Ellard Product Instructions

Transcription

1 Ellard Product Instructions Motor Controller - V3D Maxi Stock Code Description Roundthorne Ind Est Floats Road Wythenshawe Manchester M23 9WB Tel: +44 (0) Fax: +44 (0) Iss: V3D (Maxi) Motor Controller Doc No: INS V3D Maxi! The installation should only be carried out by competent personal and in accordance with current legislation Please read the instructions carefully prior to installation

2 LCC V3D (Maxi) Contents 1) Features and Specification V3D Board Layout V3D Layout in Standard Enclosure with Emergency/Stop and Membrane Push Buttons Installation and operation DIP Switch's and Functions... (1.4.1) Dead man / Impulse Operation (1.4.2) Emergency Closing (1.4.3) GO Function (1.4.4) Safety Edges (1.4.5) Photocells (1.4.6) Auto Close (1.4.7) After run / Safety edge monitoring (1.4.8) Radio Control 2) Connections... (2.1) Mains Power Supply Connections... (2.1.1) 3ph 415v (2.1.2) 1ph 230v Motor Connections... (2.1.3) 3ph 415v Motors (2.1.4) 1ph Motors (3 wire) (2.1.5) 1ph Motors (4 wire) (2.2) Limit Connections and Set Up... (2.2.1) Mechanical Limits (2.2.2) Electronic Limits - Damatic Encoder (2.2.3) Electronic Limits - KOSTAL Encoder (2.2.4) Quick Set up - Mechanical limits (2.2.5) Quick Set up - Electronic limits (2.3) Photocells... (2.3.1) Reflective Photocell (2.3.2) Through Beam (2.3.3) BP5 Button photocell (2.4) Safety Edges... (2.4.1) Optical (OSE) (2.4.2) 8k2 Resistive (2.4.1) Pneumatic Air Switch (2.4.4) WES - Wireless System (2.5) External Controls... (2.5.1) External Key switch (2.5.2) External Push Button (2.5.3) GO Button (2.6) Traffic Light Card... (2.7) Radio Control... (2.8) Service Counter... (3.0) Diagnostic LED's and Troubleshooting... CE Declaration 2

3 1) Features and Specification The LCCV3D (Maxi) Controller is designed with limited capabilities to operate an industrial door safely under electrical control by means of a push button or key-switch control Its intended use is to be connected to a suitable motor not exceeding the maximum load for the controller Connections are provided for Mains supply, Motor power, Mechanical or Electronic travel limits, External Push Buttons, Pneumatic, Electrical or Optical Safety Edge, Photocell, 24vDC aux power (100mA). Optional Plug in Connections for Radio Control and Traffic Light function basic functions include -, ON, CLOSE, and Auto-close via time delay provided suitable monitored safety devices are connected Features Compact unit, suitable for Low or High Level mounting in a separate enclosure Suitable for Mechanical or Electronic Limits Auto Detection of Encoder type fitted (Dalmatic, KOSTAL, Feig) Auto detection of all Connected Safety Devices eg. Photocell, Safety Edge (8K2, Optical, Pneumatic Air Switch) to Performance Level 'C' with quick Set Up Full LED Diagnostics Auto close delay time sec's Run Timer 120 sec's Facility for additional Traffic Light Card (00106) Radio control operation via 'Teleco' plug in receiver (00107) 1ch Transmitter (00130) Force control - for motors with sensor fitted Selectable safety edge reverse time with super fast mode Operation by either on membrane buttons or External push button / key-switch connection Go function Low Voltage control circuit Max load: - 400v (or) 230v Auxiliary 24v DC supply, Max load 100mA Service Counter Power Supply Requirements 230v AC 50Hz (1ph) or 400v AC 50Hz (3ph) (selectable) Mains power supply Neutral connection not required to power the control board Recommended power supply protection by: 6A Type 'C' Single Pole MCB - 1ph (or) 10A Type 'C' Triple Pole MCB - 3ph EN (2007) Emission Residential Directives - EMC Directive 2014/30 EU Directive - Low Voltage Directive LVD 2014 /35 EUC EN (2007) Immunity Residential EN (2007) EN (2005) Emission Immunity Industrial Industrial EN (2006) +A1(2008) +A2 (2010) RF-field immunity EN (2012) Safety of Household and similar electrical appliance/ Part 1 Power Supply 230VAC +/- 10% or 400VAC +/- 10% Max Motor Load Max Accessories Load Working Temp Humidity 230VAC or 400VAC 24v d.c -10 to +55 C Up to 93% RH Non Condensing Must be fitted to an enclosure with a minimum rating of IP54 3

4 (1.1) V3D Board Layout LCC V3D Mini Basic (Full version) PCB VERSION R1717 Version -SOFTWARE _V02_03 PCB Dimensions 175 x 85 mm (L x W) COM OP CL PHOTO +24v v OUTPUT SED IN PULSE IN SAFETY CHAIN DATA - DATA + 0v +12v MECHANICAL LIMIT ON ON BOARD CONTROL BUTTONS CLOSE TELECO RADIO RECEIVER TRAFFIC LIGHT AUX 1 N/O 30V 50mA PNE/8k2 CONF/SER FAIL CONF/SER FAIL DIP Sw FUNCTION SELECTOR LED INDICATION EXTERNAL DEVICES OPTICAL CLOSE ON BR GR WT 230V V~ 400V L1(L) SUPPLY VOLTAGE SELECTOR GO FUNCTION E - U A2 L2(N) L3 SUPPLY SUPPLY AND MOTOR EARTH MOTOR V W 4

5 (1.2) V3D layout in Standard Enclosure (01098) with Emergency Stop Button (00119) and Menbrane Pushbutton (00105) CONF/SER FAIL A x 20mm Cable Glands

6 (1.3) Installation and Operation 1. This Controller should be mounted in a suitable enclosure with a minimum IP 54 rating or suitable rating for the environment and should be: a) Vertically mounted and free from vibration b) Not exposed and free from dust and debris c) Fitted with appropriate cable glands to maintain the IP rating of the enclosure selected d) Fitted with appropriate wall fixings use to secure the unit 2. Ensure that all power is off before connecting any wiring to the controller referring to connection details in this manual 3. Check all connections are secure upon completion (1.4) DIP Switches and Functions DIP Function Off On SW 1 Impulse / Dead man - ON Dead man Impulse SW 2 Impulse / Dead man - CLOSE Dead man Impulse SW 3 Auto Close Off Active SW 4 Electronic After Run/ Edge Monitoring Off Active SW 5 Force Control (multiturn) Off Active SW 6 Force Control (Fine sense) Off Active SW 7 Not Used - Future option x x SW 8 Safety Edge - Super fast reverse Off 0.05 sec's SW 9 Safety Edge - Normal (Sw 8 must be OFF) 0.25 sec's 0.1 sec's SW 10 Travel Limit Type Mechanical Electronic (1.4.1) Dead-man / Impulse Operation With both DIP Sw OFF, the controller will operate in a hold to run condition, any release of the control button will stop the motor Impulse ON / Dead-man CLOSE By moving DIP Sw 1 to ON the controller will operate as Impulse ON (one press to run) and Dead-man CLOSE (hold to run) Impulse ON / CLOSE (one press to run) By moving DIP Sw to ON the controller will operate in an Impulse condition (one press to run), in both ON and CLOSE directions (1.4.2) Emergency Closing Should a fault develop on the photocell or safety edge circuit, a constant RED 'FAIL' LED will show when the close button is pressed However closure is still possible by entering a unique sequence (down, down, down, up, up, up) within 6 seconds - the door can then be brought to the close position by pressing the CLOSE button 6

7 (1.4.3) GO function By connection of a single N/O push button into the 'GO function' terminals the unit will now operate in the following sequential mode each time the button is pressed - ON - CLOSE - ON Operation starting with door Door at fully CLOSED position Press 1 Door travels to ON limit - No stop possible Press 2 From fully open position door travels in the CLOSE direction Press 3 Door stops and RE-ONS to top position (if traveling) Press 4 As press 2 etc In order to comply with current standards, operation in the above two conditions requires the additional connection of 2 suitable monitored safety devices eg. photocell and safety edge (1.4.4) Safety Edges (see Sec 2.5) The V3D controller is built to accommodate different types of safety edges, optical (OSE), 8k2 Resistive and Pneumatic Air Switch, Each type of safety edge is connected to its own dedicated terminals (1.4.5) Photocell (see Sec 2.6) The V3D controller has connections to accommodate a photocell, eg reflective, through beam or a self contained button photocell All photocell supply power is taken from the auxiliary 24v on the PCB but must not exceed 100mA (1.4.6) Auto-Close (1-240 sec's) By moving DIP Sw 3 to the ON position the default time time of 15 sec's is loaded To change from the default the time, run the door to the full open position the press both ON and CLOSE buttons until the RED 'FAULT' LED comes on (approx 5 sec's) and begins to flash Wait required time then press the CLOSE button Auto close can only be selected if DIP Sw 2 is ON and safety devices connected (1.4.7)After-Run/Safety Edge Monitoring - (Pneumatic Safety Edge Only) By moving DIP Sw 4 to the ON position, the after run and monitoring of the edge is selected This uses the CLOSE limit switch (set at 50mm from the floor) as a safety override limit When the CLOSE limit switch is activated the operator electronically over-runs this limit position for a max of 0.3 seconds until a signal from the compressed safety edge is received If no signal is received the unit will revert to dead man until the fault is cleared (1.4.8) Radio Control (operation same as 'GO' function) This function will only operate providing the controller has 2 forms of safety connected (safety edge and photocell) and both these safety devices are made operational This feature is provided by inserting the Teleco RSM433A03 card into the socket provided Once the transmitters have been tuned to the receiver the V3D will operate in the following sequence by pressing the same button on the transmitter:- 7

8 6 (2.1.1) Connection for (3ph) 415v Power Supply (2.1) Connections for Mains power supply and motor SUPPLY VOLTAGE SELECTOR 230V V~ 400V SUPPLY L1 L1(L) L2 L2(N) L3 L3 3PH A2 EARTH CONF/SER FAIL SUPPLY AND MOTOR EARTH Mains Supply (2.1.2) Connection for (1ph) 230v Power Supply 230V V~ 400V L1(L) Motor L2(N) 230V SUPPLY V~ L3 400V L L1(L) N L2(N) A2 U V L3 3PH A2 8 W EARTH VOLTAGE SELECTOR SUPPLY SUPPLY AND MOTOR EARTH

9 6 (2.1.3) Connection for 415v (3ph) motor (Phase1) U (Phase 2) V (Phase 3) W (V) (U) (W) A2 Typical 3 wire 3ph motor Note: The motor EARTH wire must be connected to the main terminal MOTOR EARTH (2.1.4) Connection for 230v (1ph) 3 wire motor (open) U Common V (close) W (com) (open) (close) A2 Typical 3 wire 1ph motor Note: The motor EARTH wire must be connected to the main terminal MOTOR EARTH (2.1.5) Connection for 230v (1ph) 4 wire motor CRIMP WIRES (Start) 230V (Run) U V~ (Start) V 400V (Run) W L1(L) NEUTRAL (Run) (Start) U (switched 'N' / 'L) To 'N' (permanent 'N') A2 1PH L2(N) L3 FIT LINK LIVE (Start) V (permanent 'L') SUPPLY EARTH MOTOR EARTH (Run) (Cap XuF) W (switched 'L' / 'N) Note: The motor EARTH wire must be connected to the main terminal 9

10 (2.2.1) Mechanical Limit Connections (White) COM - LIMIT COMMON OP - ON LIMIT CL - CLOSE LIMIT (Red) (Brown) MECHANICAL LIMIT CL OP COM Set DIP Sw 10 = OFF, then set limits as instruction (see 2.2.4) (2.2.2) Dalmatic Encoder Connections (2.2.3) KOSTAL Encoder Connections +12v 0v DATA + 0v +12v (Blue) (Green) (Yellow) (Black) (Red) PULSE IN SAFETY CHAIN DATA - DATA + 0v +12v PULSE IN SAFETY CHAIN DATA - DATA + 0v +12v Set DIP Sw 10 = ON, then set limits as instructions (See 2.2.5) Set DIP Sw 10 = ON, then set limits as instruction (See 2.2.5) (2.2) Connections for Mechanical and Electronic llmits DATA - SAFETY CHAIN PULSE IN SED IN - 24v + OUTPUT PHOTO +24v CL OP COM COM - LIMIT COMMON OP - ON LIMIT CL - CLOSE LIMIT CONF/SER FAIL A2 10

11 11 (2.2.4) Quick Set Up - Mechanical Limits Fit Motor and Mains Power Connections Fit Links as shown in Any Safety Devices used? Yes Connect safety devices where shown No Set Dip Sw 1 = ON (Impulse ON) Dip 2 = ON (Impulse CLOSE) Turn DIP Sw10 = OFF Yes Any Safety Devices used? No Set Dip Sw 1 = ON (Impulse ON) Dip 2 = OFF (dead-man CLOSE) Briefly press open button Does door travel up? No Yes Correct motor direction Run door to ON position and set Open Limit Cam Press and hold ON and buttons together until 'CONF' LED comes on (approx 10 sec's) - Then release 'FAULT' LED will begin to flash twice Press button once 'FAULT' LED will stop flashing Run door to CLOSE position and set Close Limit Cam

12 (2.2.5) Quick Set Up - Electronic Limits Fit Motor and Mains Power Connections Fit Links and Encoder Wiring as shown in either (Dalmatic Encoder) or (KOSTAL Encoder) Any Safety Devices used? No Yes Connect safety devices where shown 12 Turn DIP Sw10 = ON Set Dip Sw 1 = ON (Impulse ON) Dip 2 = ON (Impulse CLOSE) Briefly press open button Does door travel up? No Yes Correct motor direction Yes Any Safety Devices used? No Set Dip Sw 1 = ON (Impulse ON) Dip 2 = OFF (dead-man CLOSE) Press and hold ON and buttons together until 'CONF' LED comes on (approx 10 sec's) - Then release 'FAULT' LED will begin to flash twice Run door to CLOSE position and set Press button once Run door to ON position and set Press button once

13 (2.3.1) Reflective Photocell (2.3.2) Through Beam Photocell REFLECTOR N/O N/O TRANS REC TRANS +24v 0v COM COM +24v 0v +24v 0v BP5 Button cells + Power 12-30VDC VAC + Test Input VDC + Transistor Output - 35VDC 50mA Black Wire (Transmitter 1) Shield Black Wire (Transmitter 2) Shield Grey Wire (Receiver 1) Shield Grey Wire (Receiver 2) Shield LED SW White (Receiver 1) Grey Wire (Transmitter 1) Black Wire Black + gnd T+ T- OC OE T1 S T2 S R1 S R2 S PHOTO +24v - 24v OUTPUT + PHOTO +24v - 24v OUTPUT + (2.3.3) BP5 Button Photocell Grey wire SET UP 1. Connect black sensor with black wire to transmitter 1 connection 2. Connect white sensor with grey wire to receiver 1 connection 3. Connect power as shown - 24v OUTPUT PROGRAMMING PHOTO +24v + (2.3) Connections for various photocell types 1. Press and hold program button until LED blinks once then release (enters program mode) 2. Press program button twice to select N/C output - LED blinks twice (selects output type) 3. Press program button button once LED blink once (this de-activates the test input) 4. LED blinks quickly for approx 10 secs unit will exit program mode PHOTO +24v - 24v + OUTPUT SED IN PULSE IN SAFETY CHAIN DATA - DATA + 0v +12v AUX 1 N/O 30V 50mA PNE/8k BR GR OPTICAL CONF/SER FAIL WT CLOSE ON GO FUNCTION E A2 13

14 BROWN GREEN WHITE OPTICAL SAFETY TRANS BROWN WHITE 8k2 RESISTIVE OPTICAL SAFETY RECEIVER WES BASE +V 0V OUT1 COM OPTICAL BR GR WT PNE/8k v OUTPUT AIR SWITCH (2.4) Connections for Various Safety Edge types (2.4.1) Optical (OSE) Safety Edge (2.4.2) 8k2 Resistive Safety Edge (2.4.3) Pneumatic N/C Air Switch (2.4.4) Wireless 'WES' System WES SENSOR Optical (OSE) Safety Edge (Stock code 01018) 8k2 Resistive Safety Edge PNE/8k2 Pneumatic Safety Edge PNE/8k2 Wireless Safety Edge (WES System) PHOTO +24v - 24v + OUTPUT SED IN PULSE IN SAFETY CHAIN DATA - DATA + 0v +12v When Connecting any safety edge, the link fitted in 'PNE/8k2 connection must be removed AUX 1 N/O 30V 50mA PNE/8k BR GR OPTICAL CONF/SER FAIL WT CLOSE ON GO FUNCTION E A2 14

15 (2.5) Connections for External Controls (2.5.1) Key-switch CLOSE ON GO FUNCTION MSAPZ1-2T (16A) E - (2.5.2) Triple push button station CLOSE ON GO FUNCTION E - (2.5.3) Single push button station for 'GO' function CLOSE ON GO FUNCTION E - ALL CONTROL CIRCUIT LINKS 'MUST' BE FITTED WHERE SHOWN UNLESS EXTERNAL S ARE BEING MADE AUX 1 N/O 30V 50mA PNE/8k2 BR GR OPTICAL CONF/SER FAIL WT CLOSE ON E A2 15

16 (2.6) Connection for Traffic Light Card (-) or (N) (+) or (L) Traffic Light power must be provided by an Independent power supply (+) or (L) (-) or (N) (+) or (L) (-) or (N) RED GREEN Notes When using the flashing light feature- only use LED type lamps Power supply for lamps MAX 230Vac /24Vdc Fuse rating 2A For sequences of operation see table N L RED GREEN TRAFFIC LIGHT

17 (P1) Program Button To Program - (using Receiver) (P2) Delete Button With the card inserted in the panel and power on Press and hold Button "P1" buzzer will give a continuous tone Whilst holding Button "P1" press and hold Button on transmitter - buzzer will sound intermittently Repeat above to program extra transmitters Mem (Ch1) Relay (2.7)Radio Control Operation Teleco TXP433A02 Radio Transmitter Low Level Programming - (Using Transmitter) Ch1 Button Program Button Press button on rear of transmitter, buzzer will emit a continuous tone Within 5 seconds press and hold the transmitter button buzzer will give an intermittent tone Repeat above for other transmitters To Delete - (Single Transmitters) Teleco RSM434A03 Radio Receiver Press and hold Button "P2" buzzer will give a continuous tone Whilst holding Button "P2" press and hold Button on transmitter - buzzer will sound intermittently Transmitter is removed from memory Repeat above to delete other transmitters To Delete - (All Transmitters) TELECO RADIO RECEIVER Press and hold Button "P2" buzzer will give a continuous tone then release Within 0.5 seconds press and hold Button "P2" buzzer will sound intermittently Keep Button "P2" held until buzzer gives a continuous tone All transmitters have now been erased Operation starting with door Door at fully CLOSED position Press 1 Door travels to ON limit - No stop possible Press 2 From fully open position door travels in the CLOSE direction Press 3 Door stops and RE-ONS to top position (if traveling) Press 4 As press 2 etc

18 (2.8) Service Counter The V3D incorporates an in built counter that registers how many operations the door has performed This counter is not pre-settable, it is a counter only and can only be read using the LED indicators at a periodic service interval that is agreed by the installer To read the service counter proceed as follows: Send door to full close position then press ON and CLOSE simultaneously then release Observe the number of flashes of the (yellow) and (red) FAIL LED's ON button moves to the next column CLOSE button moves to the pervious column button returns to normal run First column to be read is the 10's 1 x yellow LED followed by (x) no of red FAIL LED Press ON button once Next column to be read is the 100's 2 x yellow LED followed by (x) no of red FAIL LED Press ON button once Next column to be read is the 1,000's 3 x yellow LED followed by (x) no of red FAIL LED Press ON button once Next column to be read is the 10,000's 4 x yellow LED followed by (x) no of red FAIL LED Press ON button once Last column to be read is the 100,000's 5 x yellow LED followed by (x) no of red FAIL LED To Reset Service counter: Example: Note: Units are not displayed No of Yellow No of Red 10's 1 8 Press ON 100's 2 Press ON 2 1,000's 3 1 Press ON , Close door fully 2. Press both ON and CLOSE simultaneously then release 3. Do not exit this mode for 4 minutes 10,000's 100,000's 4 Press ON Count =

19 (3.0) LED Indication - Trouble shooting Green - '' LED Constant The Unit has power Mains power to PCB Yellow - 'CONF/SER' LED Constant 1 sec Flash Service counter reached Confirming of learning process Reset service counter Flashes once learning process has been completed Red - 'FAIL' LED Constant If safety device has failed when CLOSE push button is pressed 1 Short Flash No answer from encoder - Check RS485 2 Short Flash Limits and/or Safety Devices not learned 4 Short Flash Both limits set in same position 7 Short Flash Encoder position outside its limit positions - Reset travel Limits 8 Short Flash Kostal encoder power failure Check / replace faulty Safety Device Check DATA +, DATA - connections, Change Encoder Re-learn Limits and / or Safety Devices Reset Limits Return door to within limit positions or reset limits Check encoder 12v supply 1 Long Flash In Auto-close learning mode Set Auto-close time or Cancel Auto-close if not used 2 Long Flash Force control (speed) not learned Applies to Motors with Force control feature only 3 Long Flash Door stopped by force control Applies to Motors with Force control feature only 4 Long Flash Door stopped by Runtime Applies to Motors with Force control feature only 5 Long Flash Door stopped by Force control wear Applies to Motors with Force control feature only 6 Long Flash Tacho failure - Pulses missing Applies to Motors with Force control feature only Yellow - '' LED Constant Stop Activated 1 Long Flash Safety Chain Activated 2 Long Flash Photocell - Safety test failed 3 Long Flash Safety edge - Safety Test Failed 4 Long Flash Stop Circuit - Safety Test Failed 5 Long Flash Haul Chain - Safety Test Failed 6 Long Flash EPROM failure, Service Counter, or door moved by Force Control 7 Long Flash EPROM failure at power up 8 Long Flash Welded contactor fail 9 Long Flash Internal Watchdog Timeout 10 Long Flash Main Processor Crystal Fail Release and restore any circuits Replace Haul Chain - Restore to electrical mode Check Photocell for any blockages / photocell out of line / faulty Check Safety Edge activation / connections Check all circuit activation / connections Check Haul Chain activation / connections Change PCB / reset service counter / reset limits Switch off re-apply power / change PCB Change PCB Change PCB Change PCB Yellow - 'SERVICE' LED - (On Membrane Push Button) Constant Stop Activated or service required Constant 1 Sec Flash If safety device has failed when CLOSE push button is pressed Confirming learning process 1 Short Flash No answer from encoder - Check RS485 2 Short Flash Limits and/or Safety Devices not learned 4 Short Flash Both limits set in same position 7 Short Flash Encoder position outside its limit positions - Reset travel Limits 8 Short Flash Kostal encoder power failure Release and restore any circuits Check / replace faulty Safety Device Flashes once learning process has been completed Check DATA +, DATA - connections, Change Encoder Re-learn Limits and / or Safety Devices Reset Limits Return door to within limit positions or reset limits Check encoder 12v supply / Replace Encoder 1 Long Flash 2 Long Flash Force control (speed) not learned Applies to Motors with Force control feature only 3 Long Flash Door stopped by force control 4 Long Flash Door stopped by Runtime Applies to Motors with Kostal encoder fitted only Applies to Motors with Force control feature only 5 Long Flash Door stopped by Force control wear Applies to Motors with Force control feature only 6 Long Flash Tacho failure - Pulses missing Applies to Motors with Force control feature only Continuous Long Flash In Auto-close learning mode Fail state of PNE edge monitoring (check edge giving signal when reaching floor Set Auto-close time or Cancel Auto-close if not used Pneumatic Safety edge not compressed on ground when After Run Monitoring is turned on Red - 'CIRCUIT ERROR' LED Constant PCB Circuit Fail Check 12v and 24v supplies for short circuits / Replace PCB 19

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21 Ellard Ltd Ellard House Floats Road Roundthorne Ind Est Wythenshawe, Manchester M23 9WB Tel: +44 (0) Fax: +44 (0)