 1 02 1 41 0 72 7 071 230 50 14 3 6 8 MI20 1 2 86 1 36 2 02 0 96 7 071 230 60 16 7 6 MI20 1 3 20 1 52 2 26 1 07 7 071 380 60 8 7 4 6 MI20 2 3 48 1 84 2 46 1 30 3 536 400 50 8 2 4 3 MI20 2 3 28 1 72
156. thout notice R amp M Materials Handling Inc REY ME 4501 Gateway Boulevard Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 MATERIALS HANDLING INC 14 1 14 Fault CAN bus F_CAN CAN bus communication fault e Check the CAN bus wiring e Check that the value of parameter 4 11 1 Hoist cnt in each unit corresponds to the number of units connected with the CAN bus e Check that each connected unit has an unique address parameter 6 1 Hoist name e Check with parameter 2 1 SW version that each connected unit has the same software version eo When parameters 4 11 2 and 4 11 3 are set to YES running is not allowed after Fault CAN bus The situation can be reset by switching the power off and on again This must be done for each unit preferably simultaneously by using the main disconnect of the crane power supply If the power off reset is done one by one the fault may appear to be cleared in the first unit however running is possible only after resetting all other units too 14 1 15 Fault Bridge OL F_BOL Overload in calculated bridge load e Check with parameter 4 11 4 B nom load that the load settings are the same in all connected units 14 1 16 Fault Bridge RS F_Brs Fault in multi hoisting requests for running not simultaneous e Check parameter 4 11 2 Run sup in each unit connected to the CAN bus If the parameter is set to YES the request must come simultaneou
157. ting active service status Service name 3 3 4 Sum load solo hoist load mode In multi hoist applications the display shows the summed tare load as the first display at power on Toggling between the tared sum load the actual sum load and the actual load of each connected hoist individually is done with the up and down buttons Power ON Tared load Actual load Actual load Actual load Actual load vost A B aet A B iS P B Hoist Cc eee Host Hoist C ay 3 a si ni 0 1 0000 Password 13 105 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc R amp M 4501 Gateway Boulevard me Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC 3 4 Menus Monitoring items and parameters are presented in menus The menus are accessible with passwords The right to read and or modify parameters within a menu depends on the selected password 3 4 1 Moving in menus Toggling between the menus is done with the up and down arrow buttons When the desired menu has been selected it is entered with the ENT button If there are submenus in the main menu they are selected and entered in the same way as described above Returning to the higher menu level is done with the ESC button 3 4 2 Password When the ENT key is pushed the display shifts to the password request menu With the ESC key or when an incorrect
158. tion values for the load sensor method 3 4 1 Load 1 nn n t The higher test load value set with parameter 3 3 1 3 4 2 Input 1 n nn V The load measurement voltage in the analogue input Ain1 corresponding to the test load 3 4 3 Load 2 nn n t The lower test load value set with parameter 3 3 3 3 4 4 Input 2 n nn V The load measurement voltage in the analogue input Ain1 corresponding to the load 2 Param Name Value Description Set to OFF to temporarily by pass of the overload protection OFF state automatically switches 3 5 OL protect ON to ON state after power off or after 30 minutes activating the OFF state When rated load is over 110 then hoisting is only possible with slow speed 84 105 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M MATERIALS HANDLING INC R amp M Materials Handling Inc 4501 Gateway Boulevard Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 16 4 Start up menu Menu 4 4 Start up Start menu Accessible password level 4 Param Name Value Description 4 1 MFI1 Multi Functional Input 1 parameters 4 1 1 MFI1 oper NU Selects the function of MFI1 NU Not used Intl Intermediate load limit Tare Load tare SRope Slack rope by pass ST RT Start and run time counter 2OLL Second overload limit Level Levelling limit
159. tor torque for hoisting with slow speed test load The value n depends on the motor type The calibration Mhs1 procedure will automatically write the correct value 3 2 3 nn nn Motor torque for hoisting with fast speed test load The value n depends on the motor type The calibration Mhf1 procedure will automatically write the correct value 3 2 4 nan nn Motor torque for lowering with slow speed test load The value n depends on the motor type The calibration Mis1 procedure will automatically write the correct value 3 2 5 nan nn Motor torque for lowering with fast speed test load The value n depends on the motor type The calibration MIf1 procedure will automatically write the correct value 3 2 6 0 00t The lower test load value usually the empty hook A load in the range of 0 30 x hoist nominal load can be Load 2 0 00t used 3 2 7 nn nn Motor torque for hoisting with slow speed load 2 The value n depends on the motor type The calibration Mhs2 procedure will automatically write the correct value 3 2 8 nn nn Motor torque for hoisting with fast speed load 2 The value n depends on the motor type The calibration Mhf2 procedure will automatically write the correct value 3 2 9 nan nn Motor torque for lowering with slow speed load 2 The value n depends on the motor type The calibration Mls2 procedure will automatically write the correct value 3 2 10 nan nn Motor tor
160. total run time and starts of either the trolley and or bridge travel motion When this option is activated a complete overview of the usage of the crane is recorded Read only menu for condition monitoring values and measured values 1 Monitor 1 Accessible with the customer s password Param Name Value Description 1 1 Cond mon Condition monitoring menu Total hours of running time when MFI1 input is closed Can be used to monitor the total running 1 1 7 MFI1 RT n h time of another machinery i e the trolley drive Active only if parameter 4 1 1 is set to ST RT and the MFI1 input is connected Total amount of starts when MFI1 input is closed Can be used to monitor the total amount of 1 1 8 MFI1 ST n starts of another machinery i e the trolley drive Active only if parameter 4 1 1 is set to ST RT and the MFI1 input is connected Total hours of running time when MFI2 input is closed Can be used to monitor the total running 1 1 9 MFI2 RT n h time of another machinery i e the bridge drive Active only if parameter 4 2 1 is set to S TRT and the MFI2 input is connected Total amount of starts when MFI2 input is closed Can be used to monitor the total amount of 1 1 10 MFI2 ST n starts of another machinery i e the bridge drive Active only if parameter 4 2 1 is set to ST RT and the MFI2 input is connected 32 105 R amp M Materials Handling I
161. train gauge sensor and EDS143 or KAE400 ESD142 and two strain gauge sensor is used simultaneously the needed current is much over 50mA Furthermore the current of relay card ESD143 alternates depending on the state of the relays That affects to the output voltage of the Control Pro and also to the accuracy of the load measuring In worst case the relay card starts to vibrate because of voltage alternation That is why external power supply is used whenever ESD143 or two strain gauge sensors and KAE400 ESD142 is used After tests it has been decided that ETA Power Source WRM22FWX U from Perel Oy is started to use Test results can be seen below Technical data Type WRM22FWX U Input Voltage AC115 230V Input Current 0 45A Input Range AC85 264V DC110 350V Input Frequency 50 60Hz Output Voltage V 2 12VDC Output Current A 0 8A 0 5A Operating Temperature 5 to 40 C unit without coer 5 to 50 C Operating Humidity 30 to 85 RH non condensing Connection There are two separate 12 VDC outputs V1 G1 V2 G2 at the power supply What we need is 12 VDC for KAE400 ESD142 and strain gauge sensor and 24 VDC for ESD143 Therefore one 12 VDC output V1 is connected to the ground of the other one G2 This way voltage between V2 and G1 will rise to up 24 VDC Instead of 18 VAC 24 VDC is connected to the ESD143 So external AC transformer is not needed anymore Zeros of the ESD143 X1 1 X1
162. trol speed 0 means that the function is not applied Load rate change to fast speed is allowed when actual load change within 200ms lt 10 is the factory default parameter 4 7 2 Setting range 0 10 steps of 1 A small value makes the hoist to drive in slow speed for a longer period to ensure that the load is stabilised not stuck to the unloading platform etc and no more vibrations caused by the ropes and or other mechanics A larger value maximum 10 allows faster acceleration to fast speed 29 105 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc R amp M 4501 Gateway Boulevard MINANE Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC 6 Monitoring Items 6 1 General In order to read the monitoring items and to program the unit the hoist monitoring unit is equipped with a display The monitoring items of the hoist monitoring unit consist of variable read only values These monitoring items are of great advantage when efficiently planning maintenance preventive repairs troubleshooting and general overhauls In addition the monitoring values will accurately show the usage of the hoist The values are stored in the memory of the hoist monitoring unit The stored values remain also during power off situations After power off situation the previously stored values are taken into a
163. und 36 CAN H CAN bus high 37 CAN L CAN bus low 38 CAN GD _ CAN bus neutral w Input request is not directly connected to the output Output voltage comes from Control Voltage Line OL via Safety Relay and Control relay See simplified pictures 0L10 l z eee Control voltage UP DOWN FAST HOUT wad A K1 A K2 A K4 Connections on eldrawings Unit s internal connections 9 105 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc REY ME 4501 Gateway Boulevard Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 MATERIALS HANDLING INC 2 2 Product description sticker 2 CID 48V S No H02389 ID 52292509 Supply voltage max 690V 50 60Hz Control 42 48V 50 60Hz KCI Made in Finland Sno tT smo FERERERETETEN Pat pending US 09 940 514 EP01000460 7 C E CSA US 09 940 464 EP01000405 9 1 Supply voltage Control Voltage 2 Unit type 3 Tested year week tester 4 Serial number 5 Product specific code Unit types Unit type Serial number Product specific code Control voltage CID 48V Hxxxxx ID 52292509 42 48 VAC CID 115V TXXXXX ID 52292510 110 230 VAC 10 105 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handli
164. unit is OK and blinks when the hoist is running Toggle between actual load orange LED off and tare load orange LED on Scrolling down Toggle between actual load orange LED off and tare load orange LED on Scrolling up Entering the password level Selecting a menu and accept parameter changes W a o Action LED Red LED Left Orange LED Centre Green LED Right Illuminated continuously Fault Tare load value displayed OK not running Blinking Warning and Service OK running Not illuminated OK Actual load value displayed Fault OK state means that the hoist control unit is working normally and no fault or error has been detected When a driving output or the run feedback in inverter application is active the green LED is blinking Warning means that a condition monitoring value exceeds the corresponding design value Running the hoist is possible but safe using is not guaranteed 11 105 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc R amp M 4501 Gateway Boulevard MINANE Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC Service state means that a limit value set for the next service has been expired This is indicated to the crane user but the hoist can still be run normally Fault state means that a serious problem has been detected Ru
165. up contactor two step control or hoist up request inverter drive 3 FOUT Provides the control voltage to fast speed contactor two step control or fast stop control stop limit or fault in inverter drive 4 OL Control voltage line 5 ON Control voltage neutral 6 MFI2 Multifunction input 2 programmable 7 MFI 1 Multifunction input 1 programmable 8 FIN Fast speed request or run feedback in inverter drive 9 LIN Lowering request 10 HIN Hoisting request 11 ROUT Relay output programmable 12 RIN 13 Not used 14 Not used 15 L3 Input voltage measurement phase L3 16 Not used 17 L2 Input voltage measurement phase L2 18 Not used 19 Li Input voltage measurement phase L1 8 105 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc R amp M 4501 Gateway Boulevard ae Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC Connector X2 Terminal Signal Description 20 PE Protective earth 21 TP11 i 22 TP12 Thermistor input 1 23 TP21 i 24 TP22 Thermistor input 2 25 10V Load sensor supply 10 12 VDC 26 AIN1 Analogue input 1 27 AIN2 Analogue input 2 28 AIN3 Analogue input 3 29 IB Current transformer common 30 OV Load sensor supply 0 V 31 Not used EA Current loop for display 34 AN Analogue output 35 ANO Analogue output gro
166. ust identify the supply voltage frequency e See chapter Overload protection Motor torque of this manual 69 105 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc REY ME 4501 Gateway Boulevard Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 MATERIALS HANDLING INC 14 1 2 Fault Motor OT F_OT Hoist motor overtemperature e Check that 4 4 1 T1 operat corresponds to the actual sensor of the hoist THERMISTOR INPUT motor TERM SISAANTULO e Check that 4 5 1 T2 operat corresponds to the actual sensor of the hoist motor TP24 TP14 _TP42 TP22 e When NTC type sensor is selected check parameter 4 10 2 OT limit e Lowering can be allowed by setting 4 10 1 OT run Down e Unplug the terminal X2 and measure the temperature sensor s resistance between terminal 21 and 22 also between terminal 23 and 24 PTC sensor or bimetal switch the resistance should be less than 1kohm NTC sensor The resistance should be between 0 5kohm and 100 kohm See Appendix 4 Motor temperature NTC charts e Measure the internal resistance of temperature input s from terminal s pins by multimeter disconnect the orange terminal X2 When input is okay the input s internal resistance is 6 3 kohm HOISTING MOTOR 14 1 3 Fault Int relay F_SR A fault detected in the internal safety relay e Interna
167. y a Letter Name Go to menu 3 1 1 Hang a higher test load of 80 130 of the rated load of the hoist in the hook and make sure the load hangs freely and steady Enter the value of the test load in tons Confirm the correct value with the ENT button The text Up Slow appears on the display Drive the hoist in slow speed upwards until the next text appears Drive the hoist in fast speed upwards until the next text appears Drive the hoist in slow speed downwards until the next text appears Drive the hoist in fast speed downwards until the next text appears Hang a lower test load of less than 30 of the rated load of the hoist in the hook Typically this is an empty hook Make sure the load hangs freely and steady Enter the value of the test load in tons empty hook 0 00t Confirm the correct value with the ENT button The text Up Slow appears on the display Drive the hoist in slow speed upwards until the next text appears Drive the hoist in fast soeed upwards until the next text appears Drive the hoist in slow speed downwards until the next text appears Drive the hoist in fast speed downwards until the next text appears or Run the calibration sequence according to the display instruction w When the calibration is done write down the load setup values of parameter group 3 2 in the commissioning table 58 105 R amp M Materials Handling Inc reserves the right to alter or amend

service manual for hoist control device

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