Control for Festooning Systems
Contents
1. 24 6 10 Frequency CONVErTEr iii 25 6 11 Enabling operation cirie ira 25 T PANT STN a E E A A EA AE A EAA A eine E 21 8 APPNO iii iaia 28 8 1 Schematic sketch of festoon SyStem ii 28 8 2 Schematic sketch of MCT control ii 29 MCT motorized heavy duty cable trolleys www conductix com Page 3 of 29 Operating Instructions Comgue Z CTIX D DELACHAUX GROUP Control for festoon systems GE PLC RX3i and Vacon NXP converter BAL0500 0010 E 1 Target audience for operating instructions The operating instructions are intended for qualified specialists who design and program controls for crane systems install the festoon systems operate them and who are familiar with the requirements regarding work safety and accident prevention These operation instructions are only valid together with the operating instruction for festoon systems BAL0300 0006 contenting additional notes for the use of festoon systems 2 General information 2 1 General safety information Safety and hazard information Safety and hazard information is identified in these operating instructions by symbols Signal words are used to indicate the degree of hazard Always observe safety and hazard information and work carefully to avoid accidents bodily harm or property damage DANGER Indicates an immediately hazardous situation which if not avoided may result in death or serious injury WARNING Indicate2. 5 2 Software CESSI 14 o 2200 UE Cc IA 15 22 Cene 15 www conductix com Page 2 of 29 Operating Instructions Cova Z CTIX D DELACHAUX GROUP Control for festoon systems GE PLC RX3i and Vacon NXP converter 00 9 2 9 Memory VOCS viata cates svc tecestctnnwestednetea cetntesentevapinstensctececuddeonceseeiessiesececaties 15 5 3 PROFIBUS COMMUNICATION 15 dt a E A lia iaia an EE 15 5 3 2 Configuring the PROFIBUS Master Module i 15 5 3 3 Adding Slave Devices to the PROFIBUS Master ii 16 5 3 4 Configuring Module Data Areas ii 16 5 4 Description of WMF_GLW_BLOCK Inputs 16 5 5 Description of WMF_GLW_BLOCK outputs ccccseceeeeeeeeeeeeeeeeeeeeseeeees 17 5 6 Program chart and implementation into PLC Program 18 6 Flow charts and descriptioNS ii 20 6 1 Overview and definitiONS ii 20 6 2 Procedure in case of alarms and faults e 21 6 3 Main contactor ON Anti condensation heater ON 22 6 4 Analysis Ol CraNe SIGNA Sicario ii 22 6 5 Scaling of speed setpoint value of motorized cable trolley 22 6 6 Monitoring overspeed ii 23 6 7 Switching off by limit SWItCheS i 23 6 8 Monitoring limit switch FUNCTION i 23 6 9 Monitoring tooth DElSs
3. CRANE_SWITCH_ON BOOL Crane main switch ON MAIN _CON_ON BOOL O output main contactor of drive HEAT CON ON GOOL contactor motor anti condensation 6 4 Analysis of crane signals At lower speed range motorized cable reels are controlled by joy stick signals negative or positive direction At higher speeds and for detection of acceleration and deceleration scaled main trolley speed is used MST_SW_POS BOOL po Input joy stick of trolley positive direction MST_SW_NEG BOOL pe Input joy stick of trolley negative direction ACT_SPEED_CRAB REAL Actua main trolley speed in 6 5 Scaling of speed setpoint value of motorized cable trolley To adjust the speed of the motorized cable trolley motor speed setpoint value the actual main trolley speed has to be multiplied by a scaling factor The scaling factor will be calculated for each drive by Conductix Wampfler and has to be incured as a given constant by the customer during PLC programming If necessary adjusting of scaling factor has to be done during commissioning of the festoon system Scaling main trolley speed to speed SPEED_NORM_SET setpoint value of aGLW 0 0 1 0 www conductix com Page 22 of 29 Operating Instructions Congue Z CTIX D DELACHAUX GROUP Control for festoon systems GE PLC RX3i and Vacon NXP converter BAL0500 0010 E ACT_SPEED 100 7 ofmaintrolley FACTOR_SPEED_SET_VALUE PrO CR TA IO SETPOINT_SPEED 100 eee 2 6 6 Moni
4. VAC 24 VDC Magnetic limit switch MCT 3 water side 110 230 VAC 24 VDC Magnetic limit switch MCT 3 land side 110 230 VAC 24 VDC For the connection of the festoon cables the customer has to provide a terminal box with the appropriate dimensions Screened cables have to be used for fixed installed motor and temperature sensor cables and for signal cables MCT No Connection 1 Motor phase U Motor phase V Motor phase W Motor PE Motor screen Motor temperature sensor Motor phase U Motor phase V Motor phase W Motor PE Motor screen Motor temperature sensor Motor phase U WIN N N N N IN A A mst www conductix com Page 12 of 29 Operating Instructions Cova Z CTIX D DELACHAUX GROUP Control for festoon systems GE PLC RX3i and Vacon NXP converter BAL0500 0010 E Motor phase V Motor phase W 1 a a w www conductix com Page 13 of 29 Operating Instructions Cova Z CTIX D DELACHAUX GROUP Control for festoon systems GE PLC RX3i and Vacon NXP converter BAL0500 0010 E 5 Description of the interface module This function block is used as interface module for all interface signals between the superior crane control and the control of motorized cable trolleys MCT It is applicable for PLC GE FANUC PACSystems RX3i system As frequency converter Vacon NPX with integrated Profibus interface will be used Numbering of function and data blocks is free Because of the instance data block no flag
5. are responsible for the trouble free operation as well as for determination of responsibilities with regard to installation and maintenance of the products 3 5 Requirements on the personnel WARNING Injury due to insufficient qualifications Improper use can result in serious injury to person and property Therefore Only have special activities performed by persons mentioned in the respective chapters of these operating instructions The following qualifications have been mentioned in these operating instructions for different areas of operation e Qualified specialists can assess the tasks assigned to them and recognize possible hazards based upon their specialized training knowledge and experiences as well as knowledge about applicable conditions The responsibilities for the work on and with the products installation maintenance must be clearly defined and observed so that there is no unclear allocation of responsibilities and duties under the safety aspect Only persons capable of reliable work may work on or with the products No work methods may be performed that affect the safety of persons the environment or the described product The personnel are obligated to immediately report to the operator any changes occurring on the products which could have an effect on safety www conductix com Page 8 of 29 Operating Instructions Cova Z CTIX D DELACHAUX GROUP Control for festoon systems ALOCO 0010 E GE PLC R
6. assignment is necessary The function blocks are pre programmed with order related parameters parameter adjusting during commissioning might be necessary WARNING Injury due to wrong parameter adjustment Wrong parameter adjustment might cause to malfunction and damage to the festoon system Parameter adjustment only according to manufacturer instruction and in short steps Because of the instance data block no flag assignment is necessary d NOTE By changing of the numbers of function and data blocks no interference to modules of other manufacturers or functions is allowed 5 1 PLC hardware description 5 1 1 Controller CPU The Conductix Wampfler standard software is written for using the GE FANUC PACSystems RX3i system with the CPU IC695CPU310 installed in the customer PLC system 5 1 2 Communication controller PROFIBUS The communication to the frequency converters requires a PROFIBUS module type IC695PBM300 This has to be installed in the customer PLC system 5 2 Software description The Conductix Wampfler standard software is written with the GE FANUC software PROFICY Machine Edition for running in a PLC System GE FANUC PACSystems RX3i www conductix com Page 14 of 29 Operating Instructions Comgue Z CTIX D DELACHAUX GROUP Control for festoon systems GE PLC RX3i and Vacon NXP converter BAL0500 0010 E 5 2 1 General All program blocks are written as UDFB blocks User Defined Function Blocks in
7. converter BAL0500 0010 E 3 1 Intended use The machines are designed and constructed for the intended use only The controls for festoon systems are only used for project specific requirements WARNING Possible injury resulting from improper use Any application that deviates from or goes beyond the intended use of the machine can result in a hazardous situation Any claims against the manufacturer and or its representatives for damages resulting from improper use of the products are excluded Non intended use includes the following e Exceeding be lower than projected supply voltages e Changing of the delivered software modules e Changing bridging and or deactivation of control circuits or interlockings e Bridging and or deactivating electrical sensors or switches e Use of non approved protective devices e Re adjustment of protective devices e Changing atmospheric conditions including a change to projected physical location e Main trolley speed higher than 50 of nominal speed in case of a fault Intended use is also considered to be the correct observance of the operating conditions as well as the data and instructions of these operating instructions 3 2 Content of the operating instructions Before beginning work operation and maintenance personnel must have read and understood the operating instructions This also applies if the aforementioned personnel has already worked with this type or similar machines or h
8. limit switch function control Optional Only if limit switches for positive direction waterside are installed If not exists inputs have to be connected to 1 www conductix com Page 16 of 29 Operating Instructions Conauezix D DELACHAUX GROUP Control for festoon systems GE PLC RX3i and Vacon NXP converter BAL0500 0010 E 5 5 Description of WMF_GLW_ BLOCK outputs Output variables of function block MAIN_CON_ON BOOL Output main contactor of drive HEAT _CON_ON BOOL Output contactor motor anti condensation heater Signal output aGLW is ok and no fault Customer has to interlock trolley main drive with this signal In case of Low signal main trolley speed has to be limited to maximum 50 Signal output fault limit switch positive direction FAIL_SWITCH_POS BOOL Limit switch was OFF at position POS_SWITCH_CONTRC Signal output fault limit switch negative direction FAIL_SWITCH_NEG BOOL _ Limit switch was OFF at position POS_SWITCH_CONTRC Signal output fault frequency converter or fault communication to frequency converter Faults Warnings Faults have priority over warnings ENABLE_AGLW BOOL FAIL_FU BOOL FAIL_MEM_FU WORD Optional Only in case of limit switch function control www conductix com Page 17 of 29 Operating Instructions Comgugzix DELACHAUX GROUP Control for festoon systems GE PLC RX3i and Vacon NXP converter BAL0500 0010 E 5 6 Program c
9. only valid together with the operating instruction for festoon systems BAL0300 0006 contenting additional notes for the use of festoon systems The operator must consider the following documents as supplements of the operating instructions if applicable e Project specific technical documentation e Installation instructions e Maintenance instructions e Drawings e Spare part lists e Sketches 2 4 Limitation of liability The actual scope of delivery may vary from the data and information described here as well as the visual representations due to special models the utilization of additional order options or recent technical changes For more information please contact the manufacturer All products are subject to technical modifications 2 5 Copyright These operating instructions are to be considered as confidential They are intended solely for persons working with the product It is forbidden to pass on these operating instructions to third parties without the manufacturer s prior written consent www conductix com Page 5 of 29 Operating Instructions Cova Z CTIX Control for festoon systems D DELACHAUX GROUP BAL0500 0010 E GE PLC RX3i and Vacon NXP converter 1 NOTE This documentation is protected by copyright law The rights established herein including translation reprinting the use of figures radio transmission reproduction using photographic or similar methods or saving in electronic format rem
10. C RX3i and Vacon NXP converter BAL0500 0010 E 6 Flow charts and descriptions 6 1 Overview and definitions 0 100 ACT SPEED CRAB 0 100 MST_SW_POS MST_SW_NEG 4 increasing ACT_POS_CRAB decreasing POS_SWITCH_CONT Ze NN dal b i EE N E EE n aa ail CCC eee OSL I RS I SI SI ee me me me e e e e e e ee e e e e ee e ee e y e e RIT e m e ee RAR Ai ii DI AIN SIN SN ee ee LS_POS N LS_NEG Ifi W www conductix com Page 20 of 29 Operating Instructions Comgue Z CTIX D DELACHAUX GROUP Control for festoon systems GE PLC RX3i and Vacon NXP converter BAL0500 0010 E 6 2 Procedure in case of alarms and faults WARNING System damage from continuation of operation Damage of buffers Damage of tooth belts Possible injury from falling objects Therefore All faults must be analyzed before remedying the problem WARNING Death due to electric shock Work on electrical systems or production equipment may only be performed by specialized electricians or persons under the supervision and direction of an electrician in accordance with electrical rules qualified specialists In case of a fault of a drive unit of the festoon system it is required through the superior control crane control to immediately restrict the speed of the crane main trolley to a max of 50 of the rated crane main trolley speed The speed must not exceed 120 m min At the latest after the shift respect
11. Landside Waterside Limit switch LS MCT 3 D 1 MCT 3 MCT 2 MCT 1 APIO Landside Waterside Limit switch WS MCT MCT 3 MCT 2 MCT 1 3 2 1 WEE T a T D J I Main trolley www conductix com Page 28 of 29 Operating Instructions Cova Z CTIX D DELACHAUX GROUP Control for festoon systems GE PLC RX3i and Vacon NXP converter BAL0500 0010 E 8 2 Schematic sketch of MCT control he oe DI E 1 Si 2 I DI ui fa OU D La g E I i i z k Z 4 oi TA ea E mi cr O cpa E E 7 Zp zi LL Ca ee Cl oo o Qp E A ae Power supply Vampfler software in Customers Crane Control crane PL www conductix com Page 29 of 29
12. Operating Instructions Connuerix D DELACHAUX GROUP Control for festoon systems GE PLC RX3i and Vacon NXP converter BAL0500 0010 E www conductix com Page 1 of 29 Operating Instructions Cova Z CTIX D DELACHAUX GROUP Control for festoon systems GE PLC RX3i and Vacon NXP converter 00 CONTENT Page 1 Target audience for Operating INStrUctions ii 4 2 General information sca sccsteaacencicteesecosiuctasonceeotcusncetsand Sau lt eSateeeusucessansonset ent eassectian aero eten 4 2 1 General Safety information ii 4 2 2 Information on operating INStrUCtions i 5 2 3 Applicable documents i 5 2 4 Limitation of iab iride 5 2 5 OO ICA iii a E EE EE EEE 5 2 6 nS 0 2 Pasi 6 3 SS AS iaia 6 3 1 MENG RU nee ee ee ee i T 3 2 Content of the Operating instructions 7 3 3 Changes and modifications to the Machine 7 3 4 Operatorfesponsibilil saiie ii 8 320 Requirements on the personnel iii 8 3 6 FlaZaraS DOSCE Dy PIOOUCFssriloiaiearii na Ove 9 4 Description and construction of the control i 10 4 1 OOS 0 SONY ili 10 4 2 Customers scope Of SUPPLY 11 5 Description of the interface MOdUIE ii 14 5 1 PLC hardware description ii 14 Oli Controls OPRU cipria aio 14 5 1 2 Communication controller PROFIBUS 14
13. TIX D DELACHAUX GROUP Control for festoon systems GE PLC RX3i and Vacon NXP converter BAL0500 0010 E In case of a fault main trolley speed has to be limited to maximum 50 Input motor current without load 1 1 TOOTH_BELT_CURRENT REAL 100 FAILURE TOOTH_BELT_BROKN BOOL ee output tooth belt broken ACKN_ FAILURE BOOL a Input reset fault 6 10 Frequency converter WARNING System damage from continuation of operation Damage of buffers Damage of tooth belts Possible injury from falling objects TOOTH_BELT_TIME Input delay time for tooth belt control Communication between crane PLC and frequency converter is carried out with Profibus In case of a frequency converter fault a general fault signal FAILURE_FREQ_CONVERTER occurs the signal CABLE_TROLLEY_READY will be switched off The main drive has to be stopped Reason of fault signal has to be analyzed and fixed before reset of the fault ACKN_FAILURE Fault signal FAILURE_FREQ_CONVERTER can be used for fault identification system of the crane At same time the alarm storage of the frequency converter FAILURE_BUFFER_FC may be readout In case of a fault main trolley speed has to be limited to maximum 50 CABLE_TROLLEY_READY BOOL Signal output MCT ready for operation FAILURE_FREQ_CONVERTER BOOL Signa output fault frequency converter ACKN_FAILURE BOOL Input reset fault FAILURE BUFFER FC WORD a faults and warnings of freq
14. X3i and Vacon NXP converter 3 6 Hazards posed by product The products have undergone a hazard analysis The construction and design are based on the latest technology The products are safe when used properly However an element of risk still remains The product operates using high voltage current WARNING Death due to electric shock The electrical current could cause serious bodily harm Faulty insulation or individual components could lead to personal injury through electrical shock Causes Touching or coming too close to un insulated current bearing parts Using un insulated tools Current bearing parts that are laid bare due to insulation failure Inadequate safety checks after maintenance work Use of improper fuses Ways to protect yourself Ensure that current to machines and system parts that are to undergo maintenance work is turned off and protected against reactivation Check parts to ensure that they are free of current Cover and isolate nearby live parts Check electrical equipment regularly Immediately replace loose or damaged cables or lines Always replace blown fuses with identical fuses Avoid touching live parts Use insulated tools All faults must be analyzed before remedying the problem Work on electrical systems or production equipment may only be performed by specialized electricians or persons under the supervision and direction of an electrician in accordance with ele
15. X3i and Vacon NXP converter BAL0500 0010 E In case of a fault main trolley speed has to be limited to maximum 50 ACT_SPEED_CRAB REAL Actual main trolley speed in MST_SW_POS BOOL Input joy stick of trolley positive direction MST_SW_NEG BOOL Input joy stick of trolley negative direction Input limit switch pos WATER direction not activated Input limit switch neg LAND direction not activated LS_POS BOOL LS_NEG BOOL ACT_POS_CRAB REAL Actual main trolley position in mm DIST_CONTROL_OK BOOL Position measuring system no fault POS_SWITCH_CONTRC REAL Position for monitoring limit switch signals FAIL_SWITCH_POS BOOL Output fault limit switch pos WATER FAIL_SWITCH_NEG BOOL Output fault limit switch neg LAND ACT_SPEED_CRAB REAL Actual main trolley speed in 6 9 Monitoring tooth belts WARNING System damage from continuation of operation Damage of buffers Damage of tooth belts Possible injury from falling objects Break of tooth belts of the motorized cable trolleys are controlled If motor current value TOOTH_BELT_ CURRENT during movement of main trolley is lower as adjusted value standard 30 motor run without load both tooth belts are broken fault signal FAILURE_TOOTH_BELT_BROKN will be latched After having analyzed and corrected the reason of the broken tooth belts reset is possible by the input ACKN_FAILURE www conductix com Page 24 of 29 Operating Instructions Congue Z C
16. ain reserved even for partial use Conductix Wampfler reserves the right to make technical changes without informing the recipient of these documents data Conductix Wampfler accepts no liability in as much as this is legally permissible for errors in this documentation or for damages that occur in connection with the delivery and use of the documentation 2 6 Spare parts A WARNING Injury due to wrong spare parts Wrong or faulty spare parts can result in damages malfunctions or complete failure as well as impair safety Therefore use only original spare parts of the manufacturer The use of unauthorized spare parts renders null and void all warranty service compensation and liability claims against the manufacturer or his agents dealers or representatives 3 Safety This section gives insight into all of the important safety aspects for optimal protection of personnel as well as for safe and trouble free operation The operator must observe the following standards and regulations when operating a festoon system Co EC Low Voltage Directive IEC 60204 32 Safety of electrical equipment of hoisting machines IEC 60038 IEC standard voltages IEC 60364 Electrical installations of buildings IEC 60947 Low voltage switchgear and control gear Accident prevention regulations www conductix com Page 6 of 29 Operating Instructions Cova Z CTIX D DELACHAUX GROUP Control for festoon systems GE PLC RX3i and Vacon NXP
17. as been trained by the manufacturer Reading the content of the operating instructions is a precondition to protect personnel from hazards as well as to prevent errors and therefore to operate the product safely and in a trouble free manner It is recommended that the operator have this acknowledgement of the content of the operating instructions confirmed by the personnel 3 3 Changes and modifications to the machine To avoid hazards and to ensure optimal performance no changes or modifications may be made to the machines that have not been expressly approved by the manufacturer www conductix com Page 7 of 29 Operating Instructions Cova Z CTIX D DELACHAUX GROUP Control for festoon systems GE PLC RX3i and Vacon NXP converter BAL0500 0010 E 3 4 Operator responsibility e These operating instructions must be stored on site and always be kept readily available in a location near the festoon system e The festoon system may only be operated in good technical condition Before initial commissioning a visual inspection and predefined inspection is to be performed e The instructions in this manual are to be followed completely and precisely e In addition to the safety instructions and valid accident prevention regulations the general regulations regarding accident prevention and general safety regulations as well as the valid environmental regulations are to be observed and adhered to e The operator and personnel authorized by him
18. ctrical rules qualified specialists www conductix com Page 9 of 29 Operating Instructions Comgue Z CTIX D DELACHAUX GROUP Control for festoon systems ALOCO 0010 E GE PLC RX3i and Vacon NXP converter 4 Description and construction of the control Each motorized cable trolley is controlled by its own frequency converter depending on the main trolley speed and the position of the cable trolley When the land side optional also water side final position is reached the corresponding cable trolley will be switched off by a limit switch In generator and brake operation the energy that is fed back by the motors will be dissipated in a braking resistor or in the common DC converter link The interface module supplied by Conductix Wampfler has to be integrated into the crane PLC It is applicable for PLC GE FANUC PACSystems RX3i system The frequency converters are controlled by the crane PLC via Profibus DP connection As frequency converter Vacon NPX with integrated Profibus interface will be used PLC RX3i Vacon NXP For basic sketch of festoon system see appendix 4 1 Scope of supply Scope of supply is the software module for implementation into crane PLC Necessary frequency converters and control panel for the MCT drives have to be dimensioned according to Conductix Wampfler requirements and delivered by the customer The function blocks are pre programmed with order related parameters parameter adjusting durin
19. er and Machine Edition Logic Developer PLC version 5 7 SP1 or later for configuration Review the power requirements of your system to ensure that your power supply has sufficient capacity to support the PROFIBUS module 5 3 2 Configuring the PROFIBUS Master Module The PROFIBUS Master Module IC695PBM300 has to be configured by the equipment vendors and fabrication contractors Tear no special requirements from Conductix Wampfler about the used memory areas for the setting tables A part of the addressing from the setting parameters are used by the Conductix Wampfler UDFB block WMF_COM_PB_VACON as I O parameter The Network settings of PROFIBUS Network has to be done by the equipment vendors and fabrication contractors in according to the used frequency converter www conductix com Page 15 of 29 Operating Instructions Comauezix D DELACHAUX GROUP Control for festoon systems GE PLC RX3i and Vacon NXP converter BAL0500 0010 E 5 3 3 Adding Slave Devices to the PROFIBUS Master To add the slave device a GSD file for the used frequency inverter is required This has to be installed in according to user Manual GFK 2301B chapter 3 5 3 4 Configuring Module Data Areas To configure module data areas the values for read only parameters are supplied from the GSD file that defines the PROFIBUS module s characteristics Most devices have one data area with inputs and outputs The Conductix Wampfler UDFB block WMF_aGLW_PB_VACON used for in
20. g commissioning can be necessary The documentation consists of a technical data sheet for frequency converter dimensioning The frequency converter and PLC parameters are supplied as a data file www conductix com Page 10 of 29 Operating Instructions Cova Z CTIX D DELACHAUX GROUP Control for festoon systems GE PLC RX3i and Vacon NXP converter BAL0500 0010 E 4 2 Customers scope of supply WARNING Injury due to improper installation Improper installation can result in serious injury to person and property Therefore The operation and maintenance personnel must have read and understood the operating instructions and in particular the guidelines on safety Installation of the festoon system must be performed by sufficiently qualified and trained specialists Protective gear for operation and maintenance personnel must be provided and used The system operator or his her representative is to supervise machine operation to ensure the safety of personnel when working on or with the system d NOTE 1 Correct installation and connection of the frequency converter is within the responsibility of the crane manufacturer The complete control and drive panel has to be designed and delivered by the customer The function blocks have to be called up in the main crane program according to the number of the installed motorized cable trolleys The main power supply of the festoon system has to be switched off by the c
21. hart and implementation into PLC Program WMF_GLW WMF_GLW_ACC WMF_GLW_M SIE BLOCK BLOCK BLOCK WMF_GLW WMF GLW ACC WMF_GLW M WMF_GLW WMF GLW ACC WMF GLW M BLOCK BLOCK BLOCK www conductix com Page 18 of 29 Operating Instructions Cova Z CTIX D DELACHAUX GROUP Control for festoon systems GE PLC RX3i and Vacon NXP converter BAL0500 0010 E _MAIN BLOCK At every PLC sweep or scan the MAIN block is the first block that executes in its main program The _MAIN block calls for the UDFB block WMF_GLW as a subroutine WMF_GLW BLOCK The UDFB block WMF_GLW contains the ladder logic of the signal exchange to the client ladder program This block calls several internal subroutines WMF_aGLW_PB_VACON The UDFB block WMF_aGLW_PB_VACON contains the ladder logic of the data transfer and handling from WMF_GLW block to the hardware configuration of the PROFIBUS module IC695PBM300 WMF_GLW_M BLOCK The UDFB block WMF_GLW_M contains the ladder logic of the whole internal ladder logic for motorized cable trolley This block calls several internal subroutines WMF_GLW_ACC BLOCK The UDFB block WMF_GLW_ACC BLOCK contains the ladder logic for building the speed frequency set value to the frequency drives WMF_GLW_PARA The UDFB block WMF_GLW_PARA contains all adjustable parameters and values www conductix com Page 19 of 29 Operating Instructions Cova Z CTIX D DELACHAUX GROUP Control for festoon systems GE PL
22. ively completion of the loading unloading cycle of the container ship the fault has to be analyzed and corrected Conductix Wampfler has to be informed in writing without delay Please note The operation during emergency modus longer than the loading respectively unloading cycle can cause mechanical overloading and damage of the festoon system The following faults are signalled e Failure Frequency Converter e Failure Limit switch landside e Failure Limit switch waterside e Failure Tooth belt In case of a fault of the MCT main trolley travel has to stop immediately and after stopping MCT has to be switched off by the crane PLC Before continuing of main hoist travel and MCT the fault has to be analyzed and corrected Conductix Wampfler has to be informed in writing without delay www conductix com Page 21 of 29 Operating Instructions Cova Z CTIX D DELACHAUX GROUP Control for festoon systems ALOCO 0010 E GE PLC RX3i and Vacon NXP converter 6 3 Main contactor ON Anti condensation heater ON Signal CRANE_SWITCH_ON sets output for drive main contactor MAIN_CONTACTOR_ON At the same time output for the contactor of motor anti condensation heater ANTI_COND_HEATING_ON will be switched off Signal CRANE_SWITCH_ON for the drive of the motorized cable trolley mustnt switch off before actual speed of main trolley is 0 to ensure motor deceleration of the motorized cable trolley according to the designated ramp down time
23. put and output address a memory area of 15 words defined as data area that is used to map the data area In the client ladder logic is required to reserve this data area only for using by Conductix Wampfler UDFB block WMF_aGLW_PB_VACON 5 4 Description of WMF_GLW_ BLOCK inputs Input variable of function block BOOL Enable of function block CRANE SWITCH ON BOOL Input crane main switch is ON Base for the operation of the system DIST CONTROL OK BOOL Aa customers position measuring system is ok without ACT POS CRAB REAL Input actual main trolley position as 32 bit floating point number actual position on the complete distance in mm POS_SWITCH_CONTRC REAL Input position for function check Limit switch on Input actual speed of main trolley scaled to Ael PEESO GRAR lista 100 to 100 of maximum speed SPEED NORM SET REAL Multiplier for scaling of the actual trolley speed to setpoint of aGLW speed MST_SW_POS BOOL Input joy stick of trolley moved into positive direction MST_SW_NEG BOOL Input joy stick of trolley moved into negative direction ALARM_RESET BOOL Input reset signal for fault reset LS POS BOOL Input limit switch positiv direction LS_NEG BOOL Input limit switch negativ direction MAIN_VOLT_OK BOOL _ Input circuit breakers main power supply ok CONT_VOLT_OK BOOL _ Input circuit breaker control power supply ok BRAKE_CIRC_OK BOOL Input DC link ok Optional Only in case of
24. s a possibly hazardous situation which if not avoided may result in death or serious injury CAUTION Indicates a possibly hazardous situation which if not avoided may result in moderate or minor injury CAUTION Indicates a possibly hazardous situation which if not avoided may result in property damage Tips and recommendations NOTE 1 refers to useful tips and recommendations as well as information for efficient and trouble free operation www conductix com Page 4 of 29 Operating Instructions Comgue Z CTIX D DELACHAUX GROUP Control for festoon systems GE PLC RX3i and Vacon NXP converter BAL0500 0010 E 2 2 Information on operating instructions These operating instructions describe the construction and the volume of the delivery of the control for motorized cable trolleys and help the customer to design the required control in connection with the installation of a cable festoon system with motorized cable trolleys and the safe and proper handling of the control The safety instructions and the valid accident prevention regulations and the general regulations regarding accident prevention for the area of application are to be observed Before beginning any work on the components operation and maintenance personnel must have read and understood the operating instructions and applicable documents and the Safety chapter in particular 2 3 Applicable documents These operation instructions are
25. the IEC 61131 3 language ladder logic For incorporating the UDFB s in the client application program is only a call from UDFB in the logic program main part required The input and output parameters of the UDFB have to be set by the customer to the programmed 1 0 addresses for hardware signals For examples limit switches push buttons contactor etc Also the register addresses from the hardware configuration of the PROFIBUS module have to be written to the UDFB I O parameters Other programming work is not required 5 2 2 Cycle time The maximum allowed main cycle time for the logic program has to be less then 50 milliseconds The Conductix Wampfler cable trolleys are high speed moving systems If cycle time increases the accurate positioning is disturbed 5 2 3 Memory variables The UDFB block uses only independent instance with its own set of variables to store the values of the input parameters output parameters and other values that need to persist members The set of variables assigned to a function block instance is represented in the variables tab of the navigator by a symbolic structure variable with a user defined instance name 5 3 PROFIBUS communication 5 3 1 General The RX38i PROFIBUS Master Module IC695PBM300 allows the RX3i CPU to send and receive data on a PROFIBUS DP network This module has to be located in a RX3i Universal Back plane The PROFIBUS Master module requires an RX3i CPU with firmware version 2 9 or lat
26. toring overspeed In case of pushing or pulling of the motorized cable trolley by the main trolley the speed setpoint value of the motorized cable trolley will be corrected by the control 6 7 Switching off by limit switches The speed setpoint value will be reduced according to the adjustable deceleration ramp up to the given stop frequency if the positive or negative direction limit switch is actuated by the motorized cable trolley 6 8 Monitoring limit switch function WARNING System damage from continuation of operation Damage of buffers Damage of tooth belts Possible injury from falling objects By latching of the first priority signal DIST_CONTROL_Ok and programming of the position value ACT_POS_CRAB limit switch signals will be monitored during operation according to following criterias Main trolley position ACT_POS_CRAB programmed value POS_SWITCH_CONTRC and negativ limit switch signal LS_NEG is OFF gt fault signal FAIL_SWITCH_NEG will be latched Main trolley position ACT_POS_CRAB lt programmed value POS_SWITCH_CONTRC and positiv limit switch signal LS_POS is OFF gt fault signal FAIL_SWITCH_POS will be latched After having analyzed and corrected the reason of the wrong switching performance of the limit switch reset is possible by the input ALARM_RESET www conductix com Page 23 of 29 Operating Instructions Comgugrzix DELACHAUX GROUP Control for festoon systems GE PLC R
27. uency converter S 6 11 Enabling operation The status bit ENABLE _AGLW indicating the correct function of the motorized cable trolley has to be interlocked into the enabling sequence of the setpoint limiting of the main trolley speed If the signal is 0 the main trolley speed has to be limited to maximum 50 www conductix com Page 25 of 29 Operating Instructions Cova Z CTIX D DELACHAUX GROUP Control for festoon systems GE PLC RX3i and Vacon NXP converter BAL0500 0010 E Following preconditions are necessary for enabling operation MAIN_CON_ON BRAKE_CIRC_OK CRANE_SWITCH_ON MAIN_VOLT_OK CONT_VOLT_OK FAIL_SWITCH_POS FAIL_SWITCH_NEG FAIL_FU Time Delay Start Drive Input DC link braking unit braking BRAKE_CIRC_OK BOOL resistance has no fault Main contactor crane ON Switch on main contactor and enable CRANE_SWITCH_ON BOOL operation signal after time delay a REGLERFREIGABE ENABLE_AGLW output main contactor MAIN _CON_ON BOOL MAIN_VOLT_OK BOOL CONT VOLT OK BOOL i circuit breaker control power supply is ON FAIL_SWITCH_POS BOOL output fault limit switch pos WATER FAIL_SWITCH_NEG BOOL output fault limit switch neg LAND FAIL_FU BOOL a Input frequency converter fault Time Delay Start Drive TIME meg Re ON ceay Or Stile Operation ane main contactor on internal programming ENABLE_AGLW BOOL po Qutput MCT ok without fault di circuit breaker main power supply is www conducti
28. ustomer if the crane operator leaves the crane and in case of emergency stop e g by the crane main switch NOTE Main switch and main contactor for the power supply of the control has to be installed in customer distribution cabinet The control voltage for the supply of the anti condensation heater of the motors has to be switched off by the customer when the system is put in operation CAUTION Switch off power supply of anti condensation heaters of motor during operation The motor winding might be overheated and the motor might get damaged www conductix com Page 11 of 29 Operating Instructions Comgugzix D DELACHAUX GROUP Control for festoon systems GE PLC RX3i and Vacon NXP converter BAL0500 0010 E CAUTION Damage because of wrong cable connection Wrong connected cables might cause to damage of electrical components D CAUTION Use screened cables Use of non screened cables might cause to malfunctions and damage of electrical components E Signals from field devices to the customers crane PLC as potential free contacts wired to the terminal strip signal level depends on PLC input module Designation Signal level Power supply Magnetic limit switch 110 230 VAC 24 VDC Magnetic limit switch MCT 1 water side 110 230 VAC 24 VDC Magnetic limit switch MCT 1 land side 110 230 VAC 24 VDC Magnetic limit switch MCT 2 water side 110 230 VAC 24 VDC Magnetic limit switch MCT 2 land side 110 230
29. x com Page 26 of 29 Operating Instructions Cova Z CTIX Control for festoon systems D DELACHAUX GROUP BAL0500 0010 E GE PLC RX3i and Vacon NXP converter 7 Maintenance WARNING System damage from wrong action Turn off power supply and ensure that no inadvertent activation is possible Observe the inspection and maintenance intervals described in the maintenance instructions Ensure that sufficient space for maintenance work is available Ensure that the festoon system is not inadvertently activated during maintenance work Screw joints that are disconnected during maintenance work are to be reattached and secured as instructed After finishing work collect all tools and materials and check that all are present Disassembled parts and components that were exchanged are to be collected stored in a safe place recycled or sent back WARNING Injury due to wrong spare parts The installation and or use of unauthorized spare parts or accessories can have a negative impact on the structural properties of the festoon system and therefore affect active and passive safety No liability is accepted or warranty given for damages that occur from the use of unauthorized spare parts and accessories www conductix com Page 27 of 29 Operating Instructions Connuerix D DELACHAUX GROUP Control for festoon systems PALOU 0010 E GE PLC RX3i and Vacon NXP converter 8 Appendix 8 1 Schematic sketch of festoon system
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