Columbus McKinnon pulse Installation, Operation & Service Manual

INSTALLATION, OPERATION & SERVICE MANUAL

MONITOR

Pulse™ Monitor Software Version 1.0.1

Pulse™ Monitor Card Software Revision 1.4.0

Pulse™ Monitor Card Product Revision 0.1.0.0

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P/N: 11817503 REV. AA June 2014

TABLE OF CONTENTS

Introduction �� 3

INSTALLATION

Pulse Monitor Kits �� 4–5

Software Installation �� 6

Initial Programming �� 6

Tools Required For Installation �� 7

Mounting Pulse Monitor Card �� 7

Wiring �� 8

OPERATION

Speciﬁcations �� 9

Downloading Motor Data �� 10–11

Software Functions �� 11

Cumulative Data �� 11

Monitor Version �� 12

Assigning Serial Number �� 12

Setting Time and Date �� 12

Setting Voltage �� 13

Reading Data �� 13

Voltage Graph �� 13

Data Filters �� 14

Viewing Data Type (Current vs� History) �� 14

Changing Order of Data Grid �� 15

Saving and Printing Motor Data �� 15

SERVICE

Troubleshooting Chart �� 16

Appendix 1 – Wiring Diagrams �� 17–23

Appendix 2 – Voltage Measurement Accuracy �� 24

Replacement Parts �� 24

Customer Service �� 24

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NOTE: Pulse is not a trademark of Columbus McKinnon Corporation.

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INTRODUCTION

Congratulations on the purchase of a Pulse monitor� The Pulse monitor is an electronic device that records

key information with a time/date stamp every time an AC motor is turned on� The program data can be used

as a tool to help assist you in trouble shooting hard to ﬁgure out ﬁeld problems for machinery-using AC motors

and help determine preventative maintenance intervals�

IMPORTANT! PLEASE READ!

Before proceeding any further, please read the following important information regarding the Pulse monitor and its proper handling and use:

The pulse monitor is powered by AC control voltage, which can cause electric shock resulting in personal injury or loss of life. Handle monitor card with the same care and caution as all other high voltage electrical components.

Be certain the electrical power supply is OFF and locked in the open position before attempting any electrical connections to the hoist.

Be sure to disconnect all AC input power before downloading information from or handling the Pulse monitor circuit board.

Please read this manual completely before installing the Pulse monitor.

The Pulse monitor card must be rigidly secured in the control panel as illustrated in this manual. Failure to do so may result in damage to the pulse monitor card and to the equipment being monitored

Only qualiﬁed personnel should perform service.

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PULSE MONITOR KITS

The Pulse monitor is available in several different kit varieties to accommodate individual needs�

Note: Shaw-Box World Series and Yale Global King hoists, which include the Pulse monitor card as standard, require a computer

interface kit (sold separately) to read the data� Kit variations are as follows:

PULSE MONITOR COMPUTER INTERFACE KIT WITH USB ADAPTOR

CATALOG NO� PINTERFACEUSB

Description Quantity

Pulse Monitor Computer Interface (9V battery not included) 1

Serial Extension Cable (6 ft.) 1

Pulse Monitor Software Disk 1

StarTech.com USB Adaptor Software Disk 1

Serial Port to USB Adaptor Cable (3 ft.) 1

Note: Kit also includes a DB9 to DB25 pin adapter for 25-pin RS232 serial communication which will not be needed in most cases�

PULSE MONITOR COMPUTER INTERFACE KIT WITHOUT USB ADAPTOR

CATALOG NO� PINTERFACEKIT

Description Quantity

Pulse Monitor Computer Interface (9V battery not included) 1

Serial Extension Cable (6 ft.) 2

Pulse Monitor Software Disk 1

PULSE MONITOR COMPLETE KIT CATALOG NUMBERS

PCOMPLETEKIT1 = 115 VAC CONTROL PCOMPLETEKIT2 = 24 VAC CONTROL

Description Quantity

Pulse Monitor Card 1

Card Mounting Bracket 1

Pulse Monitor Computer Interface (9V battery not included) 1

Serial Extension Cable (6 ft.) 2

Pulse Monitor Software Disk 1

StarTech.com USB Adaptor Software Disk 1

Serial Port to USB Adaptor Cable (3 ft.) 1

Pan Head Phillips Screw Self Tap #6-32 X 5/8" 6 (2 extra)

Pan Head Phillips Screw Self Tap #10-24 X 1/4" 3 (1 extra)

Terminal Wire Insulated Female Quick Connector Panduit Part no. DNR14-188F1B-C (tab size 0.187 X 0.020) 10 (3 extra)

16# Insulated Wire 15 ft.

Note: Kit also includes a DB9 to DB25 pin adapter for 25-pin RS232 serial communication which will not be needed in most cases�

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PULSE MONITOR KITS (CONTINUED)

PULSE MONITOR COMPLETE KIT

SERIAL EXTENSION CABLE

SERIAL PORT TO USB ADAPTOR CABLE

USB ADAPTOR SOFTWARE DISK

Note: Kit also includes a DB9 to DB25 pin adapter for 25-pin RS232 serial communication which will not be needed in most cases�

PULSE MONITOR CARD

COMPUTER INTERFACE

PULSE MONITOR SOFTWARE DISK

PULSE MONITOR INDIVIDUAL CARD KIT CATALOG NUMBERS

PCARDKIT1 = 115 VAC CONTROL PCARDKIT2 = 24 VAC CONTROL

Description Quantity

Pulse Monitor Card 1

Card Mounting Bracket 1

Pulse Monitor Software Disk 1

Pan Head Phillips Screw Self Tap #6-32 X 5/8" 6 (2 extra)

Pan Head Phillips Screw Self Tap #10-24 X 1/4" 3 (1 extra)

Terminal Wire Insulated Female Quick Connector Panduit Part no. DNR14-188F1B-C (tab size 0.187 X 0.020) 10 (3 extra)

16# Insulated Wire 15 ft.

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SOFTWARE INSTALLATION

Insert the Pulse software disk into your CDROM drive� Using the RUN command in your start menu button, browse to your CDROM drive� Open folder 1�0�1� Double click on the Install Pulse ﬁle� Select OK and follow instructions� During the install, say yes to installing the Microsoft�net framework program if prompted� This is necessary for the Pulse software to operate�

OBSERVE MINIMUM SYSTEM REQUIREMENTS:

Operating System* – Windows XP Pro SP2, or Windows 2000 SP4.

CPU – Pentium III, 450 MHz, RAM - 256 MB.

Hard Drive Space – 50MB.

One USB Serial Port, CDROM Drive.

*Please Note: Windows 8 & 8�1 not supported�

INITIAL PROGRAMMING

Initial programming can be done before or after the Pulse monitor card is installed� Open the Pulse software on your computer and connect the Pulse monitor card as shown in Figure 3� It is recommended that the following parameters be set before collecting any data�

SERIAL NUMBER

In the Serial Number Box, enter the serial number for the system you wish to monitor� Click on the Set button to program the serial number�

MONITOR DATE

In the Monitor Date Box, click on the Set button to set the monitor card clock to your computers clock�

Note: If this is not done, the default time for the monitor card is midnight, January 1, 1970�

USB ADAPTER INSTALLATION

DRIVER

1� Turn on computer on and boot into Windows� Do not have

USB adapter plugged into the computer

2� Insert the driver CD into your CD/DVD drive� If AutoPlay runs,

then choose to “Browse the CD”, otherwise access the contents of the CD via “my Computer”

3� In the “Proliﬁc/PL2302X” location, open the appropriate folder

for your operation system and run the setup�exe ﬁle� This will launch the driver installation wizard

4� Once the installation wizard completes, the drivers will be

installed and ready for use�

HARDWARE INSTALLATION

1� Make sure the driver installation has been completed ﬁrst�

2� Plug the USB adapter into an available USB port on the

computer system�

3� Windows will automatically detect the USB adapter and

install the drivers

4� Once installation is complete, the serial port will be ready for use�

5� If connecting the serial port to a DB25 interface, use the included

DB9 to DB25 (male) adapter

VOLTAGE

In the Voltage Box, enter the source voltage the motor is being powered by� Click on the Set button to program the source voltage�

For further information concerning these parameters, see the Software Functions section of this manual.

VERIFYING INSTALLATION

Windows XP/Vista/7

1� From the main desktop, right click on “my computer”

(“Computer” in Vista/7) then select Manage� In the new Computer Management window, select Device Manager from the left window panel�

2� Double click on the “Ports (COM & LPT)” option�

The additional ports should be visible�

3� Double click on the adapter

4� Select “Port Settings” tab

5� Click on “Advanced” and at the bottom of the pop-up screen

under “COM Port Number” make sure COM1, COM2, COM3 or COM4 is selected� The Pulse software will only detect COMs 1 thru 4�

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TOOLS REQUIRED FOR INSTALLATION

• Drill & #19 Drill Bit (ø .166")

• #1 Phillips Screw Driver

• Wire Strippers

• Connector Crimping Tool (Sized for 16# wire)

MOUNTING PULSE MONITOR CARD

1� Locate available space in control enclosure to t the required 3" X 5-1/4" X 2-1/2" envelope. Use a #19 drill bit (ø .166") and drill two

holes 4.75" +/- .02" apart. Attach the mounting bracket using (2) #10-24 X ¼" self-tapping screws at reference points A� See Figure 1�

2� Attach Pulse monitor card to mounting bracket using (4) #6-32 X 5/8" self-tapping screws at reference points B� See Figure 1�

PULSE MONITOR CARD

MOUNTING BRACKET

FIGURE 1

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WIRING

1� 1) Review electrical schematic� See Figure 2�

2� 2) See Appendix 1 for detailed wiring diagrams speciﬁc to selected Yale·Lift-Tech arrangements�

FIGURE 2

The Pulse monitor card is electronic equipment that requires earth ground to reduce potential for false data�

If a dedicated ground is not available, make sure reference ground to all control transformers have one common point�

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SPECIFICATIONS

The Pulse monitor records the following information:

MOTOR EVENT PARAMETERS

Motor direction is referenced as Up or Down� The Pulse monitor can record up to two speed points� The speed points are referenced as Slow and Fast�

The following are all the designated motor events that can be recorded:

Motor Event Data Filters

Motor Up Slow

Motor Up Fast

Motor Down Slow

Motor Down Fast

Plug Event Excessive Plugging

Motor Trip Up Thermal Shutdown

Motor Trip Up Fast Thermal Shutdown

Over Capacity Up

Over Capacity Up Fast

CURRENT MOTOR EVENTS

The Pulse monitor records all current motor events up to a maximum of 5119 events� After 5119, each new motor event will record over the oldest motor data beginning at memory count one�

HISTORY EVENTS

The Pulse monitor records the following motor events simultaneously into the current and history motor event memory registers� The motor events are plug event, motor trip and over capacity� The history event register can store up to 64 occurrences before recording over the oldest data located in memory count one�

(Normal Start), (Slow), (Up)

(Normal Start), (Fast), (Up)

(Normal Start), (Slow), (Down)

(Normal Start), (Fast), (Down)

(Plug Event)

(Motor Trip), (Up)

(Over Capacity), (Up)

PLUG EVENT (EXCESSIVE PLUGGING)

A plug event is recorded when the directional contactor (node 0A or 1A) is energized four times within any two second period of operation� The plug event is recorded simultaneously into current motor data and history data�

MOTOR TRIP EVENT

A motor trip event will be recorded when the monitor card terminal K1 measures 115 volts* and terminal K2 is at 0 volts� If the event occurs with all three terminals K1, K2 and 0A being at 0 volts followed by numerous occurrences of terminal K1 sensing 115 volts* and K2 remaining at 0 volts, only one event will be recorded�

OVER CAPACITY EVENT

An overcapacity trip will be recorded when the monitor card terminals K1 and K2 measure 115 volts* and terminal 0A being at 0 volts� If the event occurs with all three terminals K1, K2 and 0A being at 0 volts followed by numerous occurrences of terminal K1 and K2 sensing 115 volts* and 0A remaining at 0 Volts, only one event will be recorded�

VOLTAGE

For every motor event, the voltage will be measured�**

TIME / DATE STAMP

All motor events are recorded along with the time and date the motor event occurred� The real time clock in the Pulse monitor card has a default starting time of midnight, January 1, 1970� Once the Pulse monitor software connects to the card, you can change the default time to your computer's time by pressing the Set button�

* All cited voltages are nominal referenced to ground using the

115-volt monitor card� If using the 24-volt card, all non-zero voltage references will be 24 volts�

** See Appendix 2 for discussion of accuracy�

CUMULATIVE RUN TIME

Every time the motor is energized, the Pulse monitor records how long it runs and adds to the cumulative total run time� Maximum time count is 1�9 million hours� Cumulative run time is updated every 16 motor starts� Overall operating time cannot be reset to zero� Cumulative Motor Starts - Pulse monitor keeps track of overall starts of a motor� Maximum start count is 4�29 billion� The cumulative memory location is updated every 16 motor starts� Overall starts cannot be reset to zero�

MOTOR STARTS

A motor start is recognized by energization of either the slow or fast motor winding for 300ms or more�

* Pulse monitor card revision 1�4�0 - counts a motor start

when either the slow or fast winding of the motor is energized� No time constraints are in place for determining a motor start�

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DOWNLOADING MOTOR DATA

Motor event data stored in the Pulse monitor card can only be read using a personal computer (PC).

CONNECTIONS

1� Connect the Pulse monitor card, computer interface, PC and serial extension cables as shown in Figure 3�

Serial Extension Cable

Connect to

Monitor Card

*Serial Port to USB

Adaptor Cable

PULSE

MONITOR

CARD

FIGURE 3

*Note: For optional use of USB port or devices without a serial port.

2� Select com port

3� Open Pulse monitor software on computer and press the Connect button� See Figure 4�

COMPUTER

INTERFACE

Connect to

Computer

Serial Port

USB Port

PC

FIGURE 4

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DOWNLOADING MOTOR DATA (CONTINUED)

4� If your connection was successful, the following message Data loaded successfully will be displayed in the lower left corner�

The monitor date, monitor version and cumulative run time / start data will also appear� See Figure 5�

FIGURE 5

SOFTWARE FUNCTIONS

CUMULATIVE DATA

The Pulse monitor card keeps track of total motor run time and total motor starts for the motor being monitored� The displayed cumulative data is automatically updated every 16 motor starts� Note this data cannot be reset� See Figure 6�

FIGURE 6

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SOFTWARE FUNCTIONS (CONTINUED)

MONITOR VERSION

The Pulse monitor software and card revision number will automatically display once you connect to the card� See Figure 7�

FIGURE 7

ASSIGNING SERIAL NUMBER

You can assign a speciﬁc serial number to the Pulse monitor card up to 20 characters for the system you wish to retrieve data from� Click on the serial number box and enter the respective serial number� Then press the Set button� See Figure 8�

FIGURE 8

SETTING TIME AND DATE

The time / date of all Pulse monitor cards default to midnight, January 1, 1970� By pressing the Set button in the Monitor Date box, the software will automatically update the time in the Pulse monitor card to match the computer being used� See Figure 9�

FIGURE 9

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SOFTWARE FUNCTIONS (CONTINUED)

SETTING MOTOR VOLTAGE

The Pulse monitor card monitors the motor voltage of your system�* Enter the correct power supply voltage required for your system, and press the Set button in the Voltage box� See Figure 10�

FIGURE 10

* See Appendix 2 for discussion of accuracy�

READING DATA

Pressing the Read Events button as shown in Figure 11 will read all data accumulated in the Pulse monitor card�

FIGURE 11

VOLTAGE GRAPH

Press the Graph button to read a graph showing a broad snapshot of what the voltage was for all motor events�* See Figure 12� Note: To view graph at a speciﬁc date or time, select pertinent date/ time in ﬁlter box�

FIGURE 12

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SOFTWARE FUNCTIONS (CONTINUED)

DATA FILTERS

Data ﬁlters allow you to narrow down the speciﬁc type of data you wish to view� The default selects all motor events for review� If there is speciﬁc data you do not wish to see, simply uncheck the respective box and that data will be removed from your data grid� The ﬁlters include the different motor event types, voltage deviation, speciﬁc date and speciﬁc time� See Figure 13�

FIGURE 13

VIEW DATA TYPE (CURRENT VS. HISTORY)

The View Data Type box allows you to choose between Current data, which is the most recent motor events up to a maximum of 5119, or History data� History data is reserved speciﬁcally for Plug Event, Motor Trip and Over Capacity events� The maximum memory count is 64 for each event type� See Figure 14�

FIGURE 14

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SOFTWARE FUNCTIONS (CONTINUED)

CHANGING ORDER OF DATA GRID

You can also change the order in which you view the motor data by clicking on any of the column headers in the data grid� For example, the default order for date and time begins with the oldest date and time stored� If you wish to begin viewing from the most recent data to the oldest data, select the Date and/or Time headers and this will reverse the order� See Figure 15�

FIGURE 15

SAVING AND PRINTING MOTOR DATA

Once you have successfully downloaded the motor data to the Pulse monitor, you can save or print the data using either the File Menu or Save and Print Hot Buttons� The ﬁle will be automatically saved as an .xml ﬁle� Use the Pulse monitor software any time you wish to review or print the ﬁle�

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TROUBLESHOOTING CHART

Symptom Corrective Action

Prompted Message: Pulse monitor could not

be read. Check cable connections and/or 9V battery located in the computer interface before attempting to reconnect.

Prompted Message: This card is blank, no records have been written to it yet; data displayed is not accurate.

False motor trips. Example: Thermal trip in down direction for hoist motion.

Event column of the data grid is blank. When the storage of events has reached memory capacity, a blank event is produced to signify the overwriting

Event has been recorded with a 1971 date stamp after the date/time has been set on the card.

Motor Starts ﬁeld equals 4294967295 and the Run Time (Hours) ﬁeld equals 1193046.5

1. Check to make sure the USB connections and/or serial connections are secure.

2. Make sure the computer interface has a 9V battery installed and that the battery is good.

3. Make sure printed circuit board in the computer interface was not inadvertently switched around when the 9V battery was installed. Labeled connectors on printed circuit board must match interface labeling. Ie: Connect to Computer or Connect to monitor card

4. Replace 9-wire serial cables. If the problem still exists, replace the computer interface.

If the card is new, upon connection you will get this message. Once the Pulse monitor card begins accumulating data, the message will disappear.

Check K1 or K2 input of Pulse card for ﬂoating voltage. Example: If motor is moving in down direction, K1 and K2 should read 0 V. If K1 or K2 reads other than 0 V, check all control transformers to verify they have a common ground. Provide common ground as necessary.

of older events. A blank event will occur in both the current and history data. Disregard as an actual event.

The date indicates that as power was applied to terminal 91 on the monitor card, voltage was already present on either terminal K1,K2,0A or 1A, then removed within 1 second of power being applied to terminal 91. In the ﬁrst second of turning on power, avoid applying a run command.

The card has not accumulated a total of 16 motor starts which is required for the Motor Starts and Run Time ﬁelds to update. Accumulate a minimum of 16 motor starts before attempting to read card data.

Data not downloading Check com port on adaptor and pulse monitor software.

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APPENDIX 1

WIRING DIAGRAMS

2-Speed Global Series 3, with geared limit switch, motor thermal switch, thermal overload relays and overcapacity limit switch�

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Columbus McKinnon Corporation

Hoist & Rigging - Americas

Amherst, NY USA

P/N: 11817503 REV. AA June 2014

APPENDIX 1 (CONTINUED)

WIRING DIAGRAMS

Global Series 3 with MAGNETEK G+ Mini variable frequency drive, geared limit switch, motor thermal switch and overcapacity limit switch.

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APPENDIX 1 (CONTINUED)

WIRING DIAGRAMS

2-Speed 700 Series hoist with geared limit switch, block limit switch and motor thermal switch�

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APPENDIX 1 (CONTINUED)

WIRING DIAGRAMS

2-Speed 800 Series hoist with geared limit switch, block limit switch and motor thermal switch�

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APPENDIX 1 (CONTINUED)

WIRING DIAGRAMS

1-Speed Cable King with geared limit switch, block limit switch, motor thermal switch and overcapacity limit switch�

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APPENDIX 1 (CONTINUED)

WIRING DIAGRAMS

Cable King with MAGNETEK G+ Mini variable frequency drive, geared limit switch, block limit switch, motor thermal switch and overcapacity limit switch�

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APPENDIX 1 (CONTINUED)

WIRING DIAGRAMS

2-Speed trolley with motor thermal switch�

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APPENDIX 2

VOLTAGE MEASUREMENT ACCURACY

While the Pulse monitor itself is capable of +/-5% voltage measurement accuracy, two additional factors may further decrease accuracy.

Motor voltage is calculated using the control voltage powering the Pulse monitor� This calculation is based on the ideal ratio of the control transformer (primary voltage to secondary voltage)� Any variation in the control transformer ratio will consistently skew the motor voltage data� Additionally, this voltage measurement is made at the point where the Pulse monitor is connected� If this point is signiﬁcantly removed from the motor being monitored, a noticeable voltage drop may exist� The user is cautioned to consider both these contributing factors while interpreting the stored voltage data�

REPLACEMENT PARTS

Description Part Number

Serial Port to USB Adaptor Cable 23596401

Serial Extension Cable 23386403

CUSTOMER SERVICE

For Customer Service, please call 1-800-888-0895

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NOTES

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NOTES

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NOTES

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140 John James Audubon Parkway • Amherst, New York 14228-1197

1-800-888-0985 • Fax 716-689-5644 • www.cmworks.com

NOTE: Pulse is not a trademark of Columbus McKinnon Corporation. P/N: 11817503 REV. AA June 2014