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RADIO CONTROL System'MDR-8400

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72-76 MHz Frequency

OWNERS MANUAL
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COnTROL CHIEF
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Booklet No. 184072 Pn. 8002-9000

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TABLE OF CONTENTS

GENERAL INFORMATION
SYSTEM SPECIFICATIONS INSTALLATION THEORY OF OPERATION OPERATOR'S INSTRUCTION MAINTENANCE

Page 1

SECTION I
GENERAL INFORMATION
INTRODUCTION
The MDR-8400 Radio Remote Control System is a microprocessor based control device which provides relay command outputs. In designing the MDR-8400, Control Chief's engineers have combined over 20 years of industrial radio remote control experience with the advanced technology of proprietary software techniques and VLSl (Very Large Scale Integrated Circuit) hardware. The result is a digital radio remote control system where the signal is highly secure and the system is reliable and easily maintained.

SYSTEM DESCRIPTION
The MDR-8400 consists of a hand held battery powered command transmitter and a Receiver/ Decoderllnterface unit. Peripheral support equipment include a battery charger, rechargeable batteries, surge suppressors and a transmitter carrying harness.

The MDR-8400 transmitter was designed to be comfortably carried and operated with one or two hands. Heavy duty "deadman" (spring return) motor control levers permits ease of operation for initiating crane motion commands to the crane mounted Receiver/Decoder/lnterface unit. Industrial grade toggle and pushbutton switches are used for activating transmitter "on" and for activating peripheral auxiliary functions. Within the transmitter the operator generated commands are converted to a digitally coded serial data stream and modulated onto a carrier frequency within the 72-76 Mhz range. A rechargeable 12 volt (.75 amp-hour) NlCAD battery supplies power to the standard transmitter. Each transmitter is custom designed. The variables which determine how a transmitter is manufactured are frequency, engraving and number of motions-auxiliaries. By matching the transmitter to the exact user criteria CONTROL CHIEF CORPORATION provides a control device which is not only technically superior but also oriented to the specific user.

RECEIVER/DECODER/INTERFACE UNIT
The standard Receiver/Decoder/lnterface unit is housed in a 24"Hx24"WxI 0"D Nema 12 rated enclosure and operates from 120 volts AC. The major components of the ReceiverlDecoder/lnterface unit are: 1. Power supplies (5 and 12 volt) 2. Card CagelMother Boardlnput-Output Terminal Strips A. 72-76 Mhz Receiver Card B. Processor Card C. I10 Relay Cards 3. Transfer Switch (ManualJRemote)

Page 2

MDR-8400 SPECIFICATIONS
GENERAL

Frequency: .................................. 72-76 MHz Operating Range: ........................ 1000 feet typical ("power our' adjustable) Temperature Range: .................. -20 degrees F to +I 40 degrees F (-30 degrees C to +60 degrees C) Battery Life: ................................ 8 hours typical (continuous operation) Nickel cadmium (.75 Amp Hour) rechargeable batteries. Environmental Conditioning:........ Transmitter and receiver both sealed against dust. System Diagnostics: .................... Built-in with LED and numerical indicators. System Address Capability: ........ 15 addresses EncodinglDecoding Method: ...... Microprocessor/softwarebased

TRANSMITTER
Dimensions: ................................ 9" or 10.5" x 7-314" x 4-112" Weight: ....................................... 6-8 pounds (including battery) Case: .......................................... Unit completely contained in a heavy gauge, aluminum housing. Carrying Method: ........................ Adjustable web beltlharness of strong, lightweight nylon fabric. Switches: .................................... Motor control switches are spring-return (deadman) lever type with five detented positions in each direction. Other switches are industrial grade and may be "lock-off" toggle, key operated, pushbutton or others as required. Supply Voltage: .......................... 12 volts DC Power Output: ............................ 50 milliwatts adjustable Frequency Stability: .................... .005% Modulation Bandwidth: ................ + 5 KHz Maximum Modulation Type: ........................ FM Digital CFSK Spurious Output: ........................ -50 dbc Duty Cycle: .................................. 100% RF Output Impedance: ................ 50 ohms

RECElVERlDECODER
Enclosure: .................................. Supply Voltage: .......................... Sensitivity: .................................. Squelch Threshold ...................... Frequency Stability: .................... l mage Rejection .......................... Spurious Response .................... Selectivity: .................................. Modulation: .................................. RF Input Impedance: .................. Output Relays: ............................ 24"Hx24"WxI 0"D Nema 12 cabinet (standard) Customer supplied 120 VAC, Single Phase 60 Hz at 500 VA .7 uV (20 db Quieting Method) 0.5 uV or less .001%
60db

70db 60 db (20 KHz Adjacent Channel) +/- 5 khz 50 ohms Contact rating 110 VAC 10 amps resistive, 7.5 amps inductive: 220 VAC 7.5 amps resistive 5 amps inductive Response Time: .......................... 68 milliseconds

Page 3

SECTION II INSTALLATION
INTRODUCTION
The installation of the MDR-8400 ReceiverlDecoderllnterface unit must be performed in a prescribed manner for proper operation and overall system satisfaction. The personnel needed to properly install a MDR-8400 Receiver/Decoderllnterface unit are an electrician and a welder.

RECEIVER/DECODER/INTERFACE MOUNTING
The ReceiverlDecoderllnterface unit is equipped with a mounting flange on both top and bottom. After a suitable location is found, the enclosure may be bolted or welded to the support structure. Care must be taken to ensure ample space is provided to open the door (not less than 18" in front) and to permit conduit entrances at the lower right area of the enclosure. The Receiver/Decoder/lnterface unit's mounting location depends on several factors:

1.

The receiver must be located at the same location as the crane's operating controls. If the crane controls are located on the bridge, then the Receiver/Decoder/lnterface unit must be mounted on the bridge. If the crane controls are located on the trolley, then the Receiver/ Decoderllnterface unit must be mounted on the trolley. A source of single phase 120 VAC, 500 VA power must be available. The unit should not be mounted where it will be subject to temperatures in excess of 140 degrees F.

2.

3.

RECEIVER/DECODER/INTERFACE INTERCONNECTING WIRING

Included with each system is a set of system drawings (Output Circuit Schematic and Output Wiring Diagram) which will aid in interconnecting the ReceiverlDecoderllnterface unit to the crane controllers. Wiring between the MDR-8400 output terminals to the crane controllers (magnetics) is a simple procedure and is comparable to wiring a manual control station (master switches or a pendant) to the .crane magnetics. The manual controls already present on the system and the ReceiverlDecoderl Interface outputs are wired in parallel. The following are guidelines for proper installation:
1.

All interconnection and power supply wiring must enter the enclosure in the lower right corner. Interconnection wiring between the MDR-8400 and the crane controller should be a minimum #I6 AWG and routed through rigid conduit or flexible conduit such as Sealtite. For interconnecting the MDR-8400 to the existing crane controller, refer to the Output Circuit Schematic and the Output Wiring Diagram included in the drawing package. These drawings show where to wire each output terminal.
CAUTION: Any device (magnet circuit) which will require power irrespective of the status of the ReceiverlDecoderllnterface unit must be wired on the line side of the main line contactor. This is necessary to prevent loss of power to the devices due to opening of the main line contactor (See Safety Features, Page 14).

2.

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Page 4

SURGE SUPPRESSORS
Supplied with each system is a quantity of surge suppressors. These are used to protect the electronic equipment from electrical line surges and to increase the life of the electrical contacts. The surge suppressors must be connected in parallel across all relay contactor coils of the crane control circuits (at the coil location). In those cases where Control Chief has supplied an intermediate relay panel, the suppressors will already be installed on the coils of the relays.

ANTENNA PLACEMENT
Included with each system is the receiving Antenna, an Antenna Mount with 25 feet of cable and the Receiver/Enclosure Cable Assembly. In order to obtain optimum system performance, it is essential the receiving antenna be properly located. Ideally, the antenna should be mounted on a vertical axis below the bottom of the bridge structure and be visible from any operational point on the floor (See Figure 2.1, Page 26)

FINAL CHECKS
The following system checks and guidelines must be adhered to prior to operating the system for the first time: 1. Ensure separate 120 VAC, 500 VA control transformer has been installed to supply power to the Receiver/Decoder/lnterface unit. Check status of the AC power supplying collector shoes1 festooning. Ensure the transmitter battery is charged to full capacity. Ensure surge suppressors are installed across ALL relay coils. The surge suppressors must be installed at the location of the controlled relay coil. The failure to install surge suppressors will cause unsatisfactory crane operation. Ensure the person(s) operating the radio remote control have been properly trained and are qualified for both the safe operation of a radio remote control unit and the safe operation of a overhead industrial crane. Ensure a main line contactor is employed on the crane and controlled by the MDR-8400 Receiver/Decoder/lnterface units "Main On" (address) and "Warning Start" relay (See Safety Features Page 14). The main line contactor is vital for emergency crane shutdown. Ensure a fail safe braking mechanism is used on the bridge drive. OSHA rules and regulations Chapter 17, Para 1910.1 79, Section (f), (6)(iii) states "On all floor, remote and pulpit operated crane bridge drives, a brake or non-coasting mechanical drive shall be provided". The braking mechanism generally employed is an electronically operated, spring close type of brake. Ensure a log book is maintained b y the Maintenance Department. The log should include a list of assigned address codes and carrier frequencies cross referenced to the proper transmitter, Receiver/Decoder/lnterface unit and crane.

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Page 5

SECTION Ill THEORY OF OPERATION

INTRODUCTION
The MDR-8400 is a state-of-the-art radio remote control system. Through the use of microprocessorbased encoding and decoding circuitry, programmed intelligence assures that the crane responds only to the commands of the operator. It is the intention of this section to supply information to the reader for a basic understanding of how the system converts operator requests to crane commands. A detailed explanation of how each printed wiring board processes the information it receives is also presented.

BASIC SYSTEM THEORY

The MDR-8400 system consists of the radio remote control transmitter and the Receiver/Decoder/ Interface unit. To encode and communicate the operator's commands to the crane, four transmitter sub-assemblies are involved: the control switches, the Logic Card, the RFIRegulator Card and the transmitter antenna. (See simplified block diagram Figure 3.1, Page 27.) To receive, decode and output the transmitted data to the crane controllers, four sub-assemblies within the Receiver/Decoder/lnterface unit are utilized: The receiving antenna, the Receiver Card, the Processor Card, and the Stepped I/O Relay Cards. (See simplified block diagram Figure 3.2, Page 28.) The following information is provided to promote an understanding of the general circuit operation of each card and each circuit's role in the overall system. A detailed explanation of how each printed wiring board processes the information it receives is also presented. This information will be useful to people responsible for maintaining the system.

The main circuitry of the transmitter unit consists of the Logic Card and the RFIRegulator Card. The Logic Card is pre-programmed to encode control switch information into a binary coded serial data stream. The RF/Regulator Card modulates the carrier with serial data by means of direct Carrier Frequency Shift Keying (CFSK).

Page 6

TRANSMITTER - LOGIC CARD

The main function of the Logic Card is to format the address switch and stepped control switch information into a binary coded serial data stream. This card's output data is fed to the RFlRegulator Card Modulator for conversion to a format suitable for sending through the atmosphere. The main circuits of the Logic Card are: 1. Address Switch 2. Diode Matrix 3. Microprocessor 4. Cutoff EnableNVatchdog A simplified block diagram is shown in Figure 3.3, Page 29. The address switch is a four (4) pole DIP (Dual In-Line Package). Positioning of each of the switches, 1 thru 4, sets the four bit transmitter address code. This code must match the setting of the Receiver1 Decoderllnterface unit Processor Card. A switch in the "on" position results in a binary one; the "off" position, a binary zero (See Figure 3.4, Page 30). A total of fifteen address codes are useable. Note: address code 0000 is not considered a valid address. The diode matrix (see figure 3.5, Page 31) feeds switch position information to U1 (Microprocessor) via the Scan and Read Lines. U1 reads the switch position status by sequentially pulling low and then releasing each of the scan lines. When a scan line is pulled low, all switches in the open position which are connected to that particular scan line will be read via the read lines as a logic one or "high". All switches in the closed position will be read as a logic zero or "low". This process will be repeated until all the stepped motor information is read into the microprocessor. The microprocessor (U1) formats the serial data stream and outputs the information through an inverting buffer (U2A) to the RFlRegulator Card. An external clock frequency of 6 MHz is supplied to U1 by means of the crystal oscillator (XI). U1 divides the external crystal frequency and outputs a 400 KHz clock frequency to a Divide-By-Three Counter (U4). The output of U4 provides a toggle signal to U1 for program loop timing. A monostable multivibrator (U3) performs a "watchdog" function of the microprocessor (UI). When the internal program of U1 is running properly, a watchdog toggle pulse will be sent to U3. Providing U3 receives this toggle pulse on a timely basis, it will output 5 volts to one of the inputs of the Cutoff Enable NAND Gate (U2B). When the battery voltage level is acceptable, 5 volts is supplied to the second input of NAND Gate (U2B) via the Battery Cutoff circuit located on the RFIRegulator Card. The output of U2B is normally low (0 volts) and is connected to the cutoff circuit on the RFlRegulator Card. Should the output of U2B go high (5 volts), such as during a low battery voltage condition or software runtime fault (watchdog), the RF circuit will be disabled by means of the cutoff Circuit.

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TRANSMllTER - LOGIC CARD - SERIAL DATA MESSAGE FORMAT

The serial data message format changes dynamically with activating command switches. If no command switches are engaged the serial'stream contains primarily data synchronization pulses. The synchronization pulses cue the receiver microprocessor to the start of the serial data stream and keep the receiver microprocessor in synchronization with the data stream. To indicate message start or string synchronization, the Logic Card sends out a synchronization pulse followed by an extended word consisting of "off' bits and then another synchronization pulse. It is within this 9 millisecond time frame that the Logic Card reads and formats the switch information. Switch information words (address, motor and auxiliary) follow the string synchronization pulse. Each is formatted into eight bits with each word preceded by a synchronization pulse. The last information in the serial data message are two CRC parity words. For safety purposes the CRC parity words verify, to the Processor Card of the Receiver/Decoder/lnterface, the correctness of the message sent. (See figure 3.6, Page 32)

TRANSMllTER - LOGIC CARD - SERIAL DATA MESSAGE

- CRC PARITY

CRC (Cyclic Redundancy Code) parity is a sophisticated method of error detection for a block of data (Serial Data Stream). The transmitting microprocessor treats the block of data as a high order polynomial. This polynomial is divided by a generator function G(x) =XI5 + X5 + 1 which is known by both the transmitting and receiving microprocessor. The quotient of this division is discarded and the remainder is appended to the end of the block of data. The receiving computer divides its received data by the same generator function G(x). If the division has no remainder the stream is valid. The advantage to this type of parity is that it can detect bursts of serial data errors.

TRANSMllTER - CARRIER FREQUENCY SHIFT KEYING (CFSK)

To transmit the serial data stream, the message must be converted to a FM (frequency modulated) signal. The RF circuitry of the RF/Regulator Card performs the conversion task utilizing a technique known as Carrier Frequency Shift Keying (See Figure 3.7, Page 33). The serial data stream enters the RF circuitry, coded as binary logic ones (5 volts) and zeros (0volts). By means of the modulator circuit, the one's and zero's key the oscillator to shift the carrier frequency. A logic one shifts the carrier "low". A logic zero shifts it "high".
The simplicity of CFSK modulating technique promotes simple RF tuning. CFSK also allows for very accurate data transmission.

TRANSMllTER - RF/REGULATOR CARD

The RF/Regulator Card performs three basic functions: supplies a regulated +5 VDC to the Logic Card, performs an RF cutoff (low battery voltage or a microprocessor run fault) and converts the incoming serial data stream to a modulated RF signal.

Page 8

TRANSMllTER - RF/REGULATOR CARD - 5 VOLT REGULATOR

By means of the external NlCAD battery, 12 volts is fed to the RFlRegulator Card through pins J1-2 and J1-3. A 5 volt regulator chip U2 supplies a low current 5V reference to the dual comparator U3 of the battery cutoff circuit. The switching regulator outputs an efficient regulated 5V.

TRANSMllTER

- RFIREGULATOR CARD - CUTOFF CIRCUITRY

When the battery voltage is above 10V the battery cutoff circuit U3B and Q8 outputs a high (5 volts) to the NAND Gate of U2B of the Logic Card. If the battery voltage drops below 1OV, then a low (0volts) is applied to U2B producing an oscillator cutoff condition.

TRANSMITTER - RFIREGULATOR CARD - RF CIRCUITRY

The serial data stream from the Logic Card enters the RFlRegulator Card at terminal J2-4 and passes to the modulator circuitry. Between J-4 and the modulator is a three position level set switch (SI). S1 is used to set the low and high transmitter deviation level of the carrier frequency. (More fully covered in the Troubleshooting and Alignment Sections) The main circuitry of the modulator consists of transistor (QI), Dual Op Amp (UIA and U1B) and two Vari-Cap Diodes (CRI and CR2). The function of the modulator is to shift the carrier frequency either high or low. To accomplish this, the serial data strearn consisting of one and zero logic data is presented to the base of Buffer Transistor Q1. Variable Resistor R5 and one-half of the Dual Op Amp (U1A) are used for setting the high frequency deviation level. The other half of the Dual Op Amp ' J2A) acts as an active filter by grounding the square wave signal, thereby removing harmonics. The rtput of U2A is applied to the Vari-Cap Diodes which serve as the frequency modulator to pull the :.quency of crystal Y1 either high or low. L3 is used to set the low frequency deviation level. 4e oscillator RF Crystal Y1 and oscillator transistor Q2 output a 72-76 MHz sine wave. Dependent )on the modulator, the signal deviates 2.0 to 3.0 KHz above or below center frequency. This shifting ~ r r i efrequency r contains the digital logic information. Before the signal can be transmitted it must be amplified. From Q2, the signal passes to DriverlBuffer Q3. Q3 is an amplifier and provides isolation between the power amplifier Q4 and the oscillator for frequency stability. Power amplifier Q4 further boosts the signal to a nominal 50 milliwatts. From Q4, the amplified carrier signal passes through impedance matching and low pass filter circuitry to the antenna (See Block Diagram Figure 3.8, Page 34). Connected to the emitter of oscillator Q2 is the oscillator cutoff circuitry consisting primarily of two transistors Q5 and Q6. When the input at J2-1 is low (0volts), it allows Q2 to oscillate by providing a DC ground to GI2 emitter. If a low battery voltage or a microprocessor program run fault occurs, a high (5 volts) level is applied to the oscillator cutoff circuit causing oscillator Q2 to turn off. Input to the circuit is provided by the NAND Gate U2B of the Logic Card.

RECEIVER/DECODER/INTERFACE UNIT
The main circuitry of the Receiver/Decoder/lnterface unit consists of the Power Supply, Mother Board, Receiver Card, Processor Card, and Stepped 110 Relay Cards. The Receiver Card converts the w o incoming RF signal to a binary coded serial data stream. The Processor Card utilizing t microprocessors, decodes the serial data stream and outputs control information to the I10 Relay Cards. The If0 Relay Cards provide output contacts to be used for interfacing directly to the crane control circuits or to an auxiliary interface panel.
Page 9

RECEIVEWOECODEWINTERFACE UNIT - POWER SUPPLY

The regulated +12V and +5V Power Supply provides the necessary current to power the MDR-8400. The +I 2V supply outputs 12V DC at 5 amps. The +5V supply outputs 5V DC at 3 amps. Output overload protection is provided by an automatic electronic current limiting circuit. Input requirements are 105 to 132 VAC at 75VA. A 2 amp overload protection fuse protects the input to the Power Supply

RECEIVER/DECODEWINTERFACE UNlT - MOTHER BOARD

The Mother Board provides the interconnection between all cards, power supply and the output terminal strips. By eliminating almost all interconnecting wiring, the Mother Board reduces potential maintenance problems (See Figure 3.9, Page 35). Jumpers (W1-W24) on the Mother Board are factory inserted. They are placed to select the use of one or two I10 Relay Cards per motor. Selection is dependent upon the control logic sequencing required. All other components, capacitors C1 thru C6 and Choke L1, are used for 12V and 5V power supply decoupling.

RECEIVEWDECODEWINTERFACE UNlT - RECEIVER CARD

The transmitted CFSK modulated RF carrier is detected by the crane mounted antenna and fed to the Receiver Card. The Receiver Card outputs to the Processor Card, a serial data stream identical to the transmitter's, and a squelch signal used in the diagnostics to indicate an "insufficient" carrier signal strength. The main circuits of the Receiver Card are:
RF Amplifier 1st Mixerfl st Local Oscillator 10.7 MHz Filter FM IF Section Low Pass Filter 6. Wave Shaper

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1. 2. 3. 4. 5.

A simplified block diagram is shown in Figure 3.10,Page 36.

From the antenna the RF signal enter,sthe Receiver Card and passes through t h e receiver front-end
which consists of tunable circuits adjdsted to allow passing of the desired RF carrier signal. The signal is then amplified (QI) and presented to one of the gates of the I st Mixer Q2. A signal 10.7 MHz less than the RF signal is generated by the 1st Local Oscillator Q3 (a dual-insulated gate, field effect transistor) and presented to the second gate of Q2. Q2 then mixes the two frequencies and outputs the difference (10.7 MHz) to filter FLI . Filter FLI allows the passing of the 10.7 MHz signal to the FM IF section contained within U1.

lnternaly, U1 contains a second mixerloscillator stage, a limiter, a quadrature detector, a noise amplifier and a squelch detector circuit. The 10.7 MHz signal from FLI and a 10.245 MHz signal provided by the oscillator of U1 and external crystal Y2, are presented to the mixer of U1. The mixer outputs the difference of these two frequencies (455 KHz) through an external filter FL2. From FL2 the 455 KHz signal re-enters U1 to the limiter and quadrature detector sections.

Page 10

The quadrature detector circuit outputs a desired demodulated signal containing the transmitted serial data and any internally generated noise. The strength of the demodulated signal versus that of the noise is proportional to the strength of the incoming carrier signal (72-76 MHz). The strongerthe carrier signal, the lower the amplitude of the noise. Amplifying then sensing one level of the noise are the Noise Amplifier and Squelch Detector sections of U1. If the rectified noise level exceeds the Squelch Threshold setting (R17), then the Squelch Detector will squelch or quiet the output of the quadrature detector. Providing the RF signal is of sufficient amplitude, the demodulated signal from the quadrature detector will be presented to the Low Pass Filter U2B. Filter U2B "cleans" the demodulated signal by removing the high frequency noise components. From U2B the signal travels to the Wave Shaper circuitry; Peak Detectors U6A and U6B, and Slicer U5A. This circuitry shapes the signal from a rounded waveform into a square waveform. The squared digital or serial data stream, which is now identical to the serial data stream generated by the transmitter Logic Card, passes through a feed-through capacitor to an inverting buffer and is sent to the Processor Card. In addition to the serial data stream, a signal from squelch circuitry (SquelchlCarrier Status] is sent to the Processor Card. A +5V signal indicates a satisfactory carrier strength level; OV indicates a squelched receiver. The signal is used by the Processor Card for diagnostic troubleshooting purposes and to key the two microprocessors as to the status of the squelch circuit. The three light emitting dies (LED'S) on the Receiver Card are for troubleshooting and will be covered in Section V.

RECEIVERIDECODERIINTERFACEUNIT PROCESSOR CARD

The receiver Processor Card performs a number of functions. Primarily, it is responsible far decoding the serial data stream and provides relay control data to the 110 Relay Cards. The card also performs safety monitoring functions and provides troubleshooting diagnostics. The main circuits of the Processor Card are:
1. 2. 3. 4. 5. 6.

5V Monitor Address Switch Serial Data Processor (SDP) InpuUOut~ut Processor (IOPI ohput ln'hibit Troubleshooting Diagnostics

A simplified block diagram of the Processor Card is shown in Figure 3.1 1, Page 37.

Decoding of the serial data stream and formatting of relay control information by the P r r Card is accomplished by two microprocessors; the Serial Data Processor (SOP) U1, and tha Inmmt Processor (IOP) U2. The serial data stream from the Receiver Card is fed to the SDP. Two conditions must be met before either microprocessor can process the data:
1. The +5V supply must be above 4.5V.

2. The SquelchlCarrier Status signal from the receiver Card must be high (5V), indicating a satisfactory carrier signal strength. Before explaining the processing of the serial data stream by the IOP and SOP,the p r o g m f peripheral hardware and its functional role will be covered.

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Comparator circuit U5 monitors the status of the 5V supply. If the supply voltage should fall below 4.5V,then U5 will provide a reset or low signal to both the SDP and the IOP. The system reset signal causes the microprocessor's internal program to reset to the beginning and prohibits the program from running as long as the low signal is preseni. A manual reset can be applied by activating switch S1. A four pole DIP Switch (S2) provides a preset address code to the SDP. The address code must beset to match the corresponding transmitter code. Monostable multivibrators USA and U9B each perform a watchdog function for the SDP and IOP, respectively. When the microprocessors' programs are running properly, a "watchdog" toggle pulse is sent to U9A and U9B. Providing these 'katchdog" circuits receive their respective toggle pulses on a timely basis, a 5V signal will be continually sent to one of the input ports of NAND Gate U15. Absence of this 5V watchdog signal results in an Output lnhibit signal or system shutdown generated by U15. For timing purposes oscillator crystal (XI) supplies a 6 MHz frequency to both the SDP and IOP. The SDP divides the 6 MHz clock frequency and outputs a 400 KHz clock frequency to a Divide-By-Four Counter (U6). The output of U6 provides a toggle signal of 100 KHz to the SDP (Ul) for program loop timing. For a troubleshooting aid, the Processor Card contains three seven-segment error display units and eiaht discrete error LED's. The error codes are covered under the Alianment and Troubleshootina sections. Error display D l is controlled by a BCD-to-7-segment ~ a t c i ~ e c o dDriver er (U8). he ~ D P (Ul) supplies error information to U8. Error displays D3 and D2 are considered one display unit with D3 indicating a'Yensn digit and D2 a "ones" digit. U10, an 8-Stage ShiWStore Register, receives error information from the IOP (2) and sends it to the appropriate BCD-to-7-Segment Latch Decoder Driver U12 or U13. Error Displays D3 and D2 are controlled by U12 and U13, respectively. The eight discrete LED's, three green and five red, are controlled by the microprocessors (U1 or U2), the Squelch Status signal, and the Output lnhibit signal from U15. For safety, an Eight Input NAND Gate, U15, generates an output signal (5V) when any of the inpu, gates recelve a low (OV). The input gates of U15 monitor the status of the IOP and SDP watchdog circuits, the IOP Data Error Signal, and the System Reset Signal from Switch S1 or Comparator U5. The Output lnhibit Signal cues the SDP and IOP to a safety fault condition and commands the Relay Cards to return all relays to the normally off mode. The serial data stream enters the Serial Data Processor (SDP, U1) on pin 38. The SOP examines the incoming data looking for the "String Synchronization" or "Message Start" word. (See Serial Data Message Format explanation, Page 8). Once recognized, the SDP will store, reformat, and output to the IOP (U2) in parallel form, the transmitter address, motor, auxiliary function and CRC parity information. The SDP also reads the Processor Card's address from S2 and sends it to the IOP. Upon receipt of the parallel data from the SDP, the IOP performs four basic functions with the information: 1. Compares the transmitted address with the processor address. 2. Calculates the CRC parity of the received data and checks the result against the transmitted CRC parity words. 3. Formats the parallel data into serial data containing 110 Relay control information as instructed by a pre-programmed routine, and outputs this information to the shift registers of the 110 Relay Cards.

4. Stores and compares outputed relay data with returning relay status informatior

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If the Address and CRC Parity evaluations are acceptable, the IOP will complete the information transfer by strobing the I/O Relay Cards' relay control registers. If data sent does not match the relay status information received back from the 110 Relay Cards, an Output lnhibit will be triggered by a data error signal from the IOP.

RECElVEWDECODER/INTERFACE UNIT - INPUTIOUTPUT RELAY CARDS

All Input/Output Relay Cards are interchangeable. The purpose of these cards is to provide relay control logic to the crane magnetics. In most situations, the relay control logic required to control the crane motors is pre-programmed via the 110 Processor to match that of the manual controls. Some applications require additional external relays for current handling or logic sequencing reasons. The main circuits of the I/O Relay Cards are:
1. Relay Control Shift Register 2. Relay Latch Driver 3. Output Relays 4. Opto-Isolators 5. Safety Monitor Shift Register

A simplified block diagram is shown in Figure 3.1 2, Page 38.

The relay control serial data from the Processor Card consists of sixteen (16) bits per motor and sixteen (16) bits total for the auxiliary functions. Each bit is capable of controlling one I10 relay. A "one" or "high" bit instructs a relay to turn on. A "zero" or "low" bit instructs a relay to turn off. Each motor card contains eight relays. Some motor logic sequences require more than eight relays. In these situations, two It0 Relay Cards are used. By means of the positive clock pulse transitions generated by the IOP of the Processor Card, the relay control serial data bits are shifted through the Serial-to-Parallel Registers (U1 and U2) of each 1 1 0 Relay Card, eventually filling all registers. The eight registers of the U1 tie directly to the relay latch1 driver circuits of U3 and U4. Once the registers are filled, a strobe pulse from the IOP simultaneously instructs the appropriated Latch Drivers of U3 and U4 on all cards to latch or unlatch. A latched driver circuit will result in turning "on" its respective relay. Also feeding the Relay Control Shift Registers U1 and U2 and the Latch1 Drivers U3 and U4 is an Output lnhibit input line from the Processor Card. In the event that an Output lnhibit signal is received, all relays are turned off. For safety reasons, a Relay Status Monitor Circuit has been incorporated into the MDR-8400. When an output relay is energized its output contacts change state. The Opto-Isolators U8 through U15 notify the Safety Monitor Registers (U6 and U7) as to the status of the contacts. Upon receipt of a strobe pulse, U6 and U7 sends the information back to the IOP of the Processor Card. The IOP compares the relay status information received against the relay control information sent. If the data does not agree, then an Output Inhibit Signal is generated. The output contacts of the I/O Relay Cards are connected via the Mother Board to the terminal strips. Direct interfacing to the crane magnetic motor controllers or to additional interfacing relays is accomplished through these terminals.

S A F t r Y FEATURES
In the development stage of the MDR-8400, safety was a design priority. The use of digital electronics and microprocessors has allowed sophisticated safety checks. Throughout the prior General Circuit Description, the various safety features have been described. A summary of several of these features are:
1. Narrow Band FM Receiver Allows only the passing of the desired frequency (See Receiver Card, Page 10). 2. Receiver Squelch Circuit Requires carrier signal strength to be of sufficient amplitude before receiver will output the serial data stream (See Receiver Card, Page 10). 3. Accurate String Synchronization String Synchronization pulses must appear at given positions throughout each serial data message (See Serial Data Message Format Page 8).
4. Correct Address Coding and CRC Parity Result Requires correct 4 bit address code and correct CRC parity result with each serial data message before the I/O Relays will respond to the message (See Logic Card Page 8).

5. Relay Status Monitoring IOP microprocessor stores and compares relay control data sent to I/O Relay Cards with returning relay status information. If the two do not match, then a data error is generated to the Output Inhibit Circuit (See lnput/Output Relay Cards Page 13).
6. Output lnhibit Signal Enacted by data error from IOP (Address fault, CRC Parity fault, relay status fault). Initiates a system shutdown by instructing the Relay Shift Registers and LatchIDrivers to return all relays to the normal "off" position (See Processor Card Page 1 1).

Page 14

SECTION IV OPERATOR'S INSTRUCTION

INTRODUCTION
The Control Chief MDR-8400 is a digital microprocessor-based radio remote control system designed to allow the operator to manipulate the crane in the most efficient and safest manner possible. The following section explains how to operate the Control Chief MDR-8400.

OVERVIEW
The MDR-8400 consists of two basic components; the transmitter and the Receiver/Decoder/ Interface unit. Peripheral support equipment includes a battery charger, rechargeable batteries and a transmitter carrying harness. A battery charger for charging the Nicad batteries is also included. When a transmitter command switch is activated after turning on the transmitter "Power On" and "Main On" switches, a digitally coded radio signal containing the operator's commands is modulated and sent via RF to the Receiver/Decoder/lnterface unit. The spring loaded motion levers are designed to return to the "deadman" or "off' position upon release. The levers operate much in the same manner as crane master switches. With electrically operated brakes, the deadman position will set the associated brake. It is also possible to operate more than one crane motion lever concurrently; such as bridge and hoist.

TRANSMllTER OPERATION
The transmitter is powered by a rechargeable battery. For safety purposes and to conserve battery power, it is recommended the transmitter "Power On" switch be turned off whenever a lift is not being made. To command a crane function, the following steps are to be followed: 1. Turn keylock power switch "on".
2. Check battery power by depressing battery test switch. If the light glows, then battery is OK.

3. Engage "Main On" switch. This action sends system address information.
4. Depress "ReseWarning" pushbutton. This action activates the main line contactor

circuit which allowing power to the crane motors. Once mainline contactor is activated depressing "Reset/Warning" pushbutton will activate any warning devices utilized. 5. Select and operate desired motor lever(s).or auxiliary command switch(es).

page 15

In the event a condition exists requiring emergency shutdown, the operator can either turn off the "Power On" keylock switch or the "Main On" switch. Either procedure will immediately open the crane main line contactor, cutting power to the crane motors and setting all electrically operated brakes.

PREVENTIVE MAINTENANCE
The portable transmitter is housed in a heavy gauge aluminum enclosure. The unit is designed to survive in an industrial environment with moderate "banging around". However, the unit does consist of solid state electronic circuitry and should not be subject to careless abuse. It is your lifeline to the crane - so take good care of it. The battery charge should last a minimum of 8 hours of continuous use. Turning the key off between lifts will conserve battery power. Battery power can be checked by depressing the battery "Push-toTest" switch. If your battery is not lasting a full 8 hours, notify your Maintenance Department.

BAJTERY MAINTENANCE
When used properly, the 12 volt Nickel cadmium batteries used to power the transmitters will provide 8 hours of continuous use. Proper battery maintenance allows for 16-20 hours of charging between uses. Prior to charging, the batteries must be completely discharged. The battery is considered to be completely discharged when the battery will no longer operate the transmitter. If the batteries are repeatedly placed on the charger before they have been completely discharged the electrochemical cycle of the batteries will be compromised and the batteries will not provide 8 hours of continuous operation.

Page 16

SECTION V MAINTENANCE
INTRODUCTION
The intent of this section is to provide maintenance information to facilitate system troubleshooting to the "board" level. To aid in locating a system problem, the MDR-8400 features both built-in LED status indicators and microprocessor controlled Numerical Display units. Troubleshooting consultation is available by calling Control Chief Corporation. For troubleshooting to the first level, it is recommended a set of spare printed circuit cards for the Receiver/Decoder/lnterface Unit and a spare operating transmitter be stocked. Within the MDR-8400 there are seven unique printed wiring boards; the transmitter's Logic Card and RFlRegulator Card and the Receiver/Decoderllnterface unit's Receiver Card, Processor Card and Stepped 110 Relay Card. To order spare parts contact your local representative. Once the problem circuit card or transmitter has been identified, return it to Control Chief for repair. Normal card level repair is less than 48 hours. For servicing to the component level, it is possible to purchase a MDR-8400 Component Service Manual Part Number 8002-9000-01. Figure 5.1 provides a list of drawings, schematics and parts lists included.

FIGURE 5.1
MDR-8400 DRAWINGS, SCHEMATICS 8 PARTS LIST
Circult Card
A

Drawing Number
8002-1001-01 8002-1003

Rev. Level
-

Ejector Color

Transmitter Logic Card Transmitter RFIRegulator Card (72 MHz) Receiver Processor Card Receiver I/O Relay Card Receiver Mother Board Receiver Module (72 MHz)

Blue Red

E
A3

8002-400 1-02 8002-4003 8002-4007 8002-4009

C
E

Yellow

NOTE: These drawings, schematics and parts list are included in the Component Service Manual which may be purchased and used for servicing to the component level.

Page 17

DIAGNOSTICS
To aid in locating the source of a system operating problem, LED Status Indicators and Numerical Display Units are incorporated into the crane mounted MDR-8400 equipment (See Figure 5.2 for location, Page 39). Utilization of the L.E.D. Status lndicators and Numerical Display Units in conjunction with the troubleshooting information contained in this section will result in rapid system problem solving. The seven-segment display units will indicate the first malfunction experienced. Only malfunctions which cause a sustained Output Inhibit will shut the system down until corrective action is taken. Temporary malfunctions or RF interference will cause a shutdown, but the system can be brought up again by depressing the transmitter Warning/Reset pushbutton. To clear the displays and reset the Processor Card depress the Reset switch located on the Processor Card. Receiver Card LED indicators are as follows:
LED
Green Yellow Red

Function (Lighted LED)

Flickers when Receiver Card is sending serial data to Processor card Lock Detect Receiver is squelched. RF signal strength is not sufficient

With transmitter on, Green LED should flicker, Yellow LED will glow and Red LED should be off. If these conditions are not met, refer to Troubleshooting Chart Figure 5.4. With transmitter off, Red LED should glow and the Green and Yellow LEDs should be off. If these conditions are not met, locate source of external RF interference.

Processor Card LED indicators are as follows:

LED
Green #1 Green #2 Green #3 Red #1 Red #2 Red #3 Red #4 Red #5

Function (lighted LED)

Correct RF carrier is present
U1 (Serial Data Processor - SDP) is receiving data U2 (InputlOutput Processor - IOP) is functional

Not used Output Inhibit has been activated SDP Fault (Check Single 7-Segment Display) IOP Fault (Check Double 7-Segment Display) Relay Fault (Check Double 7-Segment Display relay number and refer to system drawing ....3000 for location of this relay in your system.)

Page 18

Processor Card Numerical Displays Single 7-Segment Display Unit

Error Code
With SDP Fault LED (Red #3) on
1

Function

Corrective Action

String Synchronization not achieved No R.F. carrier present

Locate external RF interference and reset Processor Card Check transmitter RF power and frequency Check receiver antenna connection Check Receiver Card LED Replace Receiver Card Ensure surge suppressors are installed on all relay coils and all inductive and capacitive devices Replace Processor Card Turn system power off, wait a few seconds, turn system power on If error remains replace U1 of I10 Processor card

3
4

Fatal Hardware Fault (Output Inhibit will be active) SDPIIOP Communication Fault Ram Fault

Processor Card Numerical Displays Double 7-Segment Display Unit

Error Code
With IOP Fault LED (Red #4) On 01 02

Function

Corrective Action

SDP Fault (Refer to Code on Single -/-Segment Display Address Fault Check transmitter Main On switch. Ensure transmitter & Receiver/Decoder/lnterface unit address codes match Ensure surge suppressors are installed on all relay coils and all inductive and capacitive devices Replace Processor Card Locate external RF interference Starting with relay card 1 substitute a good relay card through each relay card position until error is corrected Retune Receiver card Retune Transmitter card Locate external RF interference Turn system power off wait a few seconds, turn system power on If error remains replace U2 of 110 processor card
&

03
04

Fatal Hardware Fault (Output Inhibit will be active) IOPISDP Communications Fault Parity Fault Unidentifiable Relay Fault

05 06

07

Word Synchronization Fault

08

Ram Fault

With "Relay Fault" LED lighted, double 7-Segment display shows faulty relay number. A relay fault of less than two seconds will cause a temporary shutdown. A relay fault of greater than two seconds will cause a permanent shutdown until the fault is corrected and the reset switch on the Receiver1 Decoder/lnterface unit Processor Card is depressed.

Page 19

TROUBLESHOOTING
Through the use of microprocessor-based circuitry, system problems and troubleshooting time hBvB been minimized. Computer software greatly reduces hardware, the chance of hardware fault<, an$. . . .. provides self-diagnostics for rapid problem identification. . .I .

.':-

Before attempting to troubleshoot the MDR-8400, it is advised the assigned s e ~ i c e personnel become well acquainted with the information provided in Section Ill,Theory of Operation. problem; with any equipment can be classified into one of the three following areas:

1.
2.

Partial System Loss Intermittent Shutdown

Loss of one or more operating function but not total shutdown. A system shutdown that can be remedied with a transmitter or Receiver/Decoder/lnterface unit Processor Card reset. No Response.

3.

Total System Shutdown

CAUTION: DO NOT REMOVE ANY CARDS IN THE RECElVEWDECODERnNTERFACE UNIT WHILE THE SYSTEM IS UNDER POWER. DISENGAGE FUSE SWITCH F1.

PARTIAL SYSTEM LOSS

For purposes of this manual, a Partial System Loss is defined as a malfunction resulting in the i~perative loss of one or more crane control functions; such as hoist will go up but not down. If such a malfunction results in a total system shutdown condition requiring a manual reset on the transmktter or Receiver/Decoder/lnterface,refer to the Intermittent or Total System Shutdown sections which follow. In most situations, the following steps should isolate the problem:
1

Try spare transmitter - Does malfunction still occur?

- No - Proceed to Step 2. - Yes - Problem is on the crane.

2 .
3.

Proceed to step 4.

Check appropriate transmitter command switch and wiring for faulty switch or connection. Check serial data output of transmitter Logic Card at TP4 (yellow with volt meter on 10 VDC scale.

- With "Power On" (key) switch only engaged, meter will read approximately 4 VDC. - Engage faulty switch. Meter needle should move to lower reading. If not, replace
Logic Card. 4. Try manual mode of operation. If problem still exists, check crane magnetics and wiring.
'

1
P I C : .

IN'rERMlTTENT SHUTDOWN
An Intermittent Shutdown is a condition whereby a momentary malfunction, loss of signal or outside noise interference results in an Output Inhibit causing a temporary crane shutdown. The situation can usual&Re remedied by activating transmitter ResetMlarning switch or the ReceiverIDecoderilnterface unit Processor Card Reset Switch. The following is a check for hardware malfunctions.
1. 2.

Try resetting Main Line Contactor by pressing the transmitter ResetMlarning switch. Check battery voltage by pressing "Battery Test" on transmitter. Try spare transmitter. If fault still exists, problem is with crane-mounted equipment. Move to Step 5. Check RF power and deviation (See RFIRegulator Card Alignment). Try manual mode. If fault remains, problem is with the crane. Check wiring and magnetics. Check diagnostics LED'S and Displays for abnormal indication (See Pages 18 EL 19). If a relay fault is indicated, replace faulty card. Press Processor Card reset switch, S1 Ensure all printed wiring cards are secure in connectors. Check all interconnection wiring and internal wiring to and from power supply. Check antenna, antenna cable and connections. Check coil arc suppressors.

3.
4.
5.
6.

7.
8.

9.
10. 11.

Cheuk for external noise source.

TOTAL SYSTEM SHUTDOWN

A Total System Shutdown is a condition whereby the crane does not respond to any MDR-8400 transmitter qeherated commands. The condition is a result of either a transmitter or Receiver/ ~ecoderlln&rfaceha'rdware fault. Two troubleshooting flow charts, one each for the transmitter and Aeceiver/Decoder/lnterface, are shown in Figures 5.3 and 5.4, Pages 40 and 41.

ALIGNMENT
Although system adjustment is not normally required, this section provides steps to determine if alignment is necessary and the procedures and equipment needed to perform the alignment. The transmitter's RFIRegulator Card and the Receidr Card located in the ReceiveriDecoderllnterfaceare the or& system d r d s which have adjustments.

b*
4

RFIREGULATOR CARD ALGNUENT

EQUIPMENT REQUIRED

Wattmeter - Bird Thruline Model 43 or equivalent with 72-76 MHz, 100 mw elemem an& female UHF (SO-239) inputloutput connectors 50 ohm dummy load termination with UHF (PL-259) connector 80 MHz frequency counter 50 ohm coaxial cable (8 inches maximum length) with two male UHF (PL-259) connectors Hex alignment tool (GC Electronics No. 9300 or equivalent) Trimmer adjustment tool (Spectrol Model 8 or equivalent) Non-metallic tuning tool (GC Electronics No. 8987 or equivalent) Antenna stand (Control Chief Part No. 0082-0051-Stand) PRELIMINARY 1.
4

Ensure a fresh battery is installed in the transmitter. With power "OW', remove the transmitter case bottom and place the transmitter on a flai' .. surface with the switches facing down.
1

2 .
3. 4. 5.

Remove the transmitter antenna and connect the wattmeter to the antenna jack using ohm coaxial cable. Install a 50 ohm dummy load on the wattmeter and rotate the meter element to ir "Forwarcf' power.

fe~;,

Turn power "on". Wattmeter should indicate 50 milliwatts + 10 mw unless power has intentionally increased for greater range. If adjustment is required, refer to Alignment Procedure, Step 2. Turn transmitter power "OW'. Replace the 50 ohm load on the wattmeter with the transmar antenna. Rotate the wattmeter element to indicate reflected power and turn the transmitter poyer Using the nonrmetallic tuning tool, adjust the tuning slug for minimum reflected replace the plastic antenna cap. Reflected power must be less than 10% of antenna. Continue with preliminary step 12.

6.

7. 8.

rr.

+-

a9

9.
10.

Turn transmitter power "Off'. Replace the 50 ohm load on the wattmeter with the transmitter antenna mounted on the antenna stand. Rotate the wattmeter element to indicate reflected power and turn the transmitter power "on". Using the trimmer adjustment tool, adjust the trimming capacitor for minimum reflected power. Reflected power must be less than 10% of forward power into antenna. Turn power "Off' and reconnect the antenna to the transmitter. Turn power "On" and loose couple the frequency counter to the antenna using a coaxial cable with a pickup loop at the end. Locate spring-return toggle switch, S1, on the RFlRegulator Card and note the "H" and "L" markings above connector, J2. Hold S1 in the "H" (high) position and read the frequency counter. Deviation should be 2 KHz to 2.5 KHz above the assigned RF carrier frequency. Hold S1 in the "L" (low) position and read the frequency counter. Deviation should be 2 KHz to 2.5 KHz below the assigned RF carrier frequency. If adjustrr~ent is required, refer to Alignment ,Procedure, Steps 4 through 6.

11.

12.

13.

ALIGNMENT PROCEDURE

1.
2.

Perform Preliminary Steps 1 through 5 above. Adjust trimmer capacitor, C20, for a peak (maximum) wattmeter reading; then adjust C15 for 50mw. For transmitters with a whip antenna continue with preliminary step 6. For transmitters with a solid antenna continue with step 9. Hold toggle switch, S1, in the "L" (low) position and adjust coil, L3, for a frequency 2 KHz below the assigned RF carrier frequency. Hold S1 in the "H" (high) position and adjust potentiometer, R5, for a frequency 2 KHz above the assigned RF carrier frequency. Recheck the frequency with S1 in the low position. This completes the RF/Regulator Card alignment. Reinstall the transmitter case bottom, being careful not to pinch any wiring in the process.

3.
4.

5.

6.
7.

Page 23

e RECEIVER CARD ALIGNMENT

EQUIPMENT REQUIRED
FM RF generator (Wavetek Model 3005 or equivalent) VOM (Simpson Model 303-3XL or equivalent) Oscilloscope 12 volt, 100 mA power supply Hex alignment tool (GC Electronics No. 9300 or equivalent) Trimmer adjustment tool (Spectral Model 8 or equivalent)

PRELIMINARY
1.

Turn "OW' power to the Receiver/Decoder/lnterface unit, disconnect the antenna cable and remove the Receiver Card. Refer to Figure 5.5. Connect power supply "common" to the aluminum case and 12 volts to FL4. Set VOM to the 1 volt AC scale. Connect the positive (+) lead to FL9 and the common lead to the case power supply "common".

2.

3.
4.
r.

/'

Ensure power is "OW' on all associated transmitters. If necessary, adjust R17 counterclockwise until a noise-level reading is obtained on the VOM and continue 2 full turns counterclockwise past this point. Note the noise reference level. This should be (-)9 db minimum.
Set the RF generator to the receiver frequency at an unmodulated output of 2 uV and connect the generator to the receiver's BNC antenna jack. Set the VOM to the 0.1 volt AC scale. To check receiver sensitivity, decrease the generator output until the VOM reads 20 db lower than the reference level obtained in Step 4. This should occur when the output is 0.7 uV or less. If the generator output is greater than 0.7 uV, refer to Alignment Procedure, Steps 2 through 9. Set the RF generator output to 10 uV unmodulated and the VOM to the 10 volt DC scale. Connect the positive (+) lead to FL9. Adjust C27 several complete turns, noting the minimum and maximum VOM readings. Set C27 at the point midway between these readings. This will be approximately 3 volts DC. Connect the positive (+) lead of the oscilloscope to FL9 and the ground lead to the case. Set the generator for a 1 KHz modulating frequency at a deviation of 2 KHz. Adjust L5 and L6 for maximum audio amplitude with minimum distortion. Set the generator output for 0.5 uV with no modulation. Adjust R17 clockwise until there is no noise on the oscilloscope. Slowly increase the generator output and verify that the receiver unsquelches. This is indicated by the presence of noise and should occur before the generator output reaches 1 uV.
.

5.
6.

7.

This completes the alignment. Reinstall the Receiver Card and apply system power.

Page 24

ALIGNMENT PROCEDURE
1.

Perform Preliminary Steps 1 through 6 above. Set the VOM to the 3 volt DC scale and connect the positive (+) lead to FL5. Set the generator for minimum outpt~ tthen , increase the unmodulated output to where the VOM reading just starts to increase. (L1 and L2 may have to be adjusted to see this increase.) Adjust L1, L2, L3, L4, L5, L6 and L7 for a maximum VOM reading; decreasing the generator output, as necessary, to remain on the 3 volt DC scale. It may be necessary to first adjust L2, if no peak is obtained by adjusting L1. Set the generator output for 30 uV and the VOM for a mid-scale reading. Repeat Step 3. (Note: Tuning L7 will produce only a minor change.) Set the VOM to the 0.1 volt AC scale and connect the positive (+) lead to FL9. Adjust the generator output for a VOM reading of approximately (-)20 db. Slightly tune all coils for the minimum level on the VOM. Set the VOM to the 1 volt AC scale and disconnect the generator cable from the antenna jack. Note the noise reference level on the VOM. This should be 09 db minimum. Set the generator output for 2 uV and reconnect the cable to the antenna jack. Set the VOM to the 0.1 Volt AC scale. Decrease the generator output until the VOM reads 20 db lower than the reference level obtained in Step 6. This should occur when the generator output is 0.7 uV or less. Continue with Preliminary Steps 7 through 10 above.
1

Page 25

Receiver Enclosure

ANTENNA PLACEMENT FIGURE 2.1

Page 26

._-_-----_____----_~---------~--------------------------------------------------------4I I

~ o d lator u

I I I

I 0

.________________------------------------STEPPED
I

Battery

CONTROL S W I TCH (ES)

LOGIC CARD

M a i n On (Address >

(72-76MHz) MDR8400 TRANSMITTER BLOCK D I A G R A M

F I G U R E 3.1

n1

-" i
DL:

-I

U" i

Page 28

ADDRESS SWITCH

D I V I D E BY TWO COUNTER U4,U2C, U2D

A

TOGGLE

GMHr
I CR YSTAL

4 0 0 KHz

X1

a
FROM CONTROL SWITCHES
T I

5
I -

0 8 SCAN L I N E S
V)

INVERTING BUFFER U2A

;

cn
W

SWITCH L I N E S

a
5

o
0
0 a

) S E R I A L DATA STREAM

CO CD

pl;'

81 COMMONS

a n

? a

8 READ L I N E S

WATCHDOG TOGGLE N A N D GATE

U3

) CUTOFF ENABLE ( T O O S C I L L A T O R OF R.F./REG.

CARD)

<- I
LOGIC CARD BLOCK DIAGRAM F I G U R E 3.3

BATTERY CUTOFF (FROM R.F./ REG. CARD)

CODE:

1001

ADDRESS SWITCH
Figure 3.4

Page 30

NOTE
bode

A-

Matrix Swltchas Olher Than Address

O~psw~tch, S2 Are Not Located on T h ~ sP W B And Are Shown For Reference Only
(1

-b

+
--Z

+ - ___C

+ 5v
A 4 1

- --

'>

R E A D LINES
(To M~croprocessur. P l r l , 2 7 thrci 3 4 )

.+
L

.-

-- -

J8-9

MOTOR 1

J6-9

. ; -S C A N

LINES )

(From M~~roprocess~r

Plns 12 Ihru 19

J4-9

4-BIT

ADDRESS

TRAM-

L Q Q C CARD DIODE M A T R I X
FIGURE 3,5

SERIAL DATA MESSAGE SYNC WLSE SYNC SYNC PULSE SYNC PULSE SYNC WLSE SYNC PUSE SYNC PULSE SYNC PUSE SYNC PUSE

WLSE

I
I I
I I

I
MOTOR 1 s m N G SYNC AUXIUARY 2 AUXILIARY 1 CRC PANTY

CRC PARTY

I
A___ _L_______I.__
"

I ,

&

..-

68 MSEC

DETAILED SERIAL DATA MESSAGE SYNC PUSE MZSSAGESTART STRING SYNC SYNC PULSE

ADDRESS

MOTOR 5

SYNC WLSE

i 1 1
0

(4 BITS)

(4 BITS)

1 1
l

NOTE: t = 833 MSEC . 6 FIGURE 3

ANTENNA

RF/ REGULATOR CARD

0 vFROM LOGIC CARD

EXAMPLE:

FREQ. 72.60MHz

2n,

72.602MHz

LOGIC 0

72.598MHz

LOGIC 1

CARRIER FREQUENCY SHIFT KEYING

Hi/Low Deviation Setting Switch S1

L1\
Buffer

v
Hi Adjust R 5 & UlA

Amplifier

Active Low Pass Filter

U1B
#

v
Variable Capacitance Diodes CR1 & C R 2

l mpedance Matching/ Low Pass Filter C20, L10, & C22

ANTENNA

fl
1st Mixer
10.7 MHz Filter

455 KHz Filter

FL2

,
Low Pass . Filter U2B

Amplifier

Oscillator, Mixer, Limiter. Quad Detector, Noise Amplif ier, & Squelch Detector

vv

Wave Shaper Peak Detector,Slicer USA,U6A & U6B

-[-nr

SERIAL DATA

F M I F SECTION

Oscillator

SQUELCH

RECEIVER CARD BLOCK DIAGRAM F I G U R E 3.10

From Receiver Card

Error Display

Error Display

PROCESSOR CARD BLOCK DIAGRAM

F I G U R E 3.1 1

Relay Card

Safety serial-ma (ln)

Processor Card "Om

To Card <Safety Serial ~ata(0ut) Next Relay or Processor Card (~epending on Slot Position) From Processor Card or Next Relay Card (~epending on Slot Position)

Clock (ln) Safety S t a e (In)

* .E
.-

C,

e 2 - 3
2
0

Relay Status

$ ,
0

5
Q3

Relay Status

t n

z =
OUTPUT RELAYS TO CRANE MAGNETICS CONTROLLERS

.$

*
Relay Control

From Prpa$sor

Relay Strobe Output Inhibit (In)

1/0 RELAY C A R D BLOCK D I A G R A M

FIGURE 3 . 1 2

Processor Card Processor Reset Switch Single 7-Segment Numerica S.D.l? Error Code

1 . 0 . Relay Cards

Receiver Status L.E.D!s

-Relay Status L.E.D.'s

Processor Status L.E.D!s [Green)

L.E.D. Fault Indicators I Red I

Double 7-Segment Numerical Display I.O.P. or Relay Fault Error Code

Receiver Card

Power Supply

L.E.D. & NUMERICAL DISPLAY DIAGNOSTICS LOCATIONS

FIGURE 5.2

Page 39

CRANE DOES NOT RESPOND TO ANY COMMANDS.

TUdN M A I N O N (ADDRESS) ON.

INPUT TO FUSE

CHECKCONNECTORS 8 WIRING.

REPAIR.

BATTERY TEST

CHECK l 2 V OUTPUT FROM FUSE F1.

1

iNOT OK

>

TURN KEY SWITCH OFF.

WIOHM METER NOT CHECK OUTPUT SIDE OF F1 . FOR SHORT CIRCUIT TO GROUND.

TO FUSE F2.

YES

OK RECEIVEWDECODER. CHECK 5V OUTPUT FROM FUSE F2. OK -NOT OK

TRANSMITTER.

TROUBLESHOOTING
P U A QT.

>

TURN KEY SWITCH OFF

W1OHM METER CHECK OUTPUT SIDE OF F2 FOR SHORT CIRCUIT TO GROUND.

OK

rJ)

FROM J I , LOGIC CARD. WIOHM METER CHECK OUTPUT SIDE OF F2 ON RFIREG. CARD FOR SHORT TO GROUND. NOT SHORTED

TROUBLESHOOT INOPERATIVE

w
TRANSMITTER REPAIR FAULTY CONNECTIONS. (SEE NOTES 1 8 2)

v
TP7 (VIOLET) FOR 0 VOLTS. OK

RFIREG.

REPLACE

\L
CHECK LOGIC CARD TP6 (BLUE) FOR 5 VOLTS. OK
\

NOT OK

OR COMPONENTS.

I
NO

v
CHECK LOGIC CARD TP5 (GRAY) FOR 5 VOLTS. OK NOTE: 1. WITH TRANSMllTER 'POWER O N (KEY) ON. USING A VOLT METER ON 10 VOLT SCALE, METER SHOULD READ APPROX. 4 VOLTS. MOVE LEVERS; VOLTAGE READING SHOULD CHANGE. IF METER READS 0 VOLTS OR 5 VOLTS, REPLACE LOGlC CARD. 2. IF VIEWING THE SERIAL DATA IS DESIRED, AN EXTERNAL TRIGGER FOR AN OSCILLOSCOPE IS AVAILABLE AT TP3 (ORANGE) ON THE LOGlC CARD.

CHECK RF POWER 6 DEVIATION. (SEE XMTR, ALIGNMENT).

F CABLE CONNECTIONS. i z

>a

AT (YELLOW) TP4 ON LOGIC CARD. IS SERIAL DATA PRESENT?

Figure 5.3

*
RMSPECT STATUS ff DUO*OSTIC LE O DISPUVS
C W M WE. NOT REIeDND

I0 A m coy*-

NO
-

NO
TURNTRANYlTTW POWER S W R M

NO

WrnANYITTER

ER SUPPLY lS

OOESWEWmKH LUNUAL W E 1

NOT

POWER S W R M (=I) ffF WSPECT REGEWER W R D S T A N I L E D's 1 5 SOUELCH IRED1 M ?

NRNTRANSMTTER WMCK I*WREW) F ! J + lC n L h A lL LED'. ICR.37.80ff A I S E S S O R C*RD AREAUTHREEW

~~~~~~~!~ VES R E C E N W U R D 10
O m YUEVH IRE4 N m N fff a
DATA AIESENT (OML
RIOCEEO

",W$zzE a

RSPECT A U rnERFaCEWa*Ki CINNECTIMS EwEWrUDDL CIIANE *UaETICS

m
OI

FUCIW?

a
(BEEHOTE?)

-minEmcaNa w l
CCNNECTIMS *RE THW SECURE? WECU V U T A G E S M 5 L l2V WRES FRCUWRDEm CONNECT~J RE. MECK5V I 1 2 3

j M D

$ 1I T ~~ ! . R M S E R T S M E I T A M U M I L V ~ T ~ AICe4EdAPPEUIS

ANTENNA INPUT

RECEIVER CARD ADJUSTMENTS

FIGURE 5 . 5

Page 42

CHIEF
CORPORATION
h

INSTALLATION QUESTIONS?
Technical Assistance Via the Telephone is available from Control Chief. Please use either of our 800 telephone numbers, depending from which state you are calling.

NOTICE
This Control Chief remote control system is designed to be employed for many different applications (material handling equipment, machine tools, gates, furnace doors, lights and et cetera). In addition to this booklet, Control Chief offers supplementary product and/or application information assistance, if requested. However, we can accept no responsibility for the proper application of the remote control system. Further, Control Chief recommends all appropriate safety and operating manuals, relatingto the controlleddevice or machine, be reviewed prior to the installationof the remote control system.
If the remote control system is being employed on material handling equipment (e.g. hoists, trolleys, monorails or cranes), all applicable ASME standards must be reviewed and followed.

I
I
I

Control Chief Corporationshall not be liablefor technicalor editorial errors or omissions contained herein; nor for incidental or consequential damages resulting from the furnishing, performance, or use of this material. The information in this booklet is subject to change without notice.

CONTROL CHIEF CORPORATION

Post Office Box 14 1 Bradford, PA 16701
800-233-30 16 800-227-2967 (PA) Fax: 8 14-368-4 133

Section 5

CHECKOUT, CONTROL MODES, AND I i SETTING

GENERAL

HOIST ADJ USTMENTS

This smartorqueB Sjr control has been adjusted at the factory. However, it is strongly suggested that the entire Smartorque Sjr control system be commissioned by a qualified Harnischfeger service representative. Even though there are very few adjustments possible on the Smartorque control, proper and safe operation are dependent upon these adjustments. Readjustment of the control should only be performed by individuals that have been thoroughly trained, and who have read and understand this manual.

Verify that ,all adjustments discussed underithe topic, . preliminary Adjustments, have been completed.
1. With no load on the hoist, close the mainline

1 1

disconnect and energize the mainline contactor. Verify that the charge lamp o n the inverter illuminates. 2. Using the pushbutton operator, jog the motor in the first point raise direction and verify that rotation of the motor is correct. Using a volt meter verify that a signal is present at the FWD terminal of the SIF-3LC-2/4 board when the FWD pushbutton is depressed. This must be done to insure the upper limit switch circuit will operate properly.
If the forward run command is present and motor rotation is incorrect, do the following.

PRELIMINARY ADJUSTMENTS
/

3.

Before energizing the control, verify that all electrical connections are tight and terminated in accordance with the system wiring diagrams.
4.

NOTICE
Application of 460 VAC to a 230 VAC inverter will destroy the inverter. Check trapsformer wiring to insure the proper voltage is being applied.

NOTICE
Power source must be limited to 500 kVA to protect against premature rectifier assembly failure. If the source exceeds 500 kVA, the installation of appropriate reactors are required. If multiple inverters are installed, individual reactors are not required. One reactor that is capable of the combined amperage is acceptable. Consult with Harnischfeger technical representatives for the required reactors.

Electric current can cause injury or death. Disconnect, lock open and tag the power source which feeds the crane o r equipment to prevent power from being applied t o the machinery while repairs are being performed.
A. Disconnect, lock open, and tag the power source which feeds the equipment being worked upon.

6.Reverse any two motor leads at the inverter or

terminal strip in the control enclosure. It is not possible to change motor rotation direction by reversing incoming power leads to the inverter.
C. Reapply power.
I

D. Jog the motor in the first point lower direction and verify proper motor rotation.

Rev. Date 4/5/95

Revised 4/5/95

Slowly run the hoist in the raise direction and verify operation of the upper limit switch. When the upper limit switch is actuated, the hoist motion should stop and the motor brake should set immediately.
6.

machinery while repairs are being perf o rrned.

A. Disconnect, lock open, and tag the power source which feeds the equipment being worked upon.

Check for clearance between the bottom block and the trolley frame. Continue to run the hoist up at increased speed, into the limit switch, to verify adequate clearance between the bottom block and the trolley frame when striking the limit switch at full speed. If necessary, adjust the geared limit switch and/or the height of the control circuit limit switch.

6.Reverse any two motor ieads at the inverter or

terminal strip in the control enclosure. It is not possible to change the rotation of the motor by reversing the incoming power leads to the Smartorque system.

C.Jog the motor in the opposite first point direction and verify correct motor rotation.
4. Slowly run the motion and verify adequate operating clearances throughout the entire length of travel.

NOTICE
The bottom block must never strike the trolley deck or drum. Failure to observe this warning may result in damage to the hoist rope and bottom block.

5. Verify operation of all track limit switches, if provided.

6.

7. Starting at floor level, run the hoist at maximum speed in the raise direction and allow the controller to quickly return to neutral.

8. Note the amount of drift that occurs and adjust the upper geared limit switch, if provided, accordingly. When running at maximum speed i n the raise direction, the geared limit switch should stop the bottom block before it contacts the weight-operated limit switch if it is provided. See notice above.
9.

Rapidly advance the controller to the "full on" position and observe the acceleration rate. If necessary, adjust the acceleration time constant to obtain the desired acceleration. If acceleration is too rapid, an over-current fault may occur in the inverter. If this happens, lengthen the acceleration time.

, control operates safely and properly in all controller

positions.

Place a rated load on the hoist. Check that the

TRAVERSE ADJUSTMENTS
Verify that all adjustments described under the topic, Preliminary Adjustments, have been completed.
1. With n o load on the unit, close the mainline disconnect and energize the mainline contactor. Verify that the charge lamp on the inverter is illuminated.

7. Rapidly advance the controller from the "full on" position to the neutral position, and observe the deceleration rate, If necessary, adjust the deceleration control constant to obtain the desired deceleration time. If deceleration is too rapid, an over-voltage fault may occur in the inverter. If this happens, lengthen the deceleration time.

CONTROL AND BRAKING MODES

The Srnartorque Sjr System permits selection of the speed control mode and braking mode. The following speed control modes are available:

Two-speed multi-step Three-speed multi-step Two-step infinitely variable Three-step infinitely variable

2. Using the pushbutton operator, jog the motor in the first point direction and verify that motor rotation is correct.
3.
If motor rotation is incorrect, do the following.

Consultation with Harnischfeger technical representatives is recommended before attempting any programming changes to the speed control constants. Electric current can cause injury or death. Disconnect, lock open and tag the power source which feeds the crane o r equipment to prevent power from being applied to the The following braking methods are available: Base block at STOP command Decelerate at STOP command

CHECKOUT, CONTROL MODES, AND SETTING

Harnischfeger Corporation, 1-414-764-6200

Multi-Step Speed Control Modes

This system allows the user to choose between twoand three-speed operation. The number of speeds depends on the settings of DS1-1 and DS1-2. Each input signal is assigned a frequency (speed) reference by DS1-4 DS1-8. Refer to Table 5-1 for the two-speed timing diagram. Refer to Table 5-2 for the three-speed timing diagram.

Upon stop command, the drive blocks the main output transistors (to electrically disco nect the motor from the drive), and the brake interlo k relay sets the motor brake.

NOTICE
The initial factory setting is "Base Block at Stop" command. Use caution in selecting "Decelerate at Stop" command. A long deceleration time will cause driven equipment to require greater stopping distances. The situation may allow equipment to impact other cranes or end stops on the runway, which may result in damage to the machinery.

Infinitely Variable Speed Control

This system provides for true infinitely variable speed' control with just two simple 120 VAC inputs. This unique software function allows the use of inexpensive pushbuttons. Two-step infinitely variable is most often used on horizontal (traverse) motions where it is acceptable to decelerate the motor when a STOP command is applied. (The control device is returned to the off position.) Refer to Table 5-3 for the Two-step infinitely variable speed control timing diagram. Threestep infinitely variable speed control is most often used on hoist motions where it is not acceptable to decelerate the motor when a STOP command is applied. (The control device is returned to the off position.) Refer to Table 5-4 for the Three-step infinitely variable speed control timing diagram.

Decelerate At Stop Command

Upon stop command, the output frequency decreases to near zero, DC current is injected for a few milliseconds, then the brake interlock relay sets the motor brake.

NOTICE
The initial factory setting is "Base Block at Stop" command. Use caution in selecting "Decelerate at Stop" command. A long deceleration time will cause driven equipment to require greater stopping distances. The situation may allow equipment to impact other cranes or end stops on the runway, which may result in damage to the machinery.
Brake Method Selectable

Base Block At Stop Command

Consultation with Harnischfeger technical representatives is recommended before attempting any programming changes to the stopping method

Time Frame 1
2

Description Run ForwardIReverse Command. Frequency output increases to hertz set by DS1-4, DSI -5 and DS1-6. Second DetentlSecond Speed Command. Frequency output increases to hertz set by DS1-7 and DS1-8. Removal of Second DetentfSecond Speed Command. Frequency output decreases to hertz set by DS1-4, DS1-5 and DS1-6. Absence of Commands. Removal of RUN Forward/Reverse. STOP. Operation depends on the setting of DS1-3.

3
i
4

Table 5-1:Two-Speed Multi-Step Speed Control Timing

Revised 4/5/95

c
Frequency butput (Hz) Fwd./Rev. Command 2nd Detent Frequency 3rd Detent Frequency

Brake Method Selectable

Time Frame 1 2 3

Description Run ForwardIReverse Command. Frequency output increases to hertz set by DS1-4 & DS1-5. Second DetentISecond Speed Command. Frequency output increases to hertz set by DS1-6 & DS1-7. Third Detentfrhlrd Speed Command. Frequency output increases to hertz set by DS1-8. Removal of Third DetenUThird Speed Command. Frequency output decreases to hertz set by DS1-6 & DS1-7. Removal of Second DetentISecond Speed Command. Frequency output decreases to hertz set by DS1-4 & DS1-5. Absence of Commands. Removal of RUN Forward/Reverse. STOP. Operation depends on the setting of DS1-3.

5
6

Table 5-2:Three-Speed Multi-Step Speed Control Timing

Stopping met hod shown is decelerate1 at STOP command. No deceleration OCCU method is immediate stop STOP command.

Time Frame 1

Description Run ForwardJReverse Command. Frequency output increases to hertz set by DS1-4

DS1-6.

2
3

Second DetenffFrequency Increase Command. Frequency output increases. The longer this contact is closed, the higher the frequency output becomes. Limited by the adjustable maximum speed (DS1-7 and DS1-8 or VR3). First DetentfFrequency Hold Command. Frequency output remains constant. Second DetenffFrequency lncrease Command. Frequency output increases. The longer this contact is closed,
the higher the frequency output becomes. Limited by the adjustable maximum speed (DS1-7 and DS1-8 or VR3).

5
6

First DetentJFrequency Hold Command. Frequency output remains constant. Second DetentIFrequency Increase Command. Frequency output increases. The longer this contact is closed, the higher the frequency output becomes. Limited by the adjustable maximum speed (DS1-7 and DS1-8 or VR3).

Table 5-3: Two-Step Infinitely Variable Speed Control Timing

CHECKOUT, CONTROL MODES, AND SElTlNG

Harnischfeger Corporation, 1-414-764-6200

Time Frame Description First DetenffFrequency Hold Command. ~ r e ~ u e n c y ' o u tremains ~ut constant. Absence of Commands = STOP Command. Output frequency decreases. The longer this input signal condition exists, the lower the output frequency becomes. ohput frequency will go to zero, and the brake will-set. Braking method shown is decelerate at STOP command only (DS1-3 = Off). First DetentIFrequency Hold Command. Frequency output remains constant.

1
8
9

10

I Absence of Commands. Removal of RUN Forward/Reverse. STOP. Operation depends on the setting of DS1-3.
1

Table 5-3: Two-Step Infinitely Variable Speed C o n t r o l Timing

t hod Selectable

Time Frame

Description Run Forward/Reverse Command. Frequency output increases to hertz set by DS1-4 DS1-6. Second DetentIFrequency Hold Command. Frequency output remains constant. Third DetenUFrequency lncrease Command. Frequency output increases. The longer this contact is closed, the higher the output frequency becomes. Limited only by the adjustable maximum speed (DS1-7 and DS1-8 or VR3). Second DetentIFrequency Hold Command. Frequency output remains constant. Third DetenUFrequency lncrease Command. Frequency output increases. The longer this contact is closed, the higher the output frequency becomes. Limited only by the adjustable maximum speed (DS1-7 and DS1-8 or VR3). Second DetentIFrequency Hold Command. Frequency output remains constant. Third DetenVFrequency Increase Command. Frequency output increases. The longer this contact is closed, the higher the output frequency becomes. Limited only by the adjustable maximum speed (DS1-7 and DS1-8 or VR3). Second DetentJFrequency Hold Command. Frequency output remains constant.

1
2

4
5

7
8 9 10 11 12 13

Run ForwardJReverse at Lower Limit Command. Frequency output decreases. The longer this input signal condition exists, the lower the output frequency becomes. Limited only by DS1-4 DS1-6.

Second DetentiFrequency Hold Command. Frequency output remains constant. Run ForwardiReverse Command. Output frequency decreases. The longer this input signal condition exists, the lower the output frequency becomes. Limited only by DS1-4 DS1-6.

'

Second DetentIFrequency Hold Command. Frequency output remains constant. Absence of Commands. Removal of RUN ForwardfReverse. STOP. Operation depends on the setting of DS1-3. Table 5-4: Three-Step Infinitely Variable Speed C o n t r o l Timing

Revised 4/5/95

r Q U l C K PROGRAMMING
Two-Speed Multi-Step Speed Control

4. Choose your second speed.

2nd Speed
I

Settlng

45 Hz

DS1-7 = off DS1-8 = off DS1-7 = off DS1-8 = on DS1-7 = on DS1-8 = off DS1-7 = on DS1-8 = on

50 Hz

To set for two-speed multi-step control, begin with DS1, which is located on the TM2 board. (DS1-1 through DS1-10)

55 Hz 60 Hz

Continue by setting RDSI and RDS2, located on the TM2 board.

1. Set your speed control method.

For two-speed multi-step speed control DS1-1 =off DS1-2 = off

2.

Select you stopping method.

Traverse (horizontal) motion Hoisting (vertical) motion DS1-3 = off DS1-3 = on

5. Set your acceleration and deceleration times. Use RDS1 to set your acceleration time. Use RDS2 to set your deceleration time.

3. Choose your-first speed.

1st Speed
I

Setting

2 HZ

DS1-4 = on DS1-5 = off DS1-6 = off DS1-4 = on DS 1-5 = off DS1-6 = on DS1-4 = on DS1-5 = on DS1-6 = off DS1-4 = on DS1-5 = on DS1-6 = on DS1-4 = off DS1-5 =off DS1-6 =off DS1-4 = off DS1-5 = off DS1-6 = on DS1-4 = off DS1-5 = on DS1-6 = off DS1-4 = off DS1-5 = on DS1-6 = on

3 HZ

5 Hz

10 Hz

15 HZ

20 HZ

6. For information about voltage/frequency patterns see Settings and Adjustments following.

Your inverter is now set up for two-speed multi-step operation. DS1-9 and DS1-10 are used for an analog input. Their settings will not affect normal operation.

CHECKOUT, CONTROL MODES, AND SETTING

Harnischfeger Corporation, 1-414-764-6200

Three-Speed Multi-Step Speed Control

1

3rd Speed 60 Hz

Setting DS1-8 = off

Continue by setting RDS1 and RDS2, located on the TM2 board. To set for three-speed multi-step control, begin with DS1, which is located on the TM2 board. (DS1-1 through D S I - 1 0 )
6.

Set your speed control method.

For three-speed multi-step speed control

Set your acceleration and deceleration times. Use RDS1 to set your acceleration time. Use RDS2 to set your deceleration time.

DS1-1 off DS1-2 = on

2.

Select you stopping method.

Traverse (horizontal) motion Hoisting (vertical) motion DS1-3 = off DS1-3 = on

3.

Choose your first speed.

1st Speed

Setting DS1-4 = off DS1-5 = off DSI-4 =off DS1-5 = on DS1-4 = on DS1-5 = off DS1-4 = on DSI-5 = on

3 Hz 5 Hz 10 Hz 15 Hz

4. Choose your second speed.

2nd Speed
15 Hz 20 Hz 30 Hz 40 Hz

Setting
I

DS1-6 = off DS1-7 = off DS1-6 = off DS1-7 = on DS1-6 = on DS1-7 = off DS1-6 = on DS1-7 = on

7. For information about voltagelfrequency patterns see Settings and Adjustments following.
Your inverter is now set up for three-speed multi-step operation. DS1-9 and DS1-10 are used for an analog input. Their settings will not affect normal operation.

5. Choose your third speed.

3rd Speed
45 Hz

Setting
J

DS1-8 = on

Revised 4/5/95

,Two-Step

Infinitely Variable Speed Control

4. Choose your maximum speed.

Maximum Speed 45 Hz

Setting DSI-7 = off DSI -8 = off DS1-7 = off DS1- $ = o n DS1-7 = on DS1-$=off DS1- 7 - on DS1- 8 = o n

To set for two-step infinitely variable speed control, begin with DS1, which is located on the TM2 board.

50 Hz 55 Hz 60 Hz

Continue by setting RDS1 and RDS2, located on the TM2 board.

1. Set your speed control method.
For two-step infinitety variable speed control 2. DS1-1 = on DS1-2 = off

Select you stopping method. Traverse (horizontal) motion

Hoisting (vertical) motion DS1-3 = off DS1-3 = on

5. Set your acceleration and deceleration times. Use RDS1 to set your acceleration time. Use RDS2 to set your deceleration time.

3. Choose your minimum speed.

.-

Minimum Speed
2 HZ

Setting

DS1-4 = on DS1-5 = off DS1-6 = off DS1-4 = on DS1-5 = off DS1-6 = on DS1-4 = on DS1-5 = on DS1-6 = off DS1-4 = on DS1-5 = on DS1-6 = on DS1-4 = off DS1-5 = off DS1-6 = off DSI -4 = off DS1-5 = off DS1-6 = on DS1-4 = off DS1-5 = on DS1-6 = off DS1-4 = off DS1-5 = on DS1-6 = on

3 HZ

5 Hz

10 Hz

15 HZ

20 HZ

25 Hz

6.

30 HZ

For information about voltage/frequency patterns see Settings and Adjustments following.

Your inverter is now set up for three-speed infinitely variable operation. DS1-9 and D S I - 1 0 are used for an analog input. Their settings will not affect normal operation.

CHECKOUT, CONTROL MODES, AND SETTING

Harnischfeger Corporation, 1-414-764-6200

Three-Step Infinitely Variable Speed Control

4.

Choose your maximum speed.

Maximum Speed
45 Hz

Setting

To set for three-step infinitely variable speed control, begin with DS1, which is located on the TM2 board.

50 Hz
55 Hz
60 Hz

(DS1-1 through DS1-10)

DS1-7 = off DS1-8 = off DS1-7 = off DS1- 8 = o n DS1-7 = on DS1- 8 = off DS1-7=on DS1- 8 = o n

Continue by setting RDS1 and RDS2, located on the TM2 board.

1. Set your speed control method.

For three-step infinitely variable speed control

DS1-1 = on DS1-2 = on 5. Set your acceleration and deceleration times. Use RDS1 to set your acceleration time. Use RDS2 to set your deceleration time.

2.

Select you stopping method.

Traverse (horizontal) motion Hoisting (vertical) motion

DS1-3 = off DS1-3 = on

,a

3.

Choose your minimum speed.

Minimum Speed
2 HZ Setting

3 HZ

5 Hz

10 Hz

15 HZ

20 HZ

DS1-4 = on DS1-5 = off DS1-6 = off DS1-4 = on DS1-5 = off DS1-6 = on DS1-4 = on DS1-5 = on DSI-6 = off DS1-4 = on DS1-5 = on DS1-6 = on DS1-4 = off DS1-5 = off DS1-6 = off DS1-4 = off DS1-5 = off OS1-6 = on DS1-4 = off DS1-5 = on DS1-6 = off DS1-4 = off DS1-5 = on DS1-6 = on

6.

For information about voltagelfrequency patterns see Settings and Adjustments following.

Your inverter is now set up for three-speed infinitely variable operation. DS1-9 and DS1-10 are used for an analog input. Their settings will not affect normal operation.

Revised 4/5/95

S E T T I N G S AND ADJUSTMENTS
General Description
Smartorque @ Sjr inverter offers many specific adjustments and setting capabilities. These adjustments are accessed on both the interface card (SIF-3LC-2/4)and the logic card (TM2) of the inverter.
Fwd./Rev.

Logic Card TM2 Adjustments and Settings.

RDS1 function - acceleration time RDS2 function - deceleration time RDS3 function select ion

- voltage/frequency output pattern

RDSl x 30 Hz 60 Hz

DS1 functions - speed control method selection I braking method selection I speed selections VR1, VR2, VR3 functions - special functions

Time =

Acceleration Time (RDSI) Deceleration Time (RDS2) Adjustments

)r-

' . ,

he acceleration time and the deceleration time can be independently set by rotary selector switches RDS1 and RDS2 located on the TM2 logic card. You may select a specific acceYdece1 time from one of sixteen preset independent ramps.

RDSI Accel.

ROS2 Decel.

(Both are shown in the initial setting position The time indicated by each notch setting in the table below is the time to accelerate (decelerate) from zero frequency to maximum frequency (f-max.). To determine acceleration to any intermediate frequency, follow the example below.

CHECKOUT, CONTROL MODES, AND SElTlNG

Harnischfeger Corporation, 1-414-764-6200

) r r

VoltagelFrequency Pattern Adjustments RDS3

smartorquemsjr inverter offers sixteen Vlf patterns specially tailored for crane and hoist applications. Rotary selector switch RDS3 determines which pattern is applied. RDS3 serves to adjust low speed "torque boost".
RDS3 - Vlf pattern initial setting for traverse motions is
2. Initial setting for hoisting motions is 8.

"A"
1.7 3

60.0

120.0

Output Frequency (Hz)

Note: Actual output voltage depends on actual input voltage. Actual output voltage may be calculated as percentage of above numbers. All relationships will be linear. Voltage/frequency Pattern Selection Procedure. Application notes for choosing optimum V/f pattern: As a general rule, notch 2 is considered the traverse Vlf pattern. As a general rule, notches 5 to 8 are considered hoisting Vlf patterns.

As a general rule, notches 9 to F are for extremely high torque applications (not for general use).
To determine the appropriate Voltagelfrequency pattern, proceed as follows:
1. Set lowest notch appropriate for your application (traverse or hoisting).
2.

Run motor under "worst-case" conditions (fully loaded hoist, etc.) A. If 1250h load test is required, then load for this condition.

3.

If operation is successful, t h e n setting is acceptable. If operation is not successful, then try again at next higher notch value.

4.

Revised 4/5/95
,

5. Continue this procedure until operation is successful.

Analog Frequency Reference Settings DSI-9 and DS1-10

VR1 Function Multi-Step Speed

I

Mode

Smartorque Sjr offers additional analog frequency reference selections for specific control voltage inputs other than 120V. Settings are shown below:
Frequency Reference Setting
I

Set by frequency setting potenti- DS1-9 = Off DS1-10 = O f f ometer or 1 - 10 VDC signal Set by 1 5 VDC signal Set by 4 20 mA signal Analog frequency setting is not
used

DS1-9 = Off DS1-10 = On DS1-9 = On DS1-10 =Off DS1-9 = On DS1-10 =On

Minimum VR1 setting by DSI-4 and DSI-5

Maximum VR1 setting by DS1-6 and DS1-7

Special Functions of V R I , VR2 and VR3

VR1, VR2, and VR3 are small potentiometers mounted on the logic card (TM2). Each of the potentiometers offers a unique function and adjusts special features.
L

Multi-Step First SpeedILower Limit Adjustment VR1. Certain applications require output frequencies that are unavailable from the menu of digital selections. Note that VR1 has a function in both infinitely variable and multi-step speed control modes. For example, the application requires 12 Hz as the first speed (multi-step mode) or the lower limit (infinitely variable mode). Note that 12 Hz is not available with digital selection by means of the appropriate DS1 switches. Under these circumstances, the VR1 potentiometer can be used to attain the desired speed. The adjustment range of VR1 is as below: VR1 Function Infinitely Variable Mode

Multi-Step Second Speed Adjustment VR2. Certain applications require output frequencies that are unavailable from the menu of digital selections. For example, an application requires 33 Hz as the second speed (multi-step mode). Note that 33 Hz is not available with digital selection by means of the appropriate DS1 switches. Under these circumstances, the VR2 potentiometercan be used to attain the desired speed. The adjustment range of VR2 is as below:
VR2 Function Multi-Step Speed Mode

CW
0 ..V)

>

CU [ 1 :

CCW
I

CW

..-

C 0
V)

~ i n i m u VR2 h setting by DS1-6 and DS1-7

Maximum VR2 setting by DSI-8

rf

>

ccw
I

~inim:m VR1 setting by DS1-4, DS1-5 and DS1-6

Maximum VR1 setting by DS1-7 and DSI-8

Multi-Step Third SpeedlUpper Limit Adjustment. Certain applications require output frequencies that are unavailable from the menu of digital selections. Note that VR3 has a function in both infinitely variable and multi-step speed control modes. For example, an application requires 55 Hz as the third speed (multi-step mode) or the upper limit (infinitely variable mode). Note that 55 Hz is not available with digital selection by means of the appropriate DS1 switches. Under these circumstances, the VR3 potentiometer can be used to

CHECKOUT, CONTROL MODES, AND SE'ITING

Harnischf eger Corporation, 1-414-764-6200

P'

attain the desired speed. The adjustment range of VR3 is as below: VR3 Function Infinitely Variable Mode

>

CCW
I

~inirnAm VR3 setting by DS1-7 and DS1-8

Maximum VR3 setting is fixed at 60 Hz

VR3 Function Multi-Step Speed Mode

I

>

CCW

Minimum VR3 setting by DS1-4 and DS1-5

Maximum VR3 setting is fixed at 60 Hz

..

INSTRUCTION MAN'WA.L

'

Software NSG618221-1
Adjustable Frequency Motor Control

Intelligent Drive for No Load Brake Hoists1 Load Brake Type Hoists & Horizontal Motions
\

!I

It

0 1994 Electromotive Systems, Inc. Milwaukee, Wisconsin

ROBERT E. CLWBAKER Electrical Erg:: ;;2.E. Mechanical Engineer P.E.

Table of Contents
Page Forward Section 1 GENERAL INFORMATION 1.1 General 1.2 Receiving & Inspection 1.3 Verify Model Number on Ratings Sticker 1.4 200V Class IMPULSE PH3 Specifications 400V Class IMPULSE PH3 Specifications 1.5 1.6 575V Class IMPULSE PH3 S~ecifications 1.7 CDBR Braking Module Specifications INSTALLATION 2.1 Location 2.2 Positioning 2.3 Overall Dimensions of IMPULSE PH3 2.4 Overall Dimensions of the CDBR Braking Units 1 2 3 4
5

6
7
8 8 9 11

Section 2

Section 3

WIRING 3.0 WIRING: Block Diagram 3.1 Main Power Wiring 3.1.1 Main Circuit Input/ Output Considerations 3.1.2 Power Wiring Diagram 3.1.3 Grounding Considerations
3.2

2
Line Voltage Selection for IMPULSE PH3 Logic Power Supply 3.1.5 Dynamic Braking Module (CDBR) 3.2.1 Dynamic Braking Module Wiring Precautions . DB Module Wiring as a Function of Drive Rating 3.2.2 3.2.3 Line Voltage Selection for CDBR Braking Modules , DC TAch Generator Wiring 3.3.1 Tach Generator Wiring Precautions 3.3.2 Tach Generator Connection Diagram (Bias Module Type) 3.3.3 Tach Generator Connection Diagram (AI-14B Type) Control Circuit Wiring 3.4.1 Control Circuit Wiring Precautions 3.4.2 Control Input Terminal Functions 3.4.3 TC-GIF-SH Interface Connections PH3 Logic Card Terminal Function Table 3.4.4 3.4.5 PH3 Logic Card Terminal Function Diagram Control Output Terminal Wiring 3.5.1 Control Output Terminal Wiring Precautions 19 20 20 21 23 24 24 25 26 27 27 28 29 30 31 32 32

13 14 14 15 15

3.3

3.4

3.5

'

..

"8'.

<.-

..

.)-

I . .

- ,

. . . ..

..",",..

.,-,U"

..,. '-...-m.>"#r...,.-.

---..-

.
'

--.. .

,.
,

-. .

-tContents

IMPULSE @' pH3 Instruction Manual . ..

Table of Contents (Cont)

Page

Section 4

DIGITAL OPERATOR 4.1 Operator Layout & Keypad Functions 4.2 Programming Mode Key Functions 4.3 Changing Constant Data in Program Mode 4.4 Local Operator Control Mode Key Functions
CONSTANT DESCRIPTIONS 5.1 What is a "CONSTANT" 5.2 Access to Various Constant Modes 5.3 An-xx Constants: Mu lti-Step Speed Reference Constants 5.4 Bn-xx Constants: Active Mode Constants Sn-xx Constants: System Mode Constants 5.5 Sn- 10 Data1 Function Tables 5.5 Sn-xx Constants: System Mode Constants (continues) Sn- 11 Sn-14: Multi-Function Input Terminals Fault Input (External Terminal Function) Programming Sn- 15 Sn- 17: Multi-Function Output Terminals 5.6 Cn-xx Constants: Control Mode Constants 5.7 Un-xx Constants: Monitor Mode Constants

33 34 36 38

Section 5

4Q 40 40 41 42 43 47-54 55 56 56 57 58 59
63 63 63 63 64 65 66 67 69 70 71 72 73

Section 6

SPECIAL FUNCTIONS (Sequence) OF PH3 6.0 Special Functions Forward 6.1 Standard Safetv Functions of PH3 6.1.1 STOP Key (of Digital Operator) Operation 6.1.2 RUN button Operation 6.1.3 Phase Loss Detection 6.2 The Basic Hoisting Sequences 6.2.1 Hoisting Sequence SE Faults 6.3 Deviation Detction (Oversveed Detection) Function 6.4 Micro-Speed Gain Function 6.5 Quick STOP Function 6.6 Plug Reverse Simulation Function 6.7 Automatic Keypad Lockout Function (Sn-03 Functions) 6.8 Overspeed (Swift Lift) Operation PERIODIC INSPECTION/ TROUBLESHOOTING 7.1 periodic Ins~ection 7.2 Troubleshooting 7.2.1 Motor/ Drive Won't Run 7.2.2 Motor Stalls or Won't Accelerate Properly 7.2.3 Fault T r i ~ Condition 7.3 Power Section Check 7.4 Spare Parts
Appendix
J

Section 7

76 76 77 79 80 82 83

87
0 1994 ELECTFOMOTlVE.SYSTEMS, INC., IN&'.
Milwaukee, Wisc: Soft NSG618221-1: 12/19/94
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We at ELECTROMOTIVE SYSTEMS, INC., Inc. appreciate your purchase of this IMPULSE PH3 model adjustable frequency drive. When properly installed, operated and maintained, the IMPULSE PH3 will provide a lifetime of reliable, troublefree operation. It is MANDATORY that the person who operates, inspects, and maintains this equipment thoroughly read and understand this manual. This manual has been designed to serve as a comprehensive, self-contained guide covering all aspects of the installation and use of the IMPULSE PH3 unit. In it, you'll find step-by-step instructions covering topics ranging from installation to preventative maintenance and troubleshooting. In Appendix 8, you'll even find a complete listing of every programming parameter, with valid ranges, factory settings, and with space to record your particular settings. If you require additional information, please feel free to contact either your local supplier or contact ELECTROMOTIVE SYSTEMS, INC., Inc. directly at 414-783-3500 (24 hour service line).

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WARNING !

1.Do not touch any circuit components while the main, AC power is on. In addition, you must wait until the red "Charge" lamp is extinguished before performing any service on the unit. It may take as along as 10 minutes for the charge on the main DC bus capacitors to drop to a safe level. Failure to adhere to this warning could result in personnel injury.
2.Do not check signals during operation.

3.Be sure to ground the IMPULSE PH3 unit using the G (E) terminal. 4.Never connect the main output terminals (T,, T , TJ to the incoming three-phase AC source. This will damage the unit !

e 1994
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ELECTROMOTIVE SYSTEMS, INC.

Milwaukee, Wisc: Soft NSG618221-1: 12119/94

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The IMPULSE PH3 represents a new age in adjustable speed motor controls. The PH3 design is complimented by the use of Insulated Gate Bipolar Transistors (IGBT) and a 16 bit microprocessor to provide unsurpassed operability and safety to the Crane and Hoist drive application. The IMPULSE PH3 incorporates a high performance, Pulse Width Modulated (PWM) design generating the optimum current waveform to produce any desired speed from a conventional AC motor. The IMPULSE PH3 is a unique blend of hardware and software specifically designed to meet the severe demands of cranes and hoists. This product is the direct result of over 10 years experience in manufacturing and in applying adjustable frequency drives to hoisting machines. Following are a few of the key features: Easily configured for conventional pendant or joystick control Can be directly interfaced with 120VAC control signals * User selected speed control methods--multi-step(up to 9) or Infinitely Variable Speed (by analog joystick or pendant) * Brake Proving at Start and Stop * Swift Lift for high speed operation of lighter loads

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Upon receipt of this product you should first check the box for possible damage sustained in transit. If damage is noticed, you should notify the freight carrier within 15 days of receipt to file a damage claim. Next, verify the specifications sticker (on the side of the unit) corresponds with your application voltage and HP. Finally, remove the front cover of the unit and check for any visible signs of shipping damage. If the inverter is to be stored for a long period of time you should return it to its original packing carton and store it in a clean, dry place, away from direct exposure to sunlight or corrosive gases. Furthermore, you should ensure the ambient storage temperature is between -20 O C and +60 OC.

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Page 2

@ 1994 ELECTROMOTIVE-SYSTEMS, I N C . , IN&'

Milwaukee, Wisc: 'soft NSG618221-1: 12/19/94
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The product will have two ratings labels on it. One is a metallic label found on the side of the unit (typically left-hand side). The other sticker will be found on the front cover of the unit, immediately below the keypad. Before you mount the unit you should first verify the voltage, current and HP ratings on these stickers match with your application requirements. The model numbering system is shown below:

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230 AFD
Rated Input Voltage (30,50/60Hz) Available in 230 or 460 or 5 7 N Models

T I T

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PH3

IMPULSE PH3 Model

Horsepower (HP) Rating

Meaning: "Inverter"

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INVERTER MODEL m)AFD-(HP)-W

200- 230 Vac

4 0 5 0 W 7 3 1 l K J

40
Inverter Rating (kW) Rated Current (A)
Max. Continuous CurrW (A)

50

60
45

75

100 75

30 130 146
I

37
160

55
224 252

183

300
337

180 205

Mar Voltage (Vac) Rated Frequency (Hz) Rated lnput Power Supply Voltage & Fresuencv . Allowable Input Voltage Fluctuation Allowable Input Frequency Fluctuation Control Method Output Freq. Control Range Output Frequency Stability Frequency Ref. Resolution Output Freq. Resolution
-

to input voltage) !30Vac, nominal (actuallyproporti 1na1

Up to 400 Hz maximum Sphase, 200,2C8,220, or 230 Vac; 50 or 60 Hz f 1OX of nominal f 5% of nominal Sinecded, Pulse Width Modulated (PWM), real-time generated 0.1 to 400 0.01% (with digital reference command, -10 to +40C); 0.1% (with analog reference command, 25 O C lPC) 0.01 Hz (digrtal operator S 99.99 Hz); 0.1 Hz (digital operator 1 100 Hz); 0.06 Hz (analog, 60 Hz); 0.1 Hz (analog 2 100 Hz) 0.01

Hz (11 30,000)

Ovwload Capacity Remote Freq. Ref. Sources AcceU Decel Times Braking Torque V F Patterns Motor Overload Protectlon Overcurrent Protectlon Level Blown Fuse Protection
-

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150%of rated for 1 minute; 130% of max. continuous for 1 minute 0- 10 Vdc (20 kn);4- 20 mA (250 Q); k 10 Vdc (optional); Serii (optional) 0.1 to 6,000 secs.; two sets; each parameter (4 total) is independentlyadjustable Approx. 20 % (if motor and inverter are sized 1:I); 150% or more is optional with Dynamic Braking 15 preset patterns (constant torque, variable toque, high starting torque); 1 field-programmablepattern Eledronic, !requency dependent, overload relay (field- programmable)

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200% of rated current Yes 400 Vdc 210 Vdc

Overvottage Protectbn Level Undervoltage Protection Level Power Loss Ridethru

--

Heatslnk ~vertem$rature Stall Prevention Ground Fault Protection

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Minimum time is 15 mS, maximum time is 2 seconds

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Thermostat trips at 90 'C (in addition, model 2037 and above also have fan loss detezon) Separate functions for accel, decel, at speed, and constanl Hp region Yes

DC Bus Voltage lndicatlon

Location Ambient OperatingTemp. Storage Temperature Humidity

I I I I I
D

Yes, charge LEDqis on until DC bus voltage drops below 50 Vdc

Indoors, protected from moisture, corrosive gases and liquids
14- 104 O F (-10- +40C) for NEMA 1 type; 14- 122 O F (-10- +50 O C ) for open chassis type 4 140 O F (-20- +60 "C)

90% relative, m n d e n s i n g 1G less than 20 Hz,0.2 G from20- 50 Hz

. P

Vibration

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Page 4

O 1994 ELECTROMOTIVESYSTEMS, INC., IN(=:*.

Milwaukee, Wisc: ' Soft NSG618221-1: 12/19/94

Instruction Manual -

INVERTER MODEL 4 6 0 0,751

380 to 460Vac
2

5 7 J l O l 5 2 0 Z J O 1 0 5 0 6 0 2 5 1 Q ) 1 3 ~ ~ J 0 0 Y #

lnvater Rating (Hp)

hvcrtsr Rating(kW)
RatedCurrent (A) M a r Continuous Cumnt (A)

05
0.4
1.6
18
I

1 0.7

2 15 4
45

3 22
46 54

75
5 5

10 7.5 16 18

15 11 24

20
15 32 36

25
185

30

40
30 64
72

50
37

60
45

75 55 128

1 0 0 1 5 0 2 0 0 2 4 ) ~ ~
75

3.7

22

110 224 29

160

185 2aD

300

28
29

8
9

12
135

40

48
54

80
90

96
1Q

165

300 340 450 600

337 380 506 675

27

45

1-44 18)

Max. Vdtage (Vac)

Rated Frequency (H3

Sphase, 380,400,415,440 oc 460 Vac, n o d (a3~atly p W 0 n a l to input -gel

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m

Up to 400 M maximum
3-phase, 380,400,415,440, or 460 Vac; 50 or 60 Hz

Rated lnput Power Supply Vdtags &

Freauencv Alkwable Input Vdtage fluctuation Allowable lnput Frequency fluctuation Contrd Method Output Freq. Control Range

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f 10% of nominal f 5% of nominal

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She-coded,Puise Width Modulated (PWM), red-limegenerated

0.1 to 400 Hz 0.01% (with digital reference command. -10 to +40nC); 0.1% (with analog reference command, 25 "C f 10C) 0.01

Output Frequency Stability

Frequency Ref. Resolution Output Freq Resdutlon

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M (digital opefator S 99.99 Hz); 0.1 Hz (digibl operator 2 100 Hz); 0.06 Hz (analog, 60 Hz); 0.1 Hz (analog 2 100 Hz)
0.01 Hz (1130,000) 150%of rated for 1 minute; 130% of maw. continuous for 1 minute

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Overload Capacity
Remote Fnq. Ref. Sources

0- 10 Vdc (20 M); 4- 20 m A (250 a); i 10 Vdc (optional); Serial (optional)

0.1 Lo 6,000

AccsVOecdTimes
BrakingTorque
VtF Patterns

secs;two sets; each parameter (4 total) is independentlyadjustable

Appmx. 20 % (if motor and Inverter are sized 1:l); 150% or more is optional with Dynamic Braking
15 preset patterns (constant torque, variable torque, high starting taque); 1 field-programnable pattern flectonic, frequency dependent, wetload relay (fieid- programmable)
200% of rated current

Motor Overload Protection Overcurrent ProtectJon Lsvd Blown Fuse PlOtCEtjon Ovwrottaga ProtectionLevel Undemthge Protectron Luvel PowecLwr Wdathru Heablnk Overbmparature Stall P m t i o n Ground Fault Protection

Yes
so0 vdc (700 Vdc)

420 Vdc M i m time i s 15 mS,mxinum time is 2 seconds Thermostat bips at 90 "C ( n i addition, model 4055 and above a!so hwe fan loss detection) Separate functions for accel, decel, at speed, and constant Up region

Yes

DC Bus Voltage Indication

Locallon Ambient OperatingTemp. Storage Temperaturn Humidity
Vibration

Yes, charge LED is on until DC bus voltage drops below 50 Vdc

Indoors, protected from moisture, corrosive gases and liquids 14- 104 "F(-10- +40C) for NEMA 1 lype; 14- 122 O F (-10- 4 0 O C ) fw open chassis type 4 140 O F (-20.40 O C )

'

90% relative, nonconddmg

1 G less than 20 Hz, 0 2 G bom 20- 50 Hz

O 1994 ELECTROMOTIVESYSTEMS, INC.

Milwaukee,Wiic: Soft NSG618221-1: 12119/94

'Page 5

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Q 1994 ELECTROMOTIVESYSTEMS, INC., INCi*.

Milwaukee. Wic: *' Soft NSG618221-1: 12119/94

Instruction Manual

Applicable Motor Output HP Max. Discharge Current (Peak A) Rated Discharge Current (A) Braking Start Voltage

30

150

60

300 250

50 40

60

250

60

20

80

18

80

15
8251950V k8V

330134513651380V f3V =8V 243 to 400V 10,200 230V, 50160Hz

6301660/690/730/760V k6V = I6V 460 to 800V

Max. Hysteresis Error

VDC

=20V
607 to 1O O O V

VAC*" Fin Overheat Power Charge lndication Location Ambient Temperature Storage Temperature Humidity Vibration Protective Configuration

NIA

NIA

10,380 480V, 50160Hz

NIA

Thermostat Charge lamp stays ON until bus voltage drops below 50Vdc Indoor (protected from corrosive gases and dust)
+I 4 to 140F (-10 to 40C) (no freezing)
-4 to 140F (-20 to 60C)

90% RH (non-condensing) 1G less than 20Hz, up to 0.2G at 20 to 50Hz

Wall-mounted enclosed type

"Note: Certain Units (large Capacity) require a Separate Power Supply as noted. See connec tion diagrams in Section 3 for details.

O 1994 ELECTROMOTIVESYSTEMS, INC.

Milwaukee, Wisc: Soft NSG618221-1: 12/19/94

'Page 7

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Installation Section 2.1

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The selection of the proper mounting location of the IMPULSE PH3 is imperative to achieve optimum performance and longevity. These units were designed and built to meet the harsh demands of industrial and commercial applications. Nevertheless, caution should always be exercised to ensure the selected location meets the following criteria: Ambient Temp.- +I4 to + 122 O F (open chassis) or +I4 to 104 O F (for NEMA 1). Protected from rain or moisture Protected from corrosive gases or liquids Sheltered from direct sunlight Free from mechanical vibration

Make sure there is sufficient clearance around the IMPULSE PH3 for cooling and maintenance purposes (see the figure below). To maximize effective air flow & cooling, the IMPULSE PH3 should be installed with its heatsink ribs oriented vertically. We also recommend removing the front cover (and the top and bottom covers on applicable units) whenever you mount the IMPULSE PH3 inside a larger enclosure. This will improve the air flow over the electronic components, and as a result, further improve the unit's reliability. Your installation should adhere to the following recommended minimum clearances.

Page 8

0 1994 ELECTROMOTIVE.SYSTEMS, INC., INC;*.

Milwaukee, Wisc: ' Soft NSG618221-1: 12/19/94

Milwaukee, Wlsc: Soft NSG618221-1: 12/19/94

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Page 10

Q 1994 ELECTROMOTlVESYSTEMS, INC., INC;'

Milwaukee, Wisc: '.Soft NSG618221-1: 12/19/94

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IMPULSE@.pH3
Instruction Manual

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@ 1994 ELECTROMOTIVE SYSTEMS, INC.

Milwaukee, Wisc: Soft NSG618221-1: 12119/94

Page 11
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Wiring
Section 3.

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Page 12

@ 1994 .ELECTROMOTlVESYSTEMS, INCV0.

Milwaukee, Wisc: Soft NSG618221-1: .12/19/94

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The wiring of the IMPULSEaPH3 can be separated into several categories- power, encoder, control inputs and control outputs. The block diagram shown below should serve as a "map" to the various subsections discussing the proper wiring of this unit. You will have no difficulty in making the proper connections if you simply follow these sections in order.

Sec. 3.2 DB WlRlNG HBC

DYNAMIC . BRAKING

+RESIST2
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Sec. 3.1 POWER WIRING

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CONTROL OUTPUTS

Sec. 3.4 CONTROL INPUTS

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120 VAC

INPUT
COMMAND

TGGIF-5H (ONTBI)

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FAULT OurPuTS

INTERFACE ClRCUrrS

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Milwaukee, Wisc: Soft NSG618221-1: 12119/94

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The basic power wiring is illustrated in the figure given on the facing page. Please remember to follow NEC guidelines when selecting the wire and branch circuit protection devices.

The main input power on L1, L2, L3 is phase sequence insensitive (may be CW or CCW). Input sequence will not effect motor rotation direction. When the inverter output terminals (TI, T2, T3) are connected to motor terminalsT1, T2, T3, respectively,the motor must rotate counterclockwise (viewed from opposite the shaft end) when a Forward Run command is given (for hoisting applications, it is mandatory that "pH3 Forward" results in lifting (Up direction). To reverse the rotation of direction interchange any two motor leads (you may also need to change the Tach Generator wiring, refer to section 3.3). Note: switching the input wiring to the inverter will not change motor direction! Never connect the incoming three-phase AC power to the inverter output terminals T I , T2, T3. Care should be taken to prevent contact of wiring leads with the IMPULSE PH3 unit enclosure since a short- circuit may result. Never connect power factor correction capacitors on the inverter input or output. Never open or close inverter output contactors (between inverter and motor) unless the motor's inrushcurrent (typically 500- 600% motor'srated current) has been taken into consideration when the inverter model was selected.

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Page 14

O 1994 ELECTROMOTIVESYSTEMS, INC.'.

Milwaukee, Wisc: 'soft NSG618221-1: 12/19/94
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HPLB= Hoist Power Bypass HPLS= Hoist Power Limit Switch Note: if these are used you must also interlock the HPLS to the PH3 via a control circuit interlock. Please refer to section 3.4 for details.

Connect a positive ground using terminal "E" on the drive chassis or power terminal strip
Wire size should be selectedaccordingto the charts on the following pages. The lead length should also be kept as short as possible. Ground resistance should be 100 ! 2 or less. Never ground the IMPULSE PH3 along with welding machines, large current machines, etc. When several IMPULSE PH3 units are used together they should all be directly groundeddo a common ground pole. Alternatively, connecting all of the IMPULSE PH3 Earth (E) ground terminals together and running a single wire to the ground pole is also acceptable. Be careful to ensure that you do not form a loop with the ground wires.
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In order to comply with most safety standards you should have some disconnecting means and branch circuit protection between the incoming three-phase power supply and the IMPULSE PH3. This branch circuit protection can either be in the form of a thermal, magnetic, Molded Case Circuit Breaker (MCCB) or dual element "slow blow" type fuses. The table given below shows the recommended MCCB or fuse and wire size for each of the IMPULSEaPH3 models.

The following guidelines are only suggested values. You should always be sure to conform to your local electrical codes and wiring practices.

200 VOLT CLASS UNITS:

EMS 2FUSE

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@ 1994 ELECTROMOTIVESYSTEMS, INC.'.

Milwaukee, Wisc: Soft NSG618221-1: 12/19/94

.
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IMPULSE@ PH3
Instruction Manual

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Section. 3.7-4

400 VOLT CLASS UNITS:

EMS 4FUSE PTBL

8 1994 ELECTROMOTIVE SYSTEMS, INC.

Milwaukee, Wisc: Soft NSG618221-1: 12119/94
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575 VOLT CLASS UNITS:

Page 18

@ 1994 ELECTROMOTIVE SYSTEMS, INC;.. Milwaukee, Wisc: Soft NSG618221-7: .12/19/94 .

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The IMPULSE PH3 logic power supply of some units (460 V 2 15HP & all 575V)is derived-froma control transformer. This transformer has multiple taps on its primary to accommodate different incoming line voltages. You select among the different primary windings by moving a jumper plug on the small pc board as shown below. The factory setting is in the 460 V position (shaded in the figure below).

460 Volt Class IMPULSE PH3 Units

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230V

415V

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Lot No. u x x

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Milwaukee, Wisc: Soft NSG618221-1: 12/19/94

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The IMPULSEoPH3 model control unit was designed exclusively for crane and hoist applications. An integral component of a hoisting system will be the dynamic braking circuit. Dynamic braking is used to dissipate the regenerative energy from the motor while lowering the load. As a result, the ratings of the DB components have been selected to conform with the actual application requirements (HMIclassification). This section gives the necessary wiring information as a function of motod drive HP rating. When you are ready to wire the DB module. please refer to the respective diagram on the following pages.

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You must select the proper wire size in accordance with NEC requirements. Bring the wiring into the Dl3 module via the holes in the bottom of the enclosure. Make a "cross-cut" in the rubber bushings supplied with the unit then feed the wire through. This will provide an extra degree of protection of the CDBR module components from environmental contaminants. Separate the DB module power wiring from all control wiring. The wiring distance between the CDBR module and the IMPULSEoPH3 unit must be less than 16.4 feet (5 meters). The wiring distance betweenthe braking resistor and the CDBR module/ inverter must be less than 32.8 feet (10 meters). If your application demands exceed the capability of a single CDBR module these units can be paralleled(consult ELECTROMOTIVE SYSTEMS applications engineers for more information). You can connect up configuration. Any application to 10 of these units in a "master/slaveW can multiple slaves, but only have one master. You configure the individual CDBR modules as being either master or slave via a small jumper plug found on the pc board. Wire the master/slave outputs as shown below with a twisted-pair, shielded cable (Belden 8760 or equiv.). Finally, you should connect all of the thermal switches (terms. #3 & 4) in bull parallel and interlock them with your run circuitry. IYPIUeWa
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Page 20

@ 1994 ELECTROMOTIVESYSTEMS,
\

IN^.;.

Milwaukee, Wisc: Soft NSG618221-1: 12/19/94

10 Hp and below (230 & 460 V):

15,20 Hp (460 V);

IMPULSE*pH3 FIG 3.2-EPMAC

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Q 1994 ELECTROMOTIVE SYSTEMS, INC.

Wisc: Soft NSG618221-1: 12119/94

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15-100 Hp (230 V):

Note: coding fans are only used on model 2110 and d e b 4090 and 4220.

Note: co&g fans are only used on mode( 2110 and modeb 4080 end 4220

IMPULSE 9H3FIG 3.2-EPMAC

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wiring .,..,
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The CDBR Braking Units supplied with the drive must be set to correspond with the incoming power supply. This is achieved by the changing position of the CP1 shunt to the desired value. You select among the different CP1 shunt values on the small pc board as shown below. The factory setting is in the 230/ 460/ 575 V position, depending upon the CDBR model no (shaded in the figure below).

230 Volt Class CDBR Units

D1 1-A91290-4

I GEN P
S3

1-

Ina
1 2

200v CLASS 230V 220v 208V 200v 3 4 5 6

@
i

460 Volt Class CDBR Units

u 1 InGEN
S3

D11-A91290-4

400V CLASS 460V 440V 415V 400V 380V

4 5 6

Note: the model CDBR4220 also has a separate voltage selector board used to power the cooling fan. You must also verify the jumper on this board is set to correspond with the three-phase, ac input voltage. See diagram on Page 19 (460VClass).

@8080@ a
0 1994 ELECTROMOTIVE SYSTEMS, INC.

Milwaukee,Wisc: Soft NSG618221-1: 12119/94

- Bpr .; Instruction Manual +

Wiring
ectron 3.3

IMPULSE ?@ y 4 3i ; -

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,

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.(

SY:

I I

The shaft-mounted tach generator is used to provide speed feedback to the IMPULSEaPH3 unit. Without this device, the control cannot operate properly. The proper tach generator must conform to the following minimum specifications:

* By P&H (wl Bias Module) (wl AI-148)

Tach Generator wiring precautions:

Use a twisted-pair, shielded cable (Belden 9730 or equiv.) Keep the Tach Generator wiring separate from power wiring (230,460 or 120 Vac) Keep the wiring length less than 300 feet. Only ground the drive end of the shield as shown in the figure below:

Shield Sheath

Cable

Jacket

To chassis ground (terminal # 12 of the IMPULSEaPH3 unit. If a drain wire is used, connect both shield and drain to # 12 (or 32).

\ /

' NEVER Connect

Insulate these areas with electrical tape.

. - -

Page 24

@ 1994 E!.ECTROMOTIVE SYSTEMS, INC:.

'

Milwaukee, Wisc: Soft NSG618221-1: 12/19/94

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@ 1994 ELECTROMOTlVE SYSTEMS, INC.

Milwaukee,Wisc: Soft NSG618221-1: 12/19/94
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@ 1994 ELECTROMOTIVE SYSTEMS, INC:'.

Milwaukee, Wkc:

I I
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oft NSG618221-1: 12/19/94

IMPULSE^^ pH3
.-.
.

Wiring
Section 3.4

~nsiiuktion ~anual

The control circuit wiring of the IMPULSE.PH3 unit must be connected to a number of pc boards (as shown in section 3.0). Section 3.4.1 will list the general wiring precautions. Section 3.4.2 provides a set of control input terminal tables, definging functions and signal levels. If you plan to deviate from the typical interconnect given in section 3.4.3 this section will be an invaluable reference.

Wiring Precautions:
Be sure to double check your control circuit interconnections before you apply power to the unit. Wiring distance should be 164 feet (50 meters) or less. Control wiring must be separated from the three-phasepower leads (L1, L2, L3, TI, T2, T3) to prevent capacitively coupled noise from entering the logic section. All 120 VAC control must be separated from the low level logic inputs. If wiring can not be separated, it should always intersect the other control wiring at right angles. Always use R-Ctype surge absorbers (not MOV) type across the coils of any contactors installed in the inverter enclosure. Use twisted shieldedor twisted- pair shieldedcable for control circuit interconnections. Be sure to only ground one end of the shield sheath as shown below:

To chassis ground (terminal # 12 or 32 of the IMPULSEoPH3 unit). If a drain wire is used, connect both shield and drain to # 12 or 32.
I

NEVER Connect

Insulate these areas with electrical tape*

o 1994

ELECTROMOTIVESYSTEMS, INC.

Milwaukee, Wisc: Soft NSG618221-1: 12119/94

Pige 27

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.The wiring diagram given below shows a typical interconnect for 5-speed control via our 120 Vac interface, the TC-GIF5H. For a complete listing of terminal functions and specifications, please refer to the tables on the following pages.
TO 2 1 ' OF 120 VAC SUPPLY
120 VAC SUPPLY

TO 'X2' OF

--

.,

L4 (Comectimto brverterT4)

q,

L7 (Comectlon to tnvefter T7)

To P&H Control Circuit

4
L8 (Connecb'onto Inverter T8)

--

I1

L11 ( C c r r m t o hverterTi 1)

- 1OVdc Speed ReferenosIrput) (0 - 1OVdc Speed Refenncs h p t )

(0

To P&H Control Circuit

(Analog Output Test P W W) (AnalogOutpll Test PdnU OL3)

Page 28

1994 ' &ECTROMOTWE SYSTEMS, INC.'.

Milwaukee, Wisc: Soft NSG618221-1: 12119/94 t

IMPULSE@^ pH3
Instruction Manual
.

. Wiring Sectron 3.4.2

These Function Descriptions Apply ONLY if Sn-10 = "06", and if Sn-I 1 = "01"
X2
F R
2
3

120 v Return Raise While 120 V signal is applied (Hz of An-01) Lower While 120 V signal is applied (Hz of An-01) Enables 2nd Speed (An-02) Enables 3rd Speed (An-03) Enables 4th Speed (An-06) Enables 5th Speed (An-05) Direct Connection to Inverter Logic Terminal 4 (Fault Reset) Direct Connection to Inverter Logic Terminal 7 (BE3 at Open) Direct Connection to lnverter Logic Terminal 8 (Brake Answerback at Closed) Direct Connection to lnverter Logic Terminal 11 (Logic Common)
(+) of 0

120 Vac, nominal input

4 5
L4

L7 L8 L11

Logic level (15Vdc or Dry

Contact)

+ (Input)

- 10Vdc Speed Reference Input

- (Input)
+ (Output)

(-) of 0

- 10Vdc Speed Reference Input

- 10Vdc Speed
Command

+ of 0 - 10Vdc Test Point is Output/ 5Vdc is Output at OL3

- (Output)

- of 0 - 1OVdc Test Point is Output/ 5Vdc is Output at OL3

0 10Vdc Output Proportional to Current or Frequency/ 5Vdc at OL3

Q 1994 ELECTROMOTIVE SYSTEMS, INC. Milwaukee, Wisc: Soft NSG618221-1: 12/19/94

page 29:'
I

Note: Except as noted below, the application of 120 Vac directly to the PH3 inverter terminal strip will cause board damage! These terminals are shown for reference purpose only. You should not need to terminate wiring directly on these terminals (except 9

- 10).

Raise while closed (Fixed)

Lower while closed (Fixed) Jog Command (An-05 Frequency Reference) Fault Reset if Momentarily Closed (Run commands must first be removed) Change by Sn-11 Change by Sn-12 Optically Isolated Inputs: + 2 4 VDC, 8mp Fixed by Sn- 10 Data SomeHmes Fixedby Sn- 10 Data/ Change by Sn-13, 14

2
3

Multi-functionInput Terminal #I; factory set for 2nd step speed Multi-functionInput Terminal #2; factory set for 3rd step speed

6 7 8 9110 11 12 13 14 15

1 3 ; factory set for 4th step speed Multi-functionInput Terminal 1

Multi-fundionInput Terminal #4; factory set for 5th step speed Multi-funa'onContact Output; factory set for brake release command Sequence Common (0 V) Earth Ground for Connection of Shield Sheath 0-10 Vdc Reference Command (if used) 4-20 mA Reference Command (if used)

Sometimes Fixed by Sn- Dala/ Change by Sn- 15

Contact Ratedl A O 250 VAC, 30 VDC

Only coMed drive side

*eM
0- 10 VDC (20 kn)
4- 20 mA (250 R)

+ 15 Vdc, 20 mA Power Supply for Speed Potentiometer

Sn-10 = 0.12.3 or 4 then: Analog Input: set for auxYiary speed command Fued byData otSn-10

20 mA, madmum 0- 10 VDUO- 1W % (20

16

kQ)
0- 10 V D U 0- 100 % (20

Sn-10 = 6.8 or 9 then: Analog lnput: set for TO Feedback for Deviation Detection Function Analog Common (0 V)

Fixed by

o,Sn-10

m)

17 18 19 20

Fault Relay Output; 18- 20 closes at fault; 19- 20 opens at fauR

Contad Rated1 A 4 3 250 VAC, 30 VDC

Sn-10 = 0.1.2,3 or 4 then: Multi-Function Analog Output; set for 0 1OVdc at 0 100% Frequency

-- - - -

Change by Sn-05.
-

21, 22

Sn-10 = 6. 8 or 9 AND Sn-06 Digit 4 = '0' then: Multi-Function Analog Output; set for 0 10Vdc at 0 100% Frequency

Change by Sn-05, Digit

Change by SrrOB,D j g ~

Output: 0- 10 VDC

Sn-10 = 6.8 or 9 AND Sn-06 Digit 4 = '1 ' then: Multi-Function Analog Output; Outpus SVdc at OL3 Fault 23 24 Not Used Multi-functionOutput W (PHC); factory set for Speed Increasing Multi-functionOutput #3 (PHC); factory set for Speed Increasing

25/ 27
26/ 27

Change by Sn-16 Change by Sn-17

Optically Isolated Output:+ 48 VDC, 50 mA

.:. -

Page 30

Q 1994 ELECTROMOTIVE SYSTEMS, INC.".

Milwaukee, Wisc: Soft NSG618221-1: 12/19/94
'

Instruction Manual

7~ I 1 Control Com

? -

20 Fault Out Common 19 NIC Fault Output 18 NIO Fault Output

I = +

1 7 $1 Run Forward
2 Run Reverse 3 Fault Input by Sn-11 4 Fault Reset by Sn-12 5 Speed Control by Sn-10 6 Speed Control by Sn-10
7 Ext. BB at Open by Sn-10

# = -I

1-z-4

+-=-I

1 - 7 0

r L 0 -

y-9

9 Brake Output 10 Brake Output

27 PHC Common
26 Multi-Function PHC

1 4
Neg Bus Pos Bus +/B1 Brake Res. 62

25 Multi-Function PHC

8 Brake Answer Back by Sn-10 15 Power Supply for Pot

21 Analog Out (-)

22 Analog Out (+5V at OL3)

X 9 I
Bias Mod

13 0-1 OVdc Speed Ref 17 O V Analog Signal Corn 14 4-2Oma Sped Ref

0 16 TG 0 - 1OVdc Feedback
TI
T2
T3

TG Feedback to Logic Cardl AI- 146 TC1 Ch. # I (k1OVdc) TC4 Common (OV) AI-148

o 1994

ELECTROMOTIVE SYSTEMS, INC.

.'+

Milwaukee,Wisc: Soft NSG618221-1: 12119194

P&

3 1

It is vital the control ouputs be wired correctly because they control the action of the brake contactor(s). The wiring is, however, straightforward. All of the complex sequencing used to control the parking brake is contained within the IMPULSEoPH3 unit, but the output of this safety- based sequence is a contact between terminals #9-10 which is connected to the coil of the brake contactor.

More By P&H

Always separate 12-V wiring from DC control and power wiring. If the two must cross, they should do so at 90angles.

You must use R-C type surge suppressors across the coils of the brake contactors to prevent potential nuisance tripping of the PH3 unit due to excessive magnetic noise when the contactors are de-energized.

contactor coivmagnetic
L

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@ 1994 ELECTROMOTIVESYSTEMS,
'.

IN^.''^^.
.--

Milwaukee, W k : ' Soft NSG618221-1: 12/19/94

. I

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IMPULSEZPH~
Instruction Manual

.Digital OpeAt&ir ':: 'SectionF4

The IMPULSEaPH3 is a completely digital controller that can be used to precisely control the motions of a standard three-phase induction motor to facilitate variable speed control. Being completely digital, there are no potentiometers or selector switches to be tampered with. Instead, the u n l is shipped with a digital keypad as standard. This device is very powerful, not only allowing convenient access to the programming parameters, but it also provides alpha-numeric indication of fault codes to simplify troubleshooting. This digital keypad will allow you to do the following:
* Program the various parameters (or constants)

Read alpha-numeric fault diagnostics Monitor the performance of the unit This digital keypad is shown below:

CIWI

fWl FW

SM FBXm REF

11

(x) (r) 1I
DRNE

Q 1994 ELECTROMOTIVE SYSTEMS, INC. Milwaukee, Wix: Soft NSG618221-1: 12/19/94

-

Page 33
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Digital Operator section 4.2

Instruction Manual ... . . . .. . ,

I

'

Some keys on the digital keypad have dual purposes, depending on whether the keypad is being used to program various parameters (or constants) or to operate the unit locally. The various keypad functions are listed below whenever the IMPULSEsPH3 is being used to program various parameters (or is in the program mode):

Depressing this key toggles operator mode between DRIVE and PROGRAM modes.

Used to increase or decrease the setting of the blinking digit of the keypad.
\

Depressing the DISPLAY key repeatedly changes the display mode. Refer to the following page for the details of the function of this key.

DATAIENTER key displays the contents of the selected programming parameter. ENTER key is used while in PROGRAM mode to permanently store program changes.

Moves the blinking digit (cursor) from left to right. RESET function is used to reset fault trips.

Page 34

Q 1994 ELECTROMOTIVE SYSTEMS, INC?;INC.

Milwaukee, Wisc: Soft NSG618221-1: 12119/94
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IMPULSE@@ pH3
Instruction Manual

Digital Operator -section4.2

Each time the DISPLAY key is pressed the display mode will be varied according to the diagram given below.
Power ON

l - l

DRIVE MODE

PROGRAM MODE

PRGM
DRIVE

b
DRIVE MODE

PROGRAMMING CONSTANTS (Please refer to the appropriate section of this manual for a detailed description of each) An (REFERENCE) mode constants are used to set the various speed settings for the multi-step speed mode of operation or the minimum speed in the infinitely variable speed modes. Bn (ACTIVE) mode constants are used to vary certain programming parameters while the inverter is running.
Sn (SYSTEM) mode constants are used to configure the broadest of inverter operating parameters.

Cn (CONTROL) mode constants are used to fine tune the inverter operating characteristics.

O n (ORDER) mode constants are used by the factory only. These constants should not be changed in any way.

@ 1994 ELECTROMOTIVE SYSTEMS, INC.

Milwaukee, Wiic: Soft NSG618221-1: 12/19/94

Page 35

.. :,9

,T

--.

Mgital Operator Section 4.3

~nstruction~~anual . '.
i

.,

Example of Changing Constant Data: Change Cn-18 (DC Injection Time at Stop) from data '0.5" to data '0.8" Change Cn-25 (Overtorque Detection Time) from data '0.1 ' to data '1 .l '
Note: the underlined digit in the keypad display column indicates .. Z . . on the dzsvluv) the cursor oosztronb ( .

K e n a d Dis~lay
An-01

press press

[eE)

to enter the program mode (you must first be stopped) three times to access the Cn family of parameters

[Dspc]

Cn-O1

press press press

[x)
) [

until you access parameter Cn-l8(DC Time at Stop)

in this parameter

Cn- 18

[ E d once to view the data programmed

to move the blinking digit

Q.5

0.5

Press press

2 times to chanage data from " 5 ' to '8"

0 . 8
End

[ Z R ]

to Enter the new data into Cn-11. Display will show "End" for approx. 1 sec., then will show data again

4
0.8
Cn- 18 Cn-25

press

[G] once to again access the Cn parameter display

press press

[x)
B

until you access parameter Cn-25(OT Detect Time)

[ Z R ]once to view the data programmed in this parameter

1 time to change the cursor from "0" to " 1"

Q. 1
Ll End

press

E [ d "End" enter the new data in Cn-25. Display will show for approx. sec., then will show the data again.
to

\L
Ll previous display mode

press

[EE)

to return to the drive (operating) mode

.- -

Page 36

Q 1994 ELECTROMOTIVE SYSTEMS, INC::INC.

Milwaukee, h q c : Soft NSG618221-1: 12/19/94
".

IMPULSE?. pH3
Instrueition Manual

..
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Digital 0p&&r :section4.2

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Digital Operator Skction 4.4

,MPULS&;

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The various keypad functions are listed below whenever the IMPULSE*PH3 is in the DRIVE Mode (or ready to run the motor, either locally or remotely via external input commands).

Red lamp lights during FORWARD run.

Red lamp lights in DRIVE mode and goes out in PROGRAM mode Depressing this key toggles operator mode between DRIVE and PROGRAM modes. Jog Key function is disabled.

Red lamp lights while commands supplying the TC-GIF card are enabled (this is normal operating mode, lights will only be out while troubleshooting the unit.) Seq= Run/Stop Ref= Speed Reference Depressing the DISPLAY key repeatedly changes the display mode. Refer to the following page for the details of the function of this key. Used to increase or decrease the setting of the blinking digit of the keypad. DATA1 ENTER key is used in DRIVE mode to store new An or Bn constants.

RNDIREV Key reverses motor direction of rotation while in keypad control mode. Red lamp lights while RUN Key is depressed.

While RUN key is pressed, the inverter output will ramp up to existing speed reference level. When STOP is released, the output will go to zero.
I

STOP key is pressed. When inverter is stopped, LED will remain on until inverter is re-started.

Moves the blinking digit (cursor) from left to right. RESET function is used to reset fault trips.

@ 1994 ELECTROMOTIVE SYSTEMS, IN~,'INC. Milwaukee, Wisc: Soft NSG618221-1: 12119/94

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' Section 4:4

Each time the DISPLAY key is pressed the display mode will be vaned according to the diagram given

PROGRAM MODE

c
DRNE MODE

0
I

DRNE MODE

I
Display of fauns which had occurred before power supply was turned off
I

PROGRAMABLE CONSTANTS

(Please refer to the appropriate section of this manual for a detailed descrMtion of each)

Output Speed (%) Display No Prefix or Suffix on Display

Un (MONITOR) mode constants are used to observe the input and output characteristics of the inverter.
An (REFERENCE) mode constants are used to set the various speed settings for the multi-step speed mode of operation or minimum speed in the infinitely variable speed control mode (An-01). Bn (ACTIVE) mode constants are used to vary certain programming parameters while the inverter is running.

Output Current Monitor Display 'A' Suffix on Display

Display o f Faults wtrich had occurred before power supply was last turned d.If there are no faults, this mode is

I I

*
Un- xx Monitor Mode Display

sl
g j
Multi-step Speed Settings Adive Constants

3.
Speed Reference ( X )Value Display 'P Prefix on K e m d

0 1994 ELECTROMOTIVE SYSTEMS, INC.

Milwaukee, Wisc: Soft NSG618221-1: 12/19/94

Page 39

--

* In this manual, the term "Constant" simply refers to one of many operating parameters which can be adjusted and/or monitored. These constants are organized according to function and grouped into several constant "modes". Each mode carries a two letter code as a designator (either An, Bn, Cn, Sn, or Un). Therefore, regardless of the existing display, it is very easy to navigate your way through the various programming constants by depressing the Display key at any time. (Please refer to Section 4 for details of the interrelationships between the constant modes.)
* There are four programming constant modes available and these are:

- Multi-step speed REFERENCE mode (An) Constants. - ACTIVE mode (Bn) Constants which can be "tuned" while the inverter
is operating.

- SYSTEM mode (Sn) Constants are available to set the inverter's broadest
operating characteristics (i.e. input1output characteristics, V/F pattern). - CONTROL mode (Cn) Constants are used to fine tune the inverter operation.
* In addition, there is one group of constants used specifically to monitor the input and output characteristics of the inverter. These are called the MONITOR mode (Un) Constants. These functions essentially eliminate the need for external test equipment or meters at the time of start-up. If a fault trip occurs, these constants can also be very useful in the troubleshooting process. See Section 5.8.

There are several levels of accessibility to the programming constant modes. As you-might expect, these options are controlled by yet another constant. This important constant is called Sn-03 and is located within the SYSTEM mode grouping. See page 44 for a detailed description of these various access levels.

f ;p?[
@ 1994 ELECTROMOTIVE SYSTEMS, INC2,INC. Milwaukee, Wisc: Soft NSG618221-1: 12119/94
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:~lnstruclion Manual

Constant Deseriptio,~ Section '5.3

Following is a table illustrating the relationshipsbetween the An constant mode and the available, preset speeds.

AM1 An-02
An43

ISpeed I/Lower Limit IMulti-Step Speed 2

Multi-Step Speed 3 Multi-Step Speed 4

I I I

0.01 Hz O.01Hz 1 Hz 1 Hz 1Hz

An44

An-05
---

Freq. Reference

An06

I Multi-Step Speed 6

Q 1994 ELECTROMOTIVE SYSTEMS, INC.

Milwaukee, Wiic: Soft NSG618221-1: 12/19/94

Page 41

Constant Descriptions Section 5.4

Instruction Manua . -... - !2~;; i%ff:

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IMPULSE@.pH,$'
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'Bn-01 'Bn-02 'Bn-03 'Bn-04 Bn-05 Bn-06 Bn-07 Bn-08 Bn-09 Bn-I0 Bn-11

Acceleration time 1 Deceleration time 1 Alternate acceleration time Alternate deceleration time Automatic Deceleration Time Change Frequency Reference Gain Frequency Reference Bias Torque Compensation Gain Motor Rated Slip Not Used--Reservedfor Future Use Analog Monitor Channel 1 Gain Analog Monitor Channel 2

0.1 Sec 0.1 Sec 0.1 Sec 0.1 Sec 0.1 Sec 1% 1% 0.1 0.1%

0.0 0.0

- 25.5
- 25.5

10.0 10.0 10.0 10.0 10.0 100 0 1.O 0.0

3
1.6

0.0 - 25.5 0.0 - 25.5

0.0 25.5

I
't

- 200 -100% - +loo%

0 0.0

- 9.9

0.0 - 9.9%

0.01 0.01

0.00 0.00

- 2.55 - 2.55

1.OO 1.OO

Bn-01

Forward Direction Acceleration Time Forward Direction Deceleration Time Reverse Direction Acceleration Time Reverse Direction Deceleration Time When data of Sn-1I

0.1 Sec
0.1 Sec

0.0
0.0

- 25.5
- 25.5 - 25.5

10.0 10.0 10.0 10.0

Bn-02
Bn-03 Bn-04

0.1 Sec 0.1 S ~ C

0.0 0.0

- 25.5
- 2.55

- Sn-14 = "02" (Enabled for Micro-Speed Gain Function)

Bn-12

Micro-Speed Gain

0.01

0.00

1.oo

Page 42

@ 1994 ELECTROMOTIVE SYSTEMS, INC.;'INC.

Milwaukee, Wisc: Soft NSG618221-1: 12119/94

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Instruction Manual

Constant ~escri~tid&'' section c... 5

Sn-01

KVA Selectkn

01

Inverter Capacity and Voltage Is Selected

01

- 33

230AFDl-PH3 230AFD3-PH3 23OAFD5-pH3 230AFD7.5-pH3 230AFDIO-PH3 230AFD15-PH3 230AFD2GPH3 230AFD30-PH3 230-pH3 230AFD50-pH3 23OAFD60-pH3 230AFD75-PH3

22 23 24

460AQ2-PH3 460AFD3-PH3 460AFD5-pH3 460AFD7.5-PH3 460AFDlO-PH3 460AFD15-PH3

44

NfA WA 575AFD5-PH3 575AFD7.5-pH3 575AFDIGPH3 575AFD 15-pH3

48

25
26

45
46

28

460AFD2O-PH3 460AFD30-PH3

575AFD2GPH3 575AFD30-PH3 575AFD40-PH3 575AFD5O-PH3

WAFD50-PH3 460AFD60-PH3 4D 4E

460AFDaPH3 d6OAFD75-PH3 460AFD 1W P H 3

2E
31

460AFD75- PH3 460A.FD 100-pH3

WA WA

d6OAFD 150-PH3 460AFD200-pH3 460AFD250-PH3 460AFD300-PH3 460AFD400-PH3

51 52

460AFD 150-PH3 460AFD200-PH3

WA WA

33 34 35 36

NIA WA
NfA

N/A

Q 1994 ELECTROMOTlVE SYSTEMS, INC.

Milwaukee, Wisc: Soft NSG618221-1: 12119/94
\
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Page 43
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c&&&t Descriptions
Sectioh 5.5

I M P U L S E $ ~ P ~- ~
Instruction".. Manual .
1 I
I

, .

.",4

Drive Mode ''-03

Program Mode

Setting & O n l y Setting & Setting & O n l y Setting & Reading Reading Reading Reading Reading Reading is is is is is is Enabled Enabled Disabled Enabled Enabled Disabled Cn, Sn, On Cn, Sn, On An,Bn An, Bn, Cn,Sn An, Bn, Sn-03 An, Bn, Cn, Sn,
On

On
Cn, Sn
On

Un

Cn, Sn,

On

*Note: Data returns to "0101" at Power Up. "Note: Held as is at Power Up

IMPULSE@@ pH3
Instruction Manual

Constant Descriptions Section 5.5

I
.
.' . "- r _
I,

*Digits read right to left. 0000

dlgil

'1st digit

0 1994 ELECTROMOTIVE SYSTEMS, INC.

,

Page 45
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Milwaukee, Wisc: Soft NSG618221-1: 12119/94

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. * ,----.------- - - - .-

---- . -..&
. I

< .:, ..*:

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, 2 :
.*.2.

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'5

Swift Llft Function is Disabled

Page 46

@ 1994 ELECTROMOTlVE SYSTEMS, INCIINC.

Milwaukee, Wisc: Soft NSG618221-1: 12/19/94

'1i

IMPULSE@^ pH3
Instruction Manual

Constant Descriptions Section 5.5

IMPULSE PH3 software offers pre-defined control modes set by the data of Sn-10. These modes are separated into two (2) groups: Group 1: Hroizontal Motion (or Load-Brake type Hoist) Control defined by Sn-I0 = 00, 01, 02, 03, or 04 Group 2: Hoisting (No-Load Brake Type) Control defined by Sn-10 = 06, 08, or 09 As delineated by the Sn-10 description on the previous page, each Control Group is capable of a variety of data, and, hence, each Control Group is capable of a variety of Speed Control methods: Multi-Step (2 or more types), and Infinitely Variable (2 or more types). Below are tables for each data of Sn-10 that details the precise terminal functions and speed reference scheme thereby enabled:

sn-10 = 6@>(~t$riz@h$al ... . :..- . . --- - -l:-.,~.&4.+($! ~oti6&~5fStep Multi-Step $peedg~on!rol). ~6rmi,dd' ~uiictibn~%"~~peed~~eference Fwctions i
,""

P &?&?* &*?*
,
, -

.a>

+ ,:,

z+

. ,

-@

4 .3 $ $ y

2+,b$

5e..v

:::,

When Sn-10 is programmed for data "OO", the terminals and speed reference scheme is defined per the below tables:

Terminal 5
0
1
1

Terminal 6 Terminal 7 0 0
1

Terminal 8 0
0

Applied Speed Reference HIGHER of the Analog Reference (TI 5) or An-01 An-02

0 0
0

An-03
An-04

1 1
1

0
1

An-05

.:.

I-

0 1994 ELECTROMOTIVE SYSTEMS, INC.

Milwaukee, Wisc: SoftNSG618221-1: 124 9/94

Page 47

Constant Descriptions Section 5.5

- . .dm& PH3 ~MPULSE??

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Instruction' Manual ,. ?,, .

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When Sn-10 is programmed for data "01",the terminals and speed reference scheme is defined per the below tables:

Fixed

Not Possible Not Possible

Multi-Speed Input 1 Multi-Speed Input 2 No Function (Sn-13 = OF) No Function (Sn-14 = OF) Auxilliary Analog Input

6
7
8

Fixed

Programmable Change by Sn- 13 Programmable Change by Sn- 14

16

Fixed

Not Possible

Page 48

@ 1994 ELECTROMOTNE SYSTEMS, INQ,;INC.

Milwaukee, Wisc: Soft NSG618221-1: 12/19/94
4 '
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IMPULSES PH3
Instruction Manual

Constant Descriptions Section 5.5

When Sn-10 is programmed for data " 0 2 ' ,the terminals and speed reference scheme is defined per the below tables:

F i x e d
Fixed
Fixed

Not Possible Not Possible Not Possible

Multi-Speed Input 1 Multi-Speed Input 2 Multi-Speed Input 3 No Function (Sn-14 = OF) Auxilliary Analog Input

7
8

Programmable Change by Sn-14

16

Fmed

Not Possible

I Terminal 5 ( Terminal 6 1 Terminal 7 I Terminal 8 1

I

Applied Speed Reference

HIGHER of An-0 1 or the Analog Reference (T13 T14)

An-02

Q 1994 ELECTROMOTIVE SYSTEMS, INC.

Milwaukee, Wisc: Soft NSG618221-1: 12/19/94

Page 49

Constant Descriptions Section 5.5

Instruction Manual
i
"3.'

I,.*

..

When Sn-10 is programmed for data '03", the terminals and speed reference scheme is defined per the below tables:

Fixed

Not Possible Not Possible

Multi-Speed Input 1 Multi-Speed Input 2 No Function (Sn-13 =OF) No Function (Sn- 14 = OF) Auxilliary Analog Input

6
7 8

Fixed

Programmable Change by Sn- 13 Programmable Change by Sn- 14

1 6

Fixed

Not Possible

Terminal 8

Applied Speed Reference

I
1

Not Used

Not Used

1 I
1

HIGHER of A n 4 1 or the Analog ~efer&ce F 3 T 1 4 )

Frequency Hold Command Frequency Increment Command (Upper Limit = Cn- 19)

Page 50

'.

1 ,

@ 1994 ELECTROMOTIVE SYSTEMS Milwaukee, Wisc: Soft NSG618221-1:

\

'

'

IMPULSE@.P P H ~
Instruction Manual

Constant Descriptions Section 5.5

When Sn-10 is programmed for data '04', the terminals and speed reference scheme is defined per the below tables:

Fixed
Fied

Not Possible Not Possible

Speed Increment Command Speed Decrement Command No Function (Sn-13 = OF) No Function (Sn-14 = OF) Auxilliary Analog Input

6 7

Programmable Change by Sn- 13 Programmable Change by Sn- 14

8
16

Fixed

Not Possible

O 1994 ELECTROMOTIVE SYSTEMS, INC.

Milwaukee, Wisc: Soft NSG618221-1: 12119/94

Page 51

Constant Descriptions
Section 5.5

Instruction Manual
-

'

. ~~.,\."Oi

When Sn-10 is programmed for data '06", the terminals and speed reference scheme is defined per the below tables: Note that the fifth (5th) step is provided by terminal 3 when Sn-11 is programmed to data "01

".

Terminal 1
2

Status Fmed

Changing Not Possible Not Possible

Initial Value Description Forward Run Command Reverse Run Command Jog Reference (5th Speed) When Sn- 11 = "01" External Fault Reset Multi-Speed Input 1 Multi-Speed Input 2 Base Block Command a t Open Brake Answerback at Closed

Fixed

3
4

Programmable Change by Sn-11 Programmable Change by Sn-12 Fmed Not Possible Not Possible Not Possible Not Possible
I

6
7
8
16

Fixed
Fixed Fixed

Fixed

Not Possible

Tach Generator Feedback for Deviation Detection Function

Page 52

Q 1994 ELECTROMOTIVE SYSTEMS, INCiINC.

Milwaukee, Wsc: Soft NSG618221-1: 12/19/94
\

IMPULSE@.pH3
Instruction Manual

Constant Descriptiow ~ection.5.5

When Sn-10 is programmed for data "08", the terminals and speed reference scheme is defined per the below tables:

l*

ITerminal 5 I Terminal 6 1 Terminal 7 I Terminal 8 I

NotUsed NotUsed

Applied Speed Reference HIGHER of An-0 1 or the Analog Reference (T 1 3 T 14) Frequency Hold Command Frequency Increment Command (Upper Limit = Cn- 19)

Q 1994 ELECTROMOTIVE SYSTEMS, INC.

Milwaukee, Wisc: Soft NSG618221-1: 12119/94

Page 53

:$$$&
*-3

A ?

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Constant Descriptions Section 5.5

IMPULSE ..;to!, .,%! P w,- - H ~

*4a2

qPtl

Instruction'Mantial
,
(4
>

When Sn-10 is programmed for data '09", the terminals and speed reference scheme is defined per the below tables:

Brake Answerback at Closed

Page 54

0 1994 ELECTROMOTIVE SYSTEMS, INCJNC. Milwaukee, Wisc: Soft NSG618221-1: 12/19/94

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IMPULSE^^ pH3

' " " " i

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Constant ~esex-iitiolls , ,

Section 5.5

Pulse Monitor

i
l

8 1994 ELECTROMOTlVE SYSTEMS, INC.

Milwaukee, WSC: Soft NSG618221-1: 12119/94
\

Page 55
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Fault Code Programming (Sn-11

- Sn-14 = 10 -IF)
-

,a>

Terminals 3, 4, 7 or 8 can be programmed for inputing an External Fault (EF). The operation of the PH3 at Fault Input can be programmed by the data of Sn-11 Sn-14 as below:

. .

,.

Ex.

Data = -1

X
Convert to 4 digit Binary

-L---1

,
8

. -,.,
*

i!.y $4:*

Page 56

Q 1994 ELECTROMOTNE
\

SYSTEMS, IN&;INC.
5,-,
'-7

Milwaukee, Wisc: Soft ~ ~ ~ 6 1 8 q 1 1211 - 1 9/94 :

;,\*

IMPULSE@* pH3
instruction Manual

Constant Descriptions Section 5.5

Sn-15

- Sn-17: Multi-Function Output Terminals 9-1 0; 25-27 and 25-28

06 07 08
09

OA
O B OC O D O F

Output is closed When PH3 is Ready for Operation Output is Closed When Undervoltage is Detected Output is Closed during Base Block Operation Output is Closed When Frequency Reference Control is from External Terminals (Open When Frequency Reference is from Keypad) Output is Closed When Start/ Stop Control is from External Terminals (Open When Start/ Stop is from Keypad) Output is Closed When Overtorque is Detected Not Used Output is Closed at Braking Resistor Fault (rr) Output is Closed at OL3 Fault

Q 1994 ELECTROMOTIVE SYSTEMS, INC.

Milwaukee,Wisc: Soft NSG618221-1: 12/19/94

Input voltage (Vin)

Mid-point output voltage (Vc)

V min for Reverse

Cn-17 Cn-18 Cn-19 Cn-20 Cn-21 Cn-22

DC injection braking current

DC injection time at stop Frequency reference upper limit Frequency reference lower limit Operator display scaling Q F max. Optional speed agree frequency BB time for direction change Overtorque detection level Overtorque detection time

1%

0-100 0

50 0.5 100
0

0.1 s 1% 1%

- 25.5

0 - 109 0 - 109 0

- 39999
0

0.1 Hz 0.1 s 1 % 0.1 s

1.5 30

Cn-23
01-24
Cn-25
1

- 2.6

- 150

0
1-5

0
160 0.1

- 200 0 - 25.5

Page 58

@ 1994 ELECTROMOTIVESYSTEMS, IN&INC.

Milwaukee, Wisc: Soft NSG618221-1: 12/19/94
I

IMPULSE". P H ~
Instruction Manual

Constant Descriptions ~ection.5.6 ,

I ref 1 for Load Check Cn-28 Cn-29 Cn-30 Cn-31 Cn-32 Cn-33 Cn-34 Cn-35 Cn-36 Cn-37 Cn-38 Cn-39 Cn40 Cn-41 Cn-42 Cn-43 Cn-44 Cn-45 Cn-46 Cn47 Cn-48 Cn-49 Cn-50 Cn-51 Cn-52 Cn-53 Motor no load current Slip Compensation delay time Carrier frequency upper limit Carrier frequency lower limit Carrier frequency gain Swift Lift current at Forward Swift Lift current at Reverse Swift Lift frequency Swift Lift acceVdece1time gain Swift Lift threshold frequency Swift Lift delay time Phase Loss frequency set level Phase Loss current detect level (Note: Data '0" disables the Phase Loss Function) Phase Loss Detection delay time
1%

F ref 2 for Load Check

I ref 2 for Load Check F ref 3 for Load Check I ref 3 for Load Check Detection time for Load Check Hold Time for Load Check Stall prevention on accel con. tor.

1 Hz 1% 1 Hz 1% 0.1 s 0.1 s
1%

- 255 30 - 200
0 0 30

60 160 60
% of lnverter

% of lnverter Rated Current

- 255

Stall prevention on accel - con. hp

Stall prevention at set speed

- 200 0.1 - 25.5 0.1 - 25.5 30 - 200

30 30

160 0.1 0.2

Rated Current

1%
1%

- 200

50 160

- 200

% of Inverter Rated Current

Not Used
% of lnverter Rated Current

0.1 s 0.1 kHz 0.1 kHz 1

1%
1% 1 Hz 0.1 1 Hz 0.1 s 1% 1% .1 s

- 99 0.0 - 25.5 0.4 - 15 0.4 - 15 0 - 99 30 - 200%

0 30-200%

30 0 15 15 0

. .fi 160
S o 160
9 4 60

- 255 0.1 - 9.9 0 - 255

0 0.1 0

% of lnverter Rated Current

1 60 0.1

- 100 0 - 200 0.0 - 25.5

- 25.5
3
40
t3

25 -1
e

Q 1994 ELECTROMOTIVE SYSTEMS, INC.

Milwaukee, Wisc: Soft NSG618221-1: 12/19/94

Page 59

~ ~ p u ~ ~ ~ l " . ! p ~ 3 - instrb'dtiori Manual

constant ~ i ~ c r i ~ t i o n ~ . Section . . , . 5.7

5

No.

Un-0 1 Un-02 Un-03 Un-04 Un-05 Un-06 Un-07

Name Freq. Refe.rence (Hz) Freq. Output Output Current Voltage Ref. DC Voltage Power Out (rt Kw) Input Term Status

Description Inverter Frequency Reference is Displayed Inverter Frequency Output is Displayed Inverter Output Current is Displayed in AMPS Inverter Output Voltage is Displayed in Volts (AC) DC Bus Voltage is Displayed in Volts (DC) Inverter Output Power is Displayed in Kilowatts Sequence Input Terminal Status is Displayed as Below:

I
Output Term Status

Terminal 1 Terminal 2 Terminal 3 Terminal 4 Terminal 5 Terminal 6 Terminal 7 Terminal 8

Sequence Output Terminals Status is Displayed as Below:

Terminals 9 10 Terminals 25 27 Terminals 26 27

Un-09 Un-10

LED Check Control Sec. Soft #

All LEDs on the Digital Operator are lit--Integrity Check Control Section EPROM Software Version is Display

9 1994 ELECTROMOTIVESYSTEMS, INC.

Milwaukee, Wisc: Soft NSG6182.21-1: 12119/94

I
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Page 62
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0 1994 ELECTROMOTIVE SYSTEMS, INC?:INC.

Milwaukee, ~ i s c : Soft NSG618221-1: 12119/94

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IMPULSE@.pH3 Instruction Manual

Special , Funqti0.n~ ...

I . q

& .

,. section3 - - . * -.

As discussed previously, the IMPULSE PH3 is a powerful combination of hardware and software specifically designed for Crane and Hoist applications. This section deals with the special software functions of IMPULSE PH3:

IMPULSE PH3 is a unique combination of hardware and software specifically tailored to the Craneand Hoist Industry. We offer a myriad of functions that uniquely apply to the special demands of performance and safety required when plant personnel operate under and around potentially deadly loads. Section 8.1 describes these simple yet vital functions:

Unlike more typical industrial applications, the Hoist or Crane drive must operate differently to provide a higher level of safety. The STOP key is just our first example of IMPULSE PH3 technolody:

= ALWAYS Enabled, Operation is programmed by Sn-05, Digit 1 = "0" DO NOT CHANGE THIS DATA!

The RUN button on the digital keypad operates differently than that typical of general purpose inverters. Safe operation of cranes and hoists in the local operation mode demands that operation only be possible when the RUN button is depressed. The absence of a RUN command demands STOP (according to the programmed stopping method, Sn-04 Digit 2). This reduces the possibility of a runaway crane.

General Purpose Method Maintained RUN

11

IMPULSEPH3 Method Momentary RUN

111

o 1994

ELECTROMOTIVE SYSTEMS, INC.

Milwaukee, Wisc: Soft NSG618221-1: 12119/94

~ i d 63 e

Phase Loss Detection compares the output current of each of the three phases to a pre-set level. If the output current of any of the phases falls below that pre-set level, an LF fault will appear on the display. Unlikeconventionalinverters in case of a phase loss, the IMPULE PH3 will immediatelyset the brake, thus retaining control of the load.

Phase Loss is

'

Disabled by data "0". Loss current comparison timer. If the

0.0 25.5 Sec

range for the time of Cn-53, the phase loss fault (PF) is output.

.- -

Page 64

G I 1994 ELECTROMOTIVESYSTEMS, INC~INC.

Milwaukee, W ~ C :Soft NSG618221-1: 12/19/94

IMPULSE?. pH3 .l'nstructionManual

Special Fuf!cfi,!!$? -Section6.2 -

As mentioned previously in this document, IMPULSE PH3 offers two basic sequences--Horizontal Mode and Hoisting Mode. The Hoisting Mode provides for a special start/ stop sequence designed especialty for No-Load Brake hoists. This sequence is enabled by Sn-10 = 6,8 or 9 and cannot be changed by any other constants. Great caution should be exercised in calculating the appropriate data for the constants pertaining to this sequence!

Timing Chart for Hoisting Sequence:

Base Block (T7 Closed)
Close
........................................................................... /#///////~////#/////////////#//////////#//#/////#/// /////////////////#/~////////////##/~///##///////#///

/C0///?//////C///##//#////#/#////#f#///~//#/////#0/~

Speed Ref. Input (TI 3 or An-xx) Run (Fwd/ Rev) Command (TI/2Closed)

I I
b
NBH(Cn-54)

Freq. Output
I

I
7

Brake Release Command (T9-Tl O Closed) Brake Answerback (T8 Closed) Actual Mechanical Brake

loub IF (IR) IF = Cn-56

IR = Cn-57

k \ \ \ \ \ \ \ \ \ \ \ \ \ \ \ \ \ \ \ \ \ \ \ \ \
C-)

BT(Cn-58)
b HT(Cn-59)

Q 1994 ELECTROMOTIVE SYSTEMS, INC. Milwaukee, Wisc: Soft NSG618221-1: 12119/94

\

pagew 65

~p&ialFunctions
Secl7on 6.2

* :;' , IMPULSE .y,pH4 .

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.+

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Instruction Manual .;
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The Hoisting Sequence has several specific fault parameters. These Faults are the "SE' faults as described below:

NOT output the Brake Release Command Within 1 Second of Run

Answerback Signal
2. Make sure that ALL connections are appropriate and

despite the Brake Release Brake Answerback IS Open. During Stopping, the Brake Answerback remains Closed for more than 1 Second despite the Brake Release Command being Output.
1. Check the status of the Brake contactor--Contactor may be frozen (welded) closed.
.

SE5

2. Make sure that ALL connections are appropriate and secure.

, -

Page 66

@ 1 994 ELECTROMOTIVE SYSTEMS, INC:;INC.

Milwaukee, ~ i s c : Soft NSG618221-1: 12/19/94
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I M P ~ ~ S E pH3 "
Instruction Manual

Special .. Functions
,

.
e

ion 6 . 3 . . . --

IMPULSE PH3 software offers a unique safety function that when programmed properly precludes the possibility of 'losing the load". The Deviation Detection circuit utilizes a direct coupled speed sensing device on the motor output shaft and compares this feedback to its own internal reference. Should the actual speed be significantly different that the commanded speed, the 'dd" fault is output and the machine is shut down. The feedback device must output a signal as below:

Where: Nfb = Actual Motor Shaft Speed TI6 Vdc: Input Vdc to Terminal 16 of PH3 Logic Card

1
109% (Higher of Cn-02 or Cn-47) 100% (Higher of Cn-02 or Cn-47)

Nfb
9.08V

T I 6 Vdc

0.92V

100% (Higher of Cn-02 or Cn-47) 109% (Higher of Cn-02 or Cn-47)

(I-

@ 1994 ELECTROMOTIVESYSTEMS, INC.

Milwaukee, Wisc: Soft NSG618221-1: 12119/94

Page 67

Special Functions
Section 6.3

IMPULSE~~,PH~
'

Instruction Manual.

Deviation Detection (Overspeed Detection) Programming:

, -

tection Window at

Deviation Detection Window at Reverse Deviation Detection Window at Reverse Deceleration. Cn-66
0 ~ 9 %

5%

'

User Choice

Deviation Detection Window at Reverse Constant Running.

Page 68

Q 1994 ELECTROMOliVE SYSTEMS, INCf,'INC.

Milwaukee, Wsc: Soft NSG618221-1: 12/19/94
.

IMPULSE@.pH3
- Instruction Manual

Special Functions Section 6.4

The IMPULSE PH3 offers the Micro-Speed Gain function for precision in hoisting. This function provides for extremely slow speed operation in addition to the normal running speeds programmed by the User. Enabled by an input to the PH3, this function multiplies the normal speed reference (any of An-01 An-06 or the Analog Reference) by the data of Bn-12. This will prove extremely useful when "spotting" the load. Please refer to the programming method, joystick operation and examples below:

ProgrammingMethod:

--

Sn-11-Sn-14 Bn-12

00- 1F
0.00 2.55

Various 1.OO

02 User Choice

Provides the Lnput to Enable MicroSpeed Operation.

Gain of Micro-Speed Operation

1.I

Joystick Operation: During Normal Operation

STOP
-*./-e

During Micro-Speed Operation

STOP

/'

**

'.

0
a

--.
*
s

3
Joystick Controller

f8
Speed = Bn-12 Normal Reference Reverse
r

' 1
Joystick Controller

Speed = 0-1 00% Reverse

P

Speed = 0-100% Forward

i

Speed = Bn-12 * Normal Reference Forward

i

An-04 An45

5QHz

10 Hz 12 Hr
0-20%

,411-04

M Hz

25 Hz

60Ht
0 - 100%
I

An45

60Hr
0-100%

30 Hz
0-50%

Analog

Analog

@ 1994 ELECTROMOTIVE SYSTEMS, INC,

Milwaukee, Wisc: Soft NSG618221-1: 12/19/94

Page 69

*'.

Special Functions
Section 6.5

IMPULSE

,gC . i
,

':;;y8! :. . ,
, ?

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P H ~

Instruction Manual

The IMPULSE PH3 offers the Quick STOP function that provides an alternate deceleration time upon STOP comand (absense of commands). Note that when decelerating from a higher speed to a lower speed the active deceleration time remains Bn-02. ONLY when the pH3 is provided a STOP command does the active deceleration time become BN-04. Please refer to the programming method and timing chart below: ProgrammingMethod:

Sn-09, digits 4 and 3 B n-04

00,01, 10, 11
25'5 Seconds

00
10.0Second

10 User Choice < Bn-02

Data " 10" enables the Quick Stop Function

Sets the Quick Stop Deceleration Time (Time from 100% speed to Stop)

Timing Chart for Quick Stop Function:

1 1

Speed Out

I
*

Time

._

Page 70

@ 1994 ELECTROMOTWESYSTEMS, INC:lNC. Milwaukee, Wsc: Soft NSG618221-1: 12119/94

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IMPULSE@^ pH3
Instruction Manual

Special ~ h c t i o i i s Section 6 i 6

The IMPULSE PH3 offers the Plug Reverse Simulation function toprovides an automatic alternate deceleration time1Acceleration time at a change direction command. Note that the Deceleration time and Acceleration time differ from the normal normal times. Please refer to the programming method and timing chart below: ProgrammingMethod:

Bn-01

Speed Out

B
Bn-02

I Time
t

-W
Figure 28

@ 1994 ELECTROMOTNE SYSTEMS, INC. Milwaukee, Wisc: Soft NSG618221-1: 12119/94

Page 71

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Special Functions Section 6 . 7

:
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The IMPULSE PH3 provides for programming security and enables an enhanced level of safety by the automatic keypad lock-out function. Enabled by the data of Sn-03, this function will automatically prohibit unauthorized personnel from making changes to the IMPULSE PH3 program data. See below programming method:

Drive Mode "-03

Program Mode

Setting & Setting & Only Setting & Only Setting & Reading Reading Reading Reading Reading Reading is is is is is is Enabled Enabled Disabled Enabled Enabled Disabled Cn, Sn,

An, Bn,

Cn, Sn,

An, Bn,

Cn,Sn

On

*Note: Data returns to "0101" at Power Up. "Note: Held as is at Power Up

Page 72

O 1994 ELECTROMO.TIVESYSTEMS, INC:;INC. Milwaukee. WSC: Soft NSG618221-1: 12/19/94

IMPULSE@.pH3 Instruction Manual

Special Functions Section 6.8

IMPULSE PH3 provides the operator withthe ability to overspeed the motor1hoist when the load is less that 100% of rated capacity. The Swift Lift function determines the value of load and if the load is less than the data of Cn-45 (Forward operation) or Cn-46 (Reverse Operation), then the pH3 will automatically acclerate to the Swift Llft frequency. Please see the below programming method.
Programming Method:

Cn-45

30 200%

3Wo

User Choice

Swift Lift Enabliing Current at Forward: Swift Lift Operation (at Forward) begins if I-Out 5 the data of Cn-45 (and F-out = Cn-49). Swift Lift Enabliing Current at Reverse: Swift Lift Operation (at Reverse) begins if I-Out 5 the data of Cn-46 (and F-out = Cn-49). Swift Lift Frequency: If the enabling conditions of Cn45146 are assured, the PH3 will accelerate to the Hz of Cn-47 Swift Lift AcceV Decel Time Gain: The acceV decel times are multiplied by the data of Cn-48 during ramp up to/ ramp down from Swift Lift Frequency. Swift Lift Threshold Frequency: The detect frequency for Cn-45/ 46. When F-Out = Cn-49 the current is compared to Cn-45/46. Swift Lift Delay Time: The delay time beginning at the Threshold Frequency (Cn-49). Used to assure that the detection current is accurate (not* detection of slack cable)

Cn-46

30 200%

WO

User Choice

Cn-47

0 HZ 255

Hz

6QHz

User Choice

Cn-48

0.0 9.9

0.1

User Choice

Cn-49

0 HZ 255 Hz

60 Hz

User Choice

Cn-50

0.0 25.5 Sec

2.0 Sec

User Choice

I
1

O 1994 ELECTROMOTIVE SYSTEMS, INC.

Milwaukee, Wisc: Soft NSG618221-1: 12/19/94

Page 73

InstructionjManual

. .-

Page 74

Milwaukee. w&:

o 1 994

ELECTROMOTIVESYSTEMS, INC~,;INC.
Soft NSG618221-1: 12/19/94

IMPULSE@^ pH3
Instruction Manual

Periodic Inspection/ Troubleshooting Section 7

f f

WARNING !

Do not touch any circuit components while the main, AC power is on. In addition, you must wait until the red "CHARGE" lamp (located just left of the terminal strip) is extinguished before performing any service on the unit. It may take as long as 10 minutes for the charge on the main DC bus capacitors to drop to a safe level. Failure to adhere to this warning could result in personnel injury. Do not check signals during operation. Be sure to ground the IMPULSE PH3 using the G (E) terminal. Never connect the main circuit output terminals (TI, T2, T3) to the main, three-phase input power supply.

--

Q 1994 ELECTROMOTNE SYSTEMS, INC.

Milwaukee, Wisc: Soft NSG618221-1: 12119/94

Page 75
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Periodic Inspection/ Troubleshooting section 7 . 1

Instruction Manual

The IMPULSE PH3 inverter is virtually maintenance free. Only a few simple items should be periodically checked and these are summarized below:

Loosened screws or

consider replacement.
Cooling Fan

Abnormal noise or vibration.

Replace. If total operation exceeds 20,000 hours, also consider replacement. Blow with compressed air (from approx. 57 to 85 PSI) Replace all of the capacitors.

Power Elements

Accumulation of dust or dirt Discoloration or odor

DC bus capacitor
J

This section is presented as a series of simple instructions/ suggestions oriented to troubleshooting with the standard keypad and an analog VOM (Simpson 260 or equivalent). Accordingly, it has been divided into four sub-sections according to the nature of theproblem: 7.2.1: Motor1drive won't run 7.2.2: Motor won't accelerate smoothly 7.2.3: Fault Trip Condition and Definition

r
.-.

Please refer directly to the appropriate sub-section and its respective table.
I

Page 76

O 1994 ELECTROMOTIVE SYSTEMS, INC.,

IN^.'.

Milwaukee, Wisc: 'Soft NSG618221-1: 12119/94

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'IMPULSE@* pH3
Instruction Manual

Periodic Inspection/ Troubleshooting Section 7.2.1

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NOinput voltage

Measure the three-phase, AC input voltage directly on the inverter terminals L1, L2, L3.

Voltage should be within tolerances given below and should be balanced within 2 %. * 200 V units: 180- 253 VAC 400 V units: 342- 506 VAC * 575 V units: 450- 633 VAC Replace fuses Or move jumper to correct location-

Keypad is not illuminated

Check glass 1A fuses on small card. Make sure voltage selector jumper is in correct position (refer to sec. 3.1.5)

Make sure the incoming power has s not been removed beforeperforming Resistance should measure 100 Charge lamp i or less. If you detect an open illuminated this check ! circuit the pre-charge resistor is A damaged pre-charge Use an analog VOM (Simpson 260 or resistor is ~YP~C caused ~I~Y a equal) and measure the resistance shorted braking transistor (see from output terminal T I (positive section 9.3)lead) to main circuit terminal BO/P.

No run command at terminal strip

Make sure the inverter is programmed for terminal strip control (Sn-04= xxx0, remote seq LED should be lit). When shipped from the factory the inverter is programmed for keypad control, not terminal strip control. Use the monitor parameter Un-07 (see section 5.8 for details) to make sure you are getting the correct inputs to the inverter's control terminal strip. Make sure the inverter is programmed for keypad control of run/ stop (Sn-04= n i x , remote seq LED on keypad is'not lit).

YOU should get an input on terminal 1 (forward run) or terminal (reverse run)

2 wire control:

No run 'Ornrnand at keypad

Set Sn-04= xxxl .

If the inverter operates from the terminal strip replace keypad.

Keypad i s blinking "bb"

Inverter is receiving an external base- Correct external wiring to VGIF-5H block ("bbU) command at the terminal tet-minalL7(depending on which is strip. Check the programming/ wiring programmed for BB command). of the multi-functioninput terminals

- .

e 1994

ELECTROMOTIVE SYSTEMS, INC.

Milwaukee, Wisc: Soft NSG618221-1: 12/19/94

Page 77

Periodic Inspectiod Troubleshooting Section 7.2.1

IMPULSE?. P H ~
Instruction Manual

No speed reference command

Use the keypad display with the N prefix to observe the level of the enabled reference. Terminal control is denoted by the illumination of the Remote Ref LED on the keypad.

Keypad control: make sure the speed reference command is present. Terminal control: make sure .the speed pot is wired correctly to terminals 15, 13, 17).

Output voltage balanced ?

Use an analog voltmeter to measure the three-phase output voltage across terminals T I , T2, T3.

Voltages should be balanced within 3 %. If you use a digital meter the readings will be distorted due to the shape of the output waveform. See section 9.3 for test method. if the rectifier bridge is damaged you should add a three-phase, AC input reactor between the incoming source and the inverter power terminals L1, L2, L3.

Tripping circuit breaker or blowing input fuses ?

Input rectifier bridge damaged

'

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@ 1994 ELECTROMOTIVESYSTEMS, INC., 1~6'.

Milwaukee, Wisc: ' Soft NSG618221-1: 12/19/94

IMPULSE@^ PH3
Instruction Manual

Periodic Inspection/ Troubleshooting Section 7.2.2

Load inertia too large.

Extend the programmed acceleration time. Open the motor conduit box and confirm the motor leads are connected for the proper voltage (208, 230, 460, etc).

If extending the time doesn't improve the situation, uncouple the load from the motor and try again. Also make sure the motor doesn't have an opened phase.

Motor connected improperly.

Check the Tach Generator & Bias Tach Generator Connected Improp- Module wiring. erly?
Low impedance motor (Wound Rotor)?

Refer to section 3 for details.

Is the motor a wound rotor type.

Considering using an output reactor between the IMPULSE PH3 and the motor. Consider installing some level of resistance in the secondary circuit.

Inverter is too small Make sure the motor's rated current Inverter's rated current is on the is less than (or equal to) the inverter's nameplate of the unit and also for load. published in Sec. 3 of thismanual. rated current.

Frequency reference drifting (not stable)

Use the keypad to monitor the frequency reference (Un-01)

Stabilize source or extend accel and decel times (Bn-01, -02, -03, 04)

1994 ELECTROMOTIVESYSTEMS, INC.

Milwaukee, Wisc: Soft NSG618221-1: 12/19/94

* . . s, y+t$,: ' tj

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Periodic Inspection/ Troubleshooting

Section 7.2.3

IMPULSE@$~H@ ..
Instruction ~ a .. i & . al

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If you should experience a fault t i p condition and then remove the main ac power supplying the inverter, the fault code (s) will be stored in memory. When you reapply power, the keypad will blink the alpha-numeric code corresponding to the original fault trip for 2 secs. then will return to the previous display mode. If you want to observe the trip condition more closely, simply depress the DSPL (Display) key until the fault trip display is accessed. This mode will carry a prefix of "U1"to indicate the first fault, "U2"to indicate the second fault, etc. A maximum of 4 sequential key until you faults can be stored in memory and you can access them by pressing the A observe all the faults (display will scroll through all registered faults, up to and including the fourth). See below table for Fault Code listinq and information:

I 1

Uul

Uu2

I 1

Undervoltage 1 Undervoltage 2

Undervoltage 2 Overcurrent

Overvoltage

Fu

DC Bus Fuse is Blown

Coo*ingFin Overheat

OH

I
Motor Overload

Inverter Overload

Overtorque Detection

Load Check Fault Built-In Brake Transistor Failure

External Fault Input

Sequence Input Error

Undervoltage status occurs for more than 2 seconds. Check the Main Power Supply for proper connections. The Control Circuit voltage becomes low during operation. Check the Main Power Supply for proper connections. Main Circuit DC contactor answerback is not present. Check the pre-charge resistor. Inverter output current exceeds 200% of transistor rated current. Check inverter wires for short, check the motor for shorted/ grounded winding. The DC Bus voltage is too high. Check the braking resistor. If Braking resistor is not present, intall Braking resistor. Check the Deceleration time. Call Electromotive Systems, Inc. immediately The main cooling heatsink of the inverter exceeds 90C. Inspect - fin for cleaniness. I - the cooling I RMS current of motor exceeds the Data of Cn-16. Check the data of Cn-16 for appropriateness. Check the mechanical system for bearing and other types of failure. Reduce the load. Output current of PH3 exceeds RMS rating of inverter. Check the mechanical system for bearing and other types of failure. Reduce the load. Output current of PH3 exceeds the data of Cn-24 for the time of Cn-25. Check the data of Cn-24 and Cn-25 for appropriateness. Inspect the mechanical system. Output current at the Load Check function exceeds the app;opriate level (one of Cn-Cn-27.29 or 3 1). Check the data of Cn-27,29 & 3 1 for appropriateness. Reduce the load. Applies to units: 200V Class: S 10HP; 400V Class: QOHP The built-in braking transistor is blown. Call Electromotive Systems immediately. EF3: External Fault is Input by Terminal 3 (Sn-11 = lx) EF4: External Fault is Input by Terminal 4 (Sn-12 = lx) EF7: External Fault is Input by Terminal 7 (Sn-13 = lx) EF8: External Fault is Input by Terminal 8 (Sn-14 = lx) Enabled only in when Sn-10 = 0, 1 , 2 , 3 or 4: Input sequence is not allowed. Check the pushbutton wires for proper connection.

Page 80

0 1994 ELECTROMOTIVE.SYSTEMS,INC., INGa.

Milwaukee, Wisc: -.Soft NSG618221-1: 12/19/94

IMPULSE@# pH3
instruction Manual

Periodic Inspection/ Troubleshooting Section-7.2;3

NV-RAM Failure

SE1SE6

Sequence Error Fault

Enabled ONLY when Sn-10 = 6 , 8 or 9. See page 66 for detaiIs.

O 1994 ELECTROMOTIVE SYSTEMS, INC.

Milwaukee, Wisc: Soft NSG618221-1: 12/19/94

a -2:'
Periodic Inspectiod Troubleshooting
Section 7.3
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If the bus fuse is blown you must install a jumper across the fuse terminals to get accurate resistance measurements. *2 If the pre-charge resistor is open, you will read infinite R between + and any output terminal unless you install a temporary jumper dcross the resistor.
*1

6 3 1994 ELECTROMOTNE-SYSTEMS, INC.,

IN^ '.

Milwaukee, Wisc: *lSoft NSG618221-1: 12119/94

IMPULSE@# PH3
Instruction Manual .

Periodic Inspectionl Troubleshooting Section 7.4

@ 1994 ELECTROMOTIVE SYSTEMS, INC.

Milwaukee, Wisc: Soft NSG618221-1: 12/19/94

Periodic Inspection/ ~roublesh&ting Section-7.4

Instruction Manual

Page 84

Q 1994 ELECTROMOTIVE SYSTEMS, INC., INC;',

Milwaukee,

is; \Soft NSG618221-1: 12/19/94

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IMPULSE:?, P H ~
Instruction Manuel

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Milwaukee, Wisc: Soft NSG618221-1: 12/19/94

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1) Use surge absorbers (R-C networks) on all relay and contactor coils.
2) Shielded cable shall be used for all low level D.C. speed reference signals (0-IOVDC, 4-20 mA). Shield should be grounded only at the AF drive side.
3) Use a minimum of #16 AWG for control wiring, and #12 AWG (or larger) for power wiring. Size according to N.E.C. table 310-16.

4) The following is required for all dual motor bridge cranes and suggested for center driven cranes, trolleys and hoists. Upsize the wiring one size for every 25 feet of distance between AF drive and motor to account for voltage drop (which becomes significant at low frequencies).

5) Use time delay fuses for AF drive input protection. They shall be sized at approximately 150% of AF drive continuous rated amperage.
6) Control and power wiring (including dynamic braking resistor wiring) shall be kept separate on terminal block strip.

7) Keep control (directional and speed command inputs to the AF drive) and power wiring from running together in parallel paths on the panel or in conduit runs. Keep control and power festoon wiring in different cables and separated.
8) If control and power wiring do meet on a panel, cross them perpendicularly. 9) Before applying power to the AF drive, check the output circuit (TI, T2, T3) for possible short circuits or ground faults.

10) Always mount the AF drive in its proper (vertical) orientation with at least 3" of clearance on all four sides. AF drives should be housed in appropriate NEMA rated enclosures for the environment in which they will be used. 11) Keep AF drive heatsink clear of any obstructions (components on panel) to ensure proper cooling air flow. 12) If using externally mounted interface boards, or remotely mounted speed reference signals, use shielded cable from the interface output or remote speed reference to the AF drive control input terminals. 13) On external input devices (control), hard contact inputs are preferred rather than solid state inputs into the control voltage input boards ( T C - G I F , TC-SIF-, TC-SLC-). 14) If the input device is a PLC triac output, a 5K ohm, 10 watt'resistor may have to be used between the signal and L2 (X2). 15) AF drives should always have the cover mounted on unit during normal operating conditions to protect the digital operator (Specific to Electromotive Systems IMPULSEaPH3 Series, 1MPULSE.G Series, IMPULSE.VG Series and IMPULSEaP series).

@ 1994 ELECTROMOTIVESYSTEMS, INC. Milwaukee, Wisc: Soft NSG618221-1: 12/19/94

Page 87

- ..

Appendix

Instruction Manual .. .

IMPULSE!$PH~, : .

16) All ground terminals or screws ("G" or "Ernmust be grounded back to earth ground.

17) If the power source is greater than 500 KVA, there should be at least 3% impedance in the line between the source and the input to the AF drive.
18) Incoming power supply voltage must be limited to 230 volts f 10% or 460 volts f 10%.
19) On existing wound rotor motor applications >25HP, a line reactor of 3% impedance shall be required on the load side of the AF drive. (Specific td Electromotive Systems IMPULSEaPH3

Series, 1MPULSE.G Series, IMPULSEaVG Series, and 1MPULSE.P series).

20) When using more than one transformer for control power, properly phase each transformer

with respect to other(s).

21) All line and ground wiring should be disconnected when any welding is being done on or to the crane.
22) When using the Impulse*S Series AF drive on existing wound rotor motor applications

oversizing the drive or installing a load reactor is suggested to avoid over-current conditions upon starting a motor.
23) When supplying single phase input to the AF drive, the amperage of the drive must be derated

by approximately one-half. (Consult Electromotive Systems.) 24) All worm gear box hoist applications require dynamic braking resistors to avoid overvoltage conditions when lowering the hook. 25) Sliding collector bars are not to be used between the drive and the motor. It must be hard wired (i.e. festoon cable).
*'

If there are any questions, or a further explanation of the above recommendations is needed, please contact Electromotive Systems at 4141'783-3500 before proceeding. The above recommendations, if followed, will help to ensure trouble-free start-up and successful operation of the adjustable frequency drive when applied to overhead material handling equipment.

**

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Page 88

O 1994 ELECTROMOTIVESYSTEMS,INC., I@, Milwaukee, ~isc':' Soft NSG618221-1: 12/19/94

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IMPULSE% P H ~
Instruction Manual

Prices: Terms:

Subject to Change Without Notice Net 30 Days

F.O.B. Electromotive Systems, Inc. ~ilwaukee, Wisconsin

Electromotive Systems, Inc., hereafter referred to as Company, guarantees all items manufactured by it against any defects of material andlor workmanship for a period of two years from the date of shipment. Company makes NO OTHER WARRANTY, EXPRESSED OR IMPLIED, AS TO THE MERCHANTABILITY OR FITNESS OF THE ITEMS FOR THEIR INTENDED USE OR AS TO THEIR PERFORMANCE. Any statement, description or specification in Company's literature is for the sole purpose of identification of items sold by the Company and imparts no guarantee, warranty or undertaking by company of any kind. Components and accessories not manufactured by Electromotive Systems are not included in this warranty and are warranted separately by their respective manufacturers Company's sole liability shall be to repair at its factory, or replace any item returned to it within two years from date of shipment, which Company finds to contain defective material or workmanship. All items to be repaired or replaced shall be shipped to Company (Note: return authorization by Company is required) within said two year period, freight prepaid, as a condition to repair or replace defective material or workmanship. Company's herein assumed responsibility does not cover defects resulting from improper installation, maintenance, or improper use. Any corrective maintenance performed by anyone other than the Company during the warranty period shall void the warranty. Company shall not be liable for damages of any kind from any cause whatsoever beyond the price of the defective Company supplied items involved. Company shall not be liable for economic loss, property damage, or other consequential damages or physical injury sustained by the purchaser or by any third party a## result of the use of any Company supplied items or material. %<,.,# &\! Company neither assumes nor author~zb ny other person to assume for Company any other liability in connection with the sale or use of items sold by Company.

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List prices or discounts are subject to change without notice. Quoted prices will be honored for a period of 30 days from the date of the written quotation unless otherwise stated. Orders of $25,000 or more, and orders for special control panels are subject to special terms and conditions of sale. Refer to those specific sections within this document. Orders are not subject to alteration or cancellation except upon written consent of Company.and payment of proper cancellation charges, when deemed applicable by Company. Materials or items may not be returned for credit, without the prior written consent of the Company. Any authorized return of materials or items shall be subject to a restocking charge equal to 2O0I0of the net invoiced amount therefor after Company determines that the material or item is in good condition and may be resold without alteration or service. Terms of payment are NET 30 days. All materials and items are sold F.O.B. Company's shipping point. Company retains a security interest in all items sold by it so long as they remain in Company's possession to secure all obligations of purchaser to Company. A processing fee will be applied to all invoices for requested prepaid freight charges other than UPS. A service charge will be incurred on past due accounts extending beyond the terms of sale described above, at a rate of 1 112% per month of the net balance extending beyond 30 days. Any claim for material or item shortages must be received by Company within 30 days of shipment and must be accompanied by copies of the bill of lading and packing slip.
@ 1994 ELECTROMOTIVE SYSTEMS, INC.
Milwaukee, Wisc: Soft NSG618221-1: 12/19/94

Page 89