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THYROMAT-BD Digital Crane Controller USER MANUAL

1. EPA PRX 11 LESE IUe Rer E 11 2 5 6 Gornlrol Paneles hsc eene ee e ao ue eR a Ee a pee n t dug 11 2 6 CONTROL SYSTEM SPECIFICATIONS sse nennen nnne n esterne rennen nnns 12 2 7 THYROMAT BD DIGITAL CRANE CONTROLLER ENCLOSURES 13 2 8 SELECTION RESISTORS eene tret Fea eu CEU E dete vo eee 14 2 9 SELECTION OF MAINS CIRCUIT BREAKERS sse eene enne nennen nnne nns 16 2 10 SELECTION OF INTERPOSING INPUT 5 0 1 00 18 2 11 SELECTION OF INTERPOSING OUTPUT RELAYS sess 18 2 12 SELECTION OF GABLES ele aee eere ace Det E qv Fee eure oce ERE Ce 19 2 12 1 Power Supply Gable8 iterom e FREE 19 2 12 2 Control Power Cables 19 2 13 SELECTION STATOR REVERSING 19 2 13 1 Contactor Switching 21 Revision 8 6a CONTENTS Print Date 24 06 2008 Automation International User Manual n Automation International 2 13 2 Contactors Drop Out 0 22 1 00000 aner nii aa nne nen
2. 108 76 EEE 108 7 2 PREVENTATIVE 22000400000 108 7 2 1 ISI TIER NT m 108 7 2 2 Ultimate Limit 109 7 3 CRANE MAINTENANCE CHECK LIST FOR SYSTEM 109 7 4 SPARE 113 8 SECTION 8 SHIPPING AND 5 4 22 1 116 8 1 116 8 1 1 116 8 1 2 9 0 5554 4015 1 0 4105 0 1185 116 9 SECTION 9 ACRONYMS AND 222 117 9 1 GENERAL eere Den 117 Revision 8 6a CONTENTS Print Date 24 06 2008 Automation International Vil User Manual Jun H Automation International 1 GENERAL 11 CONTROL SYSTEM The THYROMAT range is used to control crane hoist and travel motions using slip ring motors The controller is suited to heavy duty and continuous operations in extreme environments THYROMAT digital crane control delivers leading thyristor control technology to a new generation of crane drives It is the natural successor to MH Automation s very successful
3. T 34 34 4 Overload ESL c KREKA 34 3 4 5 NOCH Speed 1 ie 35 3 4 6 JNotchiSpeed 2 bee Et o EG E Eo Ear uere a 35 3 4 7 Notch Speed Zussen 35 3 4 8 JNotchiPllgglng s eren etre neuter terete 35 3 49 JNotch Pl ugglng V aei 35 3 4 10 11510112 PUGNO 36 3 4 11 Neutral Plugglng V beet een vain 36 3 4 12 Brake Plugging LIne ei 36 3 4 43 Maximum Stall nnns nnns 37 3 4 44 Minimum Start 0 04 0 2 00000 cease cceeeeeaeeeeseeesaeeseaeeesaeeseaeeseaeeseeeeseaeeseneeseaees 37 3 4 15 Notch 1 2 and Acceleration TIME snis nnkan na nennen nnns 37 3 4 16 Noten AccelProtlle 2 3 2212 teen a ree dise sie nosset aue 38 3 4 17 Phase Shifter Off Time ccccccccsssssecsssssseccsssesecsssesseccsseeseceesensesessesseseeseesessessenessesensesessaes 38 3 4 8 4 0 38 3 2 19 Separate Directional 39 3 4
4. One or both Rotor feedback wires between the motor Rotor resistance and the Thyromat terminals17 amp 18 are loose Measure the Ohm value across the Thyromat terminals 17 amp 18 The reading will be very low 5 ohms Warning In some cases the multimeter reading is so low that it can be mistaken as a short circuit of these wires refer to iv below iv Rotor Feedback wires short circuited To ensure that a short circuit is not the reason why the Ohm reading is low i e close to 0Q remove one of the Rotor feedback wires from the Rotor resistance connection side then measure the Ohm value of the circuit which now should be in the region of MO and will keep on increasing due to the capacitance across the terminals If the reading remains close or at 0O then the wires are short circuited If the reading is infinite while the wires remain connected to the Thyromat terminals 17 amp 18 replace the Control Card because the damage is internal v Control Card failure The cause of the problem may be due to a faulty Control card After ascertaining that the problem is not due to any of the above reasons it is suggested that the control card is replaced with another Hoist Control Card Ensure that the existing parameters are entered into the new Card if the fault persists the problem may be caused by the following reasons vi Phase Shifter failure Measure the voltage across the Thyromat terminals 17 amp 18 while a
5. Main Board Figure 4 3 illustrates the installation diagram for the digital inputs to the main board 5NIH3MO1 4315 q3ads 15915 asuaAau auvMHo2 SNIH3MO T NILSIOH 4315 5 qNooas 4315 1 4315 G34dS lt LON lt LON NOWINODS lt LON N 1a B ii Jro 2 K04 K05 Figure 4 3 Digital Inputs for the Main Board Hoist Applications K01 Hoisting command and fist speed step selection K02 Lowering command and first speed step selection K03 Second speed step selection K04 Third speed step selection K05 Final speed step selection Travel Applications K01 Forward command and first speed step selection K02 Reverse command and first speed step selection K03 Second speed step selection K04 Third speed step selection K05 Final speed step selection Revision 8 5a SECTION 4 INSTALLATION 60 Print Date 24 06 2008 User Manual H Automation International 4 4 2 Digital Inputs Connectors on the Control Panel Figure 4 4 illustrates the installation diagram for the digital inputs to the control board 11 K12 Figure 4 4 Digital Inputs for the Connectors on the Control Panel K11 Not used in standard hoist and travel applications K12 Not used in standard hoist and travel applications 4 4 3 Relay Output
6. 6 9 4 c CURNT UNBAL 1 Q2 CURNT UNBAL 2 Q2 CURNT UNBAL 3 Q3 The fault occurred during Forward plugging Refer to possible causes below 6 9 4 d CURNT UNBAL 1 Q3 CURNT UNBAL 2 Q3 CURNT UNBAL 3 Q3 The fault occurred during Reverse operations Refer to possible causes below 6 9 4 e CURNT UNBAL 1 Q4 CURNT UNBAL 2 Q4 CURNT UNBAL 3 Q4 The fault occurred during Reverse plugging Refer to possible causes below 6 9 4 f Possible causes of Current Unbalance Mains supply phase unbalance This may be caused by a sudden drop on one phase of the Mains supply usually such a condition is very serious and unlikely to affect The Crane only This condition is more likely to cause an Input phases fault Faulty Thyristor One Thyristor is only conducting on the positive or the negative cycle causing the current to drop by 5096 on the corresponding phase Faulty motor Stator windings Faulty motor Rotor windings or Slipring brushes Faulty Rotor resistor circuit Either one phase is completely open circuit or in the event of the Rotor resistors being made up of resistor banks in parallel per phase one of the parallel connections is faulty This is usually easy to identify by disconnecting the resistors from the Rotor windings two phases at least and compare the resistance value between phases A Locked Rotor Test LRT may be able to identify the problem quickly refer to LRT procedure elsewhere in this manual Rev
7. Automation International 3 2 19 Separate Directional Signals PARAMETER DESCRIPTION SCALE INCREMENT DEFAULT Yes or No This parameter defines the way the input directions are selected THYROMAT CONTROL TERMINALS THYROMAT CONTROL TERMINALS V 2 2 1 When set as This is the way that Thyromat analogue and early digital units use to select the direction or rotation of the motor For Hoisting Forward Input terminal 5 bridged to 3 For Lowering Reverse Input terminals 4 and 5 bridged to 3 When set as YES For Hoisting Forward Input terminal 5 bridged to 3 For Lowering Reverse Input terminal 4 bridged to 3 Note Any other combination will cause a J error fault which indicates that either speed steps have been selected without a defined directional signal or in the event of this parameter being set as YES two directional inputs have been selected simultaneously Revision 8 5a SECTION 3 PARAMETERS 39 Print Date 24 06 2008 User Manual H Automation International 3 4 20 Load Defaults PARAMETER NO INCREMENT DEFAULT DESCRIPTION Load factory default Yes or No parameters Load Defaults This parameter returns all the parameters to factory default settings CAUTION IF IT IS NECESSARY TO CHANGE OTHER PARAMETERS IT IS RECOMMENDED T
8. 9 Indicates peak inverse voltage PIV For supply voltage 110 volts to 415 volts replace with 16 For supply voltage 525 volts replace with 18 Note 16 1600 volt 18 1800 volt Note The Thyristors listed will in all cases be suitable as spares but installed thyristors may not necessary be the same Fans M150 fan Compact fan M150 BD 100 to 150 M450 fan Compact fan M350 BD 200 to BD 350 M500 fan Fan assembly M500 BD 400 M1000 fan Fan assembly M1000 BD 500 to BD 1000 M2000 fan Fan assembly M2000 BD 1200 to BD 2000 MOV M200 MOV MOV M100 BD 25 to BD 60 M250 MOV MOV M150 BD 100 to BD 150 M350 MOV MOV M350 BD 200 to BD 350 M500 MOV MOV M500 BD 400 M2000 MOV MOV M1000 BD 500 to BD 1000 M2000 MOV MOV M2000 BD 1200 to BD 2000 Revision 8 5a SECTION 8 SHIPPING AND STORAGE 114 Print Date 24 06 2008 User Manual Automation International Category Code Description Model al size Spare Arms 380400 ARM Thyristor Phase Arm 400A 380V 380500 ARM Thyristor Phase Arm 500A 380V 380700ARM Thyristor Phase Arm 700A 380V 3801000 ARM Thyristor Phase Arm 1000A 380V 3801200 ARM Thyristor Phase Arm 1200A 380V 3801500 ARM Thyristor Phase Arm 1500A 380V 3802000 ARM Thyristor Phase Arm 2000A 380V 525400 ARM Thyristor Phase Arm 400A 525V 525500 ARM Thyristor Phase
9. SENSITIVE AND MAY BE DAMAGED DESTROYED MAKE SURE THAT THERE ARE NO POWER FACTOR CORRECTION CAPACITORS CONNECTED TO THE MOTOR POWER CABLE NOTE Only a competent licensed Electrician or a suitably qualified person should be allowed to install the THYROMAT It is important to shield the control electronics from any magnetic inductance that could be generated by large current carrying conductors Automation International The THYROMAT has simple fasteners for connecting electrical power The connection points are clearly marked to aid installation 4 3 2 Electrical Connection Instructions Before connecting the electrical cables to the THYROMAT make sure that the unit has been firmly secured to the mounting panel refer to figure 4 2 for the electrical mounting details Revision 8 5a Print Date 24 06 2008 SECTION 4 INSTALLATION 55 2 83 User Manual H Figure 4 2 Electrical Mounting of The THYROMAT Controller Check that the integrity of the earth between the THYROMAT and mounting surface is good the measured resistance should be 0 ohms In the event that the earth does not conform make sure that the THYROMAT mountings and the mounting surface are stripped clean of paint and other contamination 1 if necessary install an additional earth strap Make sure that all the leads to the THYROMAT unit have a fair amount of slack so that they do not assert unnecessary me
10. When selecting the current carrying capacities of the resistor grids and sections the following factors need to be considered Ambient temperature Duty cycle Slow speed operations 2 9 SELECTION OF MAINS CIRCUIT BREAKERS It is critical that the selection of the mains circuit breaker for the THYROMAT must be able to protect the THYROMAT unit against most current surges It is strongly recommended that a circuit breaker type such as manufactured by Merlin Gerin part number 5 N STR2 E or similar is used The suggested circuit breaker STR electronic trip unit is one of the most flexible circuit breaker types with regards to protection settings in both the low and high short circuit protection ranges The circuit breaker also has reflex tripping which is triggered by the energy dissipated within the device when a short circuit condition is experienced The correct selection of the circuit breaker will depend on the thyristor stack current rating and the slip ring motors nominal current rating Table 2 8 lists the circuit breaker selection details for the various thyristor stacks it is possible to downsize the selected circuit breaker by matching it with current rating of the individual slip ring motor Revision 8 5a SECTION 2 SYSTEM DESGN 16 Print Date 24 06 2008 THYROMAT Mechanical Size Revision 8 5a Print Date 24 06 2008 User Manual Table 2 8 Circuit Breaker Selection THYROMAT Circuit Breaker
11. or 3 refers to CT input 1 2 or 3 Phase current loss after releasing of the brakes and during Hoist Plugging The Suffix 1 2 or 3 refers to CT input 1 2 or 3 Phase current loss after releasing of the brakes and during Forward Plugging The Suffix 1 2 or 3 refers to CT input 1 2 or 3 Phase current loss after releasing of the brakes and during Lowering Drive down The Suffix 1 2 or 3 refers to CT input 1 2 or 3 Phase current loss after releasing of the brakes and during Reverse The Suffix 1 2 or 3 refers to CT input 1 2 or 3 Phase current loss after releasing of brakes and during Lower Plugging or Counter Torque Lowering The Suffix 1 2 or 3 refers to CT input 1 2 or 3 Phase Current loss after releasing of the brakes and during Reverse Plugging The suffix 1 2 or 3 refers to CT input 1 2 or 3 A 5096 discrepancy between the phase current displayed and the highest phase current reading at the time before the brakes were released The Suffix 1 2 or 3 refers to CT input 1 2 or 3 A 5096 discrepancy between the phase current display and the highest phase current reading at the time during Hoisting The Suffix 1 2 or 3 refers to CT input 1 2 or 3 A 5096 discrepancy between the phase current display and the highest phase current reading at the time during Forward The suffix 1 2 or 3 refers to CT input 1 2 or 3 TRAVEL only when ENES only when C T s YES only when E
12. wear gt These contactors have a similar life span the directional contactors have but under normal conditions operates only at 6096 of the operations of directional contactors which means that its life span on the same crane can be extended by a factor of 1 5 when compared to the directional contactors d Thyromat unit Stack fan gt Ensure that the fan is running Parameters gt the same as written list parameters Control panel Ensure that is not loose gt Ensure that Thyromat is working according control to the user manual specification Fault history Analyze faults and find out why they are happening Refer to chapter 6 for assistance g Control limit Operation Ensure that Cross Travel is operating switch within boundaries of the limit switch h Connections Loose gt Same as Protective panel e connections i Current Input R S amp T gt Follow the steps below using Fluke converter phases e Measure between brown and blue continuity test wires while they are disconnected from CT e Use diode scale e Reading should be approximately 0 9 Output red yellow and Follow the steps below using Fluke blue phases e Measure between green common continuity test and red phase yellow phase and blue phase e Reading should be approximately 0 7 7 4 SPARE PARTS LIST Category Code Description Model al size 1050H Hoist control card All BDH 25 to BDH 200
13. 2 or 3 refers to CT input 1 2 or 3 A 50 discrepancy between the phase current display and the highest phase current reading at the time during Lower Plugging or Counter Torque Lowering A 5096 discrepancy between the phase current display and the highest phase current reading at the time during Reverse Plugging The Suffix 1 2 or 3 refers to CT input 1 2 or 3 Simultaneous loss of Rotor feedback and all 3 phase currents before the brakes were released Simultaneous loss of Rotor feedback and all 3 phase currents during operation The fault was initiated firstly by the loss of all 3 phase currents followed by the loss of Rotor feedback Simultaneous loss of Rotor feedback and all 3 phase currents during operation The fault was initiated firstly by the loss of Rotor feedback followed by the loss of all 3 phase currents Motor stator current any one of the 3 is greater than 4 x motor current for a period exceeding 1 5 sec The joystick is out of Neutral position during unit power up The joystick direction input is missing while notch 2 3 or 4 are present Y only when ems ENES only when C T s YES only when 5 YES only when CAISSES only when Y only when Calas TRUE y 6 8 4 6 9 4 6 8 4 0 6 9 4 9 6 8 4 6 9 4 6 8 5 6 8 5 0 6 8 5 6 8 6 6 8 7 6 8 8 Revision 8 5 Print Date 24 06
14. 2008 SECTION 8 SHIPPING AND STORAGE 82 FAULT User Manual FAULT DESCRIPTION HOIST TRAVEL history SSS Ses MOTOR STALL STACK TEMP H LOSS TORQUE The motor remains at standstill for 10 Y seconds while the RUN command is active Stack over temperature The Thermal switch Y V mounted on the stack is in the OPEN state Hoist loss of torque occurs when during Hoisting operation the motor slips to a speed gt 10 Lowering LOWER OVERSPEED The motor speed during COUNTER Y TORQUE LOWERING is 13096 INPUT PHASES BRAKE RELEASE DRIVE LEVEL POWER ON TEST A Phase Shifter fault has occurred which may be linked or more of the following 3 Phase supply gt 70 of Un Supply single phasing Supply phase rotation wrong At least one of the phase currents is below Y the BRAKE RELEASE CURRENT at the start during Torque proofing The minimum Phase Shifter Voltage Y Y reference determined by the Control Card is below 3 5V The standard level is 3 8V The System goes through a complex test of Y the software and associated switchgear which in the event of failure The Power on Test is displayed Usually this fault precedes another fault which is displayed in the form of a Code number as described below CODE 100 The CPU received joystick information which is out of acceptable boundaries CODE 101 CPU Watchdog reset 102 CPU supply voltage bel
15. 72ms Pull in Interposing relay LC1 D0910 pull in time 8 ms Associated contactor LC1 F185 pull in time 30 ms Revision 8 5a SECTION 2 SYSTEM DESGN 18 Print Date 24 06 2008 User Manual H Automation International Combined pull in time 38ms 2 12 SELECTION OF CABLES The following paragraphs detail the selection of power supply and control power cables 2 12 1 Power Supply Cables The specifications of the power supply cables must be calculated according to recognised standards e g BS 7671 and the cable manufacturer s recommendations Several factors need to be taken into consideration when selecting the correct power supply cables such as the ambient operating temperatures the cyclic duration factor of the application and the cable length The voltage drop across the cable under acceleration and reverse plugging conditions caused by the higher motor currents The selection of the cable should take into account the main circuit breaker to be used so that the efficient protection of the thyristor stack is not compromised therefore it is advisable to select the cables conservatively Armoured PVC insulated cables are normally used along the bridge and crab and flexible PVC or rubber insulated cables are used on festoon systems The selection of cable selection also largely depends on the environmental conditions that the crane will operate in 2 12 2 Control Power Cables The THYROMAT uses interposi
16. Arm 500A 525V 525700 ARM Thyristor Phase Arm 700A 525V 5251000 ARM Thyristor Phase Arm 1000A 525V 5251200 ARM Thyristor Phase Arm 1200A 525V 5251500 ARM Thyristor Phase Arm 1500A 525V 5252000 ARM Thyristor Phase Arm 2000A 525V SECTION 8 SHIPPING AND STORAGE Revision 8 5a Print Date 24 06 2008 115 User Manual pain n Automation International 8 SECTION 8 SHIPPING AND STORAGE 8 1 GENERAL The THYROMAT is simplistic in design and does not require any specialised packing crates or procedures When shipping or storing the system in high humidity conditions it is advisable to include a silicone gel sachet in the packaging to absorb any excess humidity 8 1 1 Shipping Complete unit It is advised that the following procedure should be followed when packaging the THYROMAT for shipping purposes Before wrapping the complete system fold a section of bubble plastic to form a pad tape the pad over the control unit s display and keypad to give it extra protection Wrap the complete unit in bubble plastic or similar material Place the complete wrapped unit into a strong cardboard box or suitable container The unit is ready for shipping Components It is advised that the following procedure should be followed when packaging the THYROMAT components for shipping purposes Each electronic card must be handled carefully and inserted into it s own indi
17. COMMISSIONING 65 Print Date 24 06 2008 User Manual n Automation International remaining on the display with periodic reset followed by the same displaying of this page an Input supply phases has occurred which does not allow the Thyromat unit to carry further testing prior to the Health Status is given Possible causes of initial power up Input phases failure e Wrong phase rotation Turn the power OFF then correct phase rotation before turning the power ON once again e The Incoming 3 phase supply is below acceptable values i e 75 of its rated supply voltage e The Incoming 3 phase supply has a phase imbalance Step 8 Input the motor parameters as necessary At this stage the only parameter which should be modified are the parameters which refer to the motor size and those are the following e C T ratio e Motor current All other parameters should remain as per default values Save the parameter changes before continuing with the tests Step 9 Perform Locked Rotor test Open rotor circuit a Ensure that there is no load on the crane hook b Turn main c b OFF Open star point from rotor resistance or open two rotor resistance phases from rotor circuit d Make sure that the brake contactor will not energize This may be achieved by opening the brake contactor coil circuit at any point in that control circuit Remove wire from terminal 13 on Thyromat e Turn Main c b ON f Wait for Thy
18. Hoist notch 1 to 4 running Revision 8 5a SECTION 8 SHIPPING AND STORAGE 86 Print Date 24 06 2008 User Manual n Automation International Command is given In the event of a faulty system the trip during start of a new cycle is delayed by 2 seconds therefore the reading of any voltage signal has to be done quickly within this period If there was signs of voltage being present during this period the Phase Shifter may be in working order To confirm this the same quick reading of all three Thyromat output voltages has to be done to ensure that the Phase Shifter is working correctly If the 3 output phases measurement proves in order then the problem may be related to loose connections on the motherboard in this case the entire unit needs replacing 6 8 2 CURRENT FEEDBACK LOSS All 3 phases Hoist applications require monitoring of all 3 motor stator currents for the efficient and safe operation of the system if the Drive can not read any motor currents it will trip on a current feedback fault as described below 6 8 2 a CURNT FDBK S The fault has occurred during the Torque proving phase before the brakes were given the command to be released Refer to possible causes below 6 8 2 b CURNT FDBK Q1 The fault occurred during Hoisting operation Refer to possible causes below 6 8 2 CURNT FDBK Q2 The fault occurred during Hoisting plugging Refer to possible causes below 6 8 2 d CURNT FDBK Q3 The fault
19. M150 M150 M350 M350 M500 M1000 M1000 M1000 M2000 M2000 M2000 M2500 Dimensions WxHxDinmm 237 x 180 x 202 237 x 180 x 202 237 x 180 x 202 296 x 180 x 225 296 x 180 x 225 293 x 450 x 250 293 x 450 x 250 515 x 525 x 355 515 x 665 x 355 515 x 665 x 355 515 x 665 x 355 789 x 855 x 443 789 x 855 x 443 789 x 855 x 443 ON REQUEST Weight Approx ON REQUEST Revision 8 5a Print Date 24 06 2008 SECTION 2 SYSTEM DESGN User Manual pan H Automation International The product range is defined as detailed in Table 2 2 Table 2 2 Product Range Definition Series Supply Control Voltage Voltage Current Explanation Alternating current ac applications BD Digital applications Hoist applications T Travel applications 025A 200A 030A 350A 060 A 400A 100A 500A 150A 700A 380 volts 415 volts 525 volts A 110 volts B 220 volts For example a product with the designated code BDH 025 380 B This would be defined as a unit having the following characteristics B Alternating current ac D Digital H Hoist 025 25 Ampere supply current 380 380 Volts supply voltage B 220 Volts control voltage Revision 8 5a SECTION 2 SYSTEM DESGN 6 Print Date 24 06 2008 User Manual 2 3 PROTECTION Table 2 3 lists the protection specifications for the THYROMAT Table 2 3 THYROMAT Protection Specifica
20. Not used Travel Applications Out 1 K06 Out 2 Not used Not used Revision 8 5a Print Date 24 06 2008 SECTION 4 INSTALLATION 62 User Manual Automation International 4 4 5 Motor Current Inputs Figure 4 7 illustrates the installation diagram for the motor current inputs recu CT CT CT 3 2 1 Yellow Current converter module OA1800 MOTOR PHASE A MOTOR PHASE B MOTOR PHASE C Figure 4 7 Motor Current Inputs Hoist Applications CTs always required Travel Applications CTs optional Revision 8 5a SECTION 4 INSTALLATION Print Date 24 06 2008 51 GENERAL User Manual 5 SECTION 5 COMMISSIONING Automation International Commissioning of the THYROMAT is simplified by default parameters displayed on the control panel e g the operating functions during the functional testing phase of the commissioning process Equipment configuration and operational adjustments in the event of unique applications are finalised when commissioning the equipment It is important to observe the warnings and cautions before commencing with the commissioning procedure 52 PREPARATION WARNINGS HIGH VOLTAGE COMPONENTS ACCIDENTAL CONTACT WITH THYRISTOR STACKS CAN RESULT IN FATAL INJURIES ONCE CONNECTED TO THE MAINS SUPPLY ALL INTERNAL COMPONENTS OF THE CONTROL UNIT EXCEPT ISOLATED I O TERMINALS ARE AT MAIN
21. PARAMETERS 29 Print Date 24 06 2008 User Manual Jum H Automation International This voltage will be applied for a maximum period of 10 seconds after this time a Motor Stall fault will trip the system 3 2 15 Ph shift on time PARAMETER DESCRIPTION SCALE INCREMENT DEFAULT 15 Ph shift on time Phase shifter on time 0 140 ms delay During contactor change over the system disables the phase shifter firing of the Thyristors to enable the reversing contactor to change over under zero current conditions This parameter allows the phase shifter to be enabled by a further on delay while the reversing contactors are in the process of changing over The total time for the reversing contactors to change over is made of Worked out example e Reversing contactors LC1 F265 e Contactor drop out time with standard LX1 FH coil 100 to 170 ms e Contactor close in time with standard LX1 FH coil 40 to 65 ms The phase shifter on delay time recommended is 80 ms Refer to parameter 16 which compliments the settings around reversing contactors change over time 3 2 16 Ph shift off time PARAMETER DESCRIPTION SCALE INCREMENT DEFAULT 16 60 240 ms This parameter complements parameter 15 above As described in parameter 15 worked out example the maximum drop out time for this specific type of contactor is 170 ms The recommended phase shifter off delay time is based on the maximum drop out time of
22. Start qe g 2 4 Neutral Figure 3 1 Timer delay example CAUTION THESE TIMERS RUN SIMULTANEOUSLY AND ARE NOT ACCUMULATIVE SETTING MORE THAN ONE NOTCH DELAY TO THE SAME VALUE WILL ALLOW THE VOLTAGE OF THE HIGHEST NOTCH SET TO BE APPLIED DIRECTLY TO THE MOTOR WITH THE INTERMEDIATE NOTCH VOLTAGES BEING BYPASSED Notes 1 Reducing the delay of the lower notches can help compensate for heavy loads to maintain a reasonably quick acceleration by progressing quicker to the next torque level Revision 8 5a 46 Print Date 24 06 2008 User Manual H Automation International 2 Reducing the delay of the lower notches too far will cause excessive currents in the motor during acceleration 3 6 10 Plugging Voltages PARAMETER DESCRIPTION INCREMENT DEFAULT Plug Volt 1 Plugging Voltage applied when notch 1 is 30 to 100 1 70 selected in the opposite direction of rotation Plug Volt 2 Plugging Voltage applied when notch 2 is 30 to 100 1 70 selected in the opposite direction of rotation 17 Plug Volt 3 Plugging Voltage applied when notch 3 is 30 to 100 1 70 selected in the opposite direction of rotation Plug Volt 4 Plugging Voltage applied when notch 4 is 30 to 100 1 70 selected in the opposite direction of rotation These parameters set the brake plugging voltage applied to the motor when the joystick is moved to the selected notch in the reverse direction to the rota
23. THYROMAT analogue crane drive Solid state electronics allows a compact design with enhanced reliability Self monitoring further improves system safety and reliability Software features and all hardware components are engineered to meet the requirements for both new and existing cranes THYROMAT digital crane control makes crane operation simple safe precise and consequently more productive MH Automation s experience and know how of crane applications combined with digital technology and thousands of man hours of engineering and design has resulted in a unique robust and reliable product Designed specifically to operate in the tough environments of steelworks THYROMAT digital is a robust crane controller suitable for all types of steelworks cranes Table 1 1 details the special features of the THYROMAT Table 1 1 Special Features SPECIAL FEATURES FEATURE ADVANTAGES Excellent reliability Increased production Low maintenance o Reduced operation costs Robust compact mechanical construction o Resistant to vibration Operates in extreme ambient conditions o Rated for continuous duty at 60 C o Control box sealed from dusty environment o Control cards protected with silicon coating High degree of safety Torque proving before operation commences Self diagnostics o Built in watchdog timers Built in electronic controller in neutral checking Opto isolation of inputs User friendly Control panel o Keyboard to enter para
24. a directional notch i e notch 2 3 or 4 are present without Hoist Lowering notch 1 Check that the direction speed interposing relays are switching correctly if not then the problem may be caused by a faulty joystick controller or the associated control cable If the relays are switching correctly measure the voltage across the Thyromat terminals as follows For a Hoist command the voltage between terminals 3 and 5 OV DC open circuit 9 to 10V DC For a Lower command the voltage between terminal 3 and 4 OV DC open circuit 9 to 10V DC 3 and 5 OV DC open circuit 9 to 10V DC In the event that all voltages measured are correct the fault may be caused by a faulty Control Card replace the Unit card with another Hoist Control Card enter the same parameters 6 8 9 Motor stall The definition of Motor stall as far as a Thyromat unit is concerned is that after a valid RUN command Hoist Lowering or Forward Reverse any speed the motor remained at standstill for a period greater that 10 sec after the brakes were given the command to be released Possible causes of motor stall trips Brake contactors didn t energised Check the Brake contactor circuit Confirm that between Thyromat terminals 10 amp 13 there is control voltage when the Thyromat is supposed to be running i e One directional contactor energised If not Replace Relay card If yes Follow the Brake control circuit and ensure tha
25. at 9 200 Hz Operation max 8G 11 ms Storage and shipping max 15 G 11 ms inside the manufacturers package Control box IP51 Power stack frames M100 to M2000 00 Over current protection set at 4 x unit rating for a period longer than 2 5 seconds Input phases rotation Input phases under voltage lt 0 7 Un Input phases single phasing Output phases unbalanced gt 50 unbalance Unit temperature stack temperature gt 95 Motor overload protection This feature is not yet implemented Loss of rotor frequency feedback Loss of torque detection Phase angle control 3 phase 6 thyristors connected in line with motor stator in anti parallel configuration 50 Hz 1 Varies with rotor resistors values used standard max 2 5 x Tn Units may be designed for greater ratings Consult MH Automation for further details Control box max 40 W Thyristor stack Approximately 3 8 W A of motor actual running current at 60 C D F 2 7 BD DIGITAL CRANE CONTROLLER ENCLOSURES The details listed in this paragraph are based on a complete THYROMAT installation This includes items such as the drive contactors relays motor protection unit and other auxiliary components equipment The listed enclosure sizes suggest the minimum requirement and should be used as a guideline only The environmental conditions used as a model for the enclosure sizes is based on the following assumptions gt Ambient temp
26. chassis plate installed inside crane girders where possible Pe of the motor for the duty the crane will operate from motor Revision 8 5a Print Date 24 06 2008 SECTION 2 SYSTEM DESGN 14 User Manual H Automation International Step 2 Calculate the mechanical power P required by the motor Use values of speed load and efficiency of the motion Step 3 Obtain the rotor current RA at determined P from motor manufacturers data tables Step 4 Calculate new R a R a Rax P4 Pe Step 5 Calculate the motors rotor resistance K400 that will give 100 rated torque at start Obtain the motors open circuit rotor voltage Ry from motor tables Kioo Ry N3 X R a Step 6 Determine the resistor values required from the selection table refer to table 2 7 Figure 2 1 illustrates the resistor configuration R1 R2 tor R1 R2 R3 R1 R2 R4 R1 R2 R4 R1 R2 R3 R4 K2 K1 Ko Figure 2 1 Resistor Configuration Revision 8 5a SECTION 2 SYSTEM DESGN 15 Print Date 24 06 2008 User Manual H Automation International Table 2 7 Resistor Values Hoists all motions with adequate torque margins 0 36 K100 Hoists large motors and motors with low torque margins Travels It is a requirement that a crane has the ability to lift 12596 of the nominal load this factor must be taken into account during commissioning process only
27. control card is replaced with another Hoist Control Card Ensure that the existing parameters are entered into the new Card if the fault persists the problem may be caused by the following reasons vi Phase Shifter failure Measure the voltage across the Thyromat terminals 17 amp 18 while a Hoist notch 1 to 4 running Command is given In the event of a faulty system the trip during start of a new cycle is delayed by 2 seconds therefore the reading of any voltage signal has to be done quickly within this period If there was signs of voltage being present during this period the Phase Shifter may be in working order To confirm this the same quick reading of all three Thyromat output voltages has to be done to ensure that the Phase Shifter is working correctly If the 3 output phases measurement proves in order then the problem may be related to loose connections on the motherboard in this case the entire unit needs replacing 6 9 2 CURRENT FEEDBACK LOSS All 3 phases Applicable only if CTs enable Yes Travel applications do not necessarily require monitoring of all 3 motor stator currents for the efficient and safe operation of the system if the Drive can not read any motor currents it will trip on a current feedback fault as described below 6 9 2 a CURNT FDBK S Not applicable to Travel motions 6 9 2 b CURNT FDBK Q1 The fault occurred during Forward operation Refer to possible causes below 6 9 2 CURNT FDBK Q2 T
28. corresponds to the Panel control voltage b Measure voltage across the relevant directional contactor If the voltage is present during start up 2 sec then the contactor mechanism or coil is faulty If not present during the start up 2 sec then check the voltage across Thyromat terminals 10 and 15 or 10 and 16 If there is no voltage then replace the Relay Card 6 If the Current Clamp shows a Current reading and the Hoist directional contactor is energising but the display remains at 0 Amps the problem may be caused by a faulty current converter circuit Ensure that the CT plug is plugged correctly Ensure that all 4 CT wires Red Yellow Blue and Green are connected to the plug While giving a Forward or Reverse notch 1 to 4 command to the Unit measure the AC voltage out of the CTs one at a time these must be a voltage 5V AC at any CT and they should be similar It is unlikely that all 3 CTs are faulty simultaneously Unplug the CTs plug and measure the DC voltage between Green and any of the 3 phases While giving a Hoist notch 1 to 4 command to the unit The Thyromat will trip on CURNT FDBK S after 2 seconds so this test needs to be done several times to cover all 3 phases If there is no voltage lt 5VDC at any one of the phase tests the Current Converter is faulty and needs replacing If there is voltage 5VDC then the problem may be the Ribbon cable that connects The Control Panel to the Co
29. during the design phase This value is to be used by the thermal model to calculate overload conditions This feature is not yet implemented 3 2 3 Overload Class PARAMETER DESCRIPTION SCALE INCREMENT DEFAULT 3 Overload class Thermal overload class type This parameter selects the Class of overload that the thermal model uses as a reference Class 2 Trip if stator current exceeds three times motor full load current for a period exceeding 7 sec Class 5 Trip if stator current exceeds three times motor full load current for a period exceeding 17sec Revision 8 5a SECTION 3 PARAMETERS 26 Print Date 24 06 2008 User Manual pum H Automation International 3 2 4 Notch 1 3 2 5 Notch 2 3 2 6 Notch 3 PARAMETER DESCRIPTION SCALE INCREMENT DEFAULT Notch 1 Notch 1 speed 5 20 Notch 2 Notch 2 speed 5 40 Notch 3 Notch 3 speed 5 50 These three parameters set the intermediate slow speeds CAUTION WHEN SPEEDS IN EXCESS OF 30 ARE SELECTED SPECIAL ROTOR RESISTANCE DESIGN MAY BE NECESSARY 10 20 30 3 2 7 Hoist plugging PARAMETER DESCRIPTION SCALE INCREMENT DEFAULT 7 Hoist plugging Enable hoist plugging Yes or No Hoist plugging to neutral is load dependent Under light load or empty hook conditions the system friction may be insufficient to decelerate the load quickly When enabled hoist plugging will detect that during upwards move
30. has completed To activate switch on the back lighting press any key the backlight will automatically go off 20 seconds later Revision 8 5a SECTION 8 SHIPPING AND STORAGE 72 Print Date 24 06 2008 User Manual Automation International DISPLAY KEYPAD a THYROMAT BD INPUTS PUTS 22 UTI E Figure 6 1 Control Panel The display has six main active menu display pages each page has four lines Table 6 1 lists the six active menu display pages with details of the four displayed lines Table 6 1 Menu Display Pages FUNCTION LINE DESCRIPTION Power up display page MH AUTOMATION This page is displayed for 2 seconds Revision 8 5a SECTION 8 SHIPPING AND STORAGE 73 Print Date 24 06 2008 ND 8 POWER UP PAGE 2 This page shows all the alphabetic type of control and software version letters and numbers for a period of number During the power up delay g approximately 2 seconds followed by time the THYROMAT status relay is de User Manual the software version numbers for Control Card and Panel Automation International after power up This page displays the energised 4 Copyright 2001 Default display page Joystick position and speed The THYROMAT BD automatically displays this page after the power up delay time To toggle between this page and the MOTOR CURRENTS page press the MENU key 219 Phase Shif
31. is initially loaded with software during manufactory phase The simple loading of default or any other parameters combination will clear the fault Revision 8 5a SECTION 8 SHIPPING AND STORAGE 96 Print Date 24 06 2008 User Manual n Automation International If the fault persists the EEprom is probably damaged and the Control Card needs replacing 6 8 17 f Code 106 CPU System fault The CPU can not process the information received because it has no meaning in the software MOTOR MODULE Possible causes Excessive electro magnetic interference f persists Fault Control Card 6 8 17 g Code 107 indicates an internal logging of an unrecognised fault error Possible causes The persistence of this fault code may indicate a particular condition possibly unique to the specific motion which causes a fault error which trips the Thyromat but it is not recognized by the error log table 6 8 17 h Code 108 Indicates an internal software command to switch on both reversing contactors simultaneously Possible causes The persistence of this fault code may indicate a particular condition possibly unique to the specific motion which causes a fault error which trips the Thyromat but it is not recognised by the error log table 6 8 17 i Code 109 Indicates an internal software command to switch off both reversing contactors when one should have been switched ON Possible causes The persistence of thi
32. occurred during Lowering operations Drive down mode Empty hook notches 1 2 or 3 or during full speed lowering Refer to possible causes below 6 8 2 e CURNT FDBK Q4 The fault occurred during Lowering plugging or slow speed lowering with an overhauling load i e counter torque lowering Refer to possible causes below 6 8 2 f Possible causes of Current feedback loss General information on Current feedback circuit The current feedback circuit in the Control Card gets its 3 phase readings from 3 Current Transformers C T s installed on the Stator phases The signal coming out of the CTs is and AC signal 5V AC 1 Amp This AC signal is then fed into the Current converter which converts the AC signal into a DC signal also 5V DC The 3 DC voltage signals are then fed into the Thyromat via the CT1 CT2 and CT3 inputs installed on the Control Panel The Control Panel is only used as a pass through for the 3 Current signals via the Ribbon Cable i Revision 8 5a SECTION 8 SHIPPING AND STORAGE 87 Print Date 24 06 2008 User Manual pain n Automation International which attaches the Control Panel to the Control Card The entire processing of the 3 phase current measurement is done in the Control Card Each phase has its DC voltage reference to the Common wire Green wire therefore any voltage measurement has to be done between the respective CT phase input and
33. on the Thyromat e Hoist first notch e Ensure that motor shaft is not turning pum H m eT SECTION 8 SHIPPING AND STORAGE Revision 8 5a Print Date 24 06 2008 109 User Manual Automation International e Measure the stator voltage and rotor stator voltage current rotor current e readings should be fairly balanced on all three phases e Rotor voltage multiply by rotor current divide by 605 should be equal or 10 to the nominal kilowatt rating of the motor if not consult Automation Power kW rotor voltage x rotor current 605 B Protective panel Check the following items Item Visual inspection or Note test a Circuit breaker Circuit breaker gt See drawings for the details type Current Seedrawings for the details settings b Main contactor Contact tips The protective panel main contactor is a Mechanical contactor that under normal working damage conditions it should not break heavy currents or have many mechanical operations in the events that one or both of the above contact tips having excessive burns or mechanical damage are happening perform a thorough investigation c Main hoist final Operation gt By pass hoist limit hoist in slow speed till limit switch it tri
34. replacing Revision 8 5a SECTION 8 SHIPPING AND STORAGE 95 Print Date 24 06 2008 User Manual n Automation International 6 8 17 Code faults 6 8 17 a 6 8 17 b 6 8 17 c 6 8 17 d code 6 8 17 e General Most of the Code faults indicate an internal Control Card fault When such a fault persists the Control Card needs to be replaced Code 100 Joystick corrupted messages The software layer which manages the joystick information reads information which is out of acceptable boundaries Possible causes Excessive electro magnetic interference f persists Faulty Control Card Code 101 CPU watchdog Reset The CPU stopped the tick of the internal watchdog Possible causes Excessive electro magnetic interference f persists Faulty Control Card Code 102 CPU voltage brown out level reached The CPU brown out voltage was reached Possible causes Thyromat 10V 5V DC supply lines dropped f persists Faulty Control Card Code 103 CPU loss of software messages The software code compares messages received for execution with the final execution of the Actual messages instructions any out of synchronization of the above causes such fault to be active Possible causes Excessive electro magnetic interference f persists Faulty Control Card Code 104 CPU failed to read valid EEprom parameters Possible causes This fault usually occurs when the Control Card
35. supply As a general rule under this test condition the rotor voltage will drop by a factor close to 1 5 of its name plate value The mechanical or electrical current depending on the design will increase by the same factor Major deviations from these general rules it may indicate problems which may require further investigation It is not possible to elaborate on the causes of the problem due to an immense variety of causes which may influence the results obtained during the tests It would be advisable to get in contact with the Technical department at MH Automation or any of their accredited representatives or agents for further assistance Step 11 After these tests are performed and assuming that both have had satisfactory results the brake contactor coil should be reconnected as recommended and proceed with the next step Step 12 No load test Run the motion in both directions notch by notch to ensure that the direction of rotation is correct and there are no other problems In the case of Hoist motions the rotary limit switch top and bottom should now be tested In the case of Travel motions slow down and end of course limits if applicable should now be tested During the No Load test ensure that there are no visible arcing on the contactors When all the contactors switching times are known it is easy to set up the parameters to avoid contactor arcing but in some cases it is not possible to determine the switch in and drop
36. the Common The CT1 is wired to the Red wire The CT2 is wired to the Yellow wire The CT3 is wired to the Blue wire Possible causes of Current feedback faults General It is assumed that the user has available a Current Clamp Analogue or Digital to assist with fault finding procedure Initial steps 1 Press the MENU key on the Control Panel to change to the CTs Page 2 Line 3 of the LCD display will show CT1 CT2 CT3 3 Line 4 of the LCD display will show 0 Amps on all 3 phases 4 Engage Hoist notch 1 if the fault still exists the contactor will remain energised for a period of 2 seconds before the CURNT FDBK S fault is displayed It is during this time that the Current readings of the Current Clamp are compared with the Current readings of the Display 5 If The Current clamp shows 0 Amps obviously the display will also show 0 Amps 5 1 Did the directional Hoist contactor energise Yes then the fault may be caused by a Ensure that all 3 phases are present at the Thyristors terminal U V W Phase Shifter trigger modules replace the Phase Shifter card C All 3 Thyristors are OPEN CIRCUIT replace unit d Motor Stator cable is faulty open circuit e Motor stator windings are faulty open circuit No then the fault may be caused by a Control supply missing ensure that the voltage across the Thyromat control terminals 10 amp 11 corresponds to the Panel co
37. the event that the results are out of acceptable boundaries Step 10 Perform locked Rotor test Closed rotor circuit this test should only be performed if the test mentioned in Step 8 is successful a Repeat step by step all the instructions referred to in Step 9 a to g h Measure the stator voltages between phases The supply voltage must remain within 90 of its rated value preferably gt 95 Look out for any major phase imbalances i Measure the stator currents per phase These currents should be fairly balanced j Measure the rotor voltages at the motor terminals between phases k Measure all three rotor currents at the motor terminals 1 Assuming that there no major unbalances in either rotor voltages or currents take the average values of both and apply them to the formula below Motor kW Rotor volts x Rotor amps 605 The resultant kW for a maximum stall voltage of 80 and a Rotor resistance of 0 36k should be approximately the same as the kW which the system has been designed for NOTE This may not correspond to the rated name plate kW of the motor if the resistance was calculated based on the motion mechanical power Usually the Revision 8 5a 67 Print Date 24 06 2008 User Manual pain n Automation International schematic diagrams will make reference to the exact motor kW which the system has been designed for Helpful Hint With the maximum stall voltage set at 8096 of the
38. to Travel motions 6 9 15 Drive level Refer to 6 8 15 6 9 16 Power On test Refer to 6 8 16 Revision 8 5a SECTION 8 SHIPPING AND STORAGE 106 Print Date 24 06 2008 User Manual n Automation International 6 9 17 Code faults Refer to 6 8 17 for a description of these fault codes 6 9 18 Healthy The logging of a Healthy fault is not a serious event but if persists it indicates that the unit had a fault to be reported but missed the reading of the fault Error stamp during fault logging Possible causes Excessive electro magnetic interference f persists Fault Control Card Revision 8 5a SECTION 8 SHIPPING AND STORAGE 107 Print Date 24 06 2008 User Manual pain n Automation International 7 SECTION 7 MAINTENANCE 7 1 GENERAL Digital technology is a reliable alternative to analogue systems and it usually does not require maintenance intense tasks The reliability of the Digital Thyromat Controller ensures that preventative and corrective maintenance is minimal Maintenance is simplified and equipment down times greatly reduced due to the modular design of the THYROMAT Added features such as Monitoring Fault History assists the user in accurately identifying failures faulty components within a short period of time with confidence It is recommended that the user retains a complete THYROMAT control unit to be used as spares The simplistic design of the unit and the mounting procedures does n
39. up of resistor banks in parallel per phase one of the parallel connections is faulty This is usually easy to identify by disconnecting the resistors from the Rotor windings two phases at least and compare the resistance value between phases A Locked Rotor Test LRT may be able to identify the problem quickly refer to LRT procedure elsewhere in this manual 6 8 5 Rotor feedback and Current feedback loss General This fault is detected when the simultaneous loss of Rotor frequency and Stator current feedback The loss of both feedback signals indicates that the motor stator is not being powered by the 3 phases via the Thyromat and the Stator reversing contactors The possible causes are Directional reversing contactor didn t energize Control circuit coil or mechanism faulty The Relay card is not switching the desired reversing contactor Check the presence of the control voltage between Thyromat terminals 10 amp 11 Check the control voltage between Thyromat terminals 10 amp 16 Hoist contactor or terminals 10 amp 15 Lower contactor If any of these Tests prove unsuccessful replace the Relay card The Phase Shifter is not triggering the 3 phase Thyristor stack Revision 8 5a SECTION 8 SHIPPING AND STORAGE 91 Print Date 24 06 2008 User Manual n Automation International Check the voltage output between Uo Vo and Wo immediately after a Hoist or Lower command If there is no sign o
40. used with Control Panel software versions 9 xx Revision 8 5a SECTION 3 PARAMETERS 34 Print Date 24 06 2008 User Manual H Automation International 3 4 PARAMETER DESCRIPTIONS TRAVEL The following paragraphs detail the various travel parameters 3 4 1 Current Transformer Ratio PARAMETER DESCRIPTION SCALE INCREMENT DEFAULT This parameter selects a current transformer ratio CT ratio Only CT ratios from the list can be used The available CT ratios are THE AVAILABLE CT RATIO S ARE Note are optional for all travel applications 3 4 2 Current Transformer Enable DESCRIPTION INCREMENT DEFAULT CT Enable CT s enable Yes or No By selecting Yes current monitoring and the overload thermal model is enabled Selecting No all the Current related measurements are disabled This means that there is no monitoring of Current overload unbalance and Overcurrent Note This may be useful when more than one motor is used with a single THYROMAT In this case it is recommended that individual motor protection is used Revision 8 5a SECTION 3 PARAMETERS 33 Print Date 24 06 2008 User Manual pan H Automation International 3 4 3 Motor Current PARAMETER DESCRIPTION SCALE INCREMENT DEFAULT This parameter sets the motor full load stator current Motor flc The value to be used is the stator current related to the mechanical power fo
41. 0 105077 Travel control card All 25 to 2000 OA 00207 Phase shifter card All BD 25 to BD 2000 box 10709 Relay control card All BD 25 to BD 2000 OA 0022 Snubber card All BD 25 to BD 2000 AO 14901 Mother board All BD 25 to BD 2000 OA 108099 Control panel All BD 25 to BD 2000 Revision 8 5a SECTION 8 SHIPPING AND STORAGE 113 Print Date 24 06 2008 User Manual Jum H Automation International Indicates control card software version Replace with code e g CCV5 01 Indicates supply voltage Replace with A 220 volt 380 volt C 400 volt D 415 volt E 460 volt 525 volt 550 volt 575 volt P 2 320 volt J 110 volt 9 Indicates motion Replace with H Hoist control T Travel control Indicates control voltage Replace with A 110 volt B 220 volt Indicates control panel software version Replace with code e g CPHV5 01 aon Mechanic Thyristors SKKT106 Thyristor semi pack M100 BD 25 to BD eo SKKT1629 Thyristor semi pack M150 BD 100 to BD 150 SKKT162 Thyristor semi pack M350 BD 200 SKKT2509 Thyristor semi pack M350 BD 350 SKKT3409 Thyristor disk M500 BD 400 SKKT12009 Thyristor disk M1000 BD 500 to BD 1000 N9809 Thyristor disk M2000 BD 1200 to BD 2000
42. 20 Load Deta hS 4 a calet un 40 3 5 Torque Application Parameters 41 3 6 PARAMETER DESCRIPTIONS TORQUE sss nnne nennen enn nnne nnns 42 3 621 FC BIET 42 3 6 2 Current Transformer 42 363 43 3 6 4 Curent transformer ratio 43 3 6 5 Motor Tull load ren treo meet 44 3 6 6 Short Circuit DelecliOri rne teet ree kh 44 3 6 7 45 3 6 8 Notch ea Accel bed ete vied eile 45 3 6 9 Notehidelays 2 dieses ide eed 46 3 6 10 Plugging 222 00 Ceci rece deba petri aed 47 3 6 11 47 3 6 12 2 48 4 SECTIO
43. 3 Q1 The fault occurred during Hoisting operation Refer to possible causes below 6 8 4 c CURNT UNBAL 1 Q2 CURNT UNBAL 2 Q2 CURNT UNBAL 3 Q3 The fault occurred during Hoisting plugging Refer to possible causes below 6 8 4 d CURNT UNBAL 1 Q3 CURNT UNBAL 2 Q3 CURNT UNBAL 3 Q3 The fault occurred during Lowering operations Drive down mode Empty hook notches 1 2 or 3 or during full speed lowering Refer to possible causes below 6 8 4 e CURNT UNBAL 1 Q4 CURNT UNBAL 2 Q4 Revision 8 5a SECTION 8 SHIPPING AND STORAGE 90 Print Date 24 06 2008 User Manual pain n Automation International CURNT UNBAL 3 Q4 The fault occurred during Lowering plugging or slow speed lowering with an overhauling load i e counter torque lowering Refer to possible causes below 6 8 4 f Possible causes of Current Unbalance Mains supply phase unbalance This may be caused by a sudden drop on one phase of the Mains supply usually such a condition is very serious and unlikely to affect The Crane only This condition is more likely to cause an Input phases fault Faulty Thyristor One Thyristor is only conducting on the positive or the negative cycle causing the current to drop by 50 on the corresponding phase Faulty motor Stator windings Faulty motor Rotor windings or Slipring brushes Faulty Rotor resistor circuit Either one phase is completely open circuit or in the event of the Rotor resistors being made
44. ATION Navigating through the Display by using the Keypad is logical and structured as detailed in figure 6 3 Menu Navigation Chart below MAIN MENU PAGE SCROLL MENU PAGE PARAMETERS MENU PAGE SET TIME MENU PAGE FAULT HISTORY MENU PAGE t t 0 x ETC CER na 1 1 Figure 6 3 Menu Navigation Chart MAIN MENU PAGE Revision 8 5a SECTION 8 SHIPPING AND STORAGE 76 Print Date 24 06 2008 User Manual Automation International 6 5 PARAMETER LISTS PAGE 6 5 1 Accessing the Parameters Page Table 6 3 details the parameters page navigation Table 6 3 Parameters Page Navigation STEP ACTION DISPLAY 1 Press the PAR key 2 Enter the password 3 Press SAVE key to enter the parameters list 4 Scroll through the parameters with lt and gt keys 5 modify a parameter scroll or y to the correct value then use the lt or gt keys to move to the next parameter 6 To save the changes made to the parameters list press the SAVE key this will exit the parameters list and save the changes The display will show SAVING for 2 seconds 7 After the saving process the display will then return to the main display page 8 NOTE By pressing RESET key one can exit parameters without saving them Revision 8 5a SECTION 8 SHIPPING AND STORAGE 77 Print Date 24 06 2008 User Manual H Automation International 6 6 SET TIME PAGE The SET TIME
45. C then the problem may be the Ribbon cable that connects The Control Panel to the Control Card or the Control Card is faulty It is easier to replace the Control card first before attempting to strip open the Control Panel to remove the Ribbon cable 6 8 3 Single Phase Current Loss Hoist applications require monitoring of all 3 motors stator currents for the efficient and safe operation of the system If the drive reads one CT current at 0 Amps while the others are 0 Amps it will trip on Current loss 6 8 3 a CURNT LOSS 1 S loss of phase 1 current CURNT LOSS 2 S loss of phase 2 current CURNT LOSS 3 S loss of phase 3 current The fault has occurred during the Torque proving phase before the brakes were given the command to be released Refer to possible causes below 6 8 3 b CURNT LOSS 1 Q1 loss of phase 1 current CURNT LOSS 2 Q1 loss of phase 2 current CURNT LOSS 3 Q1 loss of phase 3 current The fault occurred during Hoisting operation Refer to possible causes below 6 8 3 c CURNT LOSS 1 02 loss of phase 1 current CURNT LOSS 2 Q2 loss of phase 2 current CURNT 10553012 loss of phase current The fault occurred during Hoisting plugging Refer to possible causes below 6 8 3 d CURNT LOSS 1 Q3 loss of phase 1 current CURNT LOSS 2 Q3 loss of phase 2 current CURNT 10553 loss of phase 3 current The fault occurred during Lowering operations Drive down mode Empty hook notches 1 2 or 3
46. Current Ratings Frame Trip Unit 25A NS 100_ STR 22SE 40A 30 A NS 100_ STR 22SE 40A 60 A NS 100_ STR 22SE 100A 100A NS 100_ STR 22SE 100A 150A NS 160_ STR 22SE 160A NS 160_ STR 22SE 160A 200 A NS 250_ STR 22SE 160A NS 250_ STR 22SE 250A 350 A NS 400_ STR 23SE 400A 400 A NS 400_ STR 23SE 400A NS 400_ STR 23SE 400A 500 A NS 630_ STR 23SE 630A 700 A NS 630_ STR 23SE 630A 1000 A NS800 Micrologic 2 0 1200A NS1000 Micrologic 2 0 1500A NS1250 Micrologic 2 0 2000 A NS1600 Micrologic 2 0 2500 A NS2000_ Micrologic 2 0 NOTE The thermal settings are according to the slip ring motor details or in the event that these details are not available use the stator current equivalent for the applicable mechanical power requirements SECTION 2 SYSTEM DESGN Automation International 17 User Manual H Automation International 2 The short circuit protection settings for the slip ring motor are usually 3 times the motor stator current 2 10 SELECTION OF INTERPOSING INPUT RELAYS 2 11 Every Thyromat installation makes use of input signals interposing relays This is required to ensure that the 10V DC Thyromat input signals are confined to the electrical panel Such 10V DC remains within the electrical panel environment External switching of directional as well as speed notch signals may then be supplied by the crane control supply which will control these interposing relays It is stro
47. EFAULT This parameter selects a current transformer ratio CT ratio Only CT ratios from the list can be used The available CT ratios are 050 1 800 1 100 1 1000 1 200 1 1200 1 300 1 1500 1 400 1 2000 1 500 1 2500 1 600 1 3000 1 Note are optional for all travel applications Revision 8 5a SECTION 3 PARAMETERS 43 Print Date 24 06 2008 User Manual H Automation International 3 6 5 Motor full load current PARAMETER DESCRIPTION SCALE Motor Motor full load current This parameter sets the motor full load stator current Motor flc INCREMENT DEFAULT 10 63 of CT ratio The value to be used is the stator current related to the mechanical power for the specific duty CAUTION DO NOT EXCEED THE MOTOR NAMEPLATE VALUE FOR THE APPLICABLE DUTY Note This value should be determined during the design phase This value is to be used by the thermal model calculate overload conditions 3 6 6 Short Circuit Detection PARAMETER DESCRIPTION INCREMENT DEFAULT ES Short cct Short circuit 20096 to 40096 400 This parameter sets the short circuit Short cct detection level CAUTION THIS FUNCTION ALONE 15 SUFFICIENT TO PROTECT THE THYRISTORS DURING A SHORT CIRCUIT TAKE NOTE OF THE APPLICABLE RECOMMENDATIONS MADE ABOUT THE MAIN CIRCUIT BREAKER IN SECTION 2 Note The short circuit detection function assists i
48. H Automation International MECHANICAL SIZE MOUNTING HOLE ARRANGEMENT measurement in mm M500 M1000 Revision 8 5a SECTION 4 INSTALLATION 52 Print Date 24 06 2008 User Manual Automation International MECHANICAL SIZE MOUNTING HOLE ARRANGEMENT measurement in mm 4 2 5 Mounting Procedure gt Identify a suitable mounting surface gt Clean the mounting surfaces and make sure that they are free of any oil or grease Mark the mounting holes in accordance with the applicable instructions and dimensions identified in paragraphs 4 2 2 Mounting Instructions 4 2 4 Mounting Arrangements Use the spirit level to ensure that the unit will be mounted level gt Using the hammer and centre punch punch the applicable centres for the mounting holes gt Using the electric drill and applicable drill bit drill the mounting holes take care not to damage any objects and or equipment that may be mounted on the opposite side of the mounting surface gt Make sure that the mounting surfaces around the holes are stripped of paint and free of any grease or oil so that a good earth can be obtained gt With the aid of an assistant lift the THYROMAT into position Insert the fasteners provided and secure the TH
49. HAT THIS BE DONE IN A CONSERVATIVE MANNER AND ONLY WITH A FULL UNDERSTANDING OF EACH FUNCTION Note The default values have been selected so that they will apply to most applications Generally only parameters 4 and 5 will require changing to suit actual motor information Revision 8 5a SECTION 3 PARAMETERS 40 Print Date 24 06 2008 User Manual Automation International 3 5 Torque Application Parameters List Table 3 3 lists the typical parameter settings for torque version 1 00 applications Table 3 3 Torque Parameter List NO PARAMETER DESCRIPTION SCALE INCREMENT DEFAULT EN Load Defaults Load factory default parameters Yes or No No ES CTS Enable ES O L Class Type CT Ratio ES Motor flc ER Short cct Start Volts Notch 1 V CTs enable true or false True Overload class type 20r5 5 CT ratio 50 1 to 3000 1 50 1 Motor full load current 6396 of CT ratio 10 Short circuit 20096 to 40096 100 400 Start voltage applied until N1 delay 30 to 100 1 70 complete Voltage applied after N1 delay complete 30 to 100 1 70 Voltage applied after N2 delay complete and 30 to 100 1 70 notch 2 has been engaged Notch 2 V Voltage applied after N3 delay complete and 30 to 100 1 70 notch 3 has been engaged N1 Delay Delay time before notch 1 Voltage can be 50 ms to 9950ms 50ms 1000ms applied to the motor Notch 3 V N2 Delay Delay time before notch 2 Voltage can be 50 ms to 9950ms 50m
50. MN THYROMAT BD Digital Crane Controller USER MANUAL User Manual n THYROMAT BD DIGITAL CRANE CONTROLLER TABLE OF CONTENTS 1 GENE PA 1 1 1 CONTROL SYSTEM ld ia ee ed gebe i a ENS 1 11 1 Basic System 2420 0 0 3 1 1 2 THYROMAT Components Identification 4 2 SEGTION2 SYSTEM 2 pmo n Cu GE epa C PEE PP CE PEE R CES REI 5 2 1 5 2 2 BD DIGITAL CRANE CONTROLLER 5 29 PRQOTEGCTION eid ee et ods dds hee 7 2 4 BD DIGITAL CRANE CONTROLLER 7 2 41 Standard 7 2 4 2 Severe Duty Based on 40 of nominal load permanently on 8 2 5 PRINCIPLE OF in i rrr hee fees idea 9 2 54 BOK 10 202s COMPO Garde 10 2 53 Relay Cand 11 2 54 Phase Shifter ree
51. N A 49 4 1 5 etit riii 49 4 2 MEGCHANIGAL INSTALEEAT QN cene etae ttn eter edite 49 4 22 M 49 2 2 2 Revision 8 6a CONTENTS IV Print Date 24 06 2008 User Manual n Automation International 4 2 2 Mounting Instr ctioris iecore RE e 49 4 2 3 Tools and Special Equipment ssssssssssssseseseeeeeeenee nennen nnne 50 4 2 4 Mounting Arrangements 2 224 11 0 00 51 4 2 5 Mounting Procedure tii e e c aerea Fer era a 53 4 3 EBECTRIGAL INSTALLATION ie Eton e an xerunt enr 54 P scu EEECI ICE RTT 54 4 3 2 Electrical Connection 55 4 3 3 Tools and Special Equipment 59 4 4 INSTALLATION DIAGRAMS ssesssssseseseseeeenneeennen enne nenne entente 60 4 4 1 Digi
52. NTROL 72 6 1 72 6 2 SUPPLEMENTARY DISPLAY PAGES SCROLL 74 6 21 Faramello S A E EE 74 6 2 2 I paa 75 6 29 Faut Histo M 75 6 3 KEY PAD PUSH 5 75 6 4 CONTROL PANEL OPERATION tenet deus 76 E Revision 8 6a CONTENTS V Print Date 24 06 2008 User Manual n Automation International 6 5 PARAMETER LISTS PAGE iie EUER A eet a OR ed 77 6 5 1 Accessing the Parameters Page 77 6 6 SET TIME PAGE iie i e E d ee tere P e Len at e 78 6 FAULT HISTORY ice pu da 79 6 8 POSSIBLE CAUSES OF FAILURE ON HOIST 5 5 84 6 8 1 1055 OF ROTOR 84 6 8 2 CURRENT FEEDBACK LOSS All 87 6 8 8 Single Phase Current 1055 2 4 1 1 eeeaeeeeaeeeseaeeseaee
53. S only when only when C T s YES only when SECTION 8 SHIPPING AND STORAGE Automation International REFER TO 6 9 2 e 6 8 3 a 6 8 3 b 6 9 3 b 6 8 3 c 6 9 3 c 6 8 3 9 6 9 3 d 6 8 3 e 6 9 3 e 6 8 4 a 6 8 4 b 6 9 4 b 81 User Manual Automation International FAULT DESCRIPTION HOIST TRAVEL REFER CURNT UNBAL 1 Q2 CURNT UNBAL 2 Q2 CURNT UNBAL 3 Q2 CURNT UNBAL 1 Q3 CURNT UNBAL 2 Q3 CURNT UNBAL 3 Q3 CURNT UNBAL 1 Q4 CURNT UNBAL 2 Q4 CURNT UNBAL 3 Q4 RFB amp CURNT LOSS S RFB amp CURNT LOSS I RFB amp CURNT LOSS R OVERCURRENT NOT IN NEUTRAL Not logged in fault history J ERROR Not logged in fault A 5096 discrepancy between the phase current display and the highest phase current reading at the time during Hoist Plugging The Suffix 1 2 or 3 refers to CT input 1 2 or 3 A 5096 discrepancy between the phase current display and the highest phase current reading at the time during Forward Plugging The suffix 1 2 or 3 refers to CT input 1 2 or 3 A 5096 discrepancy between the phase current display and the highest phase current reading at the time during Lowering Drive down The Suffix1 2 or 3 refers to CT input 1 2 or 3 A 5096 discrepancy between the phase current display and the highest phase current reading at the time during Reverse The Suffix 1
54. S POTENTIAL WHEN THE THREE PHASE SUPPLY IS CONNECTED TO THE THYRISTOR STACK AND MOTOR CONNECTIONS U V AND W THE THYRISTOR STACK IS CONTINUALLY LIVE EVEN THOUGH THE MOTOR IS NOT RUNNING DO NOT ATTEMPT TO MAKE ANY CONNECTIONS TO THE WHILE IT IS CONNECTED TO THE MAINS POWER AFTER DISCONNECTING THE MAINS POWER USE A MULTI METER TO MAKE SURE THAT THERE IS NO SUPPLY VOLTAGE PRESENT MAKE SURE THAT ALL THE COVERS TO THE CONTROLLER ARE SECURED IN THEIR CORRECT POSITIONS BEFORE SWITCHING ON THE MAINS Revision 8 5a Print Date 24 06 2008 SECTION 5 COMMISSIONING 64 User Manual n Automation International CAUTIONS INCORRECT INSTALLATION OF THE THYROMAT BD DIGITAL CRANE CONTROLLER CAN RESULT IN DAMAGE TO EQUIPMENT AND OR PROPERTY 5 3 COMMISSIONING PROCEDURES The following paragraphs detail the sequence that the commissioning process must follow to ensure that the equipment is commissioned correctly Step 1 Ensure that all internal and external power and control connection are done according to schematic drawings Step 2 Ensure that all external circuits are clear from earth faults as well as possible short circuits which may have occurred during installation When testing cables and motors with an earth insulation meter ensure that the Thyromat drive is not connected to the equipment under test Megger high voltage testers may cause permanent damage to t
55. T LOSS 1Q4 loss of phase 1 current CURNT LOSS 2 04 loss of phase 2 current CURNT LOSS 3 Q4 loss of phase 3 current The fault occurred during Reverse plugging Refer to possible causes below 6 9 3 f Possible causes of Current loss 1 2 or 3 General It is suggested that the user reads the previous chapter 6 9 2 f to familiarise themselves more with current feedback readings Current loss means that all 3 phases CT readings 0 Amps Phase current loss means that at least one CT reading 0 Amps while at least another CT reading gt 0 Amps 694 Current unbalance Available only when CTs enable Yes General A current unbalance is only detected when at least on Phase current is lt 50 of the highest reading current provided that the highest current is at least 50 of the Motor Current the condition is validated for a period of 2 seconds at start before the brakes have been released or 800ms during operation 6 9 4 a CURNT UNBAL 1S CURNT UNBAL 2 5 CURNT UNBAL 3 5 Not applicable to Travel motions 6 9 4 0 CURNT UNBAL 1 1 CURNT UNBAL 2 1 CURNT UNBAL 3 1 Revision 8 5a SECTION 8 SHIPPING AND STORAGE 103 Print Date 24 06 2008 User Manual pan Automation International The fault occurred during Forward operation Refer to possible causes below
56. TION SCALE INCREMENT DEFAULT 2 to 20 Sec Notch 4 acceleration profile is based on ramping the motor stator voltage as opposed to Notches 1 2 and 3 acceleration profile which is based on a Speed ramp profile The system when going to Notch 4 measures the voltage applied to the motor at the time and ramps it to full voltage at the rate determined by this parameter Example e During transition from any notch to notch 4 the voltage supplied to the motor was at 50 e The parameter is set at 5 sec e It will take a further 2 5 sec to ramp the voltage from 50 to 100 3 4 17 Phase Shifter Off Time PARAMETER DESCRIPTION Ph Shift Off Tim This parameter sets the time that the Phase Shifter is disabled No current flowing to the motor to allow the directional contactors to change over without arcing ser to similar parameter for Hoist application for further details INCREMENT DEFAULT Phase shifter off time delay 60 to 240 100 ms ms 3 4 18 Notch 4 Delay This parameter when set at a value 0 inserts a time delay for engaging notch 4 full speed This is useful when the operation of the Crane requires the driver to perform short movements of the load By adding a delay time to notch 4 it will prevent the accidental jump from slow speed operation Speed ramp to full speed operation voltage Torque ramp Revision 8 5a SECTION 3 PARAMETERS 38 Print Date 24 06 2008 User Manual H
57. YROMAT to the mounting surface using the applicable tools Where bolts are used to mount the THYROMAT make sure that they are torqued down to the correct values refer to table 4 3 Mounting Fastener Torque Values gt Clean up the immediate area of all iron filings and or metal shavings gt Remove all tools and or materials used in the mounting process Revision 8 5a SECTION 4 INSTALLATION 53 Print Date 24 06 2008 User Manual Table 4 3 Mounting Fastener Torque Values SCREW BOLT 8 mm 10 mm 7 Nm 7 Nm 4 3 ELECTRICAL INSTALLATION 4 3 1 General WARNINGS DO NOT ATTEMPT TO MAKE ANY CONNECTIONS THE WHILE IT IS CONNECTED TO THE MAINS POWER LIVE AFTER DISCONNECTING THE THYROMAT FROM THE MAINS POWER USE A MULTI METER TO MAKE SURE THAT ALL POWER HAS BEEN REMOVED DISCONNECT THE MOTOR CABLES BEFORE ATTEMPTING TO TAKE ANY MEASUREMENTS ON THE MOTOR CABLES MAKE SURE THAT ALL THE COVERS TO THE CONTROLLER ARE SECURED IN THEIR CORRECT POSITIONS BEFORE SWITCHING ON THE MAINS POWER 15 Nm 15 Nm 15 Nm 15 Nm nitri Automation International Revision 8 5a Print Date 24 06 2008 SECTION 4 INSTALLATION 54 User Manual CAUTIONS DO NOT MAKE ANY VOLTAGE WITHSTAND TESTS ON ANY PART OF THE THYROMAT BD BD DIGITAL CRANE CONTROLLER DO NOT TOUCH ANY THE COMPONENTS THE CIRCUIT BOARDS THEY ARE VOLTAGE
58. ain Mains supply failure low level or phase missing Downshop supply conductor system faulty due to broken joints or current collector skid damaged or worn out Mains Supply cable faulty Phase shifter card faulty To confirm that the problem is related to a Phase shifter card replace the card and compare results 6 8 14 Brake release The Brake release fault will be logged in the event that at start of a Hoist Lower command during Torque proving the stator current any one of the phases is lower than the Brake release current parameter which is a percentage of the Motor current parameter Possible causes The Brake release current entered in parameters is too high Mains supply low or temporarily low Phase shifter faulty not triggering properly to generate the required Brake release current 6 8 15 Drive level The Thyromat Control card CPU monitors the minimum voltage level given to the Phase Shifter card which by default is at 3 8V DC In the event that this Phase shifter reference voltage goes below 3 5V DC the fault is triggered 300 later Usually a Drive level fault that persists indicates a faulty Control card that needs replacing 6 8 16 Power On test During Power On the Thyromat goes through a set of tests which when not successful causes a trip at Power Up The Power On test may be followed by the logging of another fault see code faults If the fault persists the Control Card needs
59. ain support centres The following paragraphs list some possible causes of failures and the effects it may have on the operating system 6 9 1 LOSS OF ROTOR FEEDBACK Rotor feedback is used by the THYROMAT as the motor loop speed feedback and it is essential to the operation of the unit In the event that this feedback is not present the unit has to trip to prevent it from falling into an unknown state The rotor feedback is tapped off of two of the three motor rotor phases The unit reads the rotor frequency which is inversely proportional to the rotor rotational speed i e directly proportional to the motor slip Rotor frequency Stator frequency x motor slip At standstill the rotor frequency is equal to the supply frequency which is 50 Hz as the motor starts accelerating towards its full speed the rotor frequency decreases towards 0 Hz In counter torque the rotor frequency increases from 50 Hz at standstill towards 100 Hz at 10096 speed note that in counter torque the motor field rotation is opposite to the actual rotor speed rotation hence the increase in rotor frequency output i e motor slip gt 1 Possible causes gt Directional contactor failed to energize A rotor feedback may occur if the control supply is not present when a lower or hoisting command is given to the THYROMAT Without the control voltage the directional contactors may not be energised Without stator voltage there will be no rotor feedback N
60. alues set should be specific to the torque required from each notch and checked both with light and heavy loads speed of acceleration will be affected by the values of these parameters but the time delays of the notches will provide a more effective and practical adjustment of the acceleration Revision 8 5a SECTION 3 PARAMETERS 45 Print Date 24 06 2008 User Manual H Automation International 3 6 9 Notch delays PARAMETER DESCRIPTION INCREMENT DEFAULT N1 Delay Delay time before notch 1 Voltage can be 50 ms to 9950ms 50ms 1000ms applied to the motor N2 Delay Delay time before notch 2 Voltage can be 50 ms to 9950ms 50ms 2000ms applied to the motor N3 Delay Delay time before notch 3 Voltage can be 50 ms to 9950ms 50ms 3000ms applied to the motor N4 Delay Delay time before notch 4 Voltage can be 50 ms to 9950ms 50ms 4000ms applied to the motor These parameters set the delay time from moving the joystick out of neutral before the voltage applied to the motor can progress to the next level if that notch has been selected Figure 3 1 shows an example of how these delays work if the joystick is moved from neutral to notch quickly The left graph uses the default delay settings as shown above but the right graph shows how V is skipped if the 4 Delay is set the same N3 Delay at 3 seconds 100 90 80 10 60 Start T 2 3 4 Neutral
61. ance Available only when CTs enable 103 6 9 5 Rotor feedback and Current feedback loss Available only when CTs enable Yes 105 6 9 6 2 aser deerit Ente 105 6 9 7 Notin Neutral 106 6 9 8 4 106 6 09 Molor al oti er tore 106 6 9 10 Stack Over teMpPerature ececcecceeseeeeeeneeeeeaeeceeeeceseeeeeaeeeeeeeeesaeeseaeeeeeaeeseaeesaaeeeseaeeseneeeteaeeds 106 6 9 11 LOSS of 6 106 6 9 12 E 106 6 9 13 PERPE 106 Revision 8 6a CONTENTS VI Print Date 24 06 2008 User Manual pain n 6 9414 Brake release RESTER 106 6 9 15 Drive 106 6 9 16 Power BC 106 6 9 17 5 107 SUXEMB eU 107 7 SECTION 7 MAINTENANCE 1
62. ate of the motor accurately because it can only monitor the current drawn by the motor but does not take in consideration ambient and other essential conditions which may affect the temperature rise of the motor Therefore it is recommended that wherever possible PTC thermistor probes and associated relays be used This will offer additional protection against influencing factors such as overheating due to a faulty motor ventilation fan abnormal rise in ambient temperature abnormal friction in the system due to mechanical or brake failure and unexpected severe duty operations In the case of a multi motor system it is recommended that each motor must have it s own external motor protection unit MPU to enable the individual monitoring of each motor In this event the size of the 9 Revision 8 5 SECTION 2 SYSTEM DESGN 23 Print Date 24 06 2008 User Manual p H Automation International selected MPU should accurately cover the motor s rated current range and must be set according to this current range or to the mechanical power equivalent current rating which should effectively be lower than that of the rated motor current 2 17 SELECTION OF SPARE PARTS CAUTION Only use spares provided by MH Automation in order to maintain safety and reliability of products failure to do so will render the warranty of the product null and vo
63. ation the hook slips downwards at a speed greater than 10 Possible causes Main supply low during lifting of a full or close to full load Rotor resistance single phasing or open circuit Stator voltage to low caused by a malfunctioning Phase shifter card Excessive hook load when starting from a suspended load 6 8 12 Lower overspeed The Lower overspeed protection is only effective during Lowering plugging or Lower slow Speed operation in counter torque If the speed of the motor exceeds 130 in the lowering direction during Quadrant 4 operation the trip is activated Possible causes Rotor resistance open circuit either the star point or the rotor terminals are in open circuit Motor failure Rotor windings Motor Rotor cable open circuit Faulty Phase shifter 6 8 13 Input phases The Thyromat unit Phase Shifter card measures all 3 mains supply phases and ensures that the Following conditions are met Correct Phase rotation phases are present phases are above 70 of the Nominal Supply voltage Revision 8 5a SECTION 8 SHIPPING AND STORAGE 94 Print Date 24 06 2008 User Manual n Automation International In the event of any one of these condition being not true the Phase shifter sends an Input phase trip signal to the Control card which validates it for 500ms before a trip Possible causes During commissioning the phase rotation is wrong swap the phases ag
64. chanical stresses to the electrical terminals 2 When connecting the electrical cables to the THYROMAT and thyristor stack 2 amp 3 make sure that the correct connector lug sizes are used refer to Table 4 4 Connector Lug Data Where fasteners are used to connect the electrical lugs to the THYROMAT make sure that they are torqued down to the correct values refer to Table 4 4 Connector Lug Data The THYROMAT must always have an earth connected to the earth terminal provided on the controller s terminal strip Make sure that all the leads to the thyristor stack have a fair amount of slack so that they do not assert unnecessary mechanical stresses to the electrical terminals 3 Table 4 4 Connector Lug Gauge and Sizes Current THYROMAT Mechanical Size Connector Lug Detail Rating T WIRE SIZE IN mm Revision 8 5a 25A 30 A 60A 200 A _ 350 A 400 A 100 A _ 25 150 35 480 600 960 SECTION 4 INSTALLATION Print Date 24 06 2008 Automation International 56 User Manual Automation International Current THYROMAT Mechanical Size Connector Lug Detail Rating M100 EN M1000 2000 25 4 6 30A 6x6 60 A 16x6 100A 2 25x8 _ _ 150 35 8 200 A _ 350A 400 A 120 x 12 150 12 240 x 12 LUG A or s 2 120 x 12 2 cable PH 150 x 12 2 cable PH 240 x 14 300 x 14 or f 150 x 14 2 cable PH 240 x 14 4 cabl
65. ctivate the hoist contactors which will supply voltage to the motor a short delay in time is provided before the brake is released Should the motor not move the hoist contactors will be released and the lower contactors are activated The motor is then driven in the lowering direction until the selected speed is achieved Revision 8 5a SECTION 5 COMMISSIONING 70 Print Date 24 06 2008 User Manual n Automation International If the load should become an overhauling load then the system will automatically revert to the counter torque mode This operating principle is selected for safety reasons as the hoist contactors are always activated first The resultant effect ensures for fail safe operation and the effective management of the motor and brake and allows for precision placing of material loads or cargo 5 5 TRAVEL OPERATIONS The following paragraphs detail the operational procedures during travel operations tasks 5 5 1 Travel In All Directions As soon as one of the four direction speeds on the master controller is selected the THYROMAT will activate one of the travel directional contactors that will supply power to the motor a short delay in time is provided before the brake is released Selection of one of the three slow speeds will regulate the motor to the associated speed in the event that full speed is selected the motor will accelerate smoothly until full speed is achieved Bringing the master controller back from
66. d for a period of 1 5 seconds before a trip is logged Note The Thyromat Overcurrent is intended as a secondary protection of overcurrent The primary protection is based on the correct settings of the Motion Main Circuit Breaker MCB The MCB recommended by MH Automation must have equivalent characteristics to the Merlin Gerin type NS with electronic trip relays type STR or Micrologic 2 0 or higher for units above 800A These MCBs together have fast short circuit protection usually 10ms for a recommended 3 to 4 x Nominal current have the ability of protecting not only the motor and cables but also the Thyromat solid state devices Providing that in the event of a M C B trip there is sufficient cooling time before another run attempt is conducted 6 8 7 Notin Neutral Revision 8 5a SECTION 8 SHIPPING AND STORAGE 92 Print Date 24 06 2008 User Manual pain n Automation International Not in neutral is a condition that can only be detected during powering up of the Thyromat unit The fault will remain displayed for as long as the joystick is out of Neutral position it automatically resets itself when the joystick is returned to Neutral The fault is only for indication purposes and will not be logged on Fault history log page 6 8 8 Joystick error The joystick error message will appear on the top left hand side corner of the display when the Thyromat acknowledges the switching On of any speed notches without the presence of
67. default values have been selected so that they will apply to most applications Generally only parameters 4 and 5 will require changing to suit actual motor information 3 6 2 Current Transformer Enable INCREMENT DEFAULT PARAMETER DESCRIPTION True CTS Enable CTs enable By selecting true current monitoring and the overload thermal model is enabled Selecting false the thermal short circuit and unbalance current protection is disabled true or false Note This be useful when more than motor is used with a single THYROMAT In this case it is recommended that individual motor protection devices are used Revision 8 5a SECTION 3 PARAMETERS 42 Print Date 24 06 2008 User Manual H Automation International 3 6 3 Overload Class PARAMETER DESCRIPTION INCREMENT DEFAULT 5 Class Overload class type This parameter selects the Class of overload that the thermal model uses as a reference Class 2 Trip if stator current exceeds three times motor full load current Motor flc for a period exceeding 6 77 sec Class 5 Trip if stator current exceeds three times motor full load current Motor flc for a period exceeding 16 7sec Note The percentage of thermal capacity used by the motor is displayed on the Control panel on Menu pages 1 to 3 line 2 3 6 4 Current transformer ratio 8 DESCRIPTION INCREMENT D
68. e PH 25A M5 30A M5 _ _ 60 M5 screw 100A M6 150A M6 screw 200A 350A 2 5 A FASTENER TYPE 400 A 0 M10 _ 2 M10 _ M10 M10 bolt M 12 2 12 12 bolt Revision 8 5a SECTION 4 INSTALLATION 57 Print Date 24 06 2008 User Manual H Automation International Current THYROMAT Mechanical Size Connector Lug Detail Rating mso 25A 30 A 60 A 100 A 150 200 TORQUE 350 A F VALUES IN Nm 400 A N A 15 15 15 6 25 5 e 3 75 4 S 4 28 CURRENT 2 S DENSITY IN AMPERES PER mm 2 5 2 5 2 1 Revision 8 5a SECTION 4 INSTALLATION Print Date 24 06 2008 58 User Manual 4 3 3 Tools and Special Equipment Automation International Table 4 5 lists the Tools and Special Equipment Electrical needed to connect the electrical functions of the THYROMAT Table 4 5 Tools and Special Equipment Electrical THYROMAT BD Digital Crane Controller TOOLS EQUIPMENT SECTION 4 INSTALLATION Revision 8 5a Print Date 24 06 2008 Mechanical Size 2000 59 User Manual n Automation International 4 4 INSTALLATION DIAGRAMS The following paragraph details the installation diagrams for the THYROMAT for both hoist and travel applications 4 41 Digital Inputs
69. e and date In the event that the clock is adjusted the real time clock will only activate once the SAVE key is pressed When the SAVE key is pressed all information is saved including any changes and the display reverts back to the main display page 6 2 3 Fault History This function only displays the recorded faults and the date and time that the each of the faults occurred 6 3 KEY PAD PUSH BUTTONS The keypad of the THYROMAT BD Digital Crane Controller has eight push buttons Table 6 2 lists the push buttons and their functions Table 6 2 Keypad Push Buttons PUSH BUTTON IMAGE FUNCTION Counts or moves the cursor UP and DOWN respectively dependant on which screen is active Pages the displayed screen or moves the cursor LEFT and RIGHT respectively Resets the status fault s on the display assuming that the fault s have RESET been rectified Also clears the fault history when in FAULT HISTORY page Toggles the display between DRIVE STATUS page and CURRENT MONITORING page PAR Brings up the SCROLL MENU Page Shows SAVING on the display if the menu displayed was the PARAMETERS or SET TIME display SAVE Brings up the selected Menu Page if in the SCROLL MENU Page Returns back to the SCROLL MENU Page if the menu displayed was FAULT HISTORY or MAIN MENU Revision 8 5a SECTION 8 SHIPPING AND STORAGE 75 Print Date 24 06 2008 User Manual pas Automation International 64 CONTROL PANEL OPER
70. e motor not to accelerate to full speed under load conditions During lowering operations the following aspects must be checked The motor maintains the required slow speeds When accelerated to full speed and then returned to neutral position the deceleration to full stop should be achieved within reasonable time i e approximately 3 sec At stop the brakes should apply when the motor is at standstill or just started turning in the opposite direction Failure of achieving the above may be caused by one or several of the reasons already described above for hoisting operation GENERAL NOTE It is always good practice to record in some form all current readings during the above tests These readings serve as a base for future comparisons specifically after a motor or a section of the rotor resistance has been replaced for whatever reason Step 15 During hoisting measure the peak stator currents during acceleration to full speed under full load conditions ensure that these currents are well within 2 5 x motor nominal stator current A sudden rise in current well above this value specifically during switching of any of the rotor contactors may indicate problems in the wiring of the rotor resistance This needs to be carefully checked and compared to the schematic diagrams supplied Revision 8 5a SECTION 5 COMMISSIONING 69 Print Date 24 06 2008 User Manual n Automation International 5 4 HOIST OPERATION The fo
71. e ninm Go ede 27 3 2 8 HOISLPIUQGING e ote e Pee ente etum 28 3 2 9 Lower plugging V eere erre decer ted er ede eut eene etn De 28 3 2 10 Brake releases teet ai 28 3 2 11 Start zer etienne E eL 29 3 2 12 Stop delay uiuit eet 29 3 243 Lower plugg iiec ser iecore Eua ee E SERERE ERE Y e GR 29 3 2 14 Max stall CARCER NET En 29 3 2 15 30 3 2 16 144 10111801 30 32 17 Separate Directional Signals 32 3 2 18 5 33 3 3 TRAVEL APPLICATION PARAMETERS 15 7 34 3 4 PARAMETER DESCRIPTIONS TRAVEL 33 3 4 1 Current Transformer Ratio cece cece cece eccceccececeeeeeeeeeceeeseeuaeeeeeeeseessueaeeeseceeeeseeuaeesseeeeseeeanas 33 3 4 2 Current Transformer 000000010000 33 Revision 8 6a CONTENTS Print Date 24 06 2008 User Manual n Automation International 3 4 3
72. edback loss after releasing of the Y 6 8 2 c brakes and during Hoist Plugging Current feedback loss after releasing of the Y only when 6 9 2 c brakes and Forward Plugging C T s YES CURNT FDBK Q3 Current feedback loss after releasing of the Y 6 8 2 d brakes and Lowering Drive down Current feedback loss after releasing of Y only when 6 9 2 d brakes and Reverse C T s YES provided C T s YES CURNT FDBK Q4 Current feedback loss after releasing of the Y 6 8 2 e brakes and Lower Plugging or Counter Torque Lowering Revision 8 5a SECTION 8 SHIPPING AND STORAGE 80 Print Date 24 06 2008 FAULT CURNT FDBK Q4 Current Feedback loss after releasing of brakes and Reverse Plugging CURNT LOSS 1S CURNT LOSS 2S CURNT LOSS 3S CURNT LOSS 1 Q1 CURNT LOSS 2 Q1 CURNT LOSS 3 Q1 CURNT LOSS 102 CURNT LOSS 2 Q2 CURNT LOSS 3 Q2 CURNT LOSS 1 Q3 CURNT LOSS 2 Q3 CURNT LOSS 3 Q3 CURNT LOSS 1 Q4 CURNT LOSS 2 Q4 CURNT LOSS 3 Q4 CURNT UNBAL 1 S CURNT UNBAL 2 S CURNT UNBAL 3 S CURNT UNBAL 1 Q1 CURNT UNBAL 2 Q1 CURNT UNBAL 3 Q1 Revision 8 5a Print Date 24 06 2008 User Manual FAULT DESCRIPTION Phase current loss before the brakes were released The Suffix 1 2 or 3 refers to CT input 1 2 or 3 Phase current loss after releasing of the brakes and during Hoisting The Suffix 1 2 or 3 refers to CT input 1 2 or 3 Phase current loss after releasing of the brakes and during Forward The Suffix 1 2
73. er board in this case it is advisable to replace the THYROMAT unit and send the faulty one to our nearest repair centre 6 9 1 a ROTOR FDBK S Not applicable to Travel motions 6 9 1 b ROTOR FDBK Q1 The fault occurred during Forward motion and while the system was operating in notches 1 2 or 3 Note Rotor feedback fault can not be detected during full speed operation because the Rotor frequency is close to 2 6 9 1 c ROTOR FDBK Q2 The fault occurred while the system was busy performing a Forward plugging function 6 9 1 d ROTOR FDBK Q3 The fault occurred during Reverse motion and while the system was operating in notches 1 2 or 3 Refer to possible causes below Note Rotor feedback fault can not be detected during full speed operation because the Rotor frequency is close to 2 6 9 1 e ROTOR FDBK Q4 The fault occurred during Reverse plugging Refer to possible causes below 6 9 1 f Possible causes of Rotor feedback loss i Forward contactor KM1 failed to energise Loose connection on coil circuit measure voltage across the coil Interposing relay failure when applicable measure voltage across the coil Faulty Relay Card output measure voltage across Thyromat terminals 10 and 15 This fault may be preceeded by RFB amp CURNT LOSS ii Reverse contactors KM2 failed to energise Loose connection on coil circuit measure voltage across the coil Interposing relay failure when applicab
74. erature 40 gt Maximum internal temperature of enclosure 60 gt Type of plant Ladle handling crane gt Location Indoors Degree of protection P54 Revision 8 5a Print Date 24 06 2008 SECTION 2 SYSTEM DESGN 13 User Manual Table 2 6 details the THYROMAT Enclosures Table 2 6 THYROMAT Enclosures Enclosure Size and Ventilation Table THYROMAT THYROMAT MECHANICAL Current Sizes Ratings 400A 700 A 1000A 2 000 Total Heat Dissipation of Switchgear 480 W 480 W 480 W 480 W 720 W 960 W 1 600 W 1 830 W 2 280 W 3 200 W 4 580 W 5 430 6 680 W 8 800 W 10 759 2 8 SELECTION OF RESISTORS The design and selection of the rotor resistor is detailed in the following paragraphs It is assumed that the designer has a good working knowledge of crane mechanical power calculations Step 1 Determine the electrical power manufacturers data tables Height mm 1400 1400 1400 1400 1400 1400 1400 1400 1800 1800 1800 1800 1800 1800 2100 mm 800 800 800 800 800 1800 1800 1800 1800 2100 2100 400 400 400 400 400 400 400 400 500 500 500 500 500 500 500 oe OU Automation International Remarks No forced ventilation required Forced ventilation with filters recommended Forced ventilation with filter recommended or open
75. f voltage regulation i e OV replace the Phase Shifter card The Motor Stator cable is faulty and in open circuit Measure the resistance across the 3 stator phases at the Panel stator output terminals the reading should be a low ohm reading Confirm that the fault is on the cable and not on the motor stator windings by bridging the motor stator terminals while measuring the continuity once again Ensure that the wire bridges are removed after the test The Motor Stator windings are faulty and in open circuit If the cable test above proved successful then the faulty open circuit may be inside the motor Measure the continuity of the stator windings at the motor terminals The RBF amp CURNT LOSS will be displayed with a suffix S or R Suffix S Indicates that the fault occurred during Torque proving before the brakes were released Note This is only applicable to Hoist motions Suffix 1 Indicates that the fault was caused by all 3 phase currents being at 0 Amps and during the timing out of the validation period the Rotor feedback also became 0Hz Suffix R Indicates that the fault was caused by the Rotor feedback being at OHz and during the timing out of the validation period all 3 phase currents also became 0 Amps 6 8 6 Overcurrent An Overcurrent trip is detected and logged if the Current measured on any one of the 3 phases is at least 400 higher than the Motor Current parameter value This fault is validate
76. full speed to one of the slower speeds will cause the drive torque to be removed from the motor until such time that the selected speed is achieved In the event that the master controller is brought back to the zero position braking torque will be applied to the motor until zero speed is reached If during slow speed regulation the crane begins to increase speed above the selected speed the reversing contactors will be reversed and counter torque applied until the crane s speed has reduced to the selected speed NOTE Brake plugging to neutral or between notches may be disabled by the respective parameters in this case the motor will coast to the desired speed or to stand still in the event of neutral position When the joystick is placed into the opposite direction of the actual crane movement brake plugging is always applied it can not be disabled by a parameter choice Revision 8 5a SECTION 5 COMMISSIONING 71 Print Date 24 06 2008 User Manual pain n Automation International 6 SECTION 6 OPERATION OF CONTROL PANEL 6 1 GENERAL The control panel of the THYROMAT controller consists of a liquid crystal display LCD and an eight push button keypad Figure 6 1 illustrates the display and keypad making up the complete panel The display has back lighting to aid the identification of the displayed data under darkened conditions The back lighting can only be activated in the main menu page after the power up cycle
77. future use When replacing repaired units use the original fasteners wherever necessary replace damaged or lost fasteners with physical equivalents 4 2 2 Mounting Instructions Before mounting the THYROMAT make sure that the mounting surface is of sufficient physical strength to carry the weight of the complete unit The following paragraphs list the mounting instructions for the THYROMAT refer to figure 4 1 for mounting details Figure 4 1 Mounting The THYROMAT BD Crane Controller 1 Mount the THYROMAT using the mounting holes provided by the thyristor stack 1 It is important to note that the mounting screws also provide the unit with an additional earth return make sure that the unit s mountings are clean and that a good earth is established Revision 8 5a SECTION 4 INSTALLATION 49 Print Date 24 06 2008 User Manual pan H 2 Excessive vibrations can be caused by various factors such as machine operation and or reversing contactors etc In order to minimise the vibration which contributes to the mechanical wear in the THYROMAT it is suggested that the unit should be mounted close to the edge of the designated mounting panel 2 3 The THYROMAT must be mounted to a vertical surface with the cooling fins on the thyristor stack aligned in the vertical direction 3 4 amp 5 The heat displaced by the THYROMAT must be dissipated by effective airflow Therefore provision must be made to allow for sufficien
78. gged 6 8 POSSIBLE CAUSES OF FAILURE ON HOIST SYSTEMS The aim of this chapter is to assist the user in getting to the cause of the fault as quick as possible although great effort has been put into describing as many causes of faults as possible It is almost impossible to cover every single aspect of the entire crane installation without running the risk of creating a guide which then looks more like a technical book The desired speed required repairing or correcting the fault would then be lost in the extensive reading and searching for the exact fault definition It is always far more productive for the user to become more familiar with the THYROMAT basic methods of motor control It is possible to acquire the information from this manual as well as from specific THYROMAT courses offered at our head office as well as at certain support centres The following paragraphs list some possible causes of failures and the effects it may have on the operating system 6 8 1 LOSS OF ROTOR FEEDBACK Rotor feedback is used by the THYROMAT as the motor loop speed feedback and it is essential to the operation of the unit In the event that this feedback is not present the unit has to trip to prevent it from falling into an unknown state The rotor feedback is tapped off of two of the three motor rotor phases The unit reads the rotor frequency which is inversely proportional to the rotor rotational speed i e directly proportional to the motor s
79. he drive Step 3 Ensure that the rotor resistances are wired correctly MH Automation always provides the correct values of the resistance steps on the respective rotor schematic diagram Follow these correctly to ensure that motor performance is correct from the start Ny NOTE ZA Check that the rotor feedback wiring is wired exactly in the schematic drawings Step 4 Verify that the Power supply and control supply are present at the panel and the Thyromat unit installed is rated accordingly This should be done before the Main c b and the control c b s are turned ON Step 5 Turn the control c b ON first go through the notches one by one verify that the correct input interposing relays switch in the correct sequence Step 6 Test the end of course limit switches ensuring that they will trip the correct input interposing relays Test the final limit switch and emergency stop circuit to ensure that these devices will offer the maximum protection as far as interruption of the main supply to motors and brakes is concerned This specific test is extremely important and it may not be neglected Step 7 Powering up of the Thyromat drive After ensuring that there are no earth faults or short circuits the motion main c b may be turned ON The Thyromat drive will display a power up page which indicates the type of motion and the version group of its software program In the event of this page Revision 8 5a SECTION 5
80. he fault occurred during Forward plugging Refer to possible causes below 6 9 2 d CURNT FDBK Q3 Revision 8 5a SECTION 8 SHIPPING AND STORAGE 100 Print Date 24 06 2008 User Manual n Automation International The fault occurred during Reverse operation Refer to possible causes below 6 9 2 e CURNT FDBK Q4 The fault occurred during Reverse plugging Refer to possible causes below 6 9 2 f Possible causes of Current feedback loss General information on Current feedback circuit The current feedback circuit in the Control Card gets its 3 phase readings from 3 Current Transformers C T s installed on the Stator phases The signal coming out of the CTs is and AC signal 5V AC 1 Amp This AC signal is then fed into the Current converter which converts the AC signal into a DC signal also 5V DC The 3 DC voltage signals are then fed into the Thyromat via the CT1 CT2 and CT3 inputs installed on the Control Panel The Control Panel is only used as a pass through for the 3 Current signals via the Ribbon Cable which attaches the Control Panel to the Control Card The entire processing of the 3 phase current measurement is done in the Control Card Each phase has its DC voltage reference to the Common wire Green wire therefore any voltage measurement has to be done between the respective CT phase input and the Common The CT1 is wired to the Red wire The CT2 is wired to the Yellow wire The CT3 is w
81. he motor stator terminals while measuring the continuity once again Ensure that the wire bridges are removed after the test The Motor Stator windings are faulty and in open circuit If the cable test above proved successful then the faulty open circuit may be inside the motor Measure the continuity of the stator windings at the motor terminals The RBF amp CURNT LOSS will be displayed with a suffix S or R Suffix S Indicates that the fault occurred during Torque proving before the brakes were released Note This is only applicable to Hoist motions Suffix I Indicates that the fault was caused by all 3 phase currents being at 0 Amps and during the timing out of the validation period the Rotor feedback also became OHZ Suffix R Indicates that the fault was caused by the Rotor feedback being at OHz and during the timing out of the validation period all 3 phase currents also became 0 Amps 6 9 6 Overcurrent Refer to 6 8 6 Revision 8 5a SECTION 8 SHIPPING AND STORAGE 105 Print Date 24 06 2008 User Manual n Automation International 6 9 7 Notin Neutral Refer to 6 8 7 6 9 8 Joystick error Refer to 6 8 8 6 9 9 Motor stall Refer to 6 8 9 6 9 10 Stack over temperature Refer to 6 8 10 6 9 11 Hoist Loss of torque Not applicable to Travel motions 6 9 12 Lower overspeed Not applicable to Travel motions 6 9 13 Input phases Refer to 6 8 13 6 9 14 Brake release Not applicable
82. hermal Current a Coefficient value of rotor resistance that will give rated torque at standstill Kilograms niione Kilowatt Liquid Crystal Display Misas gees Metres MA Milli amperes MAX esterne Maximum Millimetres Motor Protection Unit Milliseconds PID iii iet eet Proportional Integral Derivative Positive Temperature Co efficient esito mast Polly Vinyl Chloride RAM Random Access Memory Root Mean Square Temperature TLLA iiie Torque Motor Supply Voltage Volts Watts Revision 8 5a SECTION 9 ACRONYMS AND ABBREVIATIONS 117 Print Date 24 06 2008 User Manual H Automation International Revision 8 5a SECTION 9 ACRONYMS AND ABBREVIATIONS 118 Print Date 24 06 2008
83. hich the system will have to be restarted before operation can commence Mechanical stresses to the motor and gearbox are minimised by ramping all the supplied voltages this in turn provides constant acceleration and deceleration There are three independent slow speeds in both directions Selection of full speed causes the motor to ramp up accelerate to full speed The two acceleration contactors are activated at 5096 speed 25 Hz and 7596 speed 12 5 Hz respectively and the result is a smooth acceleration up to full speed The peak switching current during the acceleration cycle is limited to approximately twice that of the full load current Control Box CAUTIONS 1 CARE MUST BE TAKEN WHEN INSERTING CARDS INTO THE MOTHERBOARD NOT TO BEND THE CONNECTING PINS 2 DO NOT TOUCH ANY OF THE COMPONENTS ON THE CIRCUIT BOARDS THEY ARE VOLTAGE SENSITIVE AND MAY BE DAMAGED DESTROYED The control box contains the control cards necessary for the control of the motion and thyristor firing circuitry There are four individual cards that are common to the complete range The cards are contained in a box that has an IP51 rating This keeps out the harmful dust ever present in steelworks environments The Control panel secures the cards in their sockets and minimises the effects of vibration Each electronic card is covered with a conformal protective coating This coating has the following benefits gt Increased isolation between poi
84. hoisting cycle may be smoother when no load is present but it may allow a slight drop of the load when hoisting it is advisable to keep it s value between 50 and 60 in most cases When this voltage is increased it may cause slight speed overshoot during start up of no load operation 3 2 12 Stop delay PARAMETER DESCRIPTION SCALE INCREMENT DEFAULT 12 Stop delay Torque hold delay at 300 1500 ms stop This parameter sets the time for zero speed to be held at stop to allow sufficient time for the mechanical brake to be fully applied This eliminates load sagging at stop due to the slow reaction time of the mechanical brake 3 2 13 Lower plugg out PARAMETER DESCRIPTION SCALE INCREMENT DEFAULT Lower plugg out Lower plugg time out 2000 5000 ms 3000 ms The Lower plugging time out time compares to actual motor Lowering retardation profile against the profile set by this parameter In the event that the actual retardation is going to take longer than the set retardation time a Lower plug out trip will occur Note The Lower plug out time sets the profile for Lower retardation from 100 to 0 speed 3 2 14 Max stall volts PARAMETER DESCRIPTION SCALE INCREMENT DEFAULT 14 Max stall volts Maximum stall volts 70 to 100 This parameter sets the voltage which will remain applied to the motor in the event that the motor is stalled Revision 8 5a SECTION 3
85. icable connection configurations are listed in the following paragraphs 2 15 1 Star Connections Contactor thermal current Ith Motor Rotor Current Example Motor Rotor Current 100 A Contactor selected gt 100 A Ith Ith AC1 contactor rating 2 15 2 Delta Connections Contactor Ith Motor Rotor current 1 4 Example Motor Rotor Current 100A Contactor selected gt 100 1 4 71 4Alth Revision 8 5a SECTION 2 SYSTEM DESGN 22 Print Date 24 06 2008 User Manual H Automation International 2 15 3 V Connections Contactor Ith Motor Rotor Current Example Motor Rotor Current 100 A Contactor selected gt 100 A Ith 2 15 4 W Connections Contactor Ith Motor Rotor current 1 6 Example Motor Rotor Current 100A Contactor selected 2 100 1 6 62 5 Alth 2 16 MOTOR THERMAL PROTECTION UNIT This feature is not yet implemented The THYROMAT has built in motor thermal protection for Class 2 and Class 5 applications the thermal protection required can be selected from the keypad It is normally accepted to protect slip ring motors with a Class 5 l t temperature curve In severe duty applications where high ambient temperatures exist or the motor is exposed to heat radiation it is recommended that a Class 2 temperature curve is used and the motor power kW is rated accordingly so as to ensure a reliable installation This method of protection does not monitor the thermal st
86. id NOTE Although the larger higher current ratings THYROMAT units are compatible to lower currents the mounting holes will differ MH Automation maintains a stock holding of recommended spares and is able to extend valuable support for all their products Refer to Section 7 Paragraph 7 3 for further details with regards to the ordering of spares Revision 8 5a SECTION 2 SYSTEM DESGN 24 Print Date 24 06 2008 3 1 User Manual 3 SECTION PARAMETERS BDC H HOIST APPLICATION PARAMETERS LIST Table 3 1 lists the typical parameter settings for hoist version BDC H Version 10_00 applications Table 3 1 Hoist Parameter List for BDC H versions PARAMETER CT ratio Motor current Overload class Notch 1 Notch 2 Notch 3 Hoist plugging Hoist plugging V Lower plugging V Brake release Hoist Start Volts Stop delay Lower plugg out Max stall volts Ph shift on time Ph shift off tim Sep dir signals Load defaults Revision 8 5a Print Date 24 06 2008 Current transformers ratio Motor nominal current Thermal overload class type First notch speed Second notch speed Third notch speed Enable hoist plugging Hoist plugging voltage Lower plugging voltage Brake releasing current Hoisting min start volts Torque hold delay at stop Lower plugg time out Maximum stall voltage Phase shifter on time delay Phase shifter off time delay Separate directional signals Load default parameter
87. imes The THYROMAT is designed to be able to switch contactors at zero current parameters are provided to enable the user to set the correct switching times so that during contactors change over arcing is avoided It is imperative that the users makes themselves familiar with the contactors switching times relevant to the installation 2 13 2 Contactors Drop Out Times During directional contactors change over the THYROMAT provides a delay between the time that the thyristors are turned off untill the time that the contactor is de energised This will ensure that there is no current flowing in the circuit at the instant that the contactor is required to drop out This process increases the electrical life of the contactor and allows the use of contactors with AC1 ratings as opposed to contactors with AC3 Refer to Phase Shifter ON and OFF time parameters for further details 2 14 SELECTION OF CURRENT TRANSFORMERS When selecting the current transformer C T ratio the following formula gives the minimum ratio that should be considered C T rating 6096 of motor full load current Example Motor full load current 2 125A Therefore the C T ratio 125 0 6 208 3A The closest C T ratio available in the Thyromat BD is 300 1 A The available C T ratios are 050 1 800 1 100 1 1000 1 200 1 1200 1 300 1 1500 1 400 1 2000 1 500 1 2500 1 600 1 3000 1 Note CT s are required for all hoist applications and optional fo
88. ired to the Blue wire Possible causes of Current feedback faults General It is assumed that the user has available a Current Clamp Analogue or Digital to assist with fault finding procedure Initial steps 1 Press the MENU key on the Control Panel to change to the CTs Page 2 Line 3 of the LCD display will show CT1 CT2 CT3 3 Line 4 of the LCD display will show 0 Amps on all 3 phases 4 Engage Hoist notch 1 if the fault still exists the contactor will remain energised for a period of 2 seconds before the CURNT FDBK S fault is displayed It is during this time that the Current readings of the Current Clamp are compared with the Current readings of the Display 5 If The Current clamp shows 0 Amps obviously the display will also show 0 Amps 5 1 Did the directional Hoist contactor energise Yes then the fault may be caused by Revision 8 5a SECTION 8 SHIPPING AND STORAGE 101 Print Date 24 06 2008 User Manual pain Automation International a Ensure that all 3 phases are present at the Thyristors terminal U V W b Phase Shifter trigger modules replace the Phase Shifter card C All Thyristors are OPEN CIRCUIT replace unit d Motor Stator cable is faulty open circuit e Motor stator windings are faulty open circuit No then the fault may be caused by a Control supply missing ensure that the voltage across the Thyromat control terminals 10 amp 11
89. ision 8 5a SECTION 8 SHIPPING AND STORAGE 104 Print Date 24 06 2008 User Manual n Automation International 6 9 5 Rotor feedback and Current feedback loss Available only when CTs enable Yes General This fault is detected when the simultaneous loss of Rotor frequency and Stator current feedback The loss of both feedback signals indicates that the motor stator is not being powered by the 3 phases via the Thyromat and the Stator reversing contactors The possible causes are Directional reversing contactor didn t energize Control circuit coil or mechanism faulty The Relay card is not switching the desired reversing contactor Check the presence of the control voltage between Thyromat terminals 10 amp 11 Check the control voltage between Thyromat terminals 10 8 16 Reverse contactor or terminals 10 amp 15 Forward contactor f any of these Tests prove unsuccessful replace the Relay card The Phase Shifter is not triggering the 3 phase Thyristor stack Check the voltage output between Uo Vo and Wo immediately after a Hoist or Lower command If there is no sign of voltage regulation i e OV replace the Phase Shifter card The Motor Stator cable is faulty and in open circuit Measure the resistance across the 3 stator phases at the Panel stator output terminals the reading should be a low ohm reading Confirm that the fault is on the cable and not on the motor stator windings by bridging t
90. le measure voltage across the coil Faulty Relay Card output measure voltage across Thyromat terminals 10 and 16 This fault may be preceded by RFB amp CURNT LOSS iii One or both Rotor feedback wires between the motor Rotor resistance and the Thyromat terminals 17 amp 18 are loose Measure the Ohm value across the Thyromat terminals 17 amp 18 The reading will be very low 5 ohms Revision 8 5a SECTION 8 SHIPPING AND STORAGE 99 Print Date 24 06 2008 User Manual n Automation International Warning In some cases the multimeter reading is so low that it can be mistaken with a short circuit of these wires refer to iv below iv Rotor Feedback wires short circuited To ensure that a short circuit is not the reason why the Ohm reading is low i e close to 0Q remove one of the Rotor feedback wires from the Rotor resistance connection side then measure the Ohm value of the circuit which now should be in the region of MO and will keep on increasing due to the capacitance across the terminals If the reading remains close or at 0O then the wires are short circuited If the reading is infinite while the wires remain connected to the Thyromat terminals 17 amp 18 Replace the Control Card because the damage is internal v Control Card failure The cause of the problem may be due to a faulty Control card After ascertaining that the problem is not due to any of the above reasons it is suggested that the
91. lip Rotor frequency Stator frequency x motor slip At standstill the rotor frequency is equal to the supply frequency which is 50 Hz as the motor starts accelerating towards its full speed the rotor frequency decreases towards 0 Hz In counter torque the rotor frequency increases from 50 Hz at standstill towards 100 Hz at 100 speed note that in counter torque the motor field rotation is opposite to the actual rotor speed rotation hence the increase in rotor frequency output i e motor slip gt 1 Revision 8 5a SECTION 8 SHIPPING AND STORAGE 84 Print Date 24 06 2008 User Manual pain n Automation International Possible causes gt Directional contactor failed to energize A rotor feedback may occur if the control supply is not present when a lower or hoisting command is given to the THYROMAT Without the control voltage the directional contactors may not be energised Without stator voltage there will be no rotor feedback Note A directional contactor failure is more likely to give a RFB amp CURRT LOSS fault gt Rotor feedback wires loose One or both feedback wires between the motor rotor phases and the unit terminals 17 and 18 are loose gt Rotor feedback wires short circuited Both feedback wires are short circuited Remove wires from terminals 17 and 18 and measure the resistance between them It should have a low ohm reading This is because of the still in circuit motor windings resistance as
92. lipping circuit 2 5 5 Snubber Card This card protects the thyristors from supply voltage transients Together with the metal oxide varistors MOV s mounted on the thyristors the Snubber network card provides a high degree of protection NOTE The Snubber card is not used on Thyromat units bigger than 1000A the Snubber network is then installed across the Thyristors on the stack 2 5 6 Control Panel The control panel is the man machine interface MMI of the Thyromat unit It serves as a window for monitoring various motor variables such as stator currents motor speed drive status etc It is used to enter the user parameters which makes the Thyromat specific to the application Revision 8 5a SECTION 2 SYSTEM DESGN 11 Print Date 24 06 2008 2 6 User Manual CONTROL SYSTEM SPECIFICATIONS Table 2 5 details the THYROMAT controller Specifications CONTROLLER DATA Automation International Table 2 5 THYROMAT Controller Specifications TECHNICAL DATA Input voltage U V W 380 V 415 V 3 phase 50 Hz Mains supply to THYROMAT Output supply to motor Control supply Digital inputs Control voltage Outputs Current inputs Ambient operating temperature Storage temperature Relative humidity Air quality Chemical vapours Mechanical particles Supply variations Trip level of THYROMAT Uo Vo Wo Terminals 10 11 Supply variations Generated b
93. llowing paragraphs detail the operational procedures during hoisting operations 5 4 1 Hoisting As soon as one of the four hoisting speeds on the master controller is selected the THYROMAT will activate the hoist contactors which will supply voltage to the motor a short time delay is provided before the brake is released The motor will accelerate at a rate determined by the acceleration profile Selecting one of the three slow speeds will regulate the motor at the selected speed Selecting full speed will accelerate the motor smoothly until full speed is reached Accelerating rotor contactors will operate at specific speeds Bringing the master controller back from full speed to one of the slower speeds or to the zero position will cause the drive torque to be removed from the motor until such time that the selected speed is achieved If the load is light and the deceleration ramp error sufficiently large the motor will be slowed down by plugging if the Hoist plugging parameter is set to True otherwise the brake will close immediately as the joystick returns to Neutral 5 4 2 Lowering With an Overhauling Load As soon as one of the three lowering slow speeds on the master controller is selected the THYROMAT will activate the hoist contactor which will supply voltage to the motor A short time delay is provided before the brake is released n an overhauling load operation the hoist contactor remains activated providing the motor the opportu
94. lly these contactors are capable of performing 5x10 to 10x10 operations depending on the current rating and manufacturer this should be determined and preventive maintenance done to avoid the unexpected stoppages due to contactor failure A crane working 24 hours a day 365 days a year with 300 starts hour should have its directional contactors replaced every two years 5x10 or four years 10x10 If damaged replace If damaged replace Rotor contactors Contact tips Mechanical wear Thyromat switching of the rotor contactors is done at the correct rotor frequency minimizing the effect of high closing currents these contactors are not protected by zero current switching as the directional contactors are but they do not switch open inductive loads since the resistance is always in the circuit These contactors have a similar life span the directional contactors have but under normal conditions operates only at 60 of the operations of directional contactors which means that its life soan on the same crane can be extended by a factor of 1 5 when compared to the directional contactors Thyromat unit fe KS fe KS Stack fan Parameters Control panel Thyromat control Fault history VVVV v Ensure that the fan is running To be the same as written list parameters Ensure that is not loose Ensure that Thyromat is working according to the user manual specification A
95. m was busy performing a Hoist plugging function Refer to possible causes below 6 8 1 d ROTOR FDBK Q3 The fault occurred during Lowering and while the system was operating in notches 1 2 or 3 with an Empty hook Refer to possible causes below pm M H 2 2 2 22 Revision 8 5a SECTION 8 SHIPPING AND STORAGE 85 Print Date 24 06 2008 User Manual n Automation International Note Rotor feedback fault can not be detected during full speed operation because the Rotor frequency is close to OHz 6 8 1 e ROTOR FDBK Q4 The fault occurred during Counter torque slow speed Lowering Overhauling load or during Lower plugging Refer to possible causes below 6 8 1 f Possible causes of Rotor feedback loss i Hoist contactor KM1 failed to energise Loose connection on coil circuit measure voltage across the coil Interposing relay failure when applicable measure voltage across the coil Faulty Relay Card output measure voltage across Thyromat terminals 10 and 16 This fault may be preceeded by RFB amp CURNT LOSS ii Lower contactors 2 failed to energise Loose connection on coil circuit measure voltage across the coil Interposing relay failure when applicable measure voltage across the coil Faulty Relay Card output measure voltage across Thyromat terminals 10 and 15 This fault may be preceeded by RFB amp CURNT LOSS
96. ment if retardation does not occur at the desirable rate the system will apply torque in the reverse direction lowering to assist with retardation of the upwards movement The torque applied can be adjusted by enabling Yes this parameter and set the voltage level to be applied in the next parameter Under load conditions it may not be necessary to assist with retardation due to gravitational force Therefore the system applies minimum torque checks the speed of the motor being reduced due to gravity and at the correct speed applies the mechanical brake Revision 8 5a SECTION 3 PARAMETERS 27 Print Date 24 06 2008 User Manual Jum H Automation International 3 2 8 Hoist plugging V PARAMETER DESCRIPTION SCALE INCREMENT DEFAULT 8 Hoist plugging V Hoist plugging voltage 20 to 80 This parameter is only active if parameter 7 Hoist plugging Yes active Hoists with high inertia require assistance during retardation by applying braking torque The percentage of voltage to be applied controls the amount of braking torque applied to reduce the speed of the drum during hoisting This retardation function is only visible when the inertia of the hoist is of such magnitude that the speed error between actual speed and the ramp generator exceeds a certain value when moving the master controller to a slower hoisting speed or to neutral Practically it means that light loads in hoisting are plugged and mos
97. meters o Display to show real time motor information o Display faults and history Reduced down time Enables preventative maintenance Revision 8 5a 1 GENERAL 1 Print Date 24 06 2008 User Manual Automation International SPECIAL FEATURES FEATURE ADVANTAGES Excellent control Load independent control o Excellent repeatable placing of end load o Safer working environment for personnel Smooth steady control o Safe efficient load handling o Gearbox and couplings not subjected to excessive stress o Reduced current peaks Slip ring maintenance reduced Motor life extended Safe brake control o Torque proving before brake is opened o Brake is used only as a parking brake and in emergency conditions No more continual replacing of brake parts Rotor feedback speed measurement No tacho generator or pulse encoder required o mechanical modifications needed on motor shaft o No additional installation costs labour and equipment o Automatic motor condition monitoring Early warning of motor failure No maintenance of a tacho required No need for small control wires in cable loop system Simplifies the control system Reversing contactors Reversing contactors are used to change torque direction on motor o Improved reliability as compared with static bridge system Contactors are switched during zero current conditions o maintenance on contact tips o Contactor life extended Simplicity Simple quick i
98. n the protection of the motor and associated cables The control is designed to achieve tripping times in the region of 20ms Revision 8 5a SECTION 3 PARAMETERS 44 Print Date 24 06 2008 User Manual H Automation International 3 6 7 Start Volts PARAMETER DESCRIPTION INCREMENT DEFAULT Start Volts Start voltage applied until N1 delay 30 to 100 70 complete This is the initial voltage applied to the motor when the joystick controller is moved to any notch not in opposition to the direction of rotation if any This is then applied until the notch one time delay has elapsed CAUTION USING STARTING VOLTAGES GREATER THAN 75 MAY CAUSE EXCESSIVE CURRENT SPIKES AT STARTUP 3 6 8 Notch Voltages 0 PARAMETER DESCRIPTION INCREMENT DEFAULT Notch 1 V Voltage applied after N1 delay complete 3096 to 10096 1 7096 30 to 100 1 70 Notch 2 V Voltage applied after N2 delay complete and notch 2 has been engaged Notch 3 V Voltage applied after N3 delay complete and notch 3 has been engaged These parameters set the voltages applied to the motor once the relevant notch delay has completed and the notch has been engaged 30 to 100 1 70 Notes 1 Use voltages set to 75 85 90 for notches 1 to 3 to start with adjustment up or down according to the cranes requirements 2 The torque provided in each notch is proportional to the square of the voltage applied v
99. nalyze faults and find out why they are happening Refer to chapter 6 for assistance e Control limit switch Operation Ensure that Hoist is operating within boundaries of the limit switch f Connections Loose gt Same as Protective panel e SECTION 8 SHIPPING AND STORAGE Revision 8 5a Print Date 24 06 2008 111 User Manual pr ra Automation International connections 9 Current converter Input R S amp T phases continuity test Output red yellow and blue phases continuity test gt Follow the steps below using Fluke e Measure between brown and blue wires while they are disconnected from CT e Use diode scale e Reading should be approximately 0 9 gt Follow the steps below using Fluke e Measure between green common and red phase yellow phase and blue phase e Reading should be approximately 0 7 D Travel Motion Panel Note Same procedure for all the Travel motion Check the following items Item Visual inspection or Note test a Circuit breaker Circuit breaker gt See drawings for the details type Current gt See drawings for the details settings b Reverse Contact tips Thyromat switching of the directional contactors contactors is done at zero current therefore there should be minimal signs of arcing on contact tips If this is not the case the
100. ng 3 4 9 Notch Plugging V PARAMETER DESCRIPTION SCALE INCREMENT DEFAULT 9 Notch Plugging V Notch plugging voltage 0 to 90 This parameter sets the notch plugging voltage for both directions Revision 8 5a SECTION 3 PARAMETERS 35 Print Date 24 06 2008 User Manual H Automation International Notch plugging when activated makes use of dynamic reverse plugging to retard the Travel motion to the required speed the magnitude of the plugging torque is proportional to the square of the plugging voltage applied therefore the voltage setting will have an effect on the smoothness of the motion operation It is suggested that in most applications a value not higher than 50 of supply voltage is used 3 4 10 Neutral Plugging INCREMENT DEFAULT PARAMETER DESCRIPTION 10 Neutral Plugging Neutral plugging Yes or No This parameter enables or disables neutral plugging 3 4 11 Neutral Plugging V PARAMETER DESCRIPTION SCALE INCREMENT DEFAULT 11 Neutral Plugging V Neutral plugging voltage 0 to 90 Neutral plugging when activated makes use of dynamic reverse plugging to retard the travel motion to standstill The magnitude of the plugging torque is proportional to the square of the plugging voltage applied therefore the voltage setting will have an effect on the smoothness of the motion operation It is suggested that in standard applications a value not higher than 70 of sup
101. ng relays to allow the use of an external control voltage of 110 VAC or 220 VAC which is not sensitive to external noise interference Therefore the use of standard armoured control power cables is sufficient the cables should have a minimum diameter of 1 5 mm preferably a cable diameter of 2 5 mm should be used for improved mechanical strength 2 13 SELECTION OF STATOR REVERSING CONTACTORS It is only necessary to rate the contactors for thermal current Ith because the THYROMAT switches the reversing contactors at zero current and voltage The thermal current selection depends on the type of application i e Standard or Severe Crane Duties For Standard Duty applications at least 1 1 x In nominal current at AC1 rating is recommended For severe duty applications at least 1 4 x In nominal current at AC1 rating is recommended Example A slip ring motor is to be used in a severe application the motor has a mechanical rating of 100 Therefore 1 1 4 1 4 100 140 nT Ts eee Revision 8 5a SECTION 2 SYSTEM DESGN 19 Print Date 24 06 2008 User Manual H Automation International According to information provided by the manufacturer the selected contactors would be LC1 F115 which has a rating of 200 A at AC1 or 115 A at AC3 Revision 8 5a SECTION 2 SYSTEM DESGN 20 Print Date 24 06 2008 User Manual H Automation International 2 13 1 Contactor Switching T
102. ngly recommended that the interposing relays have the following characteristics for optimum system performance They must be hermetically sealed This is a requirement due to most cranes operating under severe environmental conditions that could include dust and or corrosive gases They must have a minimum contact burden of 5 mA V SELECTION OF INTERPOSING OUTPUT RELAYS Where applicable use interposing contactors between the relay outputs of the THYROMAT and the stator rotor contactors Contactors can be used as single units or where necessary may be used in parallel The rating of the continuous supply current from the relay card is at a maximum of 2A therefore the maximum continuous allowable VA rating is 220 VA at 110 V and 440 VA at 220 Vac This means that the consumption of each contactor when closed may not exceed 50 VA 110 V system or 100 VA 220 V system leaving a small margin to feed the brake contactor which uses approximately x 20 VA NOTE In the event that interposing output relays are required then the sum of the pull in and drop out times of both the contactor and interposing output relay should be taken into consideration when setting up the phase shifter ON and OFF time parameters This is to ensure that the switching under zero current remains true Example Drop out Interposing relay LC1 D0910 drop out time 12 ms Associated contactor LC1 F185 drop out time 50ms Combined drop out time
103. nity to apply counter torque in order to maintain the lowering speed In a no load condition the lower contactor may be energized to operate the drive mechanism against friction When full speed lowering is requested the lower contactor closes immediately the voltage is ramped to full voltage and the motor will accelerate to full speed Bringing the master controller back from full speed to one of the slower speeds will cause additional counter torque to be applied until such time that the selected speed is achieved In the event that the master controller is brought back to the zero position additional counter torque will be applied until the motor reaches zero speed and after a short time delay voltage to the motor is removed Should counter torque braking last for more than the time allowed by the lower plug time out parameter the brake will be automatically applied the voltage removed from the motor and a fault Plugg out time displayed on the drive 5 4 3 Regeneration Selecting full speed when lowering the THYROMAT will activate the lowering contactors Voltage is applied to the motor and after a short delay the brake is released The motor is then driven at full speed in the lowering direction 5 4 4 Lowering With a Light Load The lowering operation with light loads is slightly different from the other lowering operations As soon as one of the three lowering slow speeds on the master controller is selected the THYROMAT will a
104. nstallation Training easy to perform Understood easily by maintenance staff o Faults on crane easy to find Loss of production eliminated o Rapid acceptance by maintenance staff Large range Covers complete crane range o Control system the same for any size motor o Ideal for single motor use with emergency operation requirement Revision 8 5a 1 GENERAL 2 Print Date 24 06 2008 User Manual 1 1 1 Basic System Diagram Control 3 Phase Supply Supply Main Circuit Protection Protection Automation International Fan Mother Board 1 l SHURE lt Card ia i i Thyristor Stack 1 i Shifter Card Healthy Relay i Brake Control Switchgear Driver s T Master mm Controller Y Reversing Contactors Control THYROMAT Digital 5 Control Panel 1 Interposing Relay Rotor Rotor Contactors Resistors This The system s simplicity is illustrated in the Basic System Diagram refer to Figure 1 1 diagram is applicable to both hoist and travel operations Figure 1 1 Basic System Operational Diagram Re
105. nt 21 2 14 SELECTION OF CURRENT 21 2 15 SELECTION OF ROTOR 5 22 2 15 1 Star 0161 111 10 0 6 een 22 2 15 2 Delta Connections 22 2 15 3 WV COMMOCHONS 23 2 15 4 UEM 23 2 16 MOTOR THERMAL PROTECTION UNIT This feature is not yet implemented 23 2 17 SELECTION OF SPARE 5 46 00004 0 2 n sess ss ssa assa snas 24 3 SECTION 3 PARAMETERS 1 24 3 1 HOIST APPLICATION PARAMETERS 24 3 2 PARAMETER DESCRIPTIONS 22 22 8 25 3 2 1 O ea 1 215 0 1 1 25 eee 26 3 2 3 Overload 26 324 Notch 27 225 2 T Tcu 27 3A Gs NOC 27 3 2 7 10 PIUQGING gece ctetuer Ee reete v
106. ntrol Card or the Control Card is faulty It is easier to replace the Control card first before attempting to strip open the Control Panel to remove the Ribbon cable 6 9 3 Single Phase Current Loss Applicable only if CT enable Yes Travel applications do not necessarily require monitoring of all 3 motors stator currents for the efficient and safe operation of the system If the drive reads one CT current at 0 Amps while the others are 0 Amps it will trip on Current loss 6 9 3 a CURNT LOSS 1 S loss of phase 1 current CURNT LOSS 2 S loss of phase 2 current CURNT LOSS 3 S loss of phase 3 current Revision 8 5a SECTION 8 SHIPPING AND STORAGE 102 Print Date 24 06 2008 User Manual pain Automation International Not applicable in Travel motion applications 6 9 3 b CURNT LOSS 1 Q1 loss of phase 1 current CURNT 1055201 loss of phase 2 current CURNT LOSS 3 Q1 loss of phase current The fault occurred during Forward operation Refer to possible causes below 6 9 3 CURNT LOSS 1 02 loss of phase 1 current CURNT LOSS 2 02 loss of phase 2 current CURNT 10553 02 loss of phase current The fault occurred during Forward plugging Refer to possible causes below 6 9 3 d CURNT LOSS 103 loss of phase 1 current CURNT LOSS 2 Q3 loss of phase 2 current CURNT 10553 loss of phase 3 current The fault occurred during Reverse operations Refer to possible causes below 6 9 3 CURN
107. ntrol voltage b Measure voltage across the relevant directional contactor If the voltage is present during start up 2 sec then the contactor mechanism or coil is faulty If not present during the start up 2 sec then check the voltage across Thyromat terminals 10 and 15 or 10 and 16 If there is no voltage then replace the Relay Card 6 If the Current Clamp shows a Current reading and the Hoist directional contactor is energising but the display remains at 0 Amps the problem may be caused by a faulty current converter circuit Ensure that the plug is plugged correctly Ensure that all 4 CT wires Red Yellow Blue and Green are connected to the plug Revision 8 5a SECTION 8 SHIPPING AND STORAGE 88 Print Date 24 06 2008 User Manual pain n Automation International While giving a Hoist notch 1 to 4 command to the Unit measure the AC voltage out of the CTs one at a time these must be a voltage 5V AC at any CT and they should be similar It is unlikely that all 3 CTs are faulty simultaneously Unplug the CTs plug and measure the DC voltage between Green and any of the 3 phases While giving a Hoist notch 1 to 4 command to the unit The Thyromat will trip on CURNT FDBK S after 2 seconds so this test needs to be done several times to cover all 3 phases If there is no voltage lt 5VDC at any one of the phase tests the Current Converter is faulty and needs replacing If there is voltage lt 5VD
108. nts at different potentials gt Improved mechanical strength of components further resisting vibration Further protection to card from metallic dust and humidity 2 5 2 Control Card The control card consists of a microprocessor that interfaces with the process input and outputs The microprocessor integrates on chip program memory data memory RAM and serial communication Also on the card is the serial EEPROM keypad and display driver communication interface Revision 8 5a SECTION 2 SYSTEM DESGN 10 Print Date 24 06 2008 User Manual pum H Automation International The rotor frequency is evaluated on this card using digital signal processing This gives the motors actual speed Inputs are optically isolated achieving high integrity of the control system 2 5 3 Relay Card This card contains the five relays for switching the external contactors and the power supply for these relays 2 5 4 Phase Shifter Card This card determines the trigger delay angle for the firing of the thyristors as well as circuitry for disabling the unit in the event of incorrect phase rotation severe phase imbalance or low supply voltage The 10 Volt control voltage is derived from the main supply voltage within this card The thyristor firing circuitry uses a phase locked loop control circuit and is therefore not sensitive to incoming mains disturbances The thyristor trigger module incorporates a unique dynamic time amplitude transient c
109. number description whether it can be re set what is been measured and possible causes Revision 8 5a SECTION 8 SHIPPING AND STORAGE 79 Print Date 24 06 2008 User Manual Automation International Table 6 5 Hoist and Travel Faults FAULT FAULT DESCRIPTION HOIST TRAVEL REFER TO ROTOR FDBK S Rotor feedback loss before the brakes were Y 6 8 1 a released Rotor FDBK Q1 Rotor feedback loss after releasing of brakes Y 6 8 1 b and during Hoisting Rotor feedback loss after releasing of brakes Y 6 9 1 b and during Forward Rotor FDBK Q2 Rotor feedback loss after releasing of brakes Y 6 8 1 c and during Hoist Plugging Rotor feedback loss after releasing of brakes Y 6 9 1 c and during Forward Plugging Rotor FDBK Q3 Rotor feedback loss after releasing of brakes Y 6 8 1 d and during Lowering Drive down Rotor feedback loss after releasing of brakes Y 6 9 1 d and during Reverse Rotor FDBK Q4 Rotor feedback loss after releasing of brakes Y 6 8 1 e and during Lower Plugging or Counter Torque Lowering Rotor feedback loss after releasing of brakes Y 6 9 1 e and during Reverse Plugging CURNT FDBK S Current feedback loss all 3 phases before Y 6 8 2 a the brakes were released CURNT FDBK Q1 Current feedback loss after releasing of the Y 6 8 2 b brakes and during Hoisting Current feedback loss after releasing of the Y only when 6 9 2 b brakes and during Forward C T s Yes CURNT FDBK Q2 Current fe
110. or during full speed lowering Refer to possible causes below 6 8 3 e CURNT LOSS 1 Q4 loss of phase 1 current Revision 8 5a SECTION 8 SHIPPING AND STORAGE 89 Print Date 24 06 2008 User Manual pain n Automation International CURNT LOSS 2 Q4 loss of phase 2 current CURNT 10553014 loss of phase current The fault occurred during Lowering plugging or slow speed lowering with an overhauling load i e counter torque lowering Refer to possible causes below 6 8 3 f Possible causes of Current loss 1 2 or 3 General t is suggested that the user reads the previous chapter 6 8 2 f to familiarise themselves more with current feedback readings Current loss means that all phases CT readings 0 Amps Phase current loss means that at least one CT reading 0 Amps while at least another CT reading 0 Amps 6 8 4 Current unbalance General A current unbalance is only detected when at least on Phase current is lt 50 of the highest reading current provided that the highest current is at least 50 of the Motor Current the condition is validated for a period of 2 seconds at start before the brakes have been released or 800ms during operation 6 8 4 a CURNT UNBAL 1S CURNT UNBAL 2 5 CURNT UNBAL 3 S The fault has occurred during the Torque proving phase before the brakes were given the command to be released Refer to possible causes below 6 8 4 b CURNT UNBAL 1 01 CURNT UNBAL 2 Q1 CURNT UNBAL
111. ot require specialised knowledge The ease at which faulty components units can be replaced will greatly reduce equipment down times A second option would be to keep a spare set of modules for the THYROMAT The identification and replacement of faulty cards require a suitably qualified person to carry out the task The cards have voltage sensitive devices that can be damaged if handled incorrectly 7 2 PREVENTATIVE MAINTENANCE Because of the design of the THYROMAT there are no preventative maintenance tasks required Preventative maintenance may be required for the associated equipment that depends on the various associated equipment and the applicable manufacturer s specifications 7 2 4 Brakes CAUTION NEVER ASSUME THAT THE MECHANICAL BRAKE IS CORRECTLY SET INCORRECT SETTINGS CAN LEAD TO FAILURE AND CAN CAUSE DAMAGE TO PROPERTY AND FATAL INJURIES One item that is critical to the safety and operation of the THYROMAT is the serviceability of the mechanical brake It is important that the mechanical brake is set in such a manner that it will stop a full load without motor assistance The mechanical brake must be checked at regular intervals Revision 8 5a SECTION 8 SHIPPING AND STORAGE 108 Print Date 24 06 2008 7 2 2 Ultimate Limit Switch User Manual CAUTION pn ra ALWAYS CHECK THE ULTIMATE LIMIT SWITCH FOR CORRECT OPERATION ACCORDING REGULATIONS TO THE RELEVANT It is important tha
112. ote A directional contactor failure is more likely to give a RFB amp CURRT LOSS fault gt Rotor feedback wires loose One or both feedback wires between the motor rotor phases and the unit terminals 17 and 18 are loose gt Rotor feedback wires short circuited Both feedback wires are short circuited Remove wires from terminals 17 and 18 and measure the resistance between them It should have a low ohm reading This is because of the still in circuit motor windings resistance as well as the corresponding rotor resistors on each phase With the wires removed measure at the Thyromat terminals 17 and 18 this reading should be very high Mega ohms it should actually start increasing during the reading time This is due to an internal capacitor in parallel across these terminals If the above tests show that the external wiring is in order it is then advisable to reconnect the wires and proceed to the next test which is as follows Revision 8 5a SECTION 8 SHIPPING AND STORAGE 98 Print Date 24 06 2008 User Manual pain n Automation International Measuring the voltage across terminals 17 amp 18 while starting the motor If a voltage is present it indicates that the external circuit is sending the rotor feedback signal but the THYROMAT unit is not reading it Replace the Control Card enter the same parameters onto this card and try to run the system if the fault persists the problem may be related to the control box moth
113. out times of the contactors and a practical way of achieving no arcing is by running the Hoist motion in the lowering direction between 4 and 3 notches This way the reversing contactors as well as the rotor contactors will all be operating check for possible arcing and if present increase the Phase Shifter OFF time Step 13 Hoist only Monitor the operation of the brake contactor versus the directional contactors At the end of any cycle the brake contactor should de energize first The power will remain on the motor for a further 500 to 1050 msec depending on the setting of the respective parameter Stop delay Only after this time has expired the directional contactor will drop out Step 14 Hoist only Test under load conditions Run the motion in both directions notch by notch Specifically look out for the operation of the brake drum During Hoisting operation the brake drum must not turn in reverse lowering direction if this happens it may indicate one of the following e Load is greater than the safe working load SWL of the Hoist motion e The supply is weak and under load conditions it drops drastically e Rotor resistances are not correctly designed Revision 8 5a SECTION 5 COMMISSIONING 68 Print Date 24 06 2008 User Manual pan n Automation International e The motor is not performing as per manufacturers design this may occur after several rewinds The above mentioned problems may also be causing th
114. ow the Brown out Y level CODE 103 CPU internal loss of messages Y CODE 104 CODE 106 CPU failed to read saved parameters or does not recognise the combination of parameters stored in the EEprom CPU System fault Y An instruction taken from the EVENT queue has no meaning within the MOTOR MODULE and it can not be processed CODE 107 This fault code was created to assist during Revision 8 5a Print Date 24 06 2008 SECTION 8 SHIPPING AND STORAGE REFER TO 6 8 9 6 8 10 6 8 11 6 8 12 6 8 13 6 8 14 6 8 15 6 8 16 6 8 17 a 6 8 17 b 6 8 17 c 6 8 17 d 6 8 17 e 6 8 17 f 6 8 17 g Automation International 83 User Manual pan Automation International FAULT FAULT DESCRIPTION HOIST TRAVEL REFER TO software development phase to trap the unnecessary logging of CURRENT FEEDBACK trips CODE 108 This fault code was created to assist during software development phase to trap the instruction to accidental switching of both directional contactors CODE 109 The fault code was created to assist during software development phase to trap the instruction to accidentally turn off both directional contactors when one should have been switched ON HEALTHY The logging of a Healthy fault indicates 6 8 17 j that the system has tripped but the CPU missed the reading of the Error fault stamp and the Healthy status was instead lo
115. page is illustrated in Figure 6 4 Figure 6 4 Set Time Page The SET TIME page displays the hour minute day month and year The cursor indicates the field which can be adjusted Table 6 4 lists the field name and the range Table 6 4 Field and Range RANGE 00 to 24 00 to 59 00 to 31 01 to 12 2000 to 2099 Revision 8 5a SECTION 8 SHIPPING AND STORAGE 78 Print Date 24 06 2008 User Manual Automation International 6 7 FAULT HISTORY The THYROMAT stores a maximum of 254 faults in the order they appear and can be viewed by scrolling through the fault history pages The faults are listed in the order 01 most recent fault to 254 the oldest fault As a fault occurs it automatically takes position 01 and pushes all the recorded faults up one level until the oldest fault is bumped off the fault history list A typical fault history menu page is illustrated in figure 6 5 Figure 6 5 Fault History Menu Page The fault history data is displayed in four rows The following details the displayed data gt Row 1 The system fault number gt Row2 The fault description gt Row3 The date title gt Row4 The date and time that that failure occurred Most of the faults can be reset via the master controller s neutral position at the operator s position To clear fault history press RESET then SAVE keys in this order and all the fault history will be cleared Table 6 5 lists the fault
116. ply voltage is used 3 4 12 Brake Plugging V PARAMETER DESCRIPTION SCALE INCREMENT DEFAULT 12 Brake Plugging V Voltage to apply when 50 to 90 plugging in the opposite direction Brake plugging can not be disabled To activate Brake plugging the operator moves the joystick into any notch in the opposite direction to the actual crane direction at the time The voltage applied determines the torque to be applied to retard the Travel motion It is suggested that Brake plugging is always set to a Voltage higher than any one of the other two Plugging voltages mentioned above but not higher than 80 If the system requires a Braking voltage higher than 80 it may indicate weakness on other aspects of the motion electrical design which may be solved by a complete analysis of the system by MH Automation engineers Revision 8 5a SECTION 3 PARAMETERS 36 Print Date 24 06 2008 User Manual Jum H Automation International 3 4 13 Maximum Stall Voltage PARAMETER DESCRIPTION SCALE INCREMENT DEFAULT Max Stall V Maximum stall volts 20 to 80 This is the ceiling voltage applied to the motor in the event that the motor remains at standstill during operation i e Motor is stalled Usually a setting of 70 is sufficient to enable the motion to operate satisfactory It is sometimes necessary to increase this voltage usually in the case of bad Travelling rails with wide rail joint gaps or worn out spo
117. pplications Revision 8 5a SECTION 2 SYSTEM DESGN Print Date 24 06 2008 User Manual H Automation International Applications Power station cranes Light workshop cranes Light stores duty cranes Light general load handling cranes 2 4 2 Severe Duty Based on 40 of nominal load permanently on hook The following lists the severe duty parameters Characteristics Rated starting class 150to 600 starts per hour Cyclic duration factor 40 or 60 Max Ambient Temperature 60 C Altitude above sea level 1500 meters The typical severe duty applications are as for BS 466 1984 cranes with a group mechanism in M5 to M8 heavy duty workshop warehouse and general hook service The following lists typical severe duty applications Applications v Crane for grabbing work Ladle crane for foundry work Magnet crane for stockyard work Magnet crane for scrap yard work Process crane Shipyard crane Ladle crane Pig scrap breaking crane Ingot stripper Stocking pit mould handling crane Vertical ingot charger Furnace charging crane Forging crane Heavy mill service crane VV ON ON ON ON ON ON ON VV VV WV Heavy duty service and maintenance crane Revision 8 5a SECTION 2 SYSTEM DESGN 8 Print Date 24 06 2008 User Manual Jum H Automation International Table 2 4 details the selection of the maximum stator current ratings for both hoist and t
118. ps main contactor if not look for the TEST fault before handing over crane to the crane driver d Auxiliary hoist Operation gt By pass hoist limit hoist in slow speed till final limit switch it trips main contactor if not look for the TEST fault before handing over crane to the crane driver e Connections Loose Check all major power connections connections C Hoist Motion Panel e Check the following items Note Same procedure for all the Hoist motion Item Visual inspection or Note test a Circuit breaker Circuit breaker gt See drawings for the details type Current gt See drawings for the details settings b Reverse Contact tips Thyromat switching of the directional contactors contactors is done at zero current SECTION 8 SHIPPING AND STORAGE Revision 8 5a Print Date 24 06 2008 110 User Manual Automation International Mechanical wear Auxiliary contact blocks Mechanical interlock therefore there should be minimal signs of arcing on contact tips If this is not the case there may be a problem with the wrong setting of phase shifter On and Off time parameters Main causes of arcing are Intermittent wiring fault e Contactors have a slow switching action due to excessive wear or dust e Wrong phase shifter On and or Off time settings With time the contactors will mechanically worn out and they will need to be replaced usua
119. r the specific duty CAUTION DO NOT EXCEED THE MOTOR NAMEPLATE VALUE FOR THE APPLICABLE DUTY Note This value should be determined during the design phase This value is to be used by the thermal model to calculate overload conditions 3 4 4 Overload Class INCREMENT DEFAULT NO PARAMETER DESCRIPTION O L Class Overload class type 2015 This parameter selects the Class of overload that the thermal model uses a reference Class 2 Trip if stator current exceeds three times motor full load current Motor flc for a period exceeding 6 77 sec Class 5 Trip if stator current exceeds three times motor full load current Motor flc for a period exceeding 16 7sec Revision 8 5a SECTION 3 PARAMETERS 34 Print Date 24 06 2008 User Manual H Automation International 3 4 5 Notch Speed 1 3 4 6 Notch Speed 2 3 4 7 Notch Speed 3 PARAMETER DESCRIPTION SCALE INCREMENT DEFAULT 5 Notch 1 Notch 1 speed 5 to 20 6 Notch 2 Notch 2 speed 5 to 40 7 Notch 3 Notch 3 speed 5 to 50 These three parameters set the intermediate slow speeds CAUTION WHERE SPEEDS IN EXCESS OF 30 ARE SELECTED SPECIAL ROTOR RESISTANCE DESIGN MAY NECESSARY CONSULT YOUR LOCALL AUTOMATION REPRESENTATIVE FOR ASSISTANCE 3 4 8 Notch Plugging PARAMETER DESCRIPTION INCREMENT DEFAULT 8 Notch Plugging Notch plugging Yes or No This parameter enables or disables notch pluggi
120. r travels CT s should have a VA rating of at least 5 VA Revision 8 5a SECTION 2 SYSTEM DESGN 21 Print Date 24 06 2008 User Manual H Automation International 2 15 SELECTION OF ROTOR CONTACTORS With Thyromat control rotor contactors are mainly used in Hoist applications When rotor contactors switch ON the current raises due to a shift from a greater slip resistor to a smaller slip resistor The current peaks are limited to a value between 1 5 and 2 5 times that of the rotor rated current under full load conditions The rotor contactors will switch off under zero current conditions provided that the switching times of these contactors are faster or at least equal to the stator contactors switching times In the event that the switching times are longer the relevant parameters for phase shifter ON and OFF time delays have to be adjusted accordingly There are four basic configurations used to connect the rotor contactors the most popular configurations used are Delta and Star configurations and although not as popular V and W configurations are sometimes also used In the interests of promoting reliability MH Automation has a conservative approach to the selection of the contactors and recommends that the continuous rating of the contactors are used rather than intermediate duty which is used for the intermediate rotor contactors The formula used to select the correct rotor contactors for the appl
121. rameters and the parameters need to be set to No When set as No This is the way that THYROMAT analogue and early digital units use to select the direction or rotation of the motor For Hoisting Forward Input terminal 5 bridged to 3 For Lowering Reverse Input terminals 4 and 5 bridged to 3 When set as Yes For Hoisting Forward Input terminal 5 bridged to 3 For Lowering Reverse Input terminal 4 bridged to 3 Note Any other combination will cause a J error fault which indicates that either speed steps have been selected without defined directional signal or in the event of this parameter being set as YES two directional inputs have been selected simultaneously Revision 8 5a SECTION 3 PARAMETERS 32 Print Date 24 06 2008 User Manual H Automation International 3 2 18 Load defaults PARAMETER DESCRIPTION SCALE INCREMENT DEFAULT Yes or No This parameter returns all the parameters to factory default settings CAUTION IF IT IS NECESSARY TO CHANGE PARAMETERS IT IS RECOMMENDED THAT THIS BE DONE IN A CONSERVATIVE MANNER AND ONLY WITH A FULL UNDERSTANDING OF EACH FUNCTION Note The default values have been selected so that they will apply to most applications Generally only parameters 1 2 and 10 will require changing to suit actual motor information Revision 8 5a SECTION 3 PARAMETERS 33 Print Date 24 06 2008 User Manual Automation Interna
122. ravel in standard and severe duty applications of the various THYROMAT units Table 2 4 Maximum Motor Stator Current Ratings THYROMAT BD Stator Current Current Ratings at Standard Severe Standard 60 C Duty Duty Duty 20 5 A 17 5 25 21 50A 83A 125A 166A 291A 333 A 416A 583 A 833 A 1 000A 1 250A 1 666 2 080 2 5 PRINCIPLE OF OPERATION The THYROMAT is connected in series with the stator supply voltage The control unit varies the stator voltage of the slip ring motor by adjusting the firing angle of the inversely connected parallel thyristors in each of the three phases The motor torque is proportional to the square of the stator voltage T V where T is the motor torque and V is the stator voltage The speed of the motor is measured by the frequency of the rotor Reversing the direction of motor rotation is achieved by switching externally mounted reversing contactors at zero current Revision 8 5a SECTION 2 SYSTEM DESGN 9 Print Date 24 06 2008 2 5 1 User Manual pum H Automation International Before operation can commence safety circuits monitor the motor for incorrect phase rotation severe phase differences or unbalance and low three phase voltage supply and will only allow operation in the event that all the conditions are correct Electrical interlocking is provided to make sure that the master controller is returned to the zero position after a power or phase loss after w
123. re may be a problem with the wrong setting of phase shifter On and Off time parameters Main causes of arcing are Intermittent wiring fault e Contactors have a slow switching action due to excessive wear or dust e Wrong phase shifter On and or Off time settings Mechanical wear With time the contactors will mechanically worn out and they will need to be replaced usually these contactors are capable of performing 5x10 to 10x10 operations depending on the current rating and manufacturer this should be determined and preventive maintenance done to avoid the unexpected stoppages due to contactor failure A crane working 24 hours a day 365 days a year with 300 starts hour should have its directional contactors replaced every two years Auxiliary 5x10 or four years 10x10 contact blocks Mechanical gt f damaged replace interlock gt f damaged replace c Rotor Contact tips gt Thyromat switching of the rotor contactors contactors is done at the correct rotor frequency SECTION 8 SHIPPING AND STORAGE Revision 8 5a Print Date 24 06 2008 112 User Manual pr Automation International minimizing the effect of high closing currents these contactors not protected by zero current switching as the directional contactors are but they do not switch open inductive loads since the resistance is always in the circuit Mechanical
124. romat drive Healthy Status to be displayed 9 Move the cabin joystick to Notch 1 Hoisting h Measure the stator and rotor voltages between phases at the motor terminals i Confirm that the Stator Rotor voltage ratio falls within 10 of name plate NOTE CS Revision 8 5a 66 Print Date 24 06 2008 User Manual pain n Automation International This test may only be performed for periods of approximately 10 seconds at the time since the Thyromat drive will trip on motor stall if it remains for longer periods in Notch 1 Analyzing the results When the above mentioned voltage ratio falls within the recommended 1096 deviation the test is considered successful and the next test must now be performed When such ratio is out the recommended deviation one needs to verify why this is the case In the case of an upgraded installation it may be that the motor may have been rewound previously and its characteristics have changed slightly if the deviation is too great it may be possibly that the Rotor connections have been changed from Y to A or vice versa In this case the motor may not perform well under full load conditions and it may be necessary to replace it with a standby spare motor Under a great discrepancy on the rotor voltage the rotor resistance which was calculated around the motor name plate values is going to be inadequate too and this needs to be taken in consideration as well Consult MH Automation for advice in
125. s DESCRIPTION SCALE 50 1 to 3000 1 lt 60 of CT ratio 2015 5 to 20 5 to 40 5 to 50 Yes or No 20 to 80 50 to 100 0 to 50 30 to 80 300 1500 ms 2000 5000 ms 70 to 100 0 to 140 ms 60 to 240 ms Yes or No Yes or No SECTION 3 PARAMETERS INCREMENT DEFAULT Min 2 Amps 10A 5 Automation International 24 User Manual Jum H Automation International 3 2 PARAMETER DESCRIPTIONS HOIST The following paragraphs detail the various hoist parameters CAUTION IF IT IS NECESSARY TO CHANGE PARAMETERS IT IS RECOMMENDED THAT THIS BE DONE IN A CONSERVATIVE MANNER AND ONLY WITH A FULL UNDERSTANDING OF EACH FUNCTION 3 2 1 CT Ratio NO PARAMETER DESCRIPTION INCREMENT DEFAULT CT Ratio This parameter selects a current transformer ratio CT ratio Only CT ratios from the list below can be used THE AVAILABLE CT RATIO S ARE Note CT s are required for all hoist applications Revision 8 5a SECTION 3 PARAMETERS 25 Print Date 24 06 2008 User Manual pum H Automation International 3 2 2 Motor current PARAMETER DESCRIPTION SCALE INCREMENT DEFAULT ratio This parameter sets the motor full load stator current The value to be used is the stator current related to the mechanical power for the specific duty CAUTION DO NOT EXCEED THE MOTOR NAMEPLATE VALUE FOR THE APPLICABLE DUTY Note This value should be determined
126. s Connectors on the Main Board Figure 4 5 illustrates the installation diagram for the relay outputs from the connectors on the main board RELAY OUTPUTS MAX CURRENT 16 NOMINAL 2A AC11 220V AC 24V DC DC11 SUPPLY TO RELAY CARD mee 125 Hz FINAL LOWER TORQUE ERMEDI BRAKE ROTOR FORWARD LOWERING CONTACTOR CONTACTOR CONTROL REVERSE COUNTER CONTACTOR LIVE 110 220 AC NEUTRAL Figure 4 5 Relay Outputs for the Connectors on the Main Board gt Hoist Applications 1 Hoisting and counter torque lowering contactor 2 Lowering contactor 7 Brake contactor KM41 Intermediate or 1 rotor contactor KM42 Final or 279 rotor contactor Revision 8 5a SECTION 4 INSTALLATION 61 Print Date 24 06 2008 User Manual gt Travel Applications 1 KM2 KM7 41 42 Reverse contactor Forward contactor Brake contactor Only required in special applications Only required in special applications 4 4 4 Triac Outputs Control Panel Board Automation International Figure 4 6 illustrates the installation diagram for the triac outputs from the control board COM 1 TRIAC RATINGS 600V AC 2A MAX 100 Ma CONTINUOUS OUT 1 COM 2 NOT USED IN CRANE APPLICATIONS OUT 2 Figure 4 6 Triac Outputs from the Control Panel Board gt Hoist Applications Out 1 K06 Out 2 Not used
127. s 2000ms applied to the motor Delay time before notch 3 Voltage can be 50 ms to 9950ms 50ms 3000ms applied to the motor N3 Delay N4 Delay Delay time before notch 4 Voltage can be 50 ms to 9950ms 50ms 4000ms applied to the motor Plug Volt 1 Plugging Voltage applied when notch 1 is 30 to 100 1 70 selected in the opposite direction of rotation Plugging Voltage applied when notch 2 is 30 to 100 1 70 selected in the opposite direction of rotation Plug Volt 2 Plugging Voltage applied when notch 3 is 30 to 100 1 70 selected in the opposite direction of rotation 17 Plug Volt 3 Plugging Voltage applied when notch 4 is 30 to 100 1 70 selected in the opposite direction of rotation Plug Volt 4 15 Rotor 1 rotor contactor 40 to 100 1 50 Revision 8 5a SECTION 3 PARAMETERS 41 Print Date 24 06 2008 User Manual H Automation International 274 rotor contactor 40 to 100 1 75 3 6 PARAMETER DESCRIPTIONS TORQUE The following paragraphs detail the various torque parameters 3 6 1 Load Defaults PARAMETER DESCRIPTION INCREMENT DEFAULT EN Load Defaults Load factory default parameters Yes or No No This parameter returns all the parameters to factory default settings CAUTION IF IT IS NECESSARY TO CHANGE OTHER PARAMETERS IT IS RECOMMENDED THAT THIS BE DONE IN A CONSERVATIVE MANNER AND ONLY WITH A FULL UNDERSTANDING OF EACH FUNCTION Note The
128. s fault code may indicate a particular condition possibly unique to the specific motion which causes a fault error which trips the Thyromat but it is not recognised by the error log table 6 8 18 Healthy The logging of a Healthy fault is not a serious event but if persists it indicates that the unit had a fault to be reported but missed the reading of the fault Error stamp during fault logging Possible causes Excessive electro magnetic interference f persists Fault Control Card 6 9 POSSIBLE CAUSES OF FAILURE ON TRAVEL SYSTEMS The aim of this chapter is to assist the user in getting to the cause of the fault as quick as possible although great effort has been put into describing as many causes of faults as possible It is almost Revision 8 5a SECTION 8 SHIPPING AND STORAGE 97 Print Date 24 06 2008 User Manual pain Automation International impossible to cover every single aspect of the entire crane installation without running the risk of creating a guide which then looks more like a technical book The desired speed required repairing or correcting the fault would then be lost in the extensive reading and searching for the exact fault definition It is always far more productive for the user to become more familiar with the THYROMAT basic methods of motor control It is possible to acquire the information from this manual as well as from specific THYROMAT courses offered at our head office as well as at cert
129. seeneeseaeeseaeeseaeeseeeeseaeeseaeeess 89 6 8 4 Current 90 6 8 5 Rotor feedback and Current feedback 1055 0 40 91 6 8 6 92 Notin isi 92 6 8 8 4 0 OMON e 93 6 9 8 Stall 93 6 8 10 a e cies te ede de pe e e ra dun ee eed a deo 94 6 8 11 FIOISt LOSS OT e 94 6 8 12 Nozio i is chads 94 6 8 13 2 c E 94 6 8 14 Brake release cannonieri De e ne eo bee enone 95 6 8 15 c EO EEEE E A E 95 6 8 16 uev ee 95 6 8 17 COS TANS ED 96 6813 ST 97 6 9 POSSIBLE CAUSES OF FAILURE ON TRAVEL 5 5 97 6 9 1 LOSS OF ROTOR FEEDBACK ssssssssssssseseseeeneeenne enne eerte enn nnn nni nnne tnnt rennen nnns 98 6 9 2 CURRENT FEEDBACK LOSS All phases Applicable only if CTs enable Yes 100 6 9 8 Single Phase Current Loss Applicable only if CT enable 102 6 9 4 Current unbal
130. t air circulation 4 to aid in the cooling of the THYROMAT A minimum space of 150 mm at the top and 150 mm at the bottom of the THYROMAT 5 must be free of obstructions to allow for sufficient airflow to cool the unit 4 2 3 Tools and Special Equipment Table 4 1 lists the Tools and Special Equipment Mechanical needed to mount the THYROMAT Table 4 1 Tools and Special Equipment Mechanical THYROMAT BD Digital Crane Controller Mechanical Size TOOLS Marking Pen Ruler tape measure Spirit Level Centre Punch Drilling Machine Extension Lead 6 5 mm Drill Bit 8 mm Drill Bit Metric tap set 8 mm Metric tap set 10 mm Revision 8 5a SECTION 4 INSTALLATION Print Date 24 06 2008 Automation International 50 User Manual H Automation International 4 2 4 Mounting Arrangements Table 4 2 lists the mechanical mounting arrangement for the various THYROMAT controllers Table 4 2 Mechanical Mounting Arrangements of THYROMAT BD Digital Crane Controllers Ec MOUNTING HOLE ARRANGEMENT measurement in mm M100 M150 M350 Revision 8 5a SECTION 4 INSTALLATION 51 Print Date 24 06 2008 User Manual
131. t heavy loads are not 3 2 9 Lower plugging V PARAMETER DESCRIPTION SCALE INCREMENT DEFAULT 9 Lower plugging V Lower plugging voltage 50 to 100 The lower plugging voltage parameter sets the maximum ceiling voltage applied during lowering retardation In the event that this voltage is not sufficient to retard the motor after an initial period of 750 ms the ceiling is removed and maximum voltage may be applied CAUTION SETTING THIS VALUE TOO HIGH CAN CAUSE HIGH CURRENT PEAKS SETTING THIS VALUE TOO LOW CAN RESTRICT THE BRAKING TORQUE 3 2 10 Brake release PARAMETER DESCRIPTION SCALE INCREMENT DEFAULT 10 Brake release Brake release current 0 to 50 This parameter sets the minimum stator current required to allow the brakes to be released As a general rule this current value must be equal or greater than the motor magnetizing current If this current is not known the no load current is close enough Brake release current No load current Motor current x 100 Revision 8 5a SECTION 3 PARAMETERS 28 Print Date 24 06 2008 User Manual pan H Automation International 3 2 11 Hoist start volt PARAMETER DESCRIPTION SCALE INCREMENT DEFAULT 11 Hoist start volt Hoisting min start volts 30 80 This parameter sets up the minimum voltage applied to the motor immediately at start of a hoisting cycle When this voltage is reduced the starting up of a
132. t the electrical interlock via the contacts of the reversing contactors is functioning correctly Measure the voltage across the Brake contactor coil if there is voltage present and the contactor is not energised the contactor coil or its mechanism is faulty Other possible causes are Brake thrustor or the power cable associated with it is faulty Faulty mechanical gear train Revision 8 5a SECTION 8 SHIPPING AND STORAGE 93 Print Date 24 06 2008 User Manual n Automation International It is possible that due to an excessive hook load or a Mains volt drop with a heavy suspended load the motor is unable to develop sufficient torque to lift the load and remains stationery with a load suspected during the attempt to Lift n the case of Travels it is common to find that a joint of rail suddenly became wide and the Travelling Wheels got stuck in the gap 6 8 10 Stack over temperature The Thyromat thyristor stack has a temperature monitoring device bi metal strip which goes open circuit in the event that the stack temperature reaches levels above its maximum allowed temperature i e in the region of 90 to 100 C depending on the size of the unit To confirm that the Temperature switch is closed measure the DC voltage across its terminals for a closed switch it must be DC an open switch will measure 9 to 10V DC 6 8 11 Hoist Loss of torque A Hoist loss of torque is detected if during a Hoist oper
133. t the ultimate limit switch operates to within the tolerances specified by the applicable regulations 7 3 CRANE MAINTENANCE CHECK LIST FOR THYROMAT SYSTEM CONTROL A General equipment Check the following items Automation International rotor test Item Visual inspection or Note test a Motors Terminal Ensure that terminal bolts are tightened Slip rng Thefollowing need to be done compartment e Brushes inspection e Slip rings smoothness visual inspection e Clean carbon developed from brushes b Load test Full load test gt To be done on basis as described by OSHACT C Locked rotor Open locked gt Follow the following steps test to be done rotor test e Open star point of the resistors if there is doubt e Disconnect brake signal from terminal with regard to 13 on the Thyromat the e Hoist first notch performance of e Ensure that motor shaft is not turning the motor e Measure the stator voltage and rotor voltage which will correspond to the motor name plate voltages details allow 10 variation e Measure stator current and rotor current Rotor current suppose to be zero or else find the fault e readings should be fairly balanced on all three phases e above test is done to confirm the ratio between stator and rotor voltages Closed locked 5 Eollow the following steps e Connect star point of the resistors e Disconnect brake signal from terminal 13
134. tal Inputs Main nnne nennen nnne enne enne 60 4 4 2 Digital Inputs Connectors on the Control 404440 0 61 4 4 8 Relay Outputs Connectors on the Main 61 4 4 4 Outputs Control Panel 62 4 4 5 Motor Current Inputs nnne daaa ent rn senten ennt 63 5 SECTION 5 COMMISSIONING sa sssscstcasencasccisissasssancndsassasnecsasncaadawaisuesssaateacasaasntacnsnceans 64 5 1 GENERAL eee 64 5 2 PREPARATION 54 eani seen a eet 64 5 3 COMMISSIONING 65 5 4 HOIST OPERATION mE m 70 5 4 1 0 55 oe b EAEEREN R eed uo beo eu eru 70 5 4 2 Lowering With an Overhauling 70 5 4 3 Hegenerallon eod tee Seele te titia 70 5 4 4 Lowering With a Light mne nnne nennen rennen 70 5 5 TRAVEL OPERATIONS 71 Dod Tave 71 6 SECTION 6 OPERATION OF CO
135. ter reference and Overload capacity STATUS MONITORING PAGE 3 Status 418 Drive healthy drive status Second display page Joystick position and speed This page displays the current transformer inputs take note that the reference and speed functions are also displayed To return to STATUS MONITORING page press the MENU key 249 Phase Shifter reference and Overload capacity MOTOR 3 PHASE CURRENTS MONITORING PAGE CT2 CTS Current transformer input 000 000 000 Current transformer value in amperes 6 2 SUPPLEMENTARY DISPLAY PAGES SCROLL MENU To enter this menu press the key marked the typical displayed page is illustrated in figure 6 2 FA STORY MENU Figure 6 2 Typical Displayed Page Scroll up or down using the UP and DOWN keys to select the desired function 6 2 1 Parameters This function allows the operator to scroll through and change the settings of the pre loaded default parameters Revision 8 5a SECTION 8 SHIPPING AND STORAGE 74 Print Date 24 06 2008 User Manual pan Automation International Once this page has been accessed it can only be exited by pressing the SAVE key When the SAVE key is pressed all information is saved including any changes and the display reverts back to the main display page 6 2 2 Set Time This function allows the operator to view the current time and date and also to set the tim
136. the mentioned contactor minus parameter 15 setting value Maximum drop out time parameter 15 parameter 16 Example 170 80 90 ms The next available parameter setting is 100 ms increments of 20 ms Note In most cases the default values of both parameters is sufficient for reliable operation As a general rule deviations from the default values should only be required when contactors with current ratings greater than 225A which are Revision 8 5a SECTION 3 PARAMETERS 30 Print Date 24 06 2008 User Manual H Automation International not equipped with special fast acting coils are used For further assistance on the correct settings for a specific contactor type contact MH Automation technical department Revision 8 5a SECTION 3 PARAMETERS 31 Print Date 24 06 2008 User Manual H Automation International 3 2 17 Separate Directional Signals PARAMETER DESCRIPTION SCALE INCREMENT DEFAULT 17 Yes or No This parameter defines the way the input directions are programmed THYROMAT CONTROL TERMINALS THYROMAT CONTROL TERMINALS KO2 KO1 Parameter set to No Parameter set to Yes Note In the event that this configuration keeps on giving a j error message out it indicates that the THYROMAT unit Motherboard is not compatible with these pa
137. tion Control enclosure Thyristor stack 24 BD DIGITAL CRANE CONTROLLER SELECTION prt Automation International The selection of the THYROMAT for specific mechanical power requirements depends on the base stator current rating on of the slip ring motor to be used In the event that the base stator current ratings are not known then it is suggested that the same ratings S4 or 55 for crane duty slip ring motors be used Perform the following steps to calculate the mechanical power Step 1 Calculate the mechanical power that will be generated by the motor using the speed load and efficiency of the motion Step 2 If this data is not available use the electrical power for the specific duty Step 3 Obtain the stator current for the specific power selected Step 4 Refer to the table and select the THYROMAT The selection of the THYROMAT has been divided into two operational categories for both hoist and travel namely standard duty and severe duty The following paragraphs define standard and severe duty applications 2 41 Standard Duty The following defines standard duty Characteristics Rated starting class 150 starts per hour gt Cyclic duration factor 40 gt Max Ambient Temperature 40 C gt Altitude above sea level lt 1 500 meters The typical standard duty applications are as for BS 466 1984 cranes with a group mechanism in M3 and M4 the following lists typical standard duty a
138. tion of the motor CAUTION USING PLUGGING VOLTAGES GREATER THAN 70 ON A 30 RESISTOR WILL EXPOSE THE MOTOR AND MECHANICAL COMPONENTS TO HIGH TORQUE OUTPUTS WHICH MAY DESIRABLE IN THE LONG TERM Note The plugging voltage can be set very low in the lower notches provide gentle braking getting progressively higher as the notch position increases to provide quicker but harsher braking 4 notch may require a voltage as high as 75 to 80 to provide a quick enough response when a fast stop is required 3 6 11 1st Rotor PARAMETER DESCRIPTION INCREMENT DEFAULT 50 15 rotor contactor 40 to 100 This parameter determines the speed at which the output for the first rotor contactor is energised The installation of this contactor is recommended in travel systems where it is critical to run the motor at a speed closer to its rated synchronous speed Depending on the load driven the amount Revision 8 5a SECTION 3 PARAMETERS 47 Print Date 24 06 2008 User Manual Automation International of slip resistance left may be 0 15 p u 0 15k This should take the motor top speed to approximately 85 to 90 of its synchronous speed 3 6 12 2nd Rotor PARAMETER DESCRIPTION INCREMENT DEFAULT 274 rotor contactor 40 to 100 1 75 This parameter determines the speed at which the output for the second rotor contactor is energised The installation of this contac
139. tional 3 3 TRAVEL APPLICATION PARAMETERS LIST Table 3 2 lists the typical parameter settings for Travel version 8 00 applications Table 3 2 Travel Parameter List NO PARAMETER DESCRIPTION SCALE INCREMENT DEFAULT C T Ratio CT ratio 50 1 to 3000 1 50 1 CT enable CTs enable Yes or No c Motor Current Motor full load current 60 of CT ratio O L Class Overload class type 20r5 Notch 1 Notch 1 speed 596 to 2096 Notch 2 Notch 2 speed 596 to 4096 Notch 3 Notch 3 speed 5 to 50 Notch Plugging Notch plugging Yes or No Notch Plugging V Notch plugg voltage 0 to 90 Neutral Plugging Neutral plugging Yes or No Neutral Plugging V Neutral plugging voltage 0 to 90 Brake Plugging V Voltage to apply when plugging 50 to 90 in the opposite direction Max Stall V Maximum stall volts 20 to 80 Minimum Start V Minimum start volts 20 to 80 123 Accel Acceleration time between slow 2 to 20 Sec speed notches N4_ Accel profile Acceleration rate for full speed 2 to 20 Sec acceleration Ph Shift Off Tim Phase shifter off time delay 60 to 240 ms N4 delay Notch 4 delayed time 0 to 5 sec 2 Sep dir signals Separate directional signals Yes or No 2 BEEN M 1 Load Defaults Load factory default parameters Yes or No NOTE All Travel Control software versions 8 xx must be
140. tor is recommended in travel systems where it is critical to run the motor at a speed closer to its rated synchronous speed Depending on the load driven the amount of slip resistance left may be 0 07 p u 0 07k This should take the motor top speed to approximately 90 to 95 of its synchronous speed Revision 8 5a SECTION 3 PARAMETERS 48 Print Date 24 06 2008 User Manual pain Automation International 4 SECTION 4 INSTALLATION 4 1 GENERAL INSTALLATION The THYROMAT is a complete bolt on unit keeping the installation simple The control unit is encapsulated in it s own dust proof enclosure and is mounted to the thyristor stack Similarly the thyristor stack is a bolt on unit and is also secured to the equipment differences in the mounting arrangement of the thyristor stack depend on the model to be used The electrical interface with the equipment is by means of terminal lugs and or connector blocks Certain THYROMAT variations have protective covers over the thyristor stacks The cover serves as a protective screen to prevent damage to property and personal injury from accidental contact with the exposed live components of thyristor stacks 4 2 MECHANICAL INSTALLATION 4 2 1 General The THYROMAT is a simple item to mount THYROMAT is provided with the correct fasteners to secure the unit on to the mounting surface In the event that a repairable item is removed for repairs place the fasteners in safekeeping for
141. ts on the rails The increase of this voltage setting to accommodate for such problems should be done only as a temporary measure until the problem is repaired Long periods of exposure of the motor to STALL conditions may result in the failure of the motor windings 3 4 14 Minimum Start Voltage PARAMETER DESCRIPTION SCALE INCREMENT DEFAULT 14 20 to 80 A setting of 40 minimum voltage at start gives the travel motion a smooth slow reaction start up By increasing this voltage the travel start up becomes more aggressive the user will have the option to tune the start up reaction time of the travel by modifying this parameter 3 4 15 Notch 1 2 and 3 Acceleration Time 15 Acceleration time 2 to 20 Sec between slow speed notches This parameter sets the acceleration time between speed notches Only applicable for slow speed notches 1 2 and 3 When Notch 4 is required this ramp is bypassed Scale example A value of 5 indicates that the ramp is spanned from 0 to 5 seconds from 0 speed to 100 speed 10 speed is then reached in 0 5 second 30 speed is then reached in 1 5 second providing that other external elements such as load swing don t interfere with the torque requirements to achieve this target rate of acceleration Revision 8 5a SECTION 3 PARAMETERS 37 Print Date 24 06 2008 User Manual poe Automation International 3 4 16 Notch 4 Accel Profile PARAMETER DESCRIP
142. vidual anti static bag Wrap the spare in bubble plastic or similar material Place the complete wrapped spare into a strong cardboard box or suitable container The spare is ready for shipping 8 1 2 Storage In the event that the Thyromat BD Digital Crane Controller or any spare component is stored then it is advised that the following procedure should be followed Keep the ambient conditions in the storage area at an acceptable level temperature from 40 C to 60 C with a relative humidity less than 95 no condensation allowed Keep all equipment and spares in their respective packaging until such time that they are to be used Revision 8 5a SECTION 8 SHIPPING AND STORAGE 116 Print Date 24 06 2008 User Manual H Automation International 9 SECTION 9 ACRONYMS AND ABBREVIATIONS 9 1 GENERAL The following list acronyms and abbreviations used throughout this manual VITE Percent GC Degrees Celsius ee ee ee Amperes AE Alternating Current Acceleration C Cyclic Duration Factor CPU Central Processing Unit Current Transformer Direct Current D66 eterni Deceleration Delay EEPROM Electrically Erasable Programmable Read Only Memory eee eee Full Load Current cor P Gravitational Force prom EE Hertz Cycles per Second E Current Hl eer T
143. vision 8 5a 1 GENERAL Print Date 24 06 2008 User Manual pain n Automation International 1 1 2 THYROMAT Components Identification The following illustration details the components identification refer to Figure 1 2 This diagram is applicable to both hoist and travel motions Figure 1 2 THYROMAT Components 1 Control box 9 Control connectors on control panel 2 Control panel 10 Thyristor stack 3 Keypad 11 Heat sink 4 Display 12 Temperature switch 5 Snubber card 13 MOV 6 Phase shifter card 14 Supply connections 7 Relay card 15 Fan 8 Control card 16 Thyristor pack A Interior of control box B Mother board Revision 8 5a 1 GENERAL 4 Print Date 24 06 2008 2 1 GENERAL User Manual 2 SECTION 2 SYSTEM DESIGN Automation International The following paragraphs detail the selection of the Thyromat and associated equipment as well as the details for the operation of the THYROMAT 2 2 THYROMAT BD DIGITAL CRANE CONTROLLER RANGE Table 2 1 details the THYROMAT range THYROMAT Abbreviated Code THYROMAT BD 25 THYROMAT BD 30 THYROMAT BD 60 THYROMAT BD 100 THYROMAT BD 150 THYROMAT BD 200 THYROMAT BD 350 THYROMAT BD 400 THYROMAT BD 500 THYROMAT BD 700 THYROMAT BD 1000 THYROMAT BD 1200 THYROMAT BD 1500 THYROMAT BD 2000 THYROMAT BD 2500 Table 2 1 THYROMAT Range Ampere Rating at 60 C Mechanical Size M100 M100 M100
144. well as the corresponding rotor resistors on each phase With the wires removed measure at the Thyromat terminals 17 and 18 this reading should be very high Mega ohms it should actually start increasing during the reading time This is due to an internal capacitor in parallel across these terminals If the above tests show that the external wiring is in order it is then advisable to reconnect the wires and proceed to the next test which is as follows Measuring the voltage across terminals 17 amp 18 while starting the motor If a voltage is present it indicates that the external circuit is sending the rotor feedback signal but the THYROMAT unit is not reading it Replace the Control Card enter the same parameters onto this card and try to run the system if the fault persists the problem may be related to the control box mother board in this case it is advisable to replace the THYROMAT unit and send the faulty one to our nearest repair centre 6 8 1 a ROTOR FDBK 5 The fault has occurred during the Torque proving phase before the brakes were given the command to be released Refer to possible causes below 6 8 1 b ROTOR FDBK Q1 The fault occurred during Hoisting and while the system was operating in notches 1 2 or 3 Refer to possible causes below Note Rotor feedback fault can not be detected during full speed operation because the Rotor frequency is close to OHz 6 8 1 c ROTOR FDBK Q2 The fault occurred while the syste
145. y the THYROMAT internal regulated supply circuit Main board 110 V or 220 Vac supply Control panel 3 Phase stator current monitoring 10 C no frost to 60 C at rated current 40 C to 60 C 525 V 550 V 3 phase 50 Hz 10 15 380 V 415 V range lt 266 V 525 V 550 V range lt 367 V Variable up to mains RMS level 110 V Single phase 50 Hz 220 V Single phase 50 Hz Other voltages on request 10 15 10 V DC max 5 mA per input 5 x Relay outputs with combined common max rating 220 Vac 16A max AC11 Continuous rating 2 A AC14 as per IEC 947 5 2 x separate triac outputs 600 VAC 100mA continuous max switching current 2 A Not used in crane applications Rated at 1 A continuous max peak current 3 A 9596 no condensation allowed IEC 721 3 3 unit in operation class 3C2 IEC 721 3 3 unit in operation class 352 Revision 8 5a Print Date 24 06 2008 SECTION 2 SYSTEM DESGN 12 CONTROLLER DATA Altitude Vibration IEC 721 3 3 Shock IEC 68 2 27 Enclosure Protective functions Control method Operating frequency Braking torque Unit power dissipation User Manual Automation International TECHNICAL DATA Max 1500 m at continuous rated current Over 1500 m reduce rating by 1 for each 100 m absolute maximum altitude 3000 m Operating displacement amplitude 3 mm at 2 9 Hz Max acceleration amplitude 0 5 G

THYROMAT-BD Digital Crane Controller USER MANUAL

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