Load Monitor Hhi Rpu i

8/16/2019 Load Monitor Hhi Rpu i

1/15

Load Monitor RPU

part 1/2

device description

warnings and safety instructions

EN


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Contents

1 further hints / features of theLoad Monitor

2 Motor management

3 Device configuration

4 Errors and warnings

5 Electrical connection

6 Mechanical data

7 Technical data

1.1 safety hints ........................................................ ... page 3

1.1.1 symbols ................................................................ page 31.1.2 further, important hints ......................................... page 31.1.3 intended use ......................................................... page 41.1.4 inappropriate use .................................................. page 41.2 description ............................................................ page 41.3 special features of the Load Monitor .............. ...... page 41.3.1 features .............. .................................................. page 41.3.2 safety and internal tests (up to softwear 4)........... page 51.3.3 safety and internal tests (from softwear 5)............ page 51.3.4 permanent tests during running ........................... page 51.4 description of function .......................................... page 51.4.1 temperature control .............................................. page 5 1.4.2 operating hours counter ....................................... page 5

2.1 inching operation .................................................. page 62.2 hoisting/slow hoist ................................................ page 6

in part 2/2

4.1 warnings ............................................................... page 74.2 errors and additional risks .................................... page 8

5.1 block circuit diagram ............................................. page 95.2 inputs .................................................................... page 105.2.1 operating voltage .................................................. page 105.2.2 control switch inputs ............................................. page 105.2.3.1 RPU load sensor inputs .............. ......................... page 105.2.3.2 connection to measurement-amplifier MV35/36 ... page 11

5.2.4 temperature inputs ϑ1 and ϑ2 .............................. page 115.3 output ................................................................... page 125.3.1 contact elements for lifting and lowering .............. page 125.3.2 -err and –option relays ........................................ . page 125.3.3 -right and –left relays ............................................ page 12

6.1 dimensions ........................................................... page 136.2 methods of attachment ......................................... page 136.3 lead connection .................................................... page 136.4 rating plate ............................................................ page 136.5 terminal assignment ............................................. page 14

7.1 technical data ....................................................... page 157.2 categories of safety .............................................. page 15


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1 further hints

1.1 Safety hintsIn the instruction, the safety hints are subdivided, according thelikelihood of the danger and the feasibility of the appearance. Thedescribed arrangements of the avoidance of the dangers are absolutelyto respect.

1.1.1 symbols

This symbol is warning from an immediately threatening danger for thehealth and the life of persons. The disobey of this warning hints cause heavy injury, also with death results.

This symbol is warning from a possible dangerous situation for the

health and the life of persons. The disobey of this warning hints may cause heavy injury, also with death results.

This symbol is warning from possible dangerous situation for thehealth of persons or from damage of property or damage caused tothe environment. The disobey of this warning hints may cause injury,or damage of property or damage caused to environment.

Specific symbol:

Warning of electrical voltageCovers like front lids and cover plates, which are signed with this symbol,may only be opened by a qualified electrician or authorised person.

A touch of parts, which are energized, can lead to immediately dead.

1.1.2 further, important hints• The wire rope hoist/chain hoist may only put in operation, if itsappropriateness has been ascertained.• maintenance work may only realized at the unloaded crane.• the line connector has been switched off and has been safeguardedagainst resetting by mistake.

• the regulations of the accident prevention regulations have to beenobserved.

• for the repairing, you have to use exclusive genuine spare parts,otherwise the warranty expires.

• don´t take changing and alterations.• additionally fittings needs the permission of the manufacturer.• the electrical connection and the electrical operation may only be

executed by a qualified electrician• the warranty expires, if the assembly, the handling, the checkingand the maintenance does not happen. For operating of other persons than those, we have instructed, we don´t take any warranty.

warning

danger

attention


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1 further hints

Hint:

1.2 Description

• The commissioning of this component is not till then allowed, if it isascertained, that the construction or the device, in which the

component was build in, meets the requirements of the ECmachinery directive.

1.1.3 intended use• as extensive defined in this device description• application in electrical circuits for wire rope- and chain hoists

1.1.4 inappropr iate use• application in explosive area without explosion proof housing• to bridge the inputs of the load sensors with a resistor • application with conveyance of passengers• to cut loose of loads• technological changes at overload cut-off

• is this product “part of a machine”, the marketing authorisationholder has to take guarantee, that the product equates to the specialinstructions of the case of application

Intervention in the control or further controls requires theauthorization of the manufacturer. For failure malfunction atunauthorized engagement in the control, the manufacturer meets nowarranty.

definition "instructed persons": An "instructed person" is a qualified person with thenecessary qualification, constitutive on theoretical and practicalknowledge of hoists, for the in the manual specified necessaryoperations. This person has to estimate the safety of theconstruction in dependence of the individual case.Instructed persons with the authority, to deal with specificmaintenance to our products, are service assemblymen of themanufacturer and well skilled, with certificate designatedassemblymen.

The main language of the original text shall be the offi cial,authoritative version. These translations were provided for

better understanding. Only the language version, which waspublished in the original, is valid. Therefore check yourtranslation with the original language version o f the publication.

The Load Monitor is a programmable control, evaluation and

switching device for single or dual-speed motors. The load

monitor can be optimally adapted to the application of

controlling a hoist motor and provides a compact overall

solution. It provides the basis for safe working and long

service life. With the Load Monitor, Harrington Hoists sets a

high safety standard for hoists and hoist systems.

danger


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1 further hints

1.3 Special features of the

Load Monitor

1.4 Description of function

1.3.1 features • constant overload protection

• temperature control of hoist and travel motors• registration of operating hours• crane test can be activated by pressing a button• motor-specific data for controlling the motor are stored in a table.The motors are assigned by means of the rotary switch S1(see table 2.3).

1.3.2 safety and in ternal tests (up to so ftware version 4) After power on the device, an internal test cycle runs up for 4seconds. This will be finalized, when the user operates “lift” or“lower” for the first time. At this process, the message “systemerror” will be displayed temporarily. No movement will be happen,and the LEDs II and III are flashing up shortly, to display the testrun. This will additionally displayed via the relay "-option".(see point 5.3.2)If the display of the device will not be receipt, an error occurs. (seechapter 4.2)

After a renewed start (up/down), the device will be ready for action.

1.3.3 safety and internal tests (from software version 5) After power on the device, an internal test cycle runs up for 4seconds. During this time, all LED are always luminously, to testthem.The tests have been completed, when all LED will be off, only thegreen one is always luminously.If there will be an error during this tests, the according error-codewill be displayed. (see chapter 4.2).

If there will be no error, the device is ready for action.

1.3.4 permanent tests during running(from software version 4)

The RPU performs because for reasons of safety also duringoperation further tests, to conform the framework of existinglegislation. Further, the internal relay circuit in the device will beproved by every selection of movement. This test could possiblybe disturbed under difficult conditions and the hoist would stop itsmovement. This can be notified to a superior control via the relay

"-option". (See point 5.3.2)

1.4.1 Temperature contro lMonitoring the temperature control of the hoist motor is standard. Ifa PTC thermistor reacts this is displayed by LEDs on the LoadMonitor and the load cannot be moved again until the hoist motorhas cooled off.In addition, the "err" relay is switched and as an option, the errorcan be displayed via the relay contact "option". The travel motor

temperature "ϑ2" is also monitored. The motor PTC thermistors areevaluated via the relay contacts "left" / " right" .


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2 Motor management / 3 Device configuration

2.1 Inching operation

2.2 Hoisting / slow speed1

3 device configuration

1.4.2 Operating hours counterThe Load Monitor registers the total operating hours. They are

displayed on the operating hours counter mounted on the front ofthe device.In standard version, only the main hoist operating hours areregistered, however the device can be adjusted to register mainhoist including slow hoist operating hours by setting S2 and S4following the special functions table.

Inching operation has a damaging effect on the electrical andmechanical components of a hoist. Apart from rapid temperaturerise in the motor and excessive wear on the contacts, inchingoperation also leads to premature wear on the brake.

2.1.1 Slow speed disabling time off/on After the slow motor speed has been switched off, it cannot beswitched on again until the programmed disabling time has elapsed(prevention of inching operation at slow motor speed). The settingdepends on the motor (see part II, table 3.1)

2.1.2 Fast speed disabling time off/on After the fast motor speed has been switched off, it cannot beswitched on again until the programmed disabling time has elapsed(prevention of inching operation at fast motor speed.) During thedisabling time only the slow motor speed is available. The settingdepends on the motor (see part II, table 3.1).

2.1.3 Disabling time for change of d irection up/down

When the motor is switched off, the opposite direction of rotation ofthe motor cannot be switched on until the programmed disablingtime has elapsed. (Prevention in rapid changes of direction ofrotation). The setting depends on the motor (see part II, table 3.1).

Rapid changes of direction (reversing) also have a damaging effecton motor temperature rise and wear.

2.2.1 Starting at slow speedTo reduce the load on the hoist, from hoist motor size H71 startingis at slow speed. The starting time at slow speed depends on the

motor, see allocation table, point 2.1.

2.2.2 Braking at slow speedTo reduce the load on the brake, after the fast speed has beenswitched off slow speed is briefly switched on. The activation timedepends on the motor (see table 2.3).

in part 2/2

warning


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4.1 Warnings Warnings of this Load Monitor (RPU) represent a concretedanger, therefore you have to be react immediately. This isnecessary, because the warnings don’t bring automaticallyabout, that hoist movement will be appropriate restricted.

The warning is indicated by three (flashing) LEDs on the front ofthe Load Monitor.

Specification of warning Elimination

press button S5Load MonitorRPU

is incrane test-mode switch Load Monitor off/on

temperature input ϑ2 has check connection,

Recognized over temperature let the motor cool down,check PTC sensor

outside the permissible cut-off band: adjust cut-off threshold

+8-20% of the parameterizedthreshold

cut-off threshold exceeded, wished follow device descriptioncut-off point is bigger than 19,5mA.This is not possible, to parameterize.

cut-off threshold under-run adjust cut-off thresholdcut-off point is less than 9,0mA.This is not possible, to parameterize.

RPUis functionalstand by display

The functions of the Load Monitor are not restricted when awarning is displayed!

warning

light half: blinkinglight full: always luminously


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4.2 Errors and additional risks Various conditions may arise in the system load sensor - PTCthermistor – Load Monitor. If the load sensor value can no longer beascertained, e.g. if a cable breaks, the Load Monitor must indicate thiscondition. Conditions which no longer ensure correct functioning of thehoist are designated errors. These can be recognised immediately inthat the hoist is no longer available in upwards direction. Loweringmotions however are still permitted after errors have been detected.(Except in the case of over temperature).In addition to the red LED, the corresponding error code is displayedby three LEDs on the front of the Load Monitor (continuously light).

Apart from the error display, it is possible to indicate the errordisplay via external signal generator. The relay “err" marks allerrors. For the relay “ opt” , further states can be tuned.

Error specification Cause Eliminationbreak in connecting check sensorcable, connection,sensor supply faulty, check sensor current,

sensor errorsensor currentless then 3.2mAor bigger than24mA

sensor faulty check sensor supply,

overload load too heavy, set down overload,cut-off threshold correct cut-offtoo high threshold

over temperature hoist motor too hot let hoist motor coolPTC thermistor faulty down, check

PTC thermistors

control error lifting and lowering control wiredactivated simultaneously incorrectly

system error no control current at switch Load Monitorterminal 6, on/off internal error

no error restart, processor- wait, till internal testand relay test is over

system error1-times sensor-error sec. controller has a too

high sensor-current.4-times timeout, problems at restart the device, if

internal interface error occurs again,change the device

Load Monitor faulty no control voltage, check voltage,fuse faulty, check fuse,

Load Monitor faulty replace Load Monitor

light half: blinking

light full: always luminously

danger


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5.1 block circuit d iagram

RPU

for the secondsensor connection,use the RPU 2


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5.2 Inputs 5.2.1 Operating voltageThe operating voltage for the Load Monitor had to be connect to theterminals 1 (L) and 2 (N). The rated value of the supply voltagemust correspond to that given on the device rating plate (operatingvoltage). The permissible deviations from the rated value (voltagetolerances) must not be exceeded on any account.

For AC operating vol tage terminal 1 (L) and 2 (N)For 24DC operating vol tage (L = +) and (N = ground)

Caution: Do not connect wrongly !

• Rated voltage as per device rating plate (230, 110, 48, 42 VACand 24 VDC).• Voltage tolerance -10/+15% of rated value, 50-60 Hz• Power absorbed max. 9 VA• Suitable for continuous operation

5.2.2 Control switch inputsThe hoisting and lowering functions of the control pendant areconnected to terminals 3, 4 and 5. Terminal 3 is the input for slowhoist up, terminal 4 for slow hoist down and terminal 5 for mainhoisting speed. All common control switches used in hoistingtechnology can be connected. The control voltage must correspond

to the operating voltage of the Load Monitor (see device ratingplate). Interference voltages in the leads to the inputs aresuppressed by capacitors integrated into the Load Monitor at thecontrol inputs.

5.2.3.1 RPU load sensor inputs2-wire load sensors with a 4...20 mA signal can be connected to the

Load Monitor. To do so, a jumper must be placed betweenterminals 20 (GND) and 22 (l1-). The load sensor is then connectedto terminals 21 (l1+) and 19 (UBS). The input resistance betweenterminals 21 and 22 is 39.2 Ω.The load signals should display anapproximately linear response characteristic. The load sensorsignal must be 4.0 mA when the hoist is unloaded. This ensuresthat the RPU will reliably detect a broken wire to the load sensor.

If the load sensor is not supplied via the Load Monitor the mass ofthe external voltage supply must be connected to terminal 20.

19 20 21 22 24UBS GD I1+ I1- UB

sensor

PE

3 4 5up own fast


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Supply to load sensors:Two voltages are available for supplying load sensors or 4...20 mAamplifiers:

• 15 VDC ±5%, 50mA controlled via terminals 19 (UBS) and20 (GD, mass)

• 24 VDC, 50mA via terminals 24 (UB) and 20 (GD).

5.2.3.2 Connect ion measurement-amplif ier MV35/36Will the measurement amplifier MV35 or MV36 be constituted atthe RPU, it will have to be supplied with a separate power supply

unit (PSU).The reason is, that the current consumption (50...80mA) of thesemeasurement amplifier is higher, as the RPU can deliverand depends on the strain gauge and the justification of these unit.

The RPU delivers max. 50mA.

5.2.4 Temperature inputs ϑ1 and ϑ2 The hoist motor temperature sensor is connected to terminals 16

and 17 at temperature inputϑ1. If the hoist motor does not have

temperature sensors, terminals 16 and 17 must be connected by a

resistance of 300 Ω. The values of the temperature sensors to beconnected must meetDIN 44 080. A high-ohm input resistance or a short-circuit arerecognized as a temperature error and all outputs (7...10) areswitched off. The hoist can then no longer be moved.

After the motor has cooled off the error is automaticallyacknowledged by the Load Monitor and hoist motions permittedagain.

One or more further temperature sensors can be connected to

terminals 25, 26 at temperature inputϑ2

as temperature pre-warning. The values of the temperature sensors to be connectedmust meet DIN 44 080. A high-ohm input resistance is recognizedas over temperature and treated as a warning by the Load Monitor.

After the motor has cooled off the warning is automaticallyacknowledged by the Load Monitor.

second temperature sensor

ϑ

16 17

ϑ

ϑ2

25 26

ϑ2

Temperature sensor of hoist motor

19 20 24UBS GD UB


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5.3 Outputs 5.3.1 Contact elements for lifting and lowering• the control voltage for the hoisting and lowering contactors isconnected to terminal 6.

• terminal 7 is the output for contactor "slow up".• terminal 8 is the output for contactor "fast up".• terminal 9 is the output for contactor "slow down"• terminal 10 is the output for contactor "fast down".

• rated breaking capacity of relays:250 VAC, 5 A, operating mode AC1

5.3.2 "-err" and " -option" relaysThe "-err" relay, terminals 27 and 28, and the "-option" relay,terminals 29 and 30, are intended for transmitting error signals. Thecontacts can be changed from normally open to normally closed.

This is done in the "special functions" mode, described under table3.4.2. special functions in Part 2/2.

"Sensor error", "overload" or "over-temperature" or as fromsoftware version 4 (type label SLE21-1-(c1)-X40), a miscarriage of

the internal test by hoist movement selection, can be allocated tothe “-option” relay. As standard, the relay „-option“ isparameterized as normally open. It will open, if the internal test willmiscarriage, at selection of the hoist movement.


5.3.3 "-right" and "-left" relaysThe potential-free relays "-right" and "-left" open when activated

by ϑ2.



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6 Mechanical data

6.1 Dimensions

6.2 Methods of attachment

6.3 Lead connection

6.4 Rating plate

• 100 x 110 x 75 mm (W x H x D)

• clipped onto 35 mm top-hat rail (EN 50022-35)• screwed onto base of housing (M4) with slides (option)

• 30 box terminals with captive plus-minus screws• per box terminal: 1 x 4 mm² solid or 1 x 2.5 mm² flexible withsleeve DIN 46 228 or 2 x 1.5 mm² flexible, with sleeve DIN 46 228

The type designation is to take out of the rating plate. The hardwareand software state is also readable.

SLE 2 1 – 1 - ( b 1 ) – 1 1 0

temperature range

software versionhardware version

reference to othersafety standards

device alternatives

number of sensor inputs

submitted category toEN 954

device: SLE = RPU


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6 Mechanical data

6.5 Terminal assignment

m a i n s - N

m a i n s - L

e r r o r r e l a y

h o i s t m o t o r

t e m p e r a t u r e s e n s o r

+ 1 5 D C

s e n s o r s u p p l y

t e m p e r a t u r e s e n s o r

e . g . t r a v e l m o t o r

l o a d s e n s o r

c o n n e c t i o n

o p t i o n r e l a y

r e l a y f o r

t r a v e l m o t o r l e f t

+ 2 4 D C

s e n s o r s u p p l y

m a s s f o r s e n s o r a n d D C i n

p u t

r e l a y f o r t r a v e l m o t o r

r i g h t

o u t p u t - f a s t d o w n

o u t p u t – s l o w d o w n

o u t p u t – f a s t u p

o u t p u t – s l o w u p c o n t r o l

v o l t a g e u p / d o w n i n p u t

m a i n h o i s t f a s t i n p u t

m a i n h o i s t d o w n i n p u t

m a i n h o i s t u p


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7 Technical data

7.1 Technical data

RPU

7.2 Safety categories The RPU meets safety category 2 in acc. with EN 954-1 with themono sensor as device.

As the RPU is only single-channel the system as a whole canonly meet category 1.

RPU meet performance level c in acc. with EN ISO 13849-1 andSIL 1 in acc. with EN IEC 62061.

RPU is certified for 110/120V UL.

input power < 9 VA

temperature rangeoperationstorage

-20°C ... + 55°C (standard)-40°C ... + 70°C (optional)-40°C ... + 70°C

type of protection IP 20 EN 60 529

EMC EN 61000-6-3 (2001)EN 61000-6-2 (2001-10)

temperature inputs potential-free

- maximum total cold resistance max. 1500 Ω DIN VDE 0660-302 (DIN EN 60947-8)

- response resistance 2800 ...3500 Ohm

- maximum release resistance 1650 Ohmrelay outputs 250V / 5 A/2A

500 VA

contact inputs < 10 mA

connection terminals Box terminals for max. 2x1.5 mm² with sleeve

attachment Top-hat rail to EN 50022 TS35 or with screws

weight 0.5 kg

software filed in electronics R&D

LED display PwrErrIIIIII

} coded error numbersoperating voltages

-10 ... + 15%, 50/60 Hz

24 VDC – 300mA

24 VAC – 300mA42 VAC – 170mA48 VAC – 150mA110/120 VAC – 70mA230 VAC – 30mA

sensor supply UB (24)UBS (19)

24 VDC15 VDC switched from Load Monitortotal < 50 mA, short-circuit resistant

sensor inputs(analog) 2-wireor 4-wire

R in = 39.2 Ohm; 0 ... 25 mA

analog section accuracyresolution

± 2 %, ± 1LSB of final value8 bits (0.1mA)

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Load Monitor Hhi Rpu i