Velocity Drive Module User Manual
Contents
1. Page 18 of 29 velocity user manual kinesys Brake Type This value determines how the primary and secondary brakes work together The following values are valid O The primary brake is released for the duration of a move The Secondary Brake follows the Primary Brake This is the normal mode of operation 1 The primary brake is released for the duration of a move The Secondary Brake is released whenever the drive is enabled This mode is primarily used when the secondary brake is a very large slow acting device 2 The primary brake is released whenever the drive is active and holding the load The Secondary Brake follows the Primary Brake This mode is primarily used when controlling servo motors that are energised all the time Any other value in this parameter will act like a value of 0 Drum Circ mm To allow the drive to correctly display the distance in mm the circumference in mm of the winch drum should be entered here Max Speed mm s This value is automatically calculated from the Gearbox ratio and Drum Circumference but can be altered here if required Estop Ramp mm s s This is the ramp rate that will be used if a Fast stop is triggered externally by removing the enable line This ramp rate should be set as high as possible for the installation to allow the winch to stop in the shortest possible time Jog Ramp mm s s This is the ramp rate that will be used when th2. Velocity Drive Module User Manual Manual Revision 1 5 Drive Software Version 4 3 04 4 3 05 Kinesys Software Version 3 1 4 kinesys velocity user manual Page 2 of 29 velocity user manual kinesys Kinesys Projects Limited accepts no liability for any consequences resulting from inappropriate negligent or incorrect installation of the equipment The contents of this manual are believed to be correct at the time of printing In a commitment to a policy of continuous development and improvement Kinesys reserves the right to change the specification of the product or its performance or the contents of this manual without notice All rights reserved No parts of this manual may be reproduced or transmitted in any form or by any means electrical or mechanical including photocopying recording or by an information storage or retrieval system without permission in writing from Kinesys Projects Limited Kinesys Projects Limited 2008 Page 3 of 29 velocity user manual kinesys Contents ERA de AE AE ET NE RE EE TE EE 7 INIOAUCHOM EE N EE OE EE EE 9 Se eie oi N en 10 ET EO EE EE A 11 Drive Front VIEW iss Dee da eh Ge eo ee aguas ee Ee de nee ee 11 Drive Rear ViEW ee ese ee ee RR Re AE ee GR Re Re ee ee ee ee GR Re Re ee ee ee ee Re Re ee ee ee ee ee Re Re ee ee 13 Drive Display amp Menu System cccccceeseseseeeeeeeeeeeeeseeeseneneeeeeeeeeseseeeeneeeeeeeenees 15 DEFAULT DISPLAY Eee rear 15 SCREEN
3. upper and lower limits they will ignore any software limits set in the drive If the winch fails to move or stops moving refer to the status window on the drive display act check the displayed message against the list shown in the menu system section of this manual Running in Auto mode from a remote controller The Velocity drive module can be controlled from an external controller via interface connections on the back panel The primary method of connection is via Ethernet and allows complex systems to be controlled using the Kinesys Vector and K2 control software packages Please contact Kinesys for more details on these products To switch the drive into Auto mode move the Drive Control key switch to the enable position and the mode key switch to the auto position In this mode local control from the drive is inhibited Page 23 of 29 kinesys velocity user manual Drive operation under winch fault conditions Various fault conditions can occur at the winch and the drive will react in certain ways depending upon the severity of the fault Various conditions are listed below along with the appropriate drive response Winch Fault Drive response Ultimate Limit struck The drive will stop abruptly with no ramp down and the brakes will be applied immediately Belt brake limit active The drive will stop abruptly with no ramp down and the brakes will be applied immediately Forward
4. The drive trip code will be displayed along with this message Local Manual Mode The Mode Key switch on the front panel is in the Manual position This will allow the drive to be controlled by the forwards reverse and speed controls on the front panel Manual Up Active The Manual Up button on the front panel is being pressed Manual Down Active The Manual Down button on the front panel is being pressed VIEW MENU OPTION The View menu option allows the default display of the drive to be switched to show something other than the current position The most important of those display options are shown below View Option Description Current Position mm Will show the current position in mm Motor Current A Will show the current motor current in A Drive Load Will show the current drive load as a of full current load Note the drive is capable of driving up to 175 of full load for a few seconds Motor RPM rpm Show the current motor speed in rpm To select a display option the view key is pressed and the up and down arrow keys are used to highlight the desired display option This is then chosen by pressing the select key Page 17 of 29 kinesys velocity user manual SETUP MENU OPTION The Setup menu option allows various drive parameters to be displayed and edited A list of the menu options is shown below View Option Description Unit Address This will allo
5. and ultimate limits overload and slack rope detection and secondary brake 4 MAINS IN ensure the supply is turned off at source before inserting or removing this connection 5 ARCNET permits data network connection directly to the inverter for computer control and diagnostics 6 RS485 used for external pendants or drive interconnection 7 DRIVE CONTROL used when connecting multiple drives together or when connecting to an external emergency stop monitor and controller e g Kinesys Array ES 8 AUXILLARY Permits the connection of remote equipment including pendants and joysticks etc 9 AUXILLARY BRAKE Permits the connection of 190VDC brakes Page 13 of 29 7 Sy MOTOR BRAKE 10 kinesys velocity user manual 10 EXTERNAL FUSES Page 14 of 29 velocity user manual kinesys Drive Display amp Menu System The Velocity drive module incorporates an information and diagnostic display that allows the user to view and set parameters within the drive These configure the way that the drive calculates its motion profiles and limits the top speed and ramp rate the load will travel at The information is accessed by viewing the display and by using the eight buttons underneath and to the right of it The buttons to the right act as cursor buttons allowing the user to move up and down lists and to edit parameter values The buttons underneath the display allow the user to move between screens and to allow different
6. data to be displayed DEFAULT DISPLAY The default display is split up into three main regions System OK 1000 VIEW SETUP RESET KEYPAD The top line of the display is the status window this shows the current alarm state if multiple alarms are active each one will be displayed in turn for a second A complete list of the displayed alarms is shown later in this manual If the drive has no active alarms the message System OK will be displayed The middle part of the display shows the current position of the controlled winch or motor This is displayed in mm and is normally shown in a large font The bottom part of the display indicates the functions of the four buttons below the display The functions of these four buttons will change depending on what screen is currently being displayed The default display format will change slightly if any of the external limits are activated Overload Trip m Ken GEN SN ov 1000mm VIEW SETUP RESET KEYPAD The status window will change to two lines with the bottom line showing the state of the five limit switch inputs The display above shows the Ultimate Forward Reverse and Slack limits all intact limit and the Overload limit tripped Intact limits are shown in reverse video SCREEN SAVER After a few seconds of inactivity the display will revert so a scrolling screen saver display This display will include the message ALARMS ACTIVE if any error or trip conditio
7. supply Turn on both the circuit breakers on the front of the drive The display on the front of the drive should illuminate When you are ready to move turn the drive control key switch on the front of the drive to enable Power Off The power down procedure is performed by following the power up procedure in reverse Page 21 of 29 velocity user manual kinesys Drive Operation Running in manual mode from the Drive front panel The Velocity drive module has manual controls fitted to the front panel This allows motors to be controlled directly from the drive A clear view of the moving load must be available for safe operation To move the load from the drive turn the Drive Control key switch to the enable position and the mode key switch to the manual position The forwards and reverse buttons will illuminate The manual controls on the front of the drive use the jog ramp set in the drive under the setup menu This should be checked to ensure it is the desired value You should ensure that the speed control on the drive is set to minimum speed fully anti clockwise before commencing movement To start the winch moving simply press and hold either the forwards or reverse buttons depending on the desired direction Then slowly advance the speed control until the load is moving at the desired speed The manual controls on the front panel allow the winch to be driven between its
8. 29 Three phase neutral and earth supply phase to phase voltage 380 420 v a c 1 6mm steel front panel 2mm steel zinc plated and clear passivated finish RAL5011 stove enamelled and silk screened on front panel IP40 O 55 C 32 131 F 486 x 500 x 175 excluding connectors or front panel controls 30 kg velocity user manual kinesys Layout Drive Front View Y Ir N AN Q poker _ 2 42 O O 7 A O MODE SPEED FORWARDS REVERSE 8 orem 2 2 S CONTROL gt c gt C gt gt C IK Ic pd DG A dy Ic dC C gt JK ES C gt ae KINESYS E E z gt Ic lt gt O velocity gt 2 C lt U variable speed ac drive DO NOT OBSTRUCT AIR INTAKE CLEANRLTERREGULARLY I TL 1 INFORMATION AND DIAGNOSTIC DISPLAY displays information about the revolve movement and error messages as well as allowing configuration parameters to be edited 2 DISPLAY CURSORS these buttons allow the user to navigate the display and edit parameter values 3 DRIVE CONTROL KEYSWITCH sets the drive into one of three states drive off drive disabled and drive enabled The key is removable in any of the three positions allowing the drive to be securely disabled when left unmonitored if required 4 MANUAL OPERATION KEYSWITCH sets
9. SAVER na 15 VIEW MENU OPTION scr ee 17 RESET MENU OPTION cesan r a FEIER Nee 20 KEYPAD MENU OP TION socios 20 Power On Power Off Sequence unuuusnsuunnnnnnnnnnnennnnnnnnnnnnnnnnnennnnnnnnnnnnennnnnnnnnn 21 Ve ae ME RE AE EE EE 21 POWELON SR ME N RE OE EE N O EE 21 Drive Operation u EE OE 23 Running in manual mode from the Drive front panel ee nennen nennen 23 Running in Auto mode from a remote controller 2444s444 HH ee ee ee nennen 23 Drive operation under winch fault conditions ee ee nennen nennen nennen 24 Pin Connections AE EE EE EE EE ie 25 MAINS IN EA EE N EE EE 25 MOTOR 0 75kw 7 5kw 400v DriveS ees ee ese ee ee ee ee ee ee ee ee ee ee Re ee ee be ee ee be ee 25 MOTOR 11kw 22kw 400v Drives ees ese ee se ee ee Re AE Re ee AR Ge ee ee ee ER ee ER ee ER Re ee 25 ENCODER ssp 26 BRAKES ee i 26 LIMITS WINCH CONTROL see aaa 27 Ete ee ee ee ee ee 28 A E een enge 28 Page 5 of 29 velocity user manual kinesys Safety Advice e Carry out a full risk assessment for your particular application e Only allow competent personnel to operate the system e Test the emergency stop system on a regular basis e Never use damaged cables or connectors e Never operate motors or hoists without having a clear view of the load or reliable communication with an observer e f an unexpected move presents a potentially hazardous situation use the emergency stop button to bring all hoists to an im
10. V 17 OV OV OV OV OV BRAKES Amphenol C16 3 8 E female on panel with locking threads female on panel with locking threads Panel Connector Amphenol C016 10G008 0001 Mating Connector Amphenol C016 101008 0021 PIN FUNCTION NOTES 1 Phase L3 un switched Controlled by drive power contactor 2 Neutral un switched Controlled by drive power contactor 3 190V DC switched Controlled by secondary brake circuit 4 190V DC switched Controlled by secondary brake circuit 5 24V DC switched Controlled by secondary brake circuit 6 24V DC switched Controlled by secondary brake circuit 7 No connection 8 No connection E earth Page 26 of 29 velocity user manual LIMITS WINCH CONTROL kinesys Tourline TL25 female on panel with screw locking ring Panel connector Ten 47 Tourline TL25PF26 Mating Connector Ten 47 Tourline TL25LMO1 pin function notes E stop 1A emergency stop circuit 1 link to B if not used E stop 1B E stop 2A emergency stop circuit 2 link to D if not used E stop 2B E stop 3A emergency stop trace circuit link to F if not used E stop 3B brake 24V DC secondary brake connection brake OV DC secondary brake connection brake 24V DC secondary brake connection brake OV DC secondary brake connection 24V DC limits Sensor power supply OV limits sensor power supply home sensor datum sensor connect to 24V ultimate limi
11. e drive is controlled by the manual controls on the front panel Move Delay x1ms The drive is capable of delaying the start of a move if the brakes are applied to allow them time to release A maximum value of 2000 2s is allowed for this value DigLock Mode 0 4 This parameter specifies if the drive is digitally locked to other drives Digital locking requires extra hardware and this parameter should be left at its default value of 1 Invert Direction 0 1 This parameter allows the drive to select which direction of rotation of the drum relates to a forwards movement This value should be set as required by the installation Page 19 of 29 kinesys velocity user manual RESET MENU OPTION This key will case the Inverter Drive to be reset which will clear any drive trips shown in the status window KEYPAD MENU OPTION Pressing the menu key below the keypad option switches the drive into a debug mode that allows debugging equipment to be plugged into the program port on the front of the drive The drive will detect if this equipment has been removed after a couple of minutes and switch itself back to normal operating mode This state is indicated by the Keypad text flashing Page 20 of 29 velocity user manual kinesys Power On Power Off Sequence Power On 1 2 3 4 Make sure all relevant motor power and control connections are made correctly Turn on the 32A three phase
12. ector Intercontec CKUA 267 PIN FUNCTION U phase U V phase V W phase W E earth Brake 24V DC Brake OV view on female connector mating face Page 25 of 29 kinesys ENCODER velocity user manual Intercontec Series A 17 pin Contact R2 5 17 pin female on panel with screw locking ring Panel Connector Intercontec ASTA 035 FR 01 61 0035 000 Mating Connector Intercontec AKUA 034 MR 04 61 0035 000 pin function Servo function SinCos function HiperFace function EnDat function SSI 1 thermistor thermistor thermistor thermistor thermistor 2 thermistor OV thermistor OV thermistor OV thermistor OV thermistor OV 3 thermistor screen thermistor screen thermistor screen thermistor screen thermistor screen 4 U simulated encoder out A simulated encoder out A simulated encoder out A simulated encoder out A 5 U simulated encoder out A simulated encoder out A simulated encoder out A simulated encoder out A 6 V simulated encoder out B simulated encoder out B simulated encoder out B simulated encoder out B 7 N simulated encoder out B simulated encoder out B simulated encoder out B simulated encoder out B 8 W clock clock 9 IW clock clock 10 A Cos Cos Cos Cos 11 Z data data data 12 IZ data data data 13 A Cosref Cosref Cosref Cosref 14 B Sin Sin Sin Sin 15 B Sinref Sinref Sinref Sinref 16 V V V V
13. mediate stop e f you are unsure of any aspect of moving loads with the system stop and seek professional advice on the appropriate usage of the system e Under most fault conditions the Kinesys Velocity drive will to bring the winch to a halt in a controlled manner at a predefined emergency stop ramp rate But under the following conditions the drive will stop the winch immediatly you must take account of this eventuality in the risk assesment of any system that incorporates a Kinesys Velocity drive e Power failure will case an immediate stop e Ultimate Limit Stuck will case an immediate stop e Drive failure will cause an immediate stop Page 7 of 29 velocity user manual kinesys Introduction The Velocity drive module is a powerful ac and servo motor drive system that allows a range of motors to be controlled and positioned with absolute precision Surrounding the advanced inverter technology is a range of user features designed to make using and maintaining the Velocity module very straightforward Built in manual running controls and a full diagnostic display help the user to set the system up simply and safely and the rugged steel case and locking metal motor connections ensure a long service life even in harsh physical environments Page 9 of 29 kinesys velocity user manual Specifications POWER SUPPLY ENCLOSURE ENVIRONMENTAL OPERATING TEMPERATURE DIMENSIONS WEIGHT Page 10 of
14. missing Fast Stop Active The Enable signal on the Drive Control connector has just been lost and the drive is ramping to a stop at the emergency ramp rate Wire Groove Jump The Wire Grove Jump limit switch on the winch has tripped Belt Break The Belt brake detect switch on the winch has been activated Aux Power Fuse Fail The Auxiliary 24v power fuse has blown see the fuse holder on the back panel Main Brake Fuse PSU Fail The Main Brake Fuse has failed see the fuse holder on the back panel Sec Brake Fuse Fail The Secondary Brake Fuse has failed see the fuse holder on the back panel Main Brake Disconnect Indicates that the main brake is not drawing current when energised Sec Brake Disconnect Indicates that the secondary brake is not drawing current when energised Main Brake Fail Indicates that the main brake has not released Sec Brake Fail Indicates that the secondary brake has not released Page 16 of 29 velocity user manual kinesys 12C Comms Failure Internal Fault please contact the supplier Drive Comms Fail Internal Fault please contact the supplier Drive Off The Inverter Drive within the box is powered off this could be because e The Drive Control Switch is in the Off position e The Drive MCB is in the Off position e The Emergency stop signal on the Drive Connector is missing Drive Trip The Drive has tripped
15. ns exist ALARMS ACTIVE KINESYS Page 15 of 29 kinesys velocity user manual Pressing any key on the keypad will bring up the default screen where status messages will be shown on the ALARMS The following table lists all the alarms that could be displayed in the status window Alarm Displayed Alarm Description Reverse Limit Trip The Reverse limit switch has been hit Forward Limit Trip The Forward limit switch has been hit Overload Trip The Overload limit switch has been hit Slack Underload Trip The Slack rope limit switch has been hit Ultimate Limit Trip The Ultimate limit switch has been hit Limit Override The Mode key switch on the front panel is being held in the spring loaded Limits position which bypasses all external limits and allows a motor to be driven off a limit Note the drive is still able to sense the state of the external limits Brake Resistor Trip Contactor Jammed The main input contactor is jammed is on when the drive is expecting it to be off Drive Disabled The Drive is in a disabled state For the drive to be enabled the external drive enable signal on the Drive Control connector on the back panel needs to be intact Also the Drive Control key switch on the front panel needs to be in the Enabled position Emergency Stop Active The Emergency Stop signal on the Drive Control connector on the back panel is
16. s limit struck The drive will ramp to a stop at the emergency ramp rate The brakes will then be applied Reverse limit struck The drive will ramp to a stop at the emergency ramp rate The brakes will then be applied Slack Rope limit active The drive will ramp to a stop at the emergency ramp rate The brakes will then be applied Overload limit active The drive will ramp to a stop at the emergency ramp rate The brakes will then be applied Page 24 of 29 velocity user manual kinesys Pin Connections MAINS IN Harting HsB ILME CP Contact HBS male on panel with 2 locking levers Panel Connector Harting HsB6 male with 2 levers 09 31 006 2601 09 30 016 0301 Mating Connector Harting HsB6 female with 4 pegs 09 31 006 2701 19 30 016 1522 PIN FUNCTION 1 phase L1 2 phase L2 3 phase L3 4 5 6 neutral no connection earth shell earth MOTOR 0 75kw 7 5kw 400v Drives Intercontec Series B 5 E Contact LS1 SHE female on panel with screw locking ring Panel Connector Intercontec BSTA 085 NN 00 59 0035 000 Mating Connector Intercontec CKUA 267 PIN FUNCTION 1 phase U 2 phase V 3 E earth 4 phase W 5 Brake 24V DC 6 Brake OV MOTOR 11kw 22kw 400v Drives Intercontec Series C 6 pole female on panel with screw locking ring Panel Connector Intercontec CSTA 263 Mating Conn
17. the drive to automatic mode to be controlled by either a pendant or a computer or to manual mode for local operation 5 MANUAL SPEED sets the speed of the motor during manual operation 6 MANUAL DIRECTION press and hold these buttons to initiate manual running 7 DRIVE STATUS INDICATORS these show whether the drive is powered whether it is off disabled or enabled and whether it is moving Page 11 of 29 kinesys velocity user manual 8 DISPLAY SELECTION BUTTONS allows the user to navigate between screens on the information and diagnostic display 9 CIRCUIT BREAKERS separate circuit breakers for control and drive Turning off the control breaker will also power down the drive Page 12 of 29 velocity user manual kinesys Drive Rear View O MOTOR ENCODER JARY E NS sesat FOR PROFESSIONAL USE ONLY Refer to user manual before use G High earth leakage this equipment m earthed Disconnect the mains supply before r Power down for 10 minutes before removing cover J 5 6 7 8 1 ETHERNET Allows Ethernet connection for computer control and diagnostics 2 MOTOR amp ENCODER connections to the motor and motor encoder are made here These connections must be fully tightened to ensure a good electrical connection 3 LIMITS amp REMOTE CONNECTION connections for over travel
18. ts connect to 24V link to 24V if not used forwards limit connect to 24V link to 24V if not used reverse limit connect to 24V link to 24V if not used slack rope connect to 24V link to 24V if not used overload connect to 24V link to 24V if not used sensor 1 auxiliary sensor connect to 24V sensor 2 auxiliary sensor connect to 24V 21 reserved limits override connect to 24V to override limit switches remote data remote control HMI connection N lt xX S lt X lt C 30 D O UZZF ACITIOMMOOW remote data remote control HMI connection data ground remote control HMI connection Page 27 of 29 kinesys velocity user manual RS485 XLR5 link in and out Panel Connector Neutrik NC5MDL1 NC5FDL1 Mating Connector Neutrik NC5FX NC5MX pin function 1 Data ground 2 Rx 3 Rx 4 Tx 5 Tx CTNet XLR3 link in and out Panel Connector Neutrik NC3MDL1 NC3FDL1 Mating Connector Neutrik NC3FX NC3MX pin function 1 Data ground 2 Data A 3 Data B Page 28 of 29 velocity user manual Kinesys Projects Limited 2008 kinesys 9 kIMesys Kinesys Projects Limited Unit 2 Kempton Gate Business Centre Oldfield Road Hampton TWIS 2AF United Kingdom t 44 OO 8481 9850 f 44 0 20 8487 0396 e support kinesys co uk w www kinesys co uk Page 29 of 29
19. w the unit address to be changed For Ethernet access this drives IP address would be 192 168 18 X where X is the Unit address X will also be the drives CT net address Drive Rating This read only Parameter shows the maximum heavy duty current rating of the drive The values shown below show the correlation between current rating and the Drive Power rating at 400V 9 50A 4kw 13 00A 5 5Kw 16 50A 7 5Kw 25 00A 11kw Software Version This is a read only display of the drives current software version KinPos Version This is a read only display of the drives current positioner software version Upper Limit mm This parameter allows the upper soft limit to be adjusted This soft limit is only active when the drive is controlled from a computer The manual controls on the front panel ignore the soft limits Upper Limit mm This parameter allows the loer soft limit to be adjusted This soft limit is only active when the drive is controlled from a computer The manual controls on the front panel ignore the soft limits Set Position mm Changing this value will change the position the drive currently thinks its at It allows the drive position to be re referenced Gearbox Ratio x100 To allow the drive to correctly display the distance in mm the gearbox ratio of the winch should be entered here Note to this gearbox ratio is multiplied by 100 A gearbox ratio of 25 7 should be entered as a value of 2570
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