MH THYROMAT-BDC User Manual Download Page 105

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Revision 8.6

SECTION 7: MAINTENANCE

525400/ARM

Thyristor Phase Arm

400A 525V

525500/ARM

Thyristor Phase Arm

500A 525V

525700/ARM

Thyristor Phase Arm

700A 525V

5251000/ARM

Thyristor Phase Arm

1000A 525V

5251200/ARM

Thyristor Phase Arm

1200A 525V

5251500/ARM

Thyristor Phase Arm

1500A 525V

5252000/ARM

Thyristor Phase Arm

2000A 525V

Summary of Contents for THYROMAT-BDC

Page 1: ......

Page 2: ...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...

Page 3: ...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 Sto...

Page 4: ...l 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 5...

Page 5: ...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 Low...

Page 6: ...rspeed 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 Tes...

Page 7: ...Changed and added Loss of Phase Current Feedback Stack Temp Overload Trip H Loss of Torque Plugging Timeout 6 All Page numbering has been changed due to revision changes Section 6 begins at page 76 t...

Page 8: ...otor 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 35 3 2 13...

Page 9: ...remain active 6 76 6 8 1 1 st line as the motor loop speed feedback that is essential as the motor loop speed feedback and it is essential 6 76 6 8 1 Possible causes Rfb and current loss RFB CURRT LO...

Page 10: ...es unbalanced Change 33 to 50 2 18 Table 5 th row Motor overload protection class Delete sentence and add This feature is not yet implemented 2 22 Table M100 STR 22SE 63A STR 22SE 100A 2 27 2 16 Motor...

Page 11: ...mented 3 14 20 3 1 Version 9_00 Version 10_00 3 19 3 2 17 terminal 4 Terminals 4 and 5 3 21 26 3 3 Version 7_00 Version 8_00 3 25 3 2 18 terminal 4 Terminals 4 and 5 6 35 6 8 4 Overload Trip Add This...

Page 12: ...tions combined with digital technology and thousands of man hours of engineering and design has resulted in a unique robust and reliable product Designed specifically to operate in the tough environme...

Page 13: ...oder required o No mechanical modifications needed on motor shaft o No additional installation costs labour and equipment o No maintenance of a tacho required o No need for small control wires in cabl...

Page 14: ...6 SECTION 1 GENERAL 8 1 1 1 Basic System Diagram The system s simplicity is illustrated in the Basic System Diagram refer to Figure 1 1 This diagram is applicable to both hoist and travel operations F...

Page 15: ...his diagram is applicable to both hoist and travel motions Figure 1 2 THYROMAT Components 1 Control box 2 Control panel 3 Keypad 4 Display 5 Snubber card 6 Phase shifter card 7 Relay card 8 Control ca...

Page 16: ...x 180 x 202 6 kg THYROMAT BD 30 30 A M100 237 x 180 x 202 6 kg THYROMAT BD 60 60 A M100 237 x 180 x 202 6 kg THYROMAT BD 100 100 A M150 296 x 180 x 225 10 kg THYROMAT BD 150 150 A M150 296 x 180 x 22...

Page 17: ...s BD Digital applications H Hoist applications T Travel applications 025 A 200 A 1 000 A 030 A 350 A 1 200 A 060 A 400 A 1 500 A 100 A 500 A 2 000 A 150 A 700 A 2 500 A 380 volts 415 volts 525 volts A...

Page 18: ...he mechanical power that will be generated by the motor using the speed load and efficiency of the motion Step 2 If this data is not available use the electrical power for the specific duty Step 3 Obt...

Page 19: ...C Altitude above sea level 1 500 meters The typical severe duty applications are as for BS 466 1984 cranes with a group mechanism in M5 to M8 heavy duty workshop warehouse and general hook service Th...

Page 20: ...363 A 333 A M1000 500 A 416 A 357 A 454 A 416 A 700 A 583 A 500 A 636 A 583 A 1000 A 833 A 714 A 909 A 833 A M2000 1200 A 1 000 A 857 A 1 090 A 1 000 A 1500 A 1 250 A 1 071 A 1 363 A 1 250 A 2000 A 1...

Page 21: ...CARDS INTO THE MOTHERBOARD NOT TO BEND THE CONNECTING PINS 2 DO NOT TOUCH ANY OF THE COMPONENTS ON THE CIRCUIT BOARDS THEY ARE VOLTAGE SENSITIVE AND MAY BE DAMAGED DESTROYED The control box contains...

Page 22: ...not sensitive to incoming mains disturbances The thyristor trigger module incorporates a unique dynamic time amplitude transient clipping circuit 2 5 5 Snubber Card This card protects the thyristors...

Page 23: ...st Supply variations 10 15 Digital inputs Control voltage Generated by the THYROMAT internal regulated supply circuit 10 V DC max 5 mA per input Outputs Main board 110 V or 220 Vac supply 5 x Relay ou...

Page 24: ...edback Loss of torque detection Control method Phase angle control 3 phase 6 thyristors connected in line with motor stator in anti parallel configuration Operating frequency 50 Hz 1 Braking torque Va...

Page 25: ...with filters recommended M500 400 A 1 830 W 1400 1800 400 M1000 500 A 2 280 W 1800 1400 500 Forced ventilation with filter recommended or open chassis plate installed inside crane girders where possib...

Page 26: ...s data tables Step 4 Calculate new R 1 A R 1 A RA x Pm Pe Step 5 Calculate the motors rotor resistance K100 that will give 100 rated torque at start Obtain the motors open circuit rotor voltage RV fro...

Page 27: ...eaker for the THYROMAT must be able to protect the THYROMAT unit against most current surges It is strongly recommended that a circuit breaker type such as manufactured by Merlin Gerin part number NS...

Page 28: ...NS 400_ STR 23SE 400A M500 400 A NS 400_ STR 23SE 400A M1000 500 A NS 400_ STR 23SE 400A NS 630_ STR 23SE 630A 700 A NS 630_ STR 23SE 630A 1000 A NS800_ Micrologic 2 0 M2000 1200 A NS1000_ Micrologic...

Page 29: ...between the relay outputs of the THYROMAT and the stator rotor contactors Contactors can be used as single units or where necessary may be used in parallel The rating of the continuous supply current...

Page 30: ...used on festoon systems The selection of cable selection also largely depends on the environmental conditions that the crane will operate in 2 12 2 Control Supply Cables The THYROMAT uses interposing...

Page 31: ...nt flowing in the circuit at the instant that the contactor is required to drop out This process increases the electrical life of the contactor and allows the use of contactors with AC1 ratings as opp...

Page 32: ...e adjusted accordingly There are four basic configurations used to connect the rotor contactors the most popular configurations used are Delta and Star configurations and although not as popular V and...

Page 33: ...on This method of protection does not monitor the thermal state of the motor accurately because it can only monitor the current drawn by the motor but does not take in consideration ambient and other...

Page 34: ...lure to do so will render the warranty of the product null and void NOTE Although the larger higher current ratings THYROMAT units are compatible to lower currents the mounting holes will differ MH Au...

Page 35: ...0 1 30 7 Hoist plugging Enable Hoist plugging Yes or No No 8 Hoist plugging V Hoist plugging voltage 20 to 80 5 50 9 Lower plugging V Lower plugging voltage 50 to 100 5 80 10 Brake release I Brake rel...

Page 36: ...N A CONSERVATIVE MANNER AND ONLY WITH A FULL UNDERSTANDING OF EACH FUNCTION 3 2 1 CT Ratio NO PARAMETER DESCRIPTION SCALE INCREMENT DEFAULT 1 CT Ratio CT ratio 50 1 to 3000 1 50 1 This parameter selec...

Page 37: ...PLATE VALUE FOR THE APPLICABLE DUTY Note This value should be determined during the design phase This value is to be used by the thermal model to calculate overload conditions 3 2 3 Overload Class NO...

Page 38: ...ent to decelerate the load quickly due to the high inertia stored in the cable drum With Hoist Plugging enabled the control system will detect during upwards movement if natural retardation does not o...

Page 39: ...80 5 50 This parameter is only active if parameter 7 Hoist plugging Yes active Hoists with high inertia require assistance during retardation by applying braking torque The percentage of Hoist pluggin...

Page 40: ...is parameter sets the minimum stator current required to allow the brakes to be released As a general rule this current value must be equal or greater than the motor magnetizing current If this curren...

Page 41: ...time out time compares the actual motor Lowering retardation profile against the profile set by this parameter In the event that the actual retardation is going to take longer than the set retardatio...

Page 42: ...his case the parameter 15 setting is derived from the maximum contactor drop out time minus the close in time as in the example below Example Reversing contactors LC1 F265 Contactor drop out time with...

Page 43: ...e the maximum close in time In this case the recommended phase shifter off delay time is based on the maximum close in time of the contactor plus parameter 15 s set value i e Maximum close in time par...

Page 44: ...ith these parameters and the parameters need to be set to No When set as No This is the way that THYROMAT analogue and early digital units use to select the direction or rotation of the motor For Hois...

Page 45: ...parameter returns all the parameters to factory default settings CAUTION IF IT IS NECESSARY TO CHANGE ANY PARAMETERS IT IS RECOMMENDED THAT THIS BE DONE IN A CONSERVATIVE MANNER AND ONLY WITH A FULL...

Page 46: ...tage 0 to 90 5 40 10 Neutral PlugginV Neutral plugging Voltage 0 to 90 5 70 11 Neutral Decel P Neutral Deceleration Profile 2 to 20 sec 1sec 5 sec 12 Brake Plugging V Voltage to apply when plugging in...

Page 47: ...0 1 to 3000 1 50 1 This parameter selects a current transformer ratio CT ratio Only CT ratios from the list can be used The available CT ratios are THE AVAILABLE CT RATIO S ARE 50 1 100 1 200 1 300 1...

Page 48: ...OR THE APPLICABLE DUTY Note This value should be determined during the design phase This value is to be used by the thermal model to calculate overload conditions 3 4 4 Overload Class NO PARAMETER DES...

Page 49: ...EMENT DEFAULT 8 Notch Plugging Notch plugging Yes or No Yes This parameter enables or disables plugging between Notches Refer to Parameter 9 below for further details 3 4 9 Notch Plugging Voltage NO P...

Page 50: ...l deceleration is restricted by Parameter 10 above In the event that a quick deceleration is required the maximum Neutral plugging voltage Parameter 10 above may have to be raised to enable the motor...

Page 51: ...on i e Motor is stalled Usually a setting of 70 is sufficient to enable the motion to operate satisfactory It is sometimes necessary to increase this voltage usually in the case of bad Travelling rail...

Page 52: ...RIPTION SCALE INCREMENT DEFAULT 17 N4 Accel Acceleration rate for full speed acceleration 2 to 20 sec 1 5 Notch 4 acceleration profile is based on ramping the motor stator voltage as opposed to Notche...

Page 53: ...jump from slow speed operation Speed ramp to full speed operation voltage Torque ramp 3 2 20 Separate Directional Signals NO PARAMETER DESCRIPTION SCALE INCREMENT DEFAULT 20 Sep dir signals Separate d...

Page 54: ...ing to approximately 85 of its preselected value when the motor speed drops below a certain point The speed at which the Reduced Counter torque is applied is determined by this parameter 3 4 22 Notche...

Page 55: ...applied gently i e The Brake plugging voltage ramps using a slope of 800ms from 0 to 100 voltage When the parameter is turned to No the Brake plugging is standard and will use a ramp slope of 200ms i...

Page 56: ...Plug Plugging Voltage applied when N1 is selected in the opposite direction 30 to 100 1 50 10 Notch 2 Plug Plugging Voltage applied when N2 is selected in the opposite direction 30 to 100 1 60 11 Not...

Page 57: ...selects a current transformer ratio CT ratio Only CT ratios from the list can be used The available CT ratios are THE AVAILABLE CT RATIO S ARE 50 1 100 1 200 1 300 1 400 1 500 1 600 1 800 1 1000 1 120...

Page 58: ...R THE APPLICABLE DUTY Note This value should be determined during the design phase This value is to be used by the thermal model to calculate overload conditions 3 6 4 Overload Class NO PARAMETER DESC...

Page 59: ...PEEDS IN EXCESS OF 30 ARE SELECTED SPECIAL ROTOR RESISTANCE DESIGN MAY BE NECESSARY CONSULT YOUR LOCAL MH AUTOMATION REPRESENTATIVE FOR ASSISTANCE 3 6 9 Notch 1 Plug 3 6 10 Notch 2 Plug 3 6 11 Notch 3...

Page 60: ...RANE CONTROLLER MECHANICAL INSTALLATION 4 2 1 General The THYROMAT is a simple item to mount THYROMAT is provided with the correct fasteners to secure the unit on to the mounting surface In the event...

Page 61: ...low for sufficient air circulation to aid in the cooling of the THYROMAT A minimum space of 150 mm at the top and 150 mm at the bottom of the THYROMAT must be free of obstructions to allow for suffici...

Page 62: ...4 2 4 Mounting Arrangements Table 4 2 lists the mechanical mounting arrangement for the various THYROMAT controllers Table 4 2 Mechanical Mounting Arrangements of THYROMAT BD Digital Crane Controllers...

Page 63: ...U Us se er r M Ma an nu ua al l Revision 8 6 SECTION 4 INSTALLATION 57 MECHANICAL SIZE MOUNTING HOLE ARRANGEMENT measurement in mm M350 200 300A Thyromat M500 400A Thyromat M1000 500 1000A Thyromat...

Page 64: ...the mounting holes Using the electric drill and applicable drill bit drill the mounting holes take care not to damage any objects and or equipment that may be mounted on the opposite side of the mount...

Page 65: ...eral WARNINGS 1 DO NOT ATTEMPT TO MAKE ANY CONNECTIONS TO THE THYROMAT WHILE IT IS CONNECTED TO THE MAINS POWER LIVE 2 AFTER DISCONNECTING THE THYROMAT FROM THE MAINS POWER USE A MULTI METER TO MAKE S...

Page 66: ...nly a competent licensed Electrician or a suitably qualified person should be allowed to install the THYROMAT 2 It is important to shield the control electronics from any magnetic inductance that coul...

Page 67: ...to the THYROMAT and thyristor stack make sure that the correct connector lug sizes are used refer to Table 4 4 Connector Lug Data Where fasteners are used to connect the electrical lugs to the THYROMA...

Page 68: ...35 x 8 200 A 350 A 70 x 8 95 x 10 400 A 120 x 12 500 A 700 A 1 000 A 150 x 12 240 x 12 or 120 x 12 2 cable PH 150 x 12 2 cable PH 1 200 A 1 500 A 2 000 A 240 x 14 300 x 14 or 150 x 14 2 cable PH 240...

Page 69: ...350 M500 M1000 M2000 TORQUE VALUES IN Nm 25 A 30 A 60 A N A 100 A 150 A N A 200 A 350 A N A 5 400 A 7 500 A 700 A 1 000 A 7 7 7 1 200 A 1 500 A 2 000 A 15 15 15 CURRENT DENSITY IN AMPERES PER mm2 25 A...

Page 70: ...Controller Mechanical Size M100 M150 M350 M500 M1000 M2000 Multimeter X X X X X X Insulation tester X X X X X X Diagonal pliers X X X X X X Wire stripper or knife X X X X X X Lug crimping pliers X X...

Page 71: ...ED STEP NOT USED 1 2 3 4 5 6 7 8 9 Figure 4 3 Digital Inputs for the Main Board Hoist Applications K01 Hoisting command and first speed step selection K02 Lowering command and first speed step selecti...

Page 72: ...travel applications K12 Not used in standard hoist and travel spplications 4 4 3 Relay Outputs Connectors on the Main Board Figure 4 5 illustrates the installation diagram for the relay outputs from...

Page 73: ...n special applications 4 4 4 Triac Outputs Control Panel Board Figure 4 6 illustrates the installation diagram for the triac outputs from the control board TRIAC RATINGS 600V AC 2A MAX 100 Ma CONTINUO...

Page 74: ...N 68 4 4 5 Motor Current Inputs Figure 4 7 illustrates the installation diagram for the motor current inputs Figure 4 7 Motor Current Inputs Hoist Applications CTs always required Travel Applications...

Page 75: ...RATION WARNINGS 1 HIGH VOLTAGE COMPONENTS ACCIDENTAL CONTACT WITH THYRISTOR STACKS CAN RESULT IN FATAL INJURIES 2 ONCE CONNECTED TO THE MAINS SUPPLY ALL INTERNAL COMPONENTS OF THE CONTROL UNIT EXCEPT...

Page 76: ...e rotor resistances are wired correctly MH Automation always provides the correct values of the resistance steps on the respective rotor schematic diagram Follow these correctly to ensure that motor p...

Page 77: ...ge The Incoming 3 phase supply has a phase imbalance Step 8 Input the motor parameters as necessary At this stage the only parameter which should be modified are the parameters which refer to the moto...

Page 78: ...sary to replace it with a standby spare motor Under a great discrepancy on the rotor voltage the rotor resistance which was calculated around the motor name plate values is going to be inadequate too...

Page 79: ...reconnected as recommended and proceed with the next step Step 12 No load test Run the motion in both directions notch by notch to ensure that the direction of rotation is correct and there are no oth...

Page 80: ...peed and then returned to neutral position the deceleration to full stop should be achieved within reasonable time i e approximately 3 sec At stop the brakes should apply when the motor is at standsti...

Page 81: ...t contactor remains activated providing the motor the opportunity to apply counter torque in order to maintain the lowering speed In a no load condition the lower contactor may be energized to operate...

Page 82: ...vided before the brake is released Selection of one of the three slow speeds will regulate the motor to the associated speed in the event that full speed is selected the motor will accelerate smoothly...

Page 83: ...ete panel The display has back lighting to aid the identification of the displayed data under darkened conditions The back lighting can only be activated in the main menu page after the power up cycle...

Page 84: ...d capacity 3RD Status 4TH Drive healthy drive status Second display page MOTOR 3 PHASE CURRENTS MONITORING PAGE 1ST Joystick position and speed This page displays the current transformer inputs take n...

Page 85: ...the each of the faults occurred 6 3 KEY PAD PUSH BUTTONS The keypad of the THYROMAT BD Digital Crane Controller has eight push buttons Table 6 2 lists the push buttons and their functions Table 6 2 K...

Page 86: ...on 8 6 SECTION 6 OPERATION OF CONTROL PANEL 80 6 4 CONTROL PANEL OPERATION Navigating through the Display by using the Keypad is logical and structured as detailed in figure 6 3 Menu Navigation Chart...

Page 87: ...ey to enter the parameters list 4 Scroll through the parameters with and keys 5 To modify a parameter scroll or v to the correct value then use the or keys to move to the next parameter 6 To save the...

Page 88: ...illustrated in Figure 6 4 Figure 6 4 Set Time Page The SET TIME page displays the hour minute day month and year The cursor indicates the field which can be adjusted Table 6 4 lists the field name and...

Page 89: ...ault history list A typical fault history menu page is illustrated in figure 6 5 Figure 6 5 Fault History Menu Page The fault history data is displayed in four rows The following details the displayed...

Page 90: ...8 3 b Loss of phase 3 Yes Complete phase loss 0 Amps detected by current transformer input 3 6 8 3 c Current feedback Yes All 3 motor currents missing 6 8 4 Stack temp Yes 1 Excessive stack temperatur...

Page 91: ...6 8 16 Power On Test Yes Routine CPU Test at power up of the unit failed 6 8 17 Brake Release Yes One of several of the conditions required before the brakes are released has failed 6 8 18 Error Code...

Page 92: ...actual rotor speed rotation hence the increase in rotor frequency output i e motor slip 1 Possible causes Directional contactor failed to energize A rotor feedback may occur if the control supply is...

Page 93: ...n ascertain if there is a relevant discrepancy in readings A fault such as this one may be caused by a faulty Thyristor or by a faulty trigger module built into the Phase Shifter card The quickest way...

Page 94: ...8 3 c loss of phase 3 The loss of stator phase current occurred on C T input 3 Possible causes The possible causes of this fault are similar to the ones described under Current Unbalance Fault refer t...

Page 95: ...Possible causes Crane has been overloaded Excessive long periods of slow speed operation Unusual mechanical friction caused by failure of mechanical components such as the brakes not releasing faulty...

Page 96: ...tator or rotor causing a loss of torque on the motor Damaged stator or rotor cables Hoist loss of torque detection is disabled once the motor has achieved a speed 75 in 4 th notch This is required due...

Page 97: ...circuit breaker crane main contactor and crane main isolator The phase rotation is incorrect or has been made incorrect during maintenance routine work on supply rails Mains supply dropped below 70 of...

Page 98: ...oint failure of both signals This type of faulty condition has been split into 3 sub categories to facilitate fault finding The sub categories are 6 8 14 a RFB CURRT LOSS S This fault condition indica...

Page 99: ...he minimum drive level to drop below 3 5V but not sufficiently low to cause a CPU brownout i e 2 7V a drive level fault will be logged This usually is reset as soon as the supply voltage returns to it...

Page 100: ...further tests are performed which in the event of a failure they will be displaying their specific code These tests are watchdog test code 101 CPU brownout test code 102 CPU loss of messages code 103...

Page 101: ...Error Code 102 This error code indicates a CPU brownout reset The CPU power supply dropped below 2 7V DC 6 8 22 Error Code 103 This error code indicates a CPU reset due to an over flow of software po...

Page 102: ...aced will greatly reduce equipment down times A second option would be to keep a spare set of modules for the THYROMAT The identification and replacement of faulty cards require a suitably qualified p...

Page 103: ...to BDT 2000 2 OA 0020 2 Phase shifter card All BD 3 25 2 to BD 3 2000 2 OA 1070 4 Relay control card All BD 3 25 2 to BD 3 2000 2 OA 0022 Snubber card All BD 3 25 2 to BD 3 2000 2 AO 14901 Mother boar...

Page 104: ...will in all cases be suitable as spares but installed thyristors may not necessary be the same Fans M150 fan 4 Compact fan M150 BD 3 100 to BD 3 150 M450 fan 4 Compact fan M350 BD 3 200 to BD 3 350 M...

Page 105: ...hyristor Phase Arm 400A 525V 525500 ARM Thyristor Phase Arm 500A 525V 525700 ARM Thyristor Phase Arm 700A 525V 5251000 ARM Thyristor Phase Arm 1000A 525V 5251200 ARM Thyristor Phase Arm 1200A 525V 525...

Page 106: ...l Place the complete wrapped unit into a strong cardboard box or suitable container The unit is ready for shipping Components It is advised that the following procedure should be followed when packagi...

Page 107: ...Delay EEPROM Electrically Erasable Programmable Read Only Memory flc Full Load Current G Gravitational Force Hz Hertz Cycles per Second I Current Ith Thermal Current K Coefficient value of rotor resis...

Page 108: ......

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