MOTION-8D 8-channel hoist controller with analogue remote control User s manual

Transcription

1 MOTION-8D 8-channel hoist controller with analogue remote control User s manual First edition Copyright 2017

2 MOTION-8D Hoist Controller Dear Customer! Thank you for chose PLS Electronics product. If you have any technical question or you looking for other equipments, don t hesitate to take up the contact with our sales representative or with the manufacturer at the web site. This apparatus is an eight-channel hoist controller with analogue direction remote control. The device developed and manufactured to fulfill the EN and EN Safety of machineries directives and the EN62061 Functional safety of machineries SIL3 level. The controller is IP20 rated. Safety first! Please read carefully and understand the user manual! The wrapper of the unit is NOT baby toy! Keep it away form babies! For technical questions and original spare parts please take up the contact with our sales representative or with the manufacturer at the web site. ATTENTION! DON T USE WITHOUT PROTECTIVE GROUND! Not allowed to make a parallel connection between any outputs to increase the output current capability of the unit! Otherwise the unit can be damaged! CAUTION! Disconnect mains before open the controller for service! Service allowed only for technicians who had technical course by the sales representative or by the manufacturer! 2

3 PLS Kft 1. Control parts Front parts 1. Link out connector for start and E-Stop signals (XLR, 7-pin female) 2. Link in connector for start and E-Stop signals (XLR, 7-pin male) 3. EMERGENCY STOP button (Rotate to release type) 4. Fault state LED (Emergency stop condition occurred) 5. Reset button (Light in blue when the unit needs reset) 6. Master/Slave status indicator LEDs (the corresponding LED is ON as soon as the controller is in ready state) 7. Mains key switch 8. Input mains phase sequence indicator LEDs (the corresponding LED is ON as soon as the controller is in ready state) 9. Output protector for single-phase AUX (1P+N MCB This output is protected with the mains RCD too) 10. Mains input RCD (30mA). For safety reason use the test button with 3-times pressing test to ensure that the protection device is working properly. If you find error DO NOT USE THE DEVICE, contact the sales representatives! 11. Mains input state LEDs (they are connected after the RCD). 12. Output protector MCBs for output 1-8 (Each output is protected with C6A 3P MCBs) 3

4 MOTION-8D Hoist Controller Back parts (CEE version) 1. Mains input cable (H07 5G4 with CEE norm 5-pole 32A) or panel mounted male CEE 5-pole 32A plug 2. AUX 16A single phase output 3. Remote controller input (37-pole female, Amphenol DS3102A28-21S) 4. External Emergency Stop input 1-2 (4-pole female XLR; Dummy Plugs included) 5. CEE outputs 1-8 (4-pole CEE-norm, 16A; optional 5-pole) 6. Control fuses (T1A, 5x20mm, High Breaking Capability type) 4

5 PLS Kft Back parts (CEE+Multipin version) 1. Mains input cable (H07 5G4 with CEE norm 5-pole 32A) or panel mounted male CEE 5-pole 32A plug 2. AUX 16A single phase output 3. Remote controller input (37-pole female, Amphenol DS3102A28-21S) 4. External Emergency Stop input 1-2 (4-pole female XLR; Dummy Plugs included) 5. CEE outputs 1-4 (4-pole CEE-norm, 16A; optional 5-pole) 6. Control fuses (T1A, 5x20mm, High Breaking Capability type) pole Socapex or 16-pole Harting outputs for Motor pole Socapex or 16-pole Harting outputs for Motor 5-8 5

6 MOTION-8D Hoist Controller Remote controller parts 1. Motor direction status LEDs: RED: Going Down GREEN: Going Up Blind: Motor OFF No movement 2. Motor direction select three-position switches (UP/OFF/DOWN 1 ) 3. EMERGENCY STOP button (Rotate to release type) 4. START button (When illuminated in Green the system is ready to start movement) 1 Only if the wiring of the motors and the cables/breakout boxes are correct. The controller makes automatic phase sequence correction on the input to have always clockwise rotation on the output for UP movements and counter-clockwise rotation on the output for DOWN movements 6

7 PLS Kft 2. Installation of the unit After unpacking the apparatus is ready for use. Not to make the cable longer! If it is short, use standard extension. Operating with injured cable is perilous! CAUTION! The apparatus is NOT waterproof! Protect it from liquids! Not to use outdoors without appropriate preventive measures. If water or other liquid getting into it, dry up, and take to technician! Working with wet apparatus is PERILOUS! The manufacturer doesn t responsible if the installer/user connect the mains wrongly! The guaranty will be void if the connection order is wrong and the unit can damage too! Before power up, always control the right connection of the Lines, Neutral and the Protect Earth! Consult with the manufacturer or with trained service person if you need help in installation! Take care to have proper wiring of the motors, extension cables, connectors and breakout boxes to be sure that the motor movement will be the selected! The controller makes automatic phase sequence correction on the input to have always clockwise phase rotation on the outputs for UP movements and counter-clockwise phase rotation on the outputs for DOWN movements. The controller does not have feedback from the actual movement/status/position of the motors! SAFETY FIRST! If you are not sure about the correct wiring, consult with a technical trained people and test the motor movements on the ground with NO load! 7

8 MOTION-8D Hoist Controller 3A. Power-up sequence (stand-alone mode) Before you power up the controller connect the following parts to the controller: 1. Connect the remote cable to the backside 37-pin connector (7). Take care to be fully plugged in and fixed the input plug with the rotating ring. 2. Connect the attached dummy plugs to the external E-Stop inputs if you do not want to use external E-Stop electronics (e.g. load cells or E-Stop buttons). If you want to use, connect them but refer to the pin layout of it on the corresponding page of this manual. 3. Connect the motors to the controller (via CEE sockets or thru the multipin sockets via breakout boxes). Consider to the multipin outlet of the controller before you connect the breakout boxes. 4. Plug the unit to the mains (only after the mains input voltage has been checked). Be sure that all lines are present and L-L voltages are 400VAC ±10% and L-N voltages are 230VAC ±10% (50Hz).If not, the controller will disable the power on. 5. Switch on the mains RCD and check the mains indicator LEDs on the right side. If they are on, than follow the next steps. If not, disconnect the power and check the mains input and the control fuses on the back panel. When the parts are connected and power state LEDs are on, check the follows before you switch on the controller: 1. All E-Stop (Emergency stop) mushroom heads are released (rotate to release types) 2. All direction switches are in OFF position 3. When all steps above are done switch on the mains key switch If there is no Emergency state (no RED signal by Fault state LED) and the blue (Reset) push button lights, press the Reset button. After release of reset button the controller goes to Ready state. To ensure about it, check the Ready state LEDs (Master or Slave LED have to light on the front panel) and one of the Phase align LED have to light as well. On the remote controller the Start button have to light on Green too. Switch on the output protector MCBs. Now the controller is ready to operate. If not, go to section 4 of this manual (troubleshooting). 8

9 PLS Kft 3B. Power-up sequence (Linked mode) The Link feature is a unique solution where the E-Stop signal and the Start signal are linked to all PLS made D and S type hoist controller with keeping the double protection loop required by the machine directives. Before you power up the controller connect the following parts to the controller: 1. Connect the remote cable to the backside 37-pin connector (7). Take care to be fully plugged in and fixed the input plug with the rotating ring. 2. Connect the attached dummy plugs to the external E-Stop inputs if you do not want to use external E-Stop electronics (e.g. load cells or E-Stop buttons). If you want to use, connect them but refer to the pin layout of it on the corresponding page of this manual. 3. Connect the attached 7-pin XLR link cable(s) between the controllers what you want to have the same Start/E-Stop link connection. There is no priority which controller has to be the first on the link line. Use only the attached 2m length cable. If you need longer one, please contact your sales representatives. DO NOT CONNECT OR DISCONNECT LINK CABLES WHEN THE CONTROLLER IS IN OPERATION! ALWAYS SWITCH OF THE MAINS ON ALL CONTROLLERS BEFORE CONNECT OR DISCONNECT LINK CABLES! 4. Connect the motors to the controller (via CEE sockets or thru the multipin sockets via breakout boxes). Consider to the multipin outlet of the controller before you connect the breakout boxes. 5. Plug the unit to the mains (only after the mains input voltage has been checked). Be sure that all lines are present and L-L voltages are 400VAC ±10% and L-N voltages are 230VAC ±10% (50Hz). If not, the controller will disable the power on. 6. Switch on the mains RCD and check the mains indicator LEDs on the right side. If they are on, than follow the next steps. If not, disconnect the power and check the mains input and the control fuses on the back panel. When the parts are connected and power state LEDs are on, check the follows before you switch on the controller: 1. All E-Stop (Emergency stop) mushroom heads are released (rotate to release types). 2. All direction switches are in OFF position. 3. When all steps above are done switch on the mains key switch. 9

10 MOTION-8D Hoist Controller If there is no Emergency state (no RED signal by Fault state LED) and the blue (Reset) push button lights, press the Reset buttons on each linked controller. After release of reset buttons the controllers go to Ready state. You can press the reset buttons individually, does not need to press them in the same time. To ensure about it, check the Ready state LEDs (Master or Slave LED has to be light on the front panel) and one of the Phase align LED has to be light as well. The Master LED has to light only on the controller which has only Link OUT. All other linked controllers have to be in Slave mode (they have Link Input signal). On the remote controller the Start button has to be light on Green too. Switch on the output protector MCBs. Now the controller is ready to operate. If not, go to section 4 of this manual (troubleshooting). 4. Troubleshooting If the controller does not go to ready state, check the follows: The RED Fault indicator lights: Check the E-Stop buttons, maybe one of it is not released (turn to release) Check the external E-Stop inputs (dummy plugs are not connected or the connected external E-Stop signal source activated the E-Stop state or the connection of it is wrong). Check the remote input connector, maybe it has not plugged in properly. Check the link connections, maybe one of it has not been connected properly (only in link mode). DO NOT LEFT LINK CABLE IN ANY LINK INPUT OR OUTPUT IF YOU DO NOT WANT TO USE THE CONTROLLER IN LINK MODE! In linked mode check the power state of all linked controllers cause if anyone is off (missing phase, not proper voltage level, RCD off, mains key switch off, etc.) the system goes to E-Stop state. Check the control fuses on the back panel (T1A, 5x20mm, High Breaking Capability type) If all above are ok, contact the sales representatives for technical help! 10

11 PLS Kft The RED Fault indicator does not light but the Blue LED signal does not either: Try to press the reset button, if the controller goes to ready state the blue LED broken, contact the sales representatives for replacement part. You can use the controller without problem. If the pressing of the reset button does not take the controller to ready state should mean the follows: o One of the contactor has been welded and does not go to correct de-energized state. Contact the sales representatives for service o Check the input mains, maybe the input voltage is not properly as described above (all L-L voltages must be 400VAC ±10% and L-N voltages are 230VAC ±10% (50Hz) ). o Check the control fuses on the back panel (T1A, 5x20mm, High Breaking Capability type) If none of above fixes the problem, contact the sales representatives for service. 5. Using the controller As soon as the controller is in ready state you can start the operation of it. To make the first movements do the follows: 1. Select the motor directions on the remote controller 2. Ensure that nothing can obstruct the movement of the motors. SAFETY FIRST! 3. Press the Green button on the remote controller to start the motors. If you recognize abnormal movement stop the controller immediately by pressing one of the read head E-Stop button! 4. If your reach the desired position, release the green Start button to stop the motors. 5. If there are more controllers linked, all linked controllers will start by pressing the green start button (does not matter on which controller the start button have been pressed) 11

12 MOTION-8D Hoist Controller 6. External E-Stop input and wiring 7. Remote controller input pin layout Pin Function Pin Function A Motor 1-UP W NC (not connected) B Motor 1-DOWN X NC (not connected) C Motor 2-UP Z NC (not connected) D Motor 2-DOWN a NC (not connected) E Motor 3-UP b NC (not connected) F Motor 3-DOWN c 24VAC-A G Motor 4-UP d 24VAC-A H Motor 4-DOWN e START (DOWN-at Up/Down version) J Motor 5-UP f +24VDC K Motor 5-DOWN g GND (24VDC) L Motor 6-UP h E-Stop Out1 M Motor 6-DOWN j E-Stop Out2 N Motor 7-UP k START (UP at Up/Down version) P Motor 7-DOWN m Ready signal R Motor 8-UP n PE S Motor 8-DOWN p NC (not connected) T NC (not connected) r Optional external Reset-1 U NC (not connected) s Optional external Reset-2 V NC (not connected) Matched male type: DS3101A28-21P (AMP) 12

13 8. Multipin sockets pin layout PLS Kft The pin outlet of 16-pole Harting/ILME type connectors in H16A version is the follows: Pin number Function 1, 2, 3 L1, L2, L3 for Motor 1/5 5,6,7 L1, L2, L3 for Motor 2/6 9,10,11 L1, L2, L3 for Motor 3/7 13,14,15 L1, L2, L3 for Motor 4/8 4, 8, 12, 16 and the side PROTECTIVE EARTH (PE) connectors The pin outlet of the 16-pole Harting/ILME type connectors in H16B version is the follows: Pin number Function 1, 2, 3 L1, L2, L3 for Motor 1/5 4,5,6 L1, L2, L3 for Motor 2/6 7,8,9 L1, L2, L3 for Motor 3/7 10,11,12 L1, L2, L3 for Motor 4/8 13, 14, 15, 16 and the side connectors PROTECTIVE EARTH (PE) Recommended 16-pole male plug (optionally orderable form PLS): Male insert: HDC HE 16 MT (Tension clamp, Weidmüller order no.: ) or HDC HE 16 MS (Screw connection, Weidmüller order no.: ) House: HDC 16B TOBU 1M25G (M25 cable gland Weidmüller order no.: ) The pin outlet of 19-pole Socapex type connectors in SX version is the follows: Pin number Function 1, 2, 3 L1, L2, L3 for Motor 1/5 4,5,6 L1, L2, L3 for Motor 2/6 7,8,9 L1, L2, L3 for Motor 3/7 10,11,12 L1, L2, L3 for Motor 4/ PROTECTIVE EARTH (PE) Recommended male plug (optionally orderable form PLS): Male inline plug: P19-LM-S-M40A (solderable, for cable OD 16-28mm) Never connect or disconnect multipin connectors under load! 13

14 MOTION-8D Hoist Controller 9. CEE connectors pin layout (front view) Technical information Power supply:...tn-s 3x230V/400VAC ±10% (3 x 32A) Power draw with open outputs:...10w Output connectors:...8 x CEE16/4P (or optional 5P) Optional 2x 16-pole Harting (-H16) or 2x 19-pole Socapex (-SX) Input connectors:...7-pole XLR male/female for Link in/out 4-pole XLR female for External E-Stop signal Output protection:...3p C6A for each motor output and C16A 1P+N for AUX Output contactors:...double-locked 3P N/O+1P N/C AC-3 / 415V 9A rated; 24VAC coil Fuses:...T1A, 5x20mm, High Breaking Capability type Operating temperature:...10 C to 35 C (RH: 0-90%, non-condensing) Storage temperature: C to 60 C Dimensions: x 266 x connectors (in mm) Weight:...25Kg 14

15 Declaration of Conformity We, PLS Electronics Limited declare under sole responsibility that the product: Product name:... MOTION-8D (8-channel hoist controller series) Product model (output variations):... C (8x 4-pole 16A CEE) H16 (4x 4-pole 16A CEE and 2 x 16-pole Harting ) SX (4x 4-pole 16A CEE and 2 x 19-pole Socapex) Serial Number:... n/a Lot:... n/a Item number:... One to which this declaration relates is in conformity with the following standards: EN Electromagnetic compatibility (EMC). Part 6-4: Generic standards. Emission standard for industrial environments (IEC :2006) EN Electromagnetic compatibility (EMC). Part 6-2: Generic standards. Immunity for industrial environments (IEC :2005) EN Low-voltage switchgear and controlgear assemblies. Part 1: Type-tested and partially type-tested assemblies EN Safety of machinery. Electrical equipment of machines. Part 1: General requirements (IEC :2005, modified) EN Safety of machinery. Electrical equipment of machines. Part 32: Requirements for hoisting machines (IEC :2008) Therefore the upper indicated product qualifies the EU 2014/35/EU LV Directive and the 2014/30/EU EMC directive, considering 768/2008/EEC directive for CE. Place of issue: Szekesfehervar, HUNGARY Signature of authorised person: Date of issue: Sandor Vass Managing Director of PLS Ltd PLS Kft H-8000 Szekesfehervar, Gőzmalom utca 22. HUNGARY Tel: Fax: info@pls.huweb:

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