MH THYROMAT-BDC Manuale utente

Revision 8.6 INDEX 1

THYROMAT BD DIGITAL CRANE CONTROLLER

TABLE OF CONTENTS

SECTION PAGE

1. GENERAL

1.1. CONTROL SYSTEM..................................................................................................................... 6

1.1.1. Basic System Diagram............................................................................................................. 8

1.1.2. Thyromat Components Identification ....................................................................................... 9

2. SYSTEM DESIGN

2.1. GENERAL ................................................................................................................................... 10

2.2. THYROMAT –BD DIGITAL CRANE CONTROLLER RANGE................................................... 10

2.3. PROTECTION............................................................................................................................. 12

2.4. THYROMAT –BD DIGITAL CRANE CONTROLLER SELECTION........................................... 12

2.4.1. Standard Duty ........................................................................................................................ 12

2.4.2. Severe Duty (Based on 40% of nominal load permanently on hook) .................................... 13

2.5. PRINCIPLE OF OPERATION ..................................................................................................... 14

2.5.1. Control Box............................................................................................................................. 15

2.5.2. Control Card........................................................................................................................... 15

2.5.3. Relay Card ............................................................................................................................. 16

2.5.4. Phase Shifter Card................................................................................................................. 16

2.5.5. Snubber Card......................................................................................................................... 16

2.5.6. Control Panel.......................................................................................................................... 16

2.6. CONTROL SYSTEM SPECIFICATIONS.................................................................................... 17

2.7. THYROMAT - BD DIGITAL CRANE CONTROLLER ENCLOSURES........................................ 18

2.8. SELECTION OF RESISTORS.................................................................................................... 19

2.9. SELECTION OF MAINS CIRCUIT BREAKERS......................................................................... 21

2.10. SELECTION OF INTERPOSING INPUT RELAYS..................................................................... 23

2.11. SELECTION OF INTERPOSING OUTPUT RELAYS................................................................. 23

2.12. SELECTION OF CABLES........................................................................................................... 24

2.12.1. Power Supply Cables............................................................................................................. 24

2.12.2. Control Supply Cables............................................................................................................ 24

2.13. SELECTION OF STATOR REVERSING CONTACTORS.......................................................... 24

2.13.1. Contactor Switching Times .................................................................................................... 25

2.13.2 Contactors Drop Out Times ................................................................................................... 25

2.14. SELECTION OF CURRENT TRANSFORMERS........................................................................ 25

Revision 8.6

INDEX

SECTION PAGE

2.15. SELECTION OF ROTOR CONTACTORS.................................................................................. 26

2.15.1. Star Connections.................................................................................................................... 26

2.15.2. Delta Connections.................................................................................................................. 26

2.15.3. V Connections........................................................................................................................ 27

2.15.4 W Connections....................................................................................................................... 27

2.16. MOTOR THERMAL PROTECTION UNIT................................................................................... 27

2.17. SELECTION OF SPARE PARTS................................................................................................ 28

3. PARAMETERS

3.1. HOIST APPLICATION PARAMETER LIST ................................................................................ 29

3.2. PARAMETER DESCRIPTIONS - HOIST.................................................................................... 30

3.2.1. CT Ratio ................................................................................................................................. 30

3.2.2. Motor Current ......................................................................................................................... 31

3.2.3. Overload Class....................................................................................................................... 31

3.2.4. Notch 1................................................................................................................................... 32

3.2.5. Notch 2................................................................................................................................... 32

3.2.6. Notch 3................................................................................................................................... 32

3.2.7. Hoist Plugging........................................................................................................................ 32

3.2.8. Hoist Plugging V..................................................................................................................... 33

3.2.9. Lower Plugging V ................................................................................................................... 34

3.2.10. Brake Release I...................................................................................................................... 34

3.2.11. Hoist Start Volt ....................................................................................................................... 34

3.2.12. Stop Delay.............................................................................................................................. 35

3.2.13. Lower Plug Out....................................................................................................................... 35

3.2.14. Max Stall Volts........................................................................................................................ 35

3.2.15. Ph Shift On Time.................................................................................................................... 36

3.2.16. Ph Shift Off Time.................................................................................................................... 37

3.2.17. Separate Directional Signals.................................................................................................. 38

3.2.18. Load Defaults......................................................................................................................... 39

3.3. TRAVEL APPLICATION PARAMETER LIST ............................................................................. 40

3.4. PARAMETERS DESCRIPTIONS - TRAVEL.............................................................................. 41

3.4.1. Current Transformer Ratio ..................................................................................................... 41

3.4.2. Current Transformer Enable .................................................................................................. 41

3.4.3. Motor Current ......................................................................................................................... 42

3.4.4. Overload Class....................................................................................................................... 42

3.4.5. Notch Speed 1........................................................................................................................ 43

3.4.6. Notch Speed 2........................................................................................................................ 43

Revision 8.6 INDEX 3

3.4.7. Notch Speed 3........................................................................................................................ 43

SECTION PAGE

3.4.8. Notch Plugging....................................................................................................................... 43

3.4.9. Notch Plugging V.................................................................................................................... 43

3.4.10. Neutral Plugging V ................................................................................................................. 44

3.4.11. Neutral Deceleration Profile ................................................................................................... 44

3.4.12. Brake Plugging Volts.............................................................................................................. 44

3.4.13. Brakes on Speed.................................................................................................................... 45

3.4.14. Max Stall V ............................................................................................................................. 45

3.4.15. Min Start V.............................................................................................................................. 45

3.4.16. Notch 1; 2 and 3 Acceleration Time....................................................................................... 46

3.4.17 Notch 4_Accel Profile............................................................................................................. 46

3.4.18. Phase Shifter Off Time........................................................................................................... 46

3.4.19 Notch 4 Accel Delay............................................................................................................... 47

3.4.20. Separate Directional Signals.................................................................................................. 47

3.4.21. Plug Reduced %SP................................................................................................................ 48

3.4.22. Notches1,2 & 3 Smooth Prfl................................................................................................... 48

3.4.23. Brake Plug Soft ...................................................................................................................... 49

3.4.24. Load Defaults......................................................................................................................... 49

3.5. TORQUE APPLICATION PARAMETER LIST.............................................................................50

3.6. PARAMETER DESCRIPTIONS –TORQUE................................................................................51

3.6.1. Current Transformer Ratio ..................................................................................................... 51

3.6.2. Current Transformer Enable .................................................................................................. 51

3.6.3. Motor Current ......................................................................................................................... 52

3.6.4. Overload Class....................................................................................................................... 52

3.6.5. Notch 1 Voltage...................................................................................................................... 53

3.6.6. Notch 2 Voltage...................................................................................................................... 53

3.6.7. Notch 3 Voltage...................................................................................................................... 53

3.6.8. Notch 4 Voltage...................................................................................................................... 53

3.6.9. Notch 1 Plugging.................................................................................................................... 53

3.6.10. Notch 2 Plug........................................................................................................................... 53

3.6.11. Notch 3 Plug........................................................................................................................... 53

3.6.12. Notch 4 Plug........................................................................................................................... 53

4. INSTALLATION

4.1. GENERAL INSTALLATION......................................................................................................... 54

4.2. THYROMAT - BD DIGITAL CRANE CONTROLLER MECHANICAL INSTALLATION.............. 54

4.2.1. General................................................................................................................................... 54

4.2.2. Mounting Instructions............................................................................................................. 54

Revision 8.6

INDEX

4.2.3. Tools and Special Equipment ................................................................................................ 55

SECTION PAGE

4.2.4. Mounting Arrangements......................................................................................................... 56

4.2.5. Mounting Procedure............................................................................................................... 58

4.3. ELECTRICAL INSTALLATION.................................................................................................... 59

4.3.1. General................................................................................................................................... 59

4.3.2. Electrical Connection Instructions.......................................................................................... 60

4.3.3. Tools and Special Equipment ................................................................................................ 64

4.4. INSTALLATION DIAGRAMS....................................................................................................... 64

4.4.1 Digital Inputs –Main Board.................................................................................................... 65

4.4.2. Digital Inputs –Connectors on the Control Panel.................................................................. 66

4.4.3. Relay Outputs –Connectors on the Main Board .................................................................... 66

4.4.4. Triac Outputs –Control Panel Board..................................................................................... 67

4.4.5. Motor Current Inputs .............................................................................................................. 68

5. COMMISSIONING

5.1. GENERAL ................................................................................................................................... 69

5.2. PREPARATION........................................................................................................................... 69

5.3. COMMISSIONING PROCEDURES............................................................................................ 70

5.4. HOIST OPERATIONS................................................................................................................. 75

5.4.1. Hoisting .................................................................................................................................. 75

5.4.2. Lowering With an Overhauling Load...................................................................................... 75

5.4.3. Regeneration.......................................................................................................................... 75

5.4.4. Lowering With a Light Load.................................................................................................... 75

5.5. TRAVEL OPERATIONS.............................................................................................................. 76

5.5.1. Travel in All Directions............................................................................................................ 76

6. OPERATION OF CONTROL PANEL

6.1. GENERAL ................................................................................................................................... 77

6.2. SUPPLEMENTRY DISPLAY PAGES “SCROLL MENU”............................................................ 78

6.2.1. Parameters............................................................................................................................. 78

6.2.2. Set Time................................................................................................................................. 79

6.2.3. Fault History ........................................................................................................................... 79

6.3. KEY PAD PUSH BUTTONS........................................................................................................ 79

6.4. CONTROL PANEL OPERATION................................................................................................ 80

6.5. PARAMETER LISTS PAGE........................................................................................................ 81

6.5.1. Accessing the Parameters Page............................................................................................ 81

6.6. SET TIME PAGE......................................................................................................................... 82

6.7. FAULT HISTORY........................................................................................................................ 83

Revision 8.6 INDEX 5

SECTION PAGE

6.8. POSSIBLE CAUSES OF FAILURE............................................................................................. 85

6.8.1. Rotor Feedback...................................................................................................................... 86

6.8.2. Current Unbalance................................................................................................................. 87

6.8.3. Loss of Phase......................................................................................................................... 88

6.8.4. Current Feedback................................................................................................................... 88

6.8.5. Stack Temp ............................................................................................................................ 89

6.8.6. Overload Trip.......................................................................................................................... 89

6.8.7. Over Current........................................................................................................................... 89

6.8.8. H Loss of Torque.................................................................................................................... 90

6.8.9. Lower Overspeed................................................................................................................... 90

6.8.10. Motor Stall .............................................................................................................................. 91

6.8.11. Input Phases .......................................................................................................................... 91

6.8.12. Plugging Timeout ................................................................................................................... 91

6.8.13. Joystick Error.......................................................................................................................... 92

6.8.14. RFB & Current Loss............................................................................................................... 92

6.8.15. Not in Neutral ......................................................................................................................... 93

6.8.16. Drive Level ............................................................................................................................. 93

6.8.17. Power ON Test....................................................................................................................... 93

6.8.18. Break Release........................................................................................................................ 94

6.8.19-24. Error Codes.........................................................................................................................95

7. MAINTENANCE

7.1. GENERAL ................................................................................................................................... 96

7.2. PREVENTATIVE MAINTENANCE.............................................................................................. 96

7.2.1. Brakes .................................................................................................................................... 96

7.2.2. Ultimate Limit Switch.............................................................................................................. 97

7.3. SPARE PARTS LIST................................................................................................................... 97

8. SHIPPING AND STORAGE

8.1. GENERAL ................................................................................................................................. 100

8.1.1. Shipping ............................................................................................................................... 100

8.1.2. Storage................................................................................................................................. 100

9. ACRONYMS AND ABREVIATIONS

9.1. GENERAL ................................................................................................................................. 101

Thyromat BDC User Manual - Summary of Changes 27.05.05

Page 1 of 5

LATEST REVISIONS ON SUMMARY DOCUMENT

Please note the following changes made to Thyromat BDC Digital Crane Controller User Manual:

Note: Please be aware that small or minor layout, grammatical, or format changes are not recorded.

THYROMAT BDC USER MANUAL REV 8.5 to REV 8.6 CHANGES

Section

Page

Item

From

Index

1-5

Table of Contents updated and page numbers changed.

Power cable selection explanation: changes to content and grammar.

Overload Class 2 removed and added O/C 10

29-39

Hoist Parameters edited for software versions CHV11.XX

50-53

Torque Parameters added for CTT01.xx software version.

36/37

Explanations for Ph Shift On and Off time updated after investigation/measurements

done

40/49

Travel Parameters edited for software versions CTT01.XX

All

Page numbering has been changed due to revision changes –Section 4 begins at page

54 through page 68.

All

Page numbering has been changed due to revision changes –Section 5 begins at page

69 through page 76.

85-95

Possible causes of failure section edited. Order Changed and added: Loss of Phase,

Current Feedback, Stack Temp, Overload Trip, H Loss of Torque, Plugging Timeout

All

Page numbering has been changed due to revision changes –Section 6 begins at page

76 through page 95.

All

Page numbering has been changed due to revision changes –Section 7 begins at page

96 through page 97.

All

Page numbering has been changed due to revision changes –Section 8 begins at page

100.

All

Page numbering has been changed due to revision changes –Section 9 begins at page

101.

THYROMAT BDC USER MANUAL REV 8.4 to REV 8.5 CHANGES

Section

Page

Item

From

Page numbering has been changed due to revision changes –Section 7 begins at page

88 through page 91.

7.3

Thyristor Phase Arm spares have been added to the Spare Parts List

All

Page numbering has been changed due to revision changes in Section 7 –Section 8 now

begins at page 92

All

Page numbering has been changed due to revision changes in Section 7 –Section 9 now

begins at page 93

THYROMAT BDC USER MANUAL REV 8.3 to REV 8.4 CHANGES

Section

Page

Item

From

Page numbering has been changed due to revision changes –Section 3 now begins at

page 29 through page 45.

All

Changed the word Thyromat to THYROMAT

6.8.3

“Input Phases”

“INPUT PHASES”

6.8.9

NOTE (figure)

CAUTION (figure)

6.8.14

Rfb and Currt Loss

RFB & CURRT LOSS

Thyromat BDC User Manual - Summary of Changes 27.05.05 Page 2 of 5

Page numbering has been changed due to revision changes –Section 6 now begins at

page 69 through page 87.

THYROMAT BDC USER MANUAL REV 8.2 to REV 8.3 CHANGES

Section

Page

Item

From

Increment

2nd row

Minumum 10 A

Minimum 2 A

3.2.2

Minumum 10 A

Minimum 2 A

3.2.3

Overload class

Add: (This feature is not yet

implemented)

Caution

Moved text into Caution figure

3.2.10

Brake release current = No

load current / Motor current x

100

Brake release current % = (No load

current / Motor current) x 100

3.2.11

This parameter sets up the

minimum voltage applied to the

motor immediately at start of a

hoisting cycle.

This parameter sets up the minimum

voltage applied as a percentage of the

supply voltage to the motor

immediately at start of a hoisting

cycle.

3.2.13

“plugg out time”

“Plugging timeout”

3.2.14

(First paragraph))

Add: It is calculated as a percentage

of the supply volts.

6.1

…press the > key to de-

activate (switch-off) the back

lighting press the < key.

…press any key, the backlight will

automatically go off 20 seconds later.

Figure

6-1

Speed 000

O/L

Speed XXX

Removed O/L

Function 2nd

row

MAIN MENU

STATUS MONITORING PAGE

Remarks 2nd

row

To navigate through this page

press the menu key:-

To toggle between this page and the

motor currents page press the Menu

key.

Remarks 2nd

row

Each depression of the menu

key will display the next page;

the last page will loop back to

the first page.

Delete sentence completely.

Thyromat BDC User Manual - Summary of Changes 27.05.05

Page 3 of 5

Section

Page

Item

From

Function 3rd

row

STATUS MONITORING PAGE

MOTOR 3 PHASE CURRENTS

MONITORING PAGE

Remarks 3rd

row

This….are also displayed.

Add: To return to status monitoring

page, press the Menu key.

Add: picture of Menu key

Function

3rd row

… have been rectified.

Add: Also clears the fault history when

in fault history page.

Figure

6-3

Top figure added %

Bottom three figures added XXX

Figure

6-3

Parameters

page Navig.

Added %

Step 7

Figure

6-5

Added XXX

74-

Table 6-5

Complete revision of table contents

Below Table

6-5

Add footnote: (1) these faults can not be reset in Neutral if they still

remain active.

6.8.1

line)…as the motor loop

speed feedback that is

essential…

… as the motor loop speed feedback

and it is essential…

6.8.1 Possible

causes

Rfb and current loss

“RFB & CURRT LOSS”

6.8.1

(i.e. motorslip = 2)

(i.e. motorslip > 1)

6.8.3`

Ø Amps (1

line)

0 Amps

6.8.4

Ø Amps (1st line)

0 Amps

6.8.14 –6.8.24

Complete changes from 6.8.14 through 6.8.24

THYROMAT BDC USER MANUAL REV 8.1 to REV 8.2 CHANGES

Section

Page

Item

From

3.1.

1st parag.

10_00

10_XX

Increment

2nd row

Minimum 10 A

3.2.2 Table

Increment

Minimum 10 A

3.2.17

1st parag.

… selected

… programmed

3.2.17

Inserted drawings and text

3.2.17

All NO changed to “No”

All YES changed to “Yes”

Table 6-5

Added Drive Level and Power-on Test and Error Code 106

6.8.15

Inserted new paragraph Drive Level and Power-on Test.

6.8.15 Error Code 100 moved to 6.8.17

New item on

pg.83

Added: 6.8.22. –Error Code 106

Thyromat BDC User Manual - Summary of Changes 27.05.05

Page 4 of 5

THYROMAT BDC USER MANUAL REV 8 to REV 8.1 CHANGES

Section

Page

Item

From

3.2.7

After, applies the mechanical

brake.

Caution Inserted.

3.2.7

Set the voltage level

Set the ceiling voltage level

3.2.7

Torque applied

Maximum torque applied

6.8.13

Possible causes:

‘failure’

Possible causes:

‘failed to energise’

6.8.13

Rotor Feedback & Current

Loss

Included 3 sub-categories:

RFB & CURRT LOSS S

RFB & CURRT LOSS R

RFB & CURRT LOSS I

Table 13th row

RFB & Current Loss

RFB & CURRT LOSS (S); (R); (I)

THYROMAT BD USER MANUAL REV 7 TO REV 8 CHANGES

Section

Page

Item

From

2.2

220 (last line)

B 220 Volts control voltage

2.5.1

Coding pings unique...

Delete sentence

Table 5th row

Output phases unbalanced

Change 33% to 50%

Table 5th row

Motor overload protection:

class...

Delete sentence and add “This feature

is not yet implemented”

Table M100

STR 22SE 63A

STR 22SE 100A

2.16

Motor Thermal …

Add “This feature is not yet

implemented”

2.17

Sec 7 Paragraph 7.2.3

Paragraph 7.3

29-

3.1

Version 9_00

Version 10_00

3.2.2

Note:

Add “This feature is not yet

implemented”

3.2.17

terminal 4

Terminals 4 and 5

3.2.18.

Terminal 4

Terminals 4 and 5

Table

M500 (520)

515

Table

M1000 (520)

515

Step 7

(i.e. < 70%...

(i.e. < 75%...

Step 7

bellow

below

5.4.4

four lowering speeds

Three lowering slow speeds

6.8.4

Overload Trip

Add “This feature is not yet

implemented”

7.3

(Row 2) BDH 252) to …

BDT 252) to BDT 20002)

7.3

2) Indicate Supply voltage

Change all voltages “A” to “F” and add

“G” to “J”

7.3

5 Indicates control panel…

Moved to inside table at the bottom

7.3

Thyristors 5)

Changed all the 5) to 6)

7.3

5) Indicates peak inverse…

6) Indicates peak inverse…

Indice

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