Velocity Drive Module

User Manual

Manual Revision 1.5

Drive Software Version 4.3.04/4.3.05

Kinesys Software Version 3.1.4

kinesys velocity user manual

Page 2 of 29

velocity user manual kinesys

Kinesys Projects Limited accepts no liability for any consequences resulting from inappropriate, negligent or incorrect installation of the equipment.

The contents of this manual are believed to be correct at the time of printing. In a commitment to a policy of continuous development and improvement, Kinesys reserves the right to change the specification of the product or its performance, or the contents of this manual, without notice.

All rights reserved. No parts of this manual may be reproduced or transmitted in any form or by any means, electrical or mechanical including photocopying, recording or by an information storage or retrieval system, without permission in writing from

Kinesys Projects Limited.

© Kinesys Projects Limited 2008

Page 3 of 29

velocity user manual kinesys

Contents

Safety Advice........................................................................................................... 7

Introduction ............................................................................................................. 9

Specifications ........................................................................................................ 10

Layout .................................................................................................................... 11

Drive Front View.......................................................................................................11

Drive Rear View........................................................................................................13

Drive Display & Menu System .............................................................................. 15

DEFAULT DISPLAY..................................................................................................15

SCREEN SAVER ......................................................................................................15

VIEW MENU OPTION ..............................................................................................17

RESET MENU OPTION............................................................................................20

KEYPAD MENU OPTION .........................................................................................20

Power On/Power Off Sequence............................................................................ 21

Power On .................................................................................................................21

Power Off .................................................................................................................21

Drive Operation ..................................................................................................... 23

Running in manual mode from the Drive front panel..............................................23

Running in Auto mode from a remote controller ....................................................23

Drive operation under winch fault conditions .........................................................24

Pin Connections .................................................................................................... 25

MAINS IN..................................................................................................................25

MOTOR (0.75kw – 7.5kw 400v Drives)....................................................................25

MOTOR (11kw – 22kw 400v Drives)........................................................................25

ENCODER................................................................................................................26

BRAKES ...................................................................................................................26

LIMITS / WINCH CONTROL ....................................................................................27

RS485.......................................................................................................................28

CTNet .......................................................................................................................28

Page 5 of 29

velocity user manual kinesys

Safety Advice

x Carry out a full risk assessment for your particular application x Only allow competent personnel to operate the system x Test the emergency stop system on a regular basis x Never use damaged cables or connectors x Never operate motors or hoists without having a clear view of the load or reliable communication with an observer x If an unexpected move presents a potentially hazardous situation, use the emergency stop button to bring all hoists to an immediate stop x If you are unsure of any aspect of moving loads with the system stop and seek professional advice on the appropriate usage of the system x Under most fault conditions the Kinesys Velocity drive will to bring the winch to a halt in a controlled manner, at a predefined emergency stop ramp rate. But under the following conditions the drive will stop the winch immediatly, you must take account of this eventuality in the risk assesment of any system that incorporates a Kinesys Velocity drive. x Power failure will case an immediate stop x Ultimate Limit Stuck will case an immediate stop x Drive failure will cause an immediate stop

Page 7 of 29

velocity user manual kinesys

Introduction

The Velocity drive module is a powerful ac and servo motor drive system that allows a range of motors to be controlled and positioned with absolute precision.

Surrounding the advanced inverter technology is a range of user features designed to make using and maintaining the Velocity module very straightforward. Built-in manual running controls and a full diagnostic display help the user to set the system up simply and safely and the rugged steel case and locking metal motor connections ensure a long service life even in harsh physical environments.

Page 9 of 29

kinesys velocity user manual

Specifications

POWER SUPPLY: Three phase, neutral and earth supply: phase to phase voltage 380 – 420 v a.c.

ENCLOSURE:

ENVIRONMENTAL: IP40

OPERATING TEMPERATURE: 0 - 55°C (32 - 131 F)

DIMENSIONS:

1.6mm steel (front panel 2mm steel) zinc plated and clear passivated finish

RAL5011 stove enamelled and silk screened on front panel kg

486 x 500 x 175 (excluding connectors or front panel controls)

Page 10 of 29

7

8 velocity user manual

Layout

Drive Front View

1 kinesys

2 3 4 5 6

9

1. INFORMATION AND DIAGNOSTIC DISPLAY

displays information about the revolve movement and error messages as well as allowing configuration parameters to be edited

2. DISPLAY CURSORS

these buttons allow the user to navigate the display and edit parameter values

3. DRIVE CONTROL KEYSWITCH

sets the drive into one of three states, drive off, drive disabled and drive enabled. The key is removable in any of the three positions allowing the drive to be securely disabled when left unmonitored if required

4. MANUAL OPERATION KEYSWITCH

sets the drive to automatic mode to be controlled by either a pendant or a computer or to manual mode for local operation

5. MANUAL SPEED

sets the speed of the motor during manual operation

6. MANUAL DIRECTION

press and hold these buttons to initiate manual running

7. DRIVE STATUS INDICATORS

these show whether the drive is powered, whether it is off, disabled or enabled and whether it is moving

Page 11 of 29

kinesys velocity user manual

8. DISPLAY SELECTION BUTTONS

allows the user to navigate between screens on the information and diagnostic display

9. CIRCUIT BREAKERS

separate circuit breakers for control and drive. Turning off the control breaker will also power down the drive

Page 12 of 29

velocity user manual

Drive Rear View

1 3 9 2 kinesys

10

5 6

1. ETHERNET

7 8

Allows Ethernet connection for computer control and diagnostics.

2. MOTOR & ENCODER

connections to the motor and motor encoder are made here. These connections must be fully tightened to ensure a good electrical connection.

3. LIMITS & REMOTE CONNECTION

connections for over-travel and ultimate limits, overload and slack rope detection and secondary brake.

4. MAINS IN

ensure the supply is turned off at source before inserting or removing this connection

5. ARCNET

permits data network connection directly to the inverter for computer control and diagnostics.

6. RS485 used for external pendants or drive interconnection

7. DRIVE CONTROL

used when connecting multiple drives together or when connecting to an external emergency stop monitor and controller (e.g. Kinesys Array ES)

8. AUXILLARY

Permits the connection of remote equipment including pendants and joysticks etc.

9. AUXILLARY BRAKE

Permits the connection of 190VDC brakes.

Page 13 of 29

4

kinesys

10. EXTERNAL FUSES

velocity user manual

Page 14 of 29

velocity user manual kinesys

Drive Display & Menu System

The Velocity drive module incorporates an information and diagnostic display that allows the user to view and set parameters within the drive. These configure the way that the drive calculates its motion profiles and limits the top speed and ramp rate the load will travel at.

The information is accessed by viewing the display and by using the eight buttons underneath and to the right of it. The buttons to the right act as cursor buttons allowing the user to move up and down lists and to edit parameter values. The buttons underneath the display allow the user to move between screens and to allow different data to be displayed.

DEFAULT DISPLAY

The default display is split up into three main regions. activated.

System OK

1000

VIEW SETUP RESET KEYPAD

The top line of the display is the status window this shows the current alarm state, if multiple alarms are active each one will be displayed in turn for a second. A complete list of the displayed alarms is shown later in this manual. If the drive has no active alarms the message “System OK” will be displayed.

The middle part of the display shows the current position of the controlled winch or motor. This is displayed in mm and is normally shown in a large font .

The bottom part of the display indicates the functions of the four buttons below the display. The functions of these four buttons will change depending on what screen is currently being displayed.

The default display format will change slightly if any of the external limits are

Overload Trip

ULT FOR REV SLK

OVL

1000mm

VIEW SETUP RESET KEYPAD

The status window will change to two lines with the bottom line showing the state of the five limit switch inputs. The display above shows the Ultimate, Forward, Reverse and Slack limits all intact limit and the Overload limit tripped. Intact limits are shown in reverse video.

SCREEN SAVER

After a few seconds of inactivity the display will revert so a scrolling screen saver display. This display will include the message “** ALARMS ACTIVE **” if any error or trip conditions exist.

** ALARMS ACTIVE **

KINESYS

Page 15 of 29

kinesys velocity user manual

Pressing any key on the keypad will bring up the default screen where status messages will be shown on the

ALARMS

The following table lists all the alarms that could be displayed in the status window.

Alarm Displayed Alarm Description

Reverse Limit Trip

Forward Limit Trip

Overload Trip

The Reverse limit switch has been hit

The Forward limit switch has been hit

The Overload limit switch has been hit

Slack/Underload Trip

Ultimate Limit Trip

Limit Override

Brake Resistor Trip

Contactor Jammed

The Slack rope limit switch has been hit

The Ultimate limit switch has been hit

The Mode key switch on the front panel is being held in the spring loaded “Limits” position which bypasses all external limits and allows, a motor to be driven off a limit. Note the drive is still able to sense the state of the external limits.

Drive Disabled

Emergency Stop Active

The main input contactor is jammed is on when the drive is expecting it to be off

The Drive is in a disabled state. For the drive to be enabled, the external drive enable signal on the Drive Control connector, on the back panel, needs to be intact. Also the Drive Control key switch on the front panel needs to be in the

Enabled position

The Emergency Stop signal on the Drive Control connector, on the back panel, is missing.

The Enable signal on the Drive Control connector has just been lost and the drive is ramping to a stop at the emergency ramp rate.

Wire/Groove Jump

Belt Break

Aux Power Fuse Fail

Main Brake Fuse/PSU Fail

Sec Brake Fuse Fail

Main Brake Disconnect

Main Brake Fail

Sec Brake Fail

The Wire/Grove Jump limit switch on the winch has tripped.

The Belt brake detect switch on the winch has been activated.

The Auxiliary 24v power fuse has blown, see the fuse holder on the back panel.

The Main Brake Fuse has failed, see the fuse holder on the back panel.

The Secondary Brake Fuse has failed, see the fuse holder on the back panel.

Indicates that the main brake is not drawing current when energised

Indicates that the secondary brake is not drawing current when energised

Indicates that the main brake has not released

Indicates that the secondary brake has not released

Page 16 of 29

velocity user manual kinesys

I2C Comms Failure

Drive Comms Fail

Drive Off

Drive Trip

Internal Fault please contact the supplier

Internal Fault please contact the supplier

The Inverter Drive within the box is powered off this could be because:- x The Drive Control Switch is in the Off position. x The Drive MCB is in the Off position. x The Emergency stop signal on the Drive

Connector is missing.

The Drive has tripped. The drive trip code will be displayed along with this message.

Local Manual Mode

Manual Up Active

Manual Down Active

The Mode Key switch on the front panel is in the

Manual position. This will allow the drive to be controlled by the forwards, reverse and speed controls on the front panel

The Manual Up button on the front panel is being pressed.

The Manual Down button on the front panel is being pressed.

VIEW MENU OPTION

The View menu option allows the default display of the drive to be switched to show something other than the current position. The most important of those display options are shown below.

View Option

Current Position (mm)

Motor Current (A)

Drive Load (%)

Description

Will show the current position in mm

Will show the current motor current in A

Will show the current drive load as a % of full current load. Note the drive is capable of driving up to 175% of full load for a few seconds

Show the current motor speed in rpm Motor RPM (rpm)

To select a display option the view key is pressed and the up and down arrow keys are used to highlight the desired display option. This is then chosen by pressing the

‘select’ key.

Page 17 of 29

kinesys velocity user manual

SETUP MENU OPTION

The Setup menu option allows various drive parameters to be displayed and edited.

A list of the menu options is shown below.

View Option Description

Unit Address This will allow the unit address to be changed.

For Ethernet access this drives IP address would be 192.168.18.X where X is the Unit address. X will also be the drives CT net address.

Drive Rating

Software Version

KinPos Version

Upper Limit (mm)

Upper Limit (mm)

Set Position (mm)

Gearbox Ratio (x100)

This read only Parameter shows the maximum heavy duty current rating of the drive. The values shown below show the correlation between current rating and the Drive Power rating at

400V.

9.50A = 4kw

13.00A = 5.5Kw

16.50A = 7.5Kw

25.00A = 11kw

This is a read only display of the drives current software version.

This is a read only display of the drives current positioner software version.

This parameter allows the upper soft limit to be adjusted. This soft limit is only active when the drive is controlled from a computer. The manual controls on the front panel ignore the soft limits.

This parameter allows the loer soft limit to be adjusted. This soft limit is only active when the drive is controlled from a computer. The manual controls on the front panel ignore the soft limits.

Changing this value will change the position the drive currently thinks its at. It allows the drive position to be re-referenced.

To allow the drive to correctly display the distance in mm, the gearbox ratio of the winch should be entered here. Note to this gearbox ratio is multiplied by 100. A gearbox ratio of 25.7 should be entered as a value of 2570.

Page 18 of 29

velocity user manual

Brake Type

Drum Circ (mm)

Max Speed (mm/s)

Estop Ramp (mm/s/s)

Jog Ramp (mm/s/s)

Move Delay (x1ms)

DigLock Mode (0-4)

Invert Direction (0-1) kinesys

This value determines how the primary and secondary brakes work together. The following values are valid.

0 = The primary brake is released for the duration of a move. The Secondary Brake follows the Primary Brake. This is the normal mode of operation.

1 = The primary brake is released for the duration of a move. The Secondary Brake is released whenever the drive is enabled. This mode is primarily used when the secondary brake is a very large slow acting device.

2 = The primary brake is released whenever the drive is active and holding the load. The

Secondary Brake follows the Primary Brake. This mode is primarily used when controlling servo motors that are energised all the time.

Any other value in this parameter will act like a value of 0.

To allow the drive to correctly display the distance in mm, the circumference in mm of the winch drum should be entered here.

This value is automatically calculated from the

Gearbox ratio and Drum Circumference, but can be altered here if required.

This is the ramp rate that will be used if a Fast stop is triggered externally by removing the enable line. This ramp rate should be set as high as possible for the installation to allow the winch to stop in the shortest possible time.

This is the ramp rate that will be used when the drive is controlled by the manual controls on the front panel.

The drive is capable of delaying the start of a move if the brakes are applied, to allow them time to release. A maximum value of 2000 = 2s is allowed for this value.

This parameter specifies if the drive is digitally locked to other drives. Digital locking requires extra hardware and this parameter should be left at its default value of 1.

This parameter allows the drive to select which direction of rotation of the drum relates to a forwards movement. This value should be set as required by the installation.

Page 19 of 29

kinesys velocity user manual

RESET MENU OPTION

This key will case the Inverter Drive to be reset which will clear any drive trips shown in the status window.

KEYPAD MENU OPTION

Pressing the menu key below the keypad option, switches the drive into a debug mode that allows debugging equipment to be plugged into the program port on the front of the drive. The drive will detect if this equipment has been removed after a couple of minutes and switch itself back to normal operating mode. This state is indicated by the Keypad text flashing.

Page 20 of 29

velocity user manual kinesys

Power On/Power Off Sequence

Power On

1. Make sure all relevant motor, power and control connections are made correctly

2. Turn on the 32A three phase supply

3. Turn on both the circuit breakers on the front of the drive. The display on the front of the drive should illuminate

4. When you are ready to move turn the ‘drive control’ key switch on the front of the drive to ‘enable’

Power Off

The power down procedure is performed by following the power up procedure in reverse.

Page 21 of 29

velocity user manual kinesys

Drive Operation

Running in manual mode from the Drive front panel

The Velocity drive module has manual controls fitted to the front panel. This allows motors to be controlled directly from the drive. A clear view of the moving load must be available for safe operation.

To move the load from the drive turn the Drive Control key switch to the ‘enable’ position and the mode key-switch to the ‘manual’ position. The ‘forwards’ and

‘reverse’ buttons will illuminate.

The manual controls on the front of the drive use the jog ramp set in the drive under the setup menu. This should be checked to ensure it is the desired value. You should ensure that the speed control on the drive is set to minimum speed (fully anti-clockwise) before commencing movement.

To start the winch moving simply press and hold either the ‘forwards’ or ‘reverse’ buttons depending on the desired direction. Then slowly advance the speed control until the load is moving at the desired speed.

The manual controls on the front panel allow the winch to be driven between its upper and lower limits, they will ignore any software limits set in the drive.

If the winch fails to move or stops moving, refer to the status window on the drive display act check the displayed message against the list shown in the menu system section of this manual.

Running in Auto mode from a remote controller

The Velocity drive module can be controlled from an external controller via interface connections on the back panel. The primary method of connection is via Ethernet and allows complex systems to be controlled using the Kinesys “Vector” and “K2” control software packages. Please contact Kinesys for more details on these products.

To switch the drive into Auto mode, move the Drive Control key switch to the

‘enable’ position and the mode key-switch to the ‘auto’ position. In this mode local control from the drive is inhibited.

Page 23 of 29

kinesys velocity user manual

Drive operation under winch fault conditions

Various fault conditions can occur at the winch and the drive will react in certain ways depending upon the severity of the fault. Various conditions are listed below along with the appropriate drive response.

Winch Fault Drive response

Ultimate Limit struck The drive will stop abruptly with no ramp down and the brakes will be applied immediately

Belt brake limit active The drive will stop abruptly with no ramp down and the brakes will be applied immediately

Forwards limit struck The drive will ramp to a stop at the emergency ramp rate.

The brakes will then be applied

Reverse limit struck The drive will ramp to a stop at the emergency ramp rate.

The brakes will then be applied

Slack Rope limit active The drive will ramp to a stop at the emergency ramp rate.

The brakes will then be applied

Overload limit active The drive will ramp to a stop at the emergency ramp rate.

The brakes will then be applied

Page 24 of 29

velocity user manual kinesys

Pin Connections

MAINS IN

Harting HsB / ILME CP / Contact HBS - male on panel with 2 locking levers

Panel Connector:

Harting HsB6 male with 2 levers 09 31 006 2601 / 09 30 016 0301

Mating Connector:

Harting HsB6 female with 4 pegs 09 31 006 2701 / 19 30 016 1522

PIN FUNCTION

L1

L2

L3

4 neutral connection

6 earth shell earth

MOTOR (0.75kw – 7.5kw 400v Drives)

Intercontec Series B 5+E / Contact LS1 5+E – female on panel with screw locking ring

Panel Connector: Intercontec BSTA 085 NN 00 59 0035 000

Mating Connector: Intercontec CKUA 267 …

PIN FUNCTION

U

V

3 / E earth

W

5 Brake + 24V DC

0V

MOTOR (11kw – 22kw 400v Drives)

Intercontec Series C 6-pole - female on panel with screw locking ring

Panel Connector: Intercontec CSTA 263 …

Mating Connector: Intercontec CKUA 267 …

PIN FUNCTION

U

V

W

E earth

+ Brake + 24V DC view on female connector mating face

Page 25 of 29

kinesys

ENCODER

velocity user manual

Intercontec Series A 17-pin / Contact R2.5 17-pin – female on panel with screw locking ring

Panel Connector: Intercontec ASTA 035 FR 01 61 0035 000

Mating Connector: Intercontec AKUA 034 MR 04 61 0035 000

pin function (Servo) function (SinCos) function (HiperFace) function (EnDat) function (SSI)

2 thermistor 0V

3 thermistor screen

4 U

5 /U

6 V

7 /V

8 W

9 /W

10 A

11 Z

12 /Z

13 /A thermistor 0V thermistor screen simulated encoder out A simulated encoder out /A thermistor 0V thermistor screen simulated encoder out A simulated encoder out /A thermistor 0V thermistor screen simulated encoder out A simulated encoder out /A thermistor 0V thermistor screen simulated encoder out A simulated encoder out /A simulated encoder out B simulated encoder out /B simulated encoder out B simulated encoder out /B simulated encoder out B simulated encoder out /B simulated encoder out B simulated encoder out /B clock clock

/clock /clock

Cos Cos Cos Cos

Cosref data data data

/data /data /data

Cosref Cosref Cosref

15 /B Sinref Sinref Sinref Sinref

BRAKES

Amphenol C16-3 8+E - female on panel with locking threads female on panel with locking threads

Panel Connector: Amphenol C016 10G008 0001

Mating Connector: Amphenol C016 10I008 0021

PIN FUNCTION NOTES

1

2

3

4

5

6

Phase L3 un-switched Controlled by drive power contactor

Neutral un-switched Controlled by drive power contactor

190V DC + switched

190V DC - switched

24V DC + switched

24V DC - switched

Controlled by secondary brake circuit

Controlled by secondary brake circuit

Controlled by secondary brake circuit

Controlled by secondary brake circuit connection connection

E earth

Page 26 of 29

velocity user manual kinesys

LIMITS / WINCH CONTROL

Tourline TL25 - female on panel with screw locking ring

Panel connector: Ten-47 Tourline TL25PF26

Mating Connector: Ten-47 Tourline TL25LM01

pin function

A E-stop 1A

notes

emergency stop circuit 1 - link to B if not used

B E-stop

C E-stop 2A emergency stop circuit 2 - link to D if not used

D E-stop

E E-stop 3A

F E-stop emergency stop trace circuit - link to F if not used

3B

L

M

N

P

G

H

J

K brake +24V DC brake 0V DC brake +24V DC brake 0V DC

24V DC

0V home sensor ultimate limits

Q

R

S

T

U forwards limit reverse limit slack rope overload sensor 1

V sensor 2

W 21

X

Y limits override remote data +

Z

- remote data - data ground secondary brake connection secondary brake connection secondary brake connection secondary brake connection limits / sensor power supply limits / sensor power supply datum sensor - connect to 24V connect to 24V - link to 24V if not used connect to 24V - link to 24V if not used connect to 24V - link to 24V if not used connect to 24V - link to 24V if not used connect to 24V - link to 24V if not used auxiliary sensor - connect to 24V auxiliary sensor - connect to 24V reserved connect to 24V to override limit switches remote control HMI connection remote control HMI connection remote control HMI connection

Page 27 of 29

kinesys

RS485

XLR5 - link in and out

Panel Connector: Neutrik NC5MDL1 / NC5FDL1

Mating Connector: Neutrik NC5FX / NC5MX

pin function

ground

2 Rx-

3 Rx+

4 Tx-

5 Tx+

CTNet

XLR3 - link in and out

Panel Connector: Neutrik NC3MDL1 / NC3FDL1

Mating Connector: Neutrik NC3FX / NC3MX

pin function

ground

A velocity user manual

Page 28 of 29

velocity user manual kinesys

© Kinesys Projects Limited 2008

Kinesys Projects Limited

Unit 2, Kempton Gate Business Centre

Oldfield Road

Hampton

TW12 2AF

United Kingdom t +44 (0)20 8481 9850 f +44 (0)20 8487 0396 e [email protected]

w www.kinesys.co.uk

Page 29 of 29