R&M Materials Handling HOIST MONITORS User Manual

English 16.9.2008

SERVICE MANUAL FOR HOIST CONTROL DEVICE

R&M Materials Handling, Inc.

4501 Gateway Boulevard

Springfield, Ohio 45502

P.: [phone]

FAX: [phone]

Read the instructions supplied with the product before installation and commissioning.

Keep the instructions in a safe place for future reference.

Table of content

1 General..........................................................		5
1.1	Description.................................................	5
1.2	Directives, Standards and Patents .............	5
1.2.1	Directives ......................................................	5
1.2.2	Standards......................................................	5
1.2.3	Patent Pending..............................................	6
1.2.4	Certificate of compliance................................	6
2 Technical characteristics.............................		7
2.1	Description of terminals .............................	8
2.2	Product description sticker .......................	10
3 Display unit .................................................		11
3.1	Push-buttons............................................	11
3.2	LEDs........................................................	11
3.3	Display information ..................................	12
3.3.1 Tare load / actual load mode........................		12
3.3.2	Menu Mode .................................................	13
3.3.3	Status mode ................................................	13
3.3.4 Sum load / solo hoist load mode ..................		13
3.4	Menus......................................................	14
3.4.1	Moving in menus .........................................	14
3.4.2	Password ....................................................	14
3.4.3	Hoist selection (only multi-hoists).................	14
3.5	Parameters ..............................................	15
3.5.1	Read-only parameters .................................	15
3.5.2	Adjustable parameters.................................	15
3.6	Remote Display .......................................	16
3.6.1	General .......................................................	16
4 Parameters..................................................		18
4.1	Passwords ...............................................	20
5 Basic Functions..........................................		21
5.1	General....................................................	21
5.2	Overload protection..................................	22
5.3	Hoist motor overheating supervision ........	23

5.3.1Hoist motor overheating supervision

instructions ..............................................................		25
5.4	Supply voltage phase supervision............	26
5.4.1 Supply phase supervision instructions .........		26
5.5	RUN and fault supervision .......................	27

5.6Starting and stopping through slow speed (2

speed application only) .....................................

28

5.6.1Starting and stopping through slow speed

instructions ..............................................................	28
5.7 Sudden load increase supervision............	29

5.7.1Sudden load increase supervision instructions 29

6 Monitoring Items.........................................		30
6.1	General....................................................	30
6.2	Primary monitoring items .........................	30
6.2.1	Starts counter ..............................................	31
6.2.2	Run Time counter ........................................	31
6.2.3	Safe Working Period counter (SWP%)h.......	31
6.2.4	Hoist cycles counter ....................................	32
6.2.5	Run time and start counter for trolley and
bridge	32
6.3	Measured values......................................	33
7 Optional functions ......................................		34
7.1	General....................................................	34
7.2	Slack rope protection ...............................	34
7.2.1	Slack rope protection instructions ................	34
7.2.2	Slack rope protection connections ...............	35
7.3	Intermediate load limits ............................	35
7.3.1	Intermediate load limits parameters .............	35
7.3.2	Intermediate load limits connections ............	36

7.4Run time and start counter for trolley and

bridge................................................................

36

7.4.1Run time and start counter for trolley and

bridge parameters....................................................

37

7.4.2Run time and start counter for trolley and

bridge connections...................................................		37
7.5	Analogue output.......................................	37
7.5.1	Analogue output parameters........................	37
7.5.2	Analogue output connections.......................	38
7.6	Free relay output......................................	38
7.7	Hoist brake-wear supervision ...................	39
7.7.1	Hoist brake-wear supervision instructions ....	39
7.8	Load tare..................................................	40
7.8.1	Load tare instructions ..................................	40
7.9	Levelling function .....................................	40
7.9.1	Levelling function instructions ......................	40
7.9.2	Levelling Function Connections ...................	41
8 Multi-hoisting ..............................................		42
8.1	General....................................................	42

2/104

R&M Materials Handling, Inc. reserves the right to alter or amend the above information without notice.

	R&M Materials Handling, Inc.
	4501 Gateway Boulevard
	Springfield, Ohio 45502
	P.: [phone]
	FAX: [phone]
8.2	Multi-hoisting instructions.........................	42
8.2.1	Multi-hoisting parameters.............................	42
8.2.2	Cabling........................................................	43
8.2.3 Menus through CAN bus..............................		44
8.3	CAN-bus topology....................................	45
8.3.1	Termination resistors ...................................	45
8.3.2	Recommended topologies ...........................	46
9 Commissioning ..........................................		47
9.1	Start-up....................................................	47
9.2	Load measure..........................................	47

9.2.1Load measure type by ”Motor”, (see the

parameter 4-7-1)......................................................

47

9.2.2Load measure type by ”Sens.”, (see the

parameter 4-7-1)......................................................		47
9.3	Functional checks ....................................	48
9.3.1	Multi hoisting ...............................................	48
9.3.2	Multifunction inputs......................................	48
9.3.3 Functional free relay output ROUT...............		49
9.3.4	Analog output AOUT....................................	50
9.3.5	Slack rope ...................................................	50
9.4	Commissioning table................................	51
10 Overload protection – Load sensor ..........		52
10.1	Load sensor-system.................................	52
10.1.1	Load sensor set-up......................................	52
10.2	Load sensor parameters ..........................	52
10.3	Load calibration sequence with load sensor
	53
10.4	Manual load calibration ............................	54
11 Overload protection – Motor torque..........		55
11.1	Overload protection instructions...............	55
11.1.1	Motor torque calculation-system ..................	55
11.1.2 Motor torque calculation parameters ............		55
11.2	Connections.............................................	57

11.3Load calibration sequence with motor torque 58

11.4Zero load calibration sequence with motor toque59

11.5	Manual load calibration ............................	59
12 Load sensor adjustment ............................		61
12.1	KAE400 + Strain Gauge..........................	61
12.1.1	General .......................................................	61
12.1.2	Technical data.............................................	61
12.1.3	Wiring..........................................................	61
12.1.4	Adjustment ..................................................	62
12.1.5	Dimensions .................................................	63
12.2 ESD142 amplifier + Strain Gauge ............		63
12.2.1	ESD142 Description ....................................	63
12.2.2	Adjustment ..................................................	64
12.2.3	Zero load adjustment ...................................	64
12.2.4	Adjustment with higher load.........................	64
12.2.5	Connections ................................................	65
3/104

13 Faults and warnings ...................................		66
13.1	Faults.......................................................	66
13.1.1 Fault codes and description .........................		66
13.2	Warnings..................................................	67
13.2.1	General warnings ........................................	67
13.2.2	Service warnings .........................................	67
14 Troubleshooting .........................................		68
14.1	Fault descriptions.....................................	68
14.1.1	Fault Hoist OL F_OL..................................	68
14.1.2 Fault Motor OT F_OT ..................................		70
14.1.3	Fault Int. relay F_SR....................................	70
14.1.4 Fault RUN act. F_Run .................................		70
14.1.5	Fault Run FB – (2) .....................................	70
14.1.6	Fault Brake F_Br .........................................	71
14.1.7	Fault Br wear F_Brw...................................	71
14.1.8 Fault Sensor ch. F_SCh ..............................		72
14.1.9	Fault Curr.meas. F_Ain................................	72
14.1.10 Fault Supply vol F_SPh ...............................		73
14.1.11 Fault Phaseorder F_Sor ..............................		73
14.1.12 Fault CParameter F_CP ..............................		73
14.1.13 Fault MParameter F_MP..............................		73
14.1.14 Fault CAN bus F_CAN.................................		74
14.1.15 Fault Bridge OL F_BOL ...............................		74
14.1.16 Fault Bridge RS F_Brs.................................		74
14.1.17 Fault Slack Rope – (2) ................................		74
14.2	No Signal – (2) ........................................	74
14.3	Blank display............................................	75
14.4	The temperature sensors (NTC-wiring) ....	75
14.5	Current transformers................................	75
14.6	There is no fault, but hoist doesn’t work ...	76
14.6.1 Hoisting works, but lowering is prevented ....		76
14.6.2 Hoisting and lowering prevented..................		77
15 Replacement Instructions ..........................		78
15.1	General....................................................	78
15.2	Ordering a new Monitoring unit ................	78
15.3	Replacing.................................................	78
15.4	Parameters and Values............................	78
15.5	Flow chart ................................................	81
16 Menu structure............................................		82
16.1	Monitor 1 (Menu 1)...................................	82
16.2	Monitor 2 (Menu 2)...................................	83
16.3	Load calibration menu (Menu 3)...............	84
16.4	Start-up menu (Menu 4) ...........................	85
16.5	Service menu (Menu 5)............................	88
16.6	Design values menu (Menu 6) .................	88
16.7	GO –settings menu (Menu 7) ...................	89
Appendix 1 - Default parameters ...................		90
Appendix 2 - Version History .........................		91
Appendix 3 - Current Transformer’s
information ......................................................		93
Appendix 3.1 Current transformer table ........		95

R&M Materials Handling, Inc. reserves the right to alter or amend the above information without notice.

R&M Materials Handling, Inc.

4501 Gateway Boulevard

Springfield, Ohio 45502

P.: [phone]

FAX: [phone]

Appendix 4	- Motor temperature NTC charts 97
Appendix 5	- Example connections	............... 98
Appendix 6	- External power supply for ESD
143..................................................................		101

Appendix 7 - Replacing the condition
monitoring unit..............................................	103

4/105

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R&M Materials Handling, Inc.

4501 Gateway Boulevard

Springfield, Ohio 45502

P.: [phone]

FAX: [phone]

1 General

1.1Description

The hoist-monitoring unit is an electronic device designed to supervise and protect the hoist. The hoistmonitoring unit measures the use of the hoists and prevents hoisting or lowering in case a situation is detected which can cause a potential dangerous situation. The hoist-monitoring unit records the use of the hoist and calculates the remaining Safe Working Period “SWP” according to the FEM and ISO standards.

The hoist-monitoring unit is designed to fit a wide variety of hoists and motor drives. It can be used with variable speed control drives, as well as two speed drives. The hoist-monitoring unit contains tailored hardware and software, especially designed for crane use.

With the display, the unit can be programmed and calibrated, and stored values can be read. The hoistmonitoring unit can be equipped and installed with many different options and additional features such as:

•continuous load display

•tandem operation (up to five units)

•service-warning information

•hook levelling

•intermediate overload options

A service agent authorised by the manufacturer can provide detailed information and professional advice on a tailored solution for each application.

The hoist-monitoring unit is a safety device, installed by the manufacturer. Only service personnel authorised by the manufacturer are allowed to program and calibrate the unit. Faulty programmed or calibrated unit may cause malfunctions that results in dangerous situations.

Under no circumstances it is allowed to by-pass or remove the hoist-monitoring unit, as that would disable all supervision and safety features.

1.2Directives, Standards and Patents

1.2.1 Directives

The product conforms to the relevant safety provisions of the

•EMC Directive (2004/108/EC)

•Low Voltage Directive (2006/95/EC)

1.2.2 Standards

The product complies with the following standards:

•EN 50081-1 (1992) Generic emission standard: Residential, commercial and light industry

•EN 61000-6-2 (1999) Generic immunity standard: Industrial environment

•EN 50178 (1997) Electronic equipment for use in power installations

•EN 60204-32 (1998) Safety of machinery – Electrical equipment of machines. Part 32: Requirements for hoisting machines

•EN 12077-2 (1998) Cranes safety. Requirements for health and safety. Part 2: Limiting and indicating

devices

5/105

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R&M Materials Handling, Inc.

4501 Gateway Boulevard

Springfield, Ohio 45502

P.: [phone]

FAX: [phone]

1.2.3 Patent Pending

•US09/940,514 EP01000406,7

•US09/940,464 EP01000405,9

1.2.4 Certificate of compliance

•1334676 (LR025623)

6/105

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R&M Materials Handling, Inc.

4501 Gateway Boulevard

Springfield, Ohio 45502

P.: [phone]

FAX: [phone]

2 Technical characteristics

120.3

1
0
	8
		.
			5

		8
		.
	3
2
1

Signal name	Technical data
Maximum supply voltage	690 VAC +10%
Nominal supply frequency	50/60 Hz
Control voltage range	42…48 VAC +/- 10% or 115…230 VAC +/- 10%
Maximum power consumption	Imax = 4,5A peak value
Power consumption	6W …8W
Ambient temperature	-20ºC…+65ºC; 0ºF…+150ºF
Storage temperature	-40ºC…+85ºC; -40ºF…+185ºF
Humidity	0…100% RH, no condensation
Analogue output	0…10V, Rmin=1k
10VDC output	10…12 VDC, Imax=50mA
Potential free relay output (Programmable)	230VAC, 3A
Current loop	12 V, I = 50…70mA
CAN	0: Ucan-H = 2.5VDC, Ucan-L = 2.5VDC
	1: Ucan-H = 3.5VDC, Ucan-L = 1.5VDC
	(respect to CAN-GD)
Height (including 15mm assembly rail)	120.3mm; 4.73in
Length	123.8mm; 4.87in
Width	108.5mm; 4.27in
Tightening torque of connector terminal screw	0,4 Nm – 0,6 Nm

7/105

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4501 Gateway Boulevard

Springfield, Ohio 45502

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2.1Description of terminals

c_cid1a

1.Connector X1: Terminals 1-19 for “power signals” (high voltage)

2.Display unit with pushbuttons and three indication LEDs (optional)

3.Connector X2: Terminals 20 -38 for the measurement signals (low voltages).

4.Green LED (OK and run state indication)

5.Red LED (warning and fault indication)

6.Selection switch for display location (inside the unit or remote)

7.RS232 serial link, e.g. for PC software (optional) or PLC system

Connector X1:

	Terminal	Signal	Description
	1	LOUT	Provides the control voltage to lower down contactor (two step control) or lower down request. (inverter drive)
	2	HOUT	Provides the control voltage to hoist up contactor (two step control) or hoist up request (inverter drive)
	3	FOUT	Provides the control voltage to fast speed contactor (two step control) or fast stop control (stop limit or fault in
			inverter drive)
	4	OL	Control voltage, line
	5	ON	Control voltage, neutral
	6	MFI2	Multifunction input 2 (programmable)
	7	MFI1	Multifunction input 1 (programmable)
	8	FIN	Fast speed request or run feedback in inverter drive
	9	LIN	Lowering request
	10	HIN	Hoisting request
	11	ROUT	Relay output (programmable)
	12	RIN
	13	-	Not used
	14	-	Not used
	15	L3	Input voltage measurement, phase L3
	16	-	Not used
	17	L2	Input voltage measurement, phase L2
	18	-	Not used
	19	L1	Input voltage measurement, phase L1

8/105

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Connector X2:

	Terminal	Signal	Description
	20	PE	Protective earth
	21	TP11	Thermistor input 1
	22	TP12
	23	TP21	Thermistor input 2
	24	TP22
	25	10V	Load sensor supply, 10...12 VDC
	26	AIN1	Analogue input 1
	27	AIN2	Analogue input 2
	28	AIN3	Analogue input 3
	29	IB	Current transformer common
	30	0V	Load sensor supply, 0 V
	31	-	Not used
	32	CL-A	Current loop for display
	33	CL-B
	34	AN	Analogue output
	35	AN0	Analogue output, ground

36CAN-H CAN bus, high

37CAN-L CAN bus, low

38	CAN-GD CAN bus, neutral

Input request is not directly connected to the output. Output voltage comes from Control Voltage Line (OL) (via Safety Relay and Control relay). See simplified pictures.

C ontrol voltag e			U P		D O W N				F AS T
	M FI1 M F I2 O L			HIN		LIN			FIN

R S

R S

R H

R L R F

H O U T LO U T FO UT

A -K 1 A -K 2

A -K 4

Connections on eldrawings

Unit’s internal connections

9/105

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2.2Product description sticker

1.Supply voltage / Control Voltage 2.Unit type

3.Tested (year, week, tester) 4.Serial number

5.Product specific code

Unit types

Unit type	Serial number	Product specific code	Control voltage
CID-48V	Hxxxxx	ID: 52292509	42-48 VAC
CID-115V	Txxxxx	ID: 52292510	110-230 VAC

10/105

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3 Display unit

t

1 2 3

1.Red LED (Fault and Warning indication)

2.Orange LED (Tare load active)

3.Green LED (OK and Run indication)

The display unit shows in the large text field the actual or tared load. Also warning and fault messages are shown in the display. Parameter values can be read and set via display unit after a correct password has been given. Load information are displayed in a single row, other information are displayed in two rows. If display is inside the hoist-monitoring unit, the red display selection switch must be on the local position (up position).

Please note that the hoist-monitoring unit is designed for overload protection. The displayed load has an accuracy of approx. ±5% of the rated load and is thus not suitable to be used as a calibrated weighing scale.

3.1Push-buttons

On the display are four pushbuttons for navigating and programming.

	ESC	1. Zeroing of tare load. Press ESC button for three seconds.
		2. Moving from submenu to main menu and reject parameter changes

1.Toggle between actual load (orange LED off) and tare load (orange LED on)

2.Scrolling down

1.Toggle between actual load (orange LED off) and tare load (orange LED on)

2.Scrolling up

ENT	1.	Entering the password level
	2.	Selecting a menu and accept parameter changes

3.2LEDs

There are three LEDs inside the display unit. The left red LED is for fault or warning indication. The orange or yellow LED in the centre is active when the tare load is selected. The right green LED is on when the hoist-monitoring unit is OK and blinks when the hoist is running.

Action / LED	Red LED (Left)	Orange LED (Centre)	Green LED (Right)
Illuminated continuously	Fault	Tare load value displayed	OK, not running
Blinking	Warning and Service	-	OK, running
Not illuminated	OK	Actual load value displayed	Fault

OK state means that the hoist control unit is working normally and no fault or error has been detected. When a driving output or the run feedback in inverter application is active, the green LED is blinking.

Warning means that a condition monitoring value exceeds the corresponding design value. Running the hoist is possible, but safe using is not guaranteed.

11/105

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Service-state means that a limit value set for the next service has been expired. This is indicated to the crane user, but the hoist can still be run normally.

Fault-state means that a serious problem has been detected. Running the hoist is restricted.

3.3Display information

3.3.1 Tare load / actual load mode

Tare load can be used when the crane is operated with a load-handling device, such as a grab or spreader. When no load-handling device is used, the tare load must be set to zero with empty hook. Considering a grab crane as example the table explains the differences between tare load and actual load. Press UP or DOWN button to toggle between tare and actual load.

		Display information
Hoist application	Description	Orange LED ON	Orange LED OFF
		TARE LOAD	ACTUAL LOAD
10t grab without grab		Displayed value depends on last
		zeroing.

Only empty ropes or empty	0.2 t
			0.2 t
hook block. No load in the	or zeroing press ESC for three sec.
crane.
	Display shows now
	0.0 t
10 t grab crane	5.0 t
A grab is attached to the
ropes. Grab weight is 5 tons.	Press ESC button for three sec.		5.2 t
The grab is empty and not	Display shows
loaded.
	0.0 t
10 t grab crane	Display shows
	5.0 t		The payload + grap weight
The grab is loaded with 5 tons
			10.2 t
payload.	This is the payload of the load-
	handling device.
10 t grab crane without grab	Last zeroing was made with 5 tons
	attached. Display shows
Only empty ropes or empty	-4.8 t
			0.2 t
hook block. No load in the
	Press ESC button for three sec.
crane.
	Display shows

0.0t

When the display is in the load mode, the load can be tared (value set to zero) by pushing the ESC button about three seconds and after that display shifts into the tare load mode.

Tare function is made for each hoist individually; means tare command is not transferred to other units via CAN bus.

12/105

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3.3.2 Menu Mode

Pushing the ENT button in the tare or actual load display mode, shifts the display into the menu mode. A password is required in order to proceed. Pushing the ESC button returns to the actual load display.

3.3.3 Status mode

Status mode indicates all active faults, warnings and service warnings when applicable. The display shifts automatically into the status mode when a fault or warning occurs during power ON. If more than one fault or warning are active, all of them can be seen with arrow keys; active faults first, then warnings and service warnings. The active fault message remains visible until the fault disappears, or the message is removed by pushing the ENT button.

	Display	Description
	Fault	Status display indicating active faults status.
	Fault name
	Warning	Status display indicating active warnings status.
	Warning name
	Service	Status display indicating active service status.
	Service name

3.3.4 Sum load / solo hoist load mode

In multi-hoist applications, the display shows the summed tare load as the first display at power on. Toggling between the tared sum load, the actual sum load and the actual load of each connected hoist individually is done with the up and down buttons.

13/105

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3.4Menus

Monitoring items and parameters are presented in menus. The menus are accessible with passwords. The right to read and/or modify parameters within a menu depends on the selected password.

3.4.1 Moving in menus

Toggling between the menus is done with the up and down arrow buttons. When the desired menu has been selected, it is entered with the ENT-button. If there are submenus in the main menu, they are selected and entered in the same way as described above. Returning to the higher menu level is done with the ESC-button.

3.4.2 Password

When the ENT key is pushed the display shifts to the password request menu. With the ESC key or when an incorrect password is given, the display shifts back to the load display.

The first display of the password select menu shows four “zeros”, with the leftmost underlined. Pushing the up and down button will change the digit. The desired digit is selected with the ENT button, after which the next digit will be underlined. Repeat this procedure until the correct password is given. The display will now show the first menu “1 Monitor 1”.

(Example: Level 2 password “0732”)

3.4.3 Hoist selection (only multi-hoists)

In multi-hoist applications, where more then one unit are connected with the CAN-bus, the display will ask to select the desired unit (A, B, C, D or E) before the display shows the first menu. This way, each unit can be accessed via another unit. For example, all parameters and values of unit C can be displayed and modified via unit A.

When reading data from the display in multi hoist application, verify that you are reading the data from the correct device. The selected hoist is shown in the 0-2 display.

14/105

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3.5Parameters

3.5.1 Read-only parameters

Menu 1 (Monitor 1) and menu 2 (Monitor 2) contain read-only parameters. These menus will show the calculated and measured values of the solo hoist, connected to the selected unit.

3.5.2 Adjustable parameters

There are two sorts of adjustable parameters:

•Free adjustable (within the given limits)

•Choice from option list

When a parameter has to be adjusted, first select the desired parameter. Pushing the ENT button opens the parameter and the value can be adjusted. The free adjustable parameters will ask to adjust the digits one at the time, whereas other parameters will give the choice between a number of options.

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Example: selecting the MFI1 input to intermediate load function, with a load of 8.5 Tons.

3.6Remote Display

3.6.1 General

The display can be also located at a remote location, for example in the push button station, in the cubicle-door or in a crane driver cabin. In this way the crane operator can read load information directly from the display. All features as well as the parameter structure are the same as when the display would be located at the unit. The display in the remote location is a very effective tool for applications where the crane operator needs to have a load indication when handling loads.

Please note that the hoist-monitoring unit is designed for overload protection. The displayed load has an accuracy of approx. ±5% of the rated load and is thus not suitable to be used as a calibrated weighing scale.

16/105

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Connections and Display Selection Switch

A.Current loop to remote display

B.Display selection switch in down position for remote selection

If the display is in a remote location, the display is connected via a current loop with the hoist-monitoring unit. The current loop is between terminals 32 (CL-A) and 33 (CL-B). Because a current loop is not sensitive for electrical disturbances, it is not needed to use shielded cables for the display connection.

With the red display selection switch on top of the hoist-monitoring unit it is possible to switch between the display locations. The display selection switch must be in the down position to select the remote location active.

Remote display and display in the unit cannot work simultaneously.

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4 Parameters
1	Monitor 1	Read only menu for condition monitoring values and
		measured values.
1-1	Cond mon	Condition monitoring menu
1-1-1	SWP%	Remaining Safe Working Period of the hoist in
		percentage, starting from 100%.
1-1-2	Starts	Total number of starts
1-1-3	Run time	Total running time
1-1-4	Cycles	Total number of hoisting cycles.
1-1-5	Mean load	Average of the handled load
1-1-6	Br SWP%	Remaining Safe Working Period of the brake in
		percentage.
1-1-7	MFI1 RT	Total hours of running time, when MFI1 input is closed.
1-1-8	MFI1 ST	Total amount of starts, when MFI1 input is closed.
1-1-9	MFI2 RT	Total hours of running time, when MFI2 input is closed.
1-1-10	MFI2 ST	Total amount of starts, when MFI2 input is closed.
1-2	Measure	Measurement menu
1-2-1	Act. Load	The measured actual load value.
1-2-2	Temp 1	Temperature measured at thermistor input 1.
1-2-3	Temp 2	Temperature measured at thermistor input 2.
1-2-4	Supply L1	Line voltage of phase L1.
1-2-5	Supply L2	Line voltage of phase L2.
1-2-6	Supply L3	Line voltage of phase L3.
1-2-7	Motor I1	Motor current of phase L1.
1-2-8	Motor I2	Motor current of phase L2.
1-2-9	Motor I3	Motor current of phase L3.
1-2-10	Ain1 value	Measured voltage at analogue input AIN1.
1-2-11	Ain2 value	Measured voltage at analogue input AIN2.
1-2-12	Ain3 value	Measured voltage at analogue input AIN3.
1-2-13	Int. temp	Internal temperature of the unit.
1-2-14	Input	Indicates the status of the inputs: HIN, LIN, FIN, MFI1 &
		MFI2.
1-2-15	Output	Indicates the status of the outputs: HOUT, LOUT,
		FOUT, RS & ROUT.
1-2-16	Supply f	Supply voltage frequency (50 or 60Hz)
1-3	Min/Max	Minimum / maximum value menu
1-3-1	Min supply	Minimum measured value of the supply line voltage
		RMS.
1-3-2	Max supply	Maximum measured value of the supply line voltage
		RMS.
1-3-3	Min Int. T	Minimum measured value of the internal temperature of
		the unit.
1-3-4	Max Int. T	Maximum measured value of the internal temperature of
		the unit.
2	Monitor 2	Read only menu for advanced condition monitoring
		values and measured values. Accessible password
		level 3
2-1	SW version	Software version of the unit
2-2	RT slow	Total run-time in slow speed
2-3	RT fast	Total run-time in fast speed
2-4	No. OT	Total number of hoist motor overtemperature incidents.
2-5	No. OL	Total number of overload incidents
2-6	E-stops	Total number of emergency stops incidents
2-7	ST up	Total number of starts in up direction
2-8	ST down	Total number of starts in down direction
2-9	ST fast	Total number of starts to fast speed (counts in two
		speed control only)
2-10	Max ED	Maximum value of the calculated ED percentage

2-11	Over ED		Counts the minutes when ED value has exceed the
			nominal ED value
2-12	SWPRT%		SWP% value calculated with hoist running time
2-13	SRT3		Load sum with hoist running time, third power
2-14	SRT8		Load sum with hoist running time, eight power
2-15	SWPHC%		SWP% value calculated with hoist cycles
2-16	SL1		Load sum with hoist cycles, the first power (mean load)
2-17	SL3		Load sum with hoist cycles, the third
2-18	SL8		Load sum with hoist cycles, the eight power
2-19	Power on		The total power on time of the unit
2-20	Temp Index		Power on time of the unit, weighted with the unit’s
			temperature
2-21	Max load		Maximum measured value of the load
3		Load setup	Load calibration menu. Accessible password level 2
3-1	Cal. Motor		Load calibration when the motor torque based load
			measurement is selecte. See chapter “Load
			calibration sequence with motor torque”.
3-2	MC values		Load calibration values for the motor torque method
3-2-1	Load 1		The higher test load’s value
3-2-2	Mhs1		Motor torque for hoisting in slow speed, with load.
3-2-3	Mhf1		Motor torque for hoisting in fast speed, with load 1.
3-2-4	Mls1		Motor torque for lowering in slow speed, with load 1.
3-2-5	Mlf1		Motor torque for lowering in fast speed, with load 1,
3-2-6	Load 2		The lower test load’s value.
3-2-7	Mhs2		Motor torque for hoisting in slow speed, with load 2.
3-2-8	Mhf2		Motor torque for hoisting in fast speed, with load 2.
3-2-9	Mls2		Motor torque for lowering in slow speed, with load 2.
3-2-10	Mlf2		Motor torque for lowering in fast speed, with load 2.
3-3	Cal. Sens		Load calibration when the sensor based load
			measurement is selected. See chapter “Load
			calibration sequence with the load sensor”.
3-4	SC values		Load calibration values for the load sensor method
3-4-1	Load 1		The higher test load value.
3-4-2	Input 1		The load measurement voltage in the analogue input
			Ain1 corresponding to the higher test load
3-4-3	Load 2		The lower test load value
3-4-4	Input 2		The load measurement voltage in the analogue input
			Ain1 corresponding to the lower load
3-5	OL protect		Set to “OFF” to temporarily by-pass of the overload
			protection
4		Start-up	Startmenu. Accessible password level 4
4-1	MFI1		Multi-Functional Input 1 parameters
4-1-1	MFI1 oper.		Selects the function of MFI1:
4-1-2	MFI1 IntL		Intermediate load limit value
4-1-3	MFI1 2OLL		The second load
4-1-4	MFI1 CintL		Bridge intermediate load limit value.
4-2	MFI2		Multi-Functional Input 2 parameters
4-2-1	MFI2 oper.		Selects the function of MFI2:
4-2-2	MFI2 IntL		The (second) intermediate load limit value
4-2-3	1+2 IntL		The third intermediate load limit value
4-2-4	MFI2 2OLL		The second load limit
4-2-5	MFI2 CintL		The (second) bridge intermediate load limit value
4-2-6	1+2 CintL		The third bridge intermediate load limit value

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4-3	ROUT	Relay output parameters
4-3-1	ROUT oper.	Selects the function of the relay output
4-3-2	ROUT logic	The operation logic of the relay:
4-3-3	ROUT LoadX	The load limit to switch the relay is entered here
4-3-4	TempX meas	The temperature measurement operation
4-3-5	TempX lim	The temperature limit
4-4	T1	Temperature measurement channel 1 parameters
4-4-1	T1 operat.	Selects the function channel 1.
4-5	T2	Temperature measurement channel 2 parameters
4-5-1	T2 operat.	Selects the function channel 1.
4-6	AOUT	Analogue output parameters
4-6-1	AOUT oper.	Selects the function of the analogue output
4-6-2	Zero load	Sets the voltage level with zero-load. Range 0…10V
4-6-3	Nom. Load	Sets the voltage level with rated load. Range 0…10V
4-7	Load param	Load calculation parameters
4-7-1	Load meas.	Selects the load calculation method:
4-7-2	Load rate%	Load increase rate for controlling the hoisting in two step
		control.
4-7-3	R0_F	Resistance of fast speed windings at temperature T0
4-7-4	R0_S	Resistance of slow speed windings at temperature T0
4-7-5	T0	Resistance measuring temperature T0
4-7-6	Temp_slow	Temperature measurement channel for the motor slow
		speed windings.
4-7-7	Temp_fast	Temperature measurement channel for the motor fast
		speed windings.
4-7-8	C2F	Coefficient 2 for fast speed
4-7-9	C2S	Coefficient 2 for slow speed
4-7-10	C1F	Coefficient 1 for fast speed
4-7-11	C1S	Coefficient 1 for slow speed
4-7-12	ki	Reduction factor for current transformer [A/V]
4-7-13	Acc-t slow	Acceleration time from stop to slow speed.
4-7-14	Acc-t fast	Acceleration time from slow speed to fast speed.
4-8	Hoist ctrl	The selection for the hoist control method
4-9	Slack rope	Slack rope function parameters
4-9-1	SR select	Selects the slack rope function
4-9-2	Load limit	The slack rope limit
4-10	Single sup
4-10-1	OT run ?	Selects the action when the motor temperature exceeds
		the limit or when “Fault, Br wear” occurs
4-10-2	OT limit	When NTC type sensor is applied the limit value for the
		hoist motor overtemperature
4-10-3	Supply sup	Selects the supply voltage supervision.
4-11	Comm hoist	The settings for common hoisting (multi-hoist
		applications)
4-11-1	Hoist cnt	The number of units connected with CAN bus. Range:
		1…5
4-11-2	Run sup.	Common hoisting supervision
4-11-3	B OL	Bridge overload protection
4-11-4	B nom load	Rated load of the bridge
5	Service	Startmenu. Accessible password level 5
5-1	S limits	The limit values to indicate the need for service.
5-1-1	S Run time	Run time service limit
5-1-2	S starts	Service limit for the number of starts
5-1-3	S SWP%	Service limit for SWP%
5-1-4	S Br SWP%	Service limit for the hoist brake service life
5-2	Fault log	The logger for the latest fault situations, the number
		“n” indicates the number of faults in the logger
5-2-1	F_”XXX”	The latest fault.
5-2-2	F_”XXX”	The second latest fault.
5-2-“n”	F_”XXX”	The “n” latest fault (highest number is 30).

5-3	Reset log	Resets the fault log by pushing the ENT button..
5-3	Reset log ?	The reset action must be confirmed by pushing the ENT
		button once more
6	Design	Design values menu. Accessible password level 6
6-1	Hoist name	Identifying letter of the hoist-monitoring unit, A, B, C, D
		or E.
6-2	Unit No	The serial number of the hoist.
6-3	Class	Mechanical class for the hoist according to the FEM /
		ISO duty classes.
6-4	Nom. Load	Rated load of the single hoist connected to the unit
6-5	Nominal ED	Rated ED value of the hoist
6-6	Sp ratio	Speed ratio.
6-7	Max ST	Maximum allowed number of starts
6-8	Max E-stop	Maximum allowed number of interrupted hoists
		(emergency stops)
6-9	Max RT	Maximum allowed run-time in hours
6-10	D SRT3	Designed running hours, power three.
6-11	D SRT8	Designed running hours, power eight.
6-12	D SL3	Design constraint for hoisting cycles, power three
6-13	D SL8	Design constraint for hoisting cycles, power eight
6-14	MaxST MFI1	Max number of MFI1 starts.
6-15	MaxRT MFI1	Max running time for MFI1.
6-16	MaxST MFI2	Max number of MFI2 starts.
6-17	MaxRT MFI2	Max running time for MFI2.
6-18	Max Br	Max number of braking actions.
6-19	Max Control	Max number of Control (starts)
6-20	Password	Set password level 1 (4digits).
7	GO-setup	GO-settings menu. Accessible password level 7
7-1	Cycles	Number of hoisting cycles
7-2	MFI1 RT	MFI1 running time
7-3	MFI1 ST	MFI1 starts
7-4	MFI2 RT	MFI2 running time
7-5	MFI2 ST	MFI2 starts
7-6	RT slow	Run-time in slow speed
7-7	RT fast	Run-time in fast speed
7-8	No. OT	Number of hoist motor overtemperature incidents.
7-9	No. OL	Number of hoist overload incidents
7-10	E-stops	Number of emergency stops
7-11	ST up	Number of starts in up direction
7-12	ST down	Number of starts in down direction
7-13	ST fast	Number of starts to fast speed (two step control only)
7-14	Max ED	Maximum ED value
7-15	Over ED	Number of cases where ED value has exceeded the
		rated ED value
7-16	SRT3	Load sum with hoist running time, third power
7-17	SRT8	Load sum with hoist running time, eight power
7-18	SL1	Load sum with hoist cycles, the first power (mean load)
7-19	SL3	Load sum with hoist cycles, the third power
7-20	SL8	Load sum with hoist cycles, the eight power
7-21	Power on	The total power on time for hoist control unit
7-22	Temp Index	The power on time weighted with the hoist control unit
		temperature
7-23	Max load	The maximum value of the measured load
7-24	Br Count	The brake wear counter.

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4.1Passwords

The table below indicates the access to the menus with different password levels.

The display asks for the password when the ENT button is pushed in the main load display mode. If the given password does not match to any of the levels, the display returns to the main load display mode. If the given password matches to one of the levels, the user has access to the corresponding menus according to the table below.

Main menus	Level 1		Level 2	Level 3	Level 4		Level 5		Level 6	Level 7
1 Monitor 1	X			X	X		X		X	X
2 Monitor 2				X	X		X		X	X
3 Load Setup			X		X		X		X	X
4 Start-up					X		X		X	X
5 Service							X		X	X
6 Design									X	X
7 GO-setup										X
Passwords for different levels
Level	Password		Note
Level 1	Parameter		Given with the parameter, 6–20 Password
Level 2	0732		Fixed value, can only calibrate the load measurement
Level 3	5201		Fixed value, used to read the monitoring values
Level 4	8124		Fixed value, all menus up to input/output settings and calibration
Level 5	5029		Fixed value, all menus up to service menu
Level 6	9822		Fixed value, all menus up to design limit values
Level 7	2180		Fixed value, access to all parameters

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5 Basic Functions

5.1General

The basic functions assure the safe functioning of the hoist. The hoist-monitoring unit constantly performs a number of checks to determine if all conditions are safe in order to proceed the motion. In case the hoist-monitoring unit detects a potentially unsafe situation, the motion will be stopped. Depending on the kind of fault, both hoisting and lowering is prevented or in other cases driving in the opposite direction is allowed.

In addition to the basic functions, a wide scale of optional functions can be installed. Refer to the section “Optional functions” or contact a manufacturer’s representative for further details.

The basic functions of the hoist-monitoring unit are:

•Overload protection

•Hoist motor overtemperature supervision

•Supply phase supervision

•Run and fault supervision

•Starting and stopping through slow speed

•Sudden load increase supervision

The basic functions are factory set according to specific hoist and customer’s demand.

It is possible that few basic functions can’t be used in every hoist. (e.g. Insulated network, inverter drive)

The additional optional functions of the hoist-monitoring unit are:

•Lifetime counters

•Remote display

•Multicare

•Multi function input Options

•Potentional Free Relay Options

•Analog Output

When during run one of the supervised safety features value exceeds the limit, the unit will stop the motion. Re-starting is only possible after the reason for the fault is terminated. Note that some faults are direction dependent and running in the opposite direction will terminate the fault. Refer to the sections that describe the supervisions for details.

The hoist-monitoring unit is equipped with two LEDs that provide operational information as follows:

Action / LED	Green LED	Red LED
Illuminated continuously	OK, not running	Fault
Blinking	OK, running	Warning
Not illuminated	Fault	OK

OK state means that the hoist control unit is working normally and no fault or error has been detected. Running the hoist is possible.

Warning means that a condition-monitoring value has exceeded the design value. Running the hoist is possible, but safe operation can not be guaranteed.

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Fault means that one (or more) of the supervised safety features values exceeds the limit. Running the hoist is restricted.

For Run or Fault supervision, it is possible to connect an external indication device like a horn or lamp to the relay output. Relay output must be programmed to the desired function “OK” or “Ready”

5.2Overload protection

The overload protection can be done in two ways, either with motor torque calculation or by using a load sensor. Regardless which system is used, the hoist-monitoring unit will prevent the hoisting motion when the measured load exceeds 110% of the rated load for a period of time. A filtering delay is built in to assure trouble-free lifting of a rated load. The overload protection is reset when the measured load decreases to 80% of the rated load.

The overload protection reacts faster than the display updates the measured values. Therefore it may happen that the movement is stopped although the display indicates a load less than 110% of the rated load.

Overload level	Filtering time	Run-down time
140%	60 ms	~100 ms
125%	200 ms	~250 ms
110%	1000 ms	~1050 ms

The motor torque calculation system uses the motor voltage, current and temperature to calculate the motor torque and converts this into load information. This system cannot be used in combination with frequency converters, and can only measure the load when the motor is running. In addition to the overload protection, the hoist-monitoring unit also supervises the brake. When the calculated load value descends under -50% of the rated load during lowering, it indicates that the brake did not open. Lowering the hook is prevented, but lifting is still allowed.

Motors driven by a frequency converter are always equipped with a load sensor for load measurement.

Systems using a strain gauge type of sensor are also equipped with a load sensor amplifier to amplify the signal coming from the sensor. In case a Hall-type of sensor is used, the load sensor amplifier is not needed.

Param.	Name	Value	Description
4-7	Load param		Load calculation parameters
			Selects the load calculation method:
4-7-1	Load meas.		NU	Not used, the display show all time to 0,0t
			Motor	Motor torque calculation. Refer to chapter “Overload protection – Motor torque” of this manual
			Sens.	Load sensor measurement . Refer to chapter “Overload protection – Load sensor” of this manual

Load measurement tolerance is ±10% of nominal load by use motor torque calculation system and load measurement tolerance is ±5% of nominal load by use load sensor.

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5.3Hoist motor overheating supervision

To prevent the hoisting motor from burning up, the hoist-monitoring unit will constantly measure the internal temperature of the motor. The motor is therefore equipped with temperature sensors; PTCthermistors, NTC-thermistors or Bi-metal switches (Klixons). The hoist-monitoring unit can be programmed to either prevent both hoisting and lowering (default), or only the hoisting motion.

PTC-thermistor connections

PTC-thermistors are commonly used in most of the motors in the past. PTC-thermistors will rapidly increase their resistance when the measured temperature exceeds the limit. The maximum allowed temperature depends on the motor and is determined by the used thermistors. The hoist-monitoring unit will detect over temperature when the resistance of the PTC exceeds 4.0kOhm.

Bi-metal switches are mounted on the motor stator windings. Bi-metal switches operate as thermal-switches and will open up the contact when the measured temperature exceeds the limit. The maximum allowed temperature depends on the motor and is determined by the used Bi-metal switches. The hoist-monitoring unit will detect overtemperature when the resistance exceeds 4.0kOhm (thus open contact).

In practice, PTC-thermistors and Bi-metal switches operate in the same way. The hoist-monitoring unit stops the motion when the resistance of the temperaturemeasuring device exceeds 4.0kOhm.

NTC-thermistors connections

NTC-thermistors are used when motor torque calculation is the load measurement method. NTC-thermistors will decrease their resistance in an almost linear relation to temperature increase. The actual motor temperature is accurately measured with NTC-thermistors and the hoistmonitoring unit will stop the motion in case the resistance of the temperature-measuring device drops below the preset value.

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Thermistors operating curve

	NTC	PTC	Bi-metal
	40
	35
	30
	25
kohm	20
	15
	10
	5
	0		Over temperature
	Motor Temperature

NTC and PTC: The temperature sensor’s cable must be shielded if the cable between the unit and the temperature sensors is longer than 10m. The cable shield is connected to the ground of the hoist. It is recommended to use 360 degrees shield clamps to carry out the grounding!

Bi-metal: It is recommended to use a supplementary relay between the unit and the thermistor. In that case there is no need for a shielded cable and possible disturbance is limited to the minimum.

In case third party motors are used, please consult with the manufacturer of the motor for thermistor details.

Motors without thermistors must be protected against overheating by other means, e.g. a motor protection switch.

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5.3.1 Hoist motor overheating supervision instructions

Param.	Name		Description
4-4	T1		Temperature measurement channel 1 parameters
4-4-1	T1 operat.		Selects the function of temperature measurement channel 1:
			NU		Not used	Motor without thermistors or only one sensor that is connected to the
						temperature input 2.
			PTC		Motor thermistor or	Two speed motors typically only have one set of thermistors, for both low speed
					Bimetal thermal switch	and high speed windings.
			Bwear		Brake wear sensor	See section Hoist BrakeWear supervision
			A NTC		Type A NTC sensor	Determines the type of thermistors in the low speed windings, connected to the
			B NTC		Type B NTC sensor	temperature input 1
						Manufacturer’s hoisting motors used in motor-torque calculation overload
			C NTC		Type C NTC sensor
						systems are as a standard equipped with type B NTC thermistors
Param.	Name		Description
4-5	T2		Temperature measurement channel 2 parameters
4-5-1	T2 operat.		Selects the function of temperature measurement channel 2:
			NU		Not used	Motor without thermistors or only one sensor that is connected to the
						temperature input 1.
			PTC		Motor thermistor or	Two speed motors typically only have one set of thermistors, for both low speed
					Bimetal thermal switch	and high speed windings.
			Bwear		Brake wear sensor	See section Hoist BrakeWear supervision
			A NTC		Type A NTC sensor	Determines the type of thermistors in the low speed windings, connected to the
			B NTC		Type B NTC sensor	temperature input 1
						Manufacturer’s hoisting motors used in motor-torque calculation overload
			C NTC		Type C NTC sensor
						systems are as a standard equipped with type B NTC thermistors
Param.		Value		Description			Note
4-10							Accessible with password 4: 8124
Single sup
4-10-1		No / Down		Hoisting and lowering is prevented when the			If, for safety reasons, local legislation or customer demands,
OT run ?				overtemperature supervision trips.			lowering the load is required when the temperature supervision
							has tripped, set this parameter to: “Down”
4-10-2		150C		Sets the tripping level of the overtemperature			Consult with the motor data sheets for the maximum allowed
OT limit				supervision in degrees Celsius, steps of one			temperature for the motor. Default for manufacturer’s squirrel
				degree. Only with NTC-thermistor.
							cage motors: 150°C

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5.4Supply voltage phase supervision

The supply voltage phase supervision consists of two functions:

-Missing supply phase detection

-Incorrect supply phase order

The three supply voltage phases are wired to the hoist-monitoring unit. Each time the unit is powered up, the phase order is checked. The unit will continuously measure the existing of all three phases.

In case wrong direction of hoisting occurs (reversed phase condition), note that the two input power wires are reversed at terminal X2A!

5.4.1 Supply phase supervision instructions

Supply phase supervision parameters

Param.	Value	Description	Note
4-10			Accessible with password 4: 8124
Single sup
4-10-3	Yes	Switches the supply phase supervision on.	When the hoist monitoring-unit is connected in insulated or high
			impedance grounded network, or when the supply mains are not
			connected (i.e. inverter use), the setting must be “No”.

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5.5RUN and fault supervision

The hoisting and lowering request from the control station will come as an input to the hoist-monitoring unit. Before the hoist can start the requested motion, the hoist-monitoring unit checks if it is safe to proceed. If no limitations are detected, the hoist-monitoring unit will activate the requested output and movement will start. The unit monitors a feedback signal. When the feedback signal drops during running, the motion will stop immediately. During the starting sequence, the feedback signal must be on within 200ms in contactor control, and within 800ms in inverter control.

2 Speed Hoisting: Unit monitors a feedback signal from a current transformer to analog input 2. The current transformer measures the input current to the motor in 2 speed hoisting. During the starting sequence, the feedback signal must be on within 200ms in contactor control. When the feedback signal drops during running, the motion will stop immediately.

2 Speed, load measurement by motor

2 Speed, load measurement by sensor

When the unit supervises a hoist inverter application a brake contact from AK7 is connected to the FIN input, terminal 8, to be a brake open feedback signal. If the brake contactor does not energize during start or de-energizes during hoisting (initiated by a fault or due to brake failure) the unit will disconnect control voltage from the FOUT signal output, terminal 3, feeding the ES and RDY inputs of the inverter. During the starting sequence, in inverter control, the feedback signal at FIN must be on within 800ms.

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R&M Materials Handling, Inc. reserves the right to alter or amend the above information without notice.

R&M Materials Handling, Inc.

4501 Gateway Boulevard

Springfield, Ohio 45502

P.: [phone]

FAX: [phone]

5.6Starting and stopping through slow speed (2 speed application only)

Starting the motor directly in high speed will cause a high starting current that heats up the motor quite rapidly. To prevent the motor from overheating, the hoist-monitoring unit will always start the motion in slow speed. After a short period of time, the hoist-monitoring unit allows driving in fast speed when requested.

Stopping the motion directly from high speed will cause excessive brake wear. To protect the brake lining material, the hoist-monitoring unit will initiate slow speed for a brief moment, before the mechanical brake is closed.

This function can only be activated in two-speed systems

A.Speed

B.Position of pushbutton (0, 1, 2)

5.6.1Starting and stopping through slow speed instructions

Starting and stopping through slow speed parameters

Param.	Value	Description	Note
4-7Load param		Load calculation menu	Accessible with password 4: 8124
4-7-13	0.20s	Acceleration time from stop to slow speed 0.00s – 1.00s	See description below
4-7-14	0.30s	Acceleration time from slow speed to fast speed 0.00s – 1.00s	See description below

The parameters 4-7-13 and 4-7-14 have the following functions:

•During acceleration from zero to slow speed and deceleration from slow speed to zero, the unit will not calculate or supervise the overload protection and current measurement for a period of time determined by parameter 4-7-13.

•During acceleration from slow speed to fast speed and deceleration from fast speed to slow speed, the unit will not calculate or supervise the overload protection and current measurement for a period of time determined by parameter 4-7-14.

•The above function prevents the overload from tripping during the acceleration and deceleration moment, especially in two-step systems with motor-torque calculation based overload protection, since the starting currents are momentarily quite high.

•When accelerating from zero directly to fast speed, the motion starts in slow speed for a period determined by par. 4-7-13.

•When decelerating from fast speed to slow speed, the unit will keep the fast speed active for a period determined by par. 4-7-14.

•When decelerating from fast speed directly to zero, the unit will activate the slow speed for a fixed period of 250ms (not adjustable by parameters!).

The above function prevents the use called as “inching”, “jogging” or “tipping” operation.

Once the slow speed output is activated, it remains active for 250ms, even if the input command drops off within this time. This prevents the directional contactors to drop off during the high starting

currents.

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R&M Materials Handling, Inc. reserves the right to alter or amend the above information without notice.

R&M Materials Handling, Inc.

4501 Gateway Boulevard

Springfield, Ohio 45502

P.: [phone]

FAX: [phone]

5.7Sudden load increase supervision

In case the hoist-monitoring unit measures a sudden load increase when driving upwards in high speed, the unit will control the hoist to low speed. A sudden load increase is considered when the load exceeds 30% of the rated load of the hoist within 200ms. High speed hoisting is allowed again when the load increase in the last 200ms is less than the preset value, determined by parameter 4-7-2.

The function is completely reset when the measured load is less than 10% of the rated load of the hoist. The function has no effect when the load is bigger than 30% of the rated load of the hoist. Sudden load increase may occur e.g. due to jerky movements or starts in high speed.

L. Load

T. Time

1.First speed

2.Second speed

3.Load increase stops

This function can only be activated in two-speed application and hoist has no effect when hoisting in low speed. Sudden load increase supervision is only activate with loads below 30% of rated load and is activated only once.

5.7.1Sudden load increase supervision instructions

Sudden load increase supervision parameters

Param.	Value	Description	Note
4-7		Load calculation menu	Accessible with password 4: 8124
Load param
4-7-2	10	Load increase rate for controlling the hoisting in two step control, speed	0% means that the function is not applied
Load rate%		change to fast speed is allowed when actual load change within 200ms <	10% is the factory default
		parameter 4-7-2.
		Setting range: 0…10%, steps of 1%

A small value makes the hoist to drive in slow speed for a longer period, to ensure that the load is stabilised (not stuck to the unloading platform etc. and no more vibrations caused by the ropes and/or other mechanics).

A larger value (maximum 10) allows faster acceleration to fast speed.

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R&M Materials Handling, Inc. reserves the right to alter or amend the above information without notice.

R&M Materials Handling, Inc.

4501 Gateway Boulevard

Springfield, Ohio 45502

P.: [phone]

FAX: [phone]

6 Monitoring Items

6.1General

In order to read the monitoring items and to program the unit, the hoist-monitoring unit is equipped with a display. The monitoring items of the hoist-monitoring unit consist of variable read-only values. These monitoring items are of great advantage when efficiently planning maintenance, preventive repairs, troubleshooting and general overhauls. In addition, the monitoring values will accurately show the usage of the hoist.

The values are stored in the memory of the hoist-monitoring unit. The stored values remain also during power-off situations. After power-off situation the previously stored values are taken into account when new values are calculated.

The condition monitoring items can only be read after a correct password has been given. The manufacturer will provide a personal password with each delivery that has been acquired with this option.

	1	Monitor 1		Read only menu for condition monitoring values and measured values.
				Accessible with the customer’s password.
	Param.	Name	Value	Description
	1-1	Cond mon		Condition monitoring menu
	1-1-1	SWP%	“n” %	Remaining Safe Working Period of the hoist in percentage, starting from 100%. When the SWP
				counter descends to 0% (or even negative), a General Overhaul must be carried out.
	1-1-2	Starts	“n”	Total number of starts of the hoist in either up or down direction. *1)
	1-1-3	Run time	“n” h	Total running time of the hoist in hours. *2)
	1-1-4	Cycles	“n”	Total number of hoisting cycles. *1). The number increases by one, when a load value increase
				more than 20% of the rated load is lifted.
	1-1-5	Mean load	“n.n” t	Average of the handled load during the recorded cycles.
	1-1-6	Br SWP%	“n” %	Remaining Safe Working Period of the brake in percentage. The SWP for the brake is calculated
				according to the number of Starts and E-stops (also stops at limit switch).

6.2Primary monitoring items

The primary monitoring items are according to the ISO and FEM regulation. Depending on the hoist duty class, the hoist is given an initial Safe Working Period (SWP). The SWP counts down according to a calculation, which includes the running time with a certain load. Also the total run-time (independent on the load) and the amount of starts are directly related to the hoist’s duty class and theoretical lifetime.

The primary monitoring items, related to the FEM and ISO regulations are:

-Hoist Safe Working Period counter (SWP%)

-Starts counter

-Run Time counter

Monitoring items can only be read if the hoist-monitoring unit is equipped with a display, either mounted on the unit or in the pushbutton station.

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R&M Materials Handling, Inc. reserves the right to alter or amend the above information without notice.