LJU Trolley Controller ST 790-L

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Technical Description
Trolley Controller ST 790-L





































January 2005





General instructions

The adherence to all instructions and specifications made in the technical description and the operating stipulations is a precondition for trouble-free operation and for the fulfillment of potential warranty claims.
For this reason, before working with the device, please read the technical description and operating stipulations first!

The technical description and the operating stipulations contain important instructions on service; for this reason, they must be kept in close proximity to the device.

Utilization for the intended purpose:

The LJU vehicle controls utilize a frequency converter and are devices for industrial and commercial systems for operating three-phase-current-asynchronous motors (shunt-rotor).
These motors must be suitable for operation on frequency converters. Other loads must not be connected to the LJU vehicle controls.

All specifications regarding the technical data and the permissible conditions at the deployment site must be adhered to unconditionally.

Commissioning (starting operation for the intended purpose) is forbidden until it has been determined that the vehicle / machine is adhering to EMC guideline 89/336/EU and the conformity of the final product with machine guideline 89/392/EU is certain (please heed EN 60204).

Unless explicitly provided for, the following uses are forbidden:

• Deployment in areas where a danger of explosion exists
• Deployment in ambient environments where harmful oils, acids, gases, fumes, dusts, radiation etc. are present

Waste disposal (please pay attention to the latest regulations):
Please dispose of in accordance with the type of waste and the existing regulations e.g. in the form of:
Electronic rubbish (printed circuit boards), plastic, plate, copper etc.

Caution !

The LJU control is supplied without valid parameters.

This state is displayed by means of the message PAr on the display of the control (after switching on).

The correct function of the control is only possible after entry of the operating parameters based on the mechanical and electrical conditions of the system

The assumed risk takes place when the operating parameters are entered !




Contents

1. Overview

2. Construction

3. Function

4. Monitoring and Protection features

5. Display and Messaging Concepts

6. Operating Parameters

7. Technical Data


1. Overview

The ST-790-L controller from LJU is a micro-processor based, programmable trolley control-box for Electrified Monorail Systems (EMS) featuring a integrated Variable- Frequency-Drive (VFD) output for the connected load.
The individual functions of the Hard- and Software are standardized and neutral to existing system architecture .

With this controller, several asynchronous speeds (forward and reverse) can be administered through the use of PCM or half-wave drive commands. If necessary, synchronous speeds or Servo-mode can also be driven.
The setting of the drive speeds is represented in mm / min.

The configuration for the application of required sensors is configure-able.

The application software and operational parameters are adjusted and sent to the controller by the means of the Hand-held programming device (MU-700) via an contactless, infra-red data transmission.

This allows for a quick and optimum accomodation of various Installation-concepts and applications.

Fundamental fault-conditions of the trolley are monitored and in case of a disturbance are differentiated by messages over a 4-digit 7-segment display. In addition, a generalized signal is sent over the message-rail to the supervisory PLC system.

Every defined disturbance automatically triggers an non-delayed STOP of the trolley.



2. CONSTRUCTION

The ST-790-L trolley controller comprises of a micro-processor controlled system that commands over an internnal bus protocol the specific and compact function modules:

VFD frequency, CPU and Initiator (I/O) cards

All the connections between the compact modules as well as the external components (Motors, Sensors) are provided with plug-able connections.

The power module of the controller contains a fully digital-controlled compact-frequency drive for the use with single duty AC asynchronous motors.

The essential components of the 79x controllers assembled inside the housing are:

- sine-evaluated Pulse Width Modulation ( PWM ) with variable amplitudes for
regulating Drive-speeds and loads associated with inclined-driving.
- Soft-start with thermistors upon energization of the DC-bus circuit
- non-regulated input rectifier
- short-circuit protected AC switching with IGBT-Power Module.
Nominal power is dependent upon the switching-frequency and external heatsink.
- integrated brake-controller that is switched through an isolating transistor.
- Independent control-power supply for the internal and external components.
- Externally accessible Motor Protection Switch for switching main power feed.

The Control Module ( CPU ) consists of:
- 16-Bit-Micro-controller for all specific functions;
- Program Memory
- EEPROM for saving the operating parameters;
- Infra-red Data transmission and a Status-display ( 4 x 7-Segment-display );

The I/O card of the controller is connected to the sensors via M12 threaded plugs.
The configuration of the sensors at the I/O card is shown in the following matrix :

Hardware Configuration

Configuration 0 1 2 3 4 5 6 128+
Plug-in Port
X3 N/A MRS-1 Pos-1
X4 N/A DLS MRS-2 A-INI-2 LT-2 Pos-2 EX-OR
X5 N/A A-INI-1 LT-2 EX-OR
X6 N/A LT-1 A-INI-2 MRS-3 Pos-1 EX-OR
X7E N/A Stop MRS-3 Pos-2
X7A N/A Lamp Lamp 2 Lamp 3










The construction of the system and the EMS-trolley are displayed in the following:





3. FUNCTION

3.1. Half-wave Control

3.1.1. Driving with 2 different speeds settings and brake-release command.

Two drive-speeds, through the use of half-wave drive commands, and a direct stop utilizing a braking ramp and an Anti-collision sensor are available. The Anti-collision sensor inputs are antivalent switched (EX-OR) for protection against broken wires.

A magnet switch can be configured to reduce the speed of the trolley when driving around corners to either a parameterized speed or the active speed-command reduced to half its value. These speeds are set in mm/ min.

For the mechanical adjustment or alignment of the trolley to another process (eg. Lifting or Clamping), an individual command to lift the brake can be utilized.


Sensors: - Anti-collision fore/ aft, Antivalent ( parameter-able )
Parameter: Delay time for buffering
Delayed-start after release
Slow driving timer after release

- Magnetic switch (parameter-able)

Control: Half-wave + = V1 [mm/min] (Parameter)
Half-wave - = Brake Release
Full-wave = V2 [mm/min] (Parameter)
Over Control-rail S1

Messages: Fault message with negative half-wave
Presence message with positive half-wave Over Message-rail M





3.1.2. Driving: 2 different speeds( High Speed) and Brake release.

Two drive-speeds, through the use of half-wave drive commands, and a stop from Hi-speed after reducing the speed through the use of a Photo-eye switch and then a braking ramp of the Anti-collision sensor are available. The Anti-collision sensor inputs are antivalent switched (EX-OR) for protection against broken wires.

A single channel Lighgt-switch is used to reduce the hi-spped from a parameterized value, the stopping is then possible through the braking ramp of the Anti-collision sensor.

A magnet switch can be configured to reduce the speed of the trolley when driving around corners to either a parameterized speed or the active speed-command reduced to half its value. These speeds are set in mm/ min.

For the mechanical adjustment or alignment of the trolley to another process (eg. Lifting or Clamping), an individual command to lift the brake can be utilized.


Sensors: - Anti-collision fore/ aft, Antivalent ( parameter-able )
Parameter: Delay time for buffering
Delayed-start after release
Slow-driving timer after release

- Light Switch (photo-eye) (parameter-able)

- Magnet Switch (parameter-able)


Control: Half-wave + = V1 [mm/min] (Parameter)
Half-wave - = Brake Release
Full-wave = V2 [mm/min] (Parameter)
Over Control-rail S1

Messages: Fault message with negative half-wave
Presence message with positive half-wave Over Message-rail M






3.1.3. Driving with 3 different Speeds

Three drive-speeds, through the use of half-wave drive commands, and a direct stop utilizing a braking ramp and an Anti-collision sensor are available. The Anti-collision sensor inputs are antivalent switched (EX-OR) for protection against broken wires.

A magnet switch can be configured to reduce the speed of the trolley when driving around corners to either a parameterized speed or the active speed-command reduced to half its value. These speeds are set in mm/ min.

Sensors: - Anti-collision fore/ aft, Antivalent ( parameter-able )
Parameter: Delay time for buffering
Delayed-start after release
Slow-driving timer after release

- Magnet Switch (parameter-able)

Control: Half-wave + = V1 [mm/min] (Parameter)
Half-wave - = V2 [mm/min] (Parameter)
Full-wave = V3 [mm/min] (Parameter)
Over Control-rail S1
Messages: Fault message with negative half-wave
Presence message with positive half-wave Over Message-rail M





3.1.4. Driving with 3 different speeds ( High Speed )

Three drive-speeds, through the use of half-wave drive commands, and a stop from Hi-speed after reducing the speed through the use of a Photo-eye switch and then a braking ramp of the Anti-collision sensor are available. The Anti-collision sensor inputs are antivalent switched (EX-OR) for protection against broken wires.

A single channel Lighgt-switch is used to reduce the hi-spped from a parameterized value, the stopping is then possible through the braking ramp of the Anti-collision sensor.

A magnet switch can be configured to reduce the speed of the trolley when driving around corners to either a parameterized speed or the active speed-command reduced to half its value. These speeds are set in mm/ min.

A stopping switch for "halt-mode“can be installed on the trolley. Through the use of a message lamp, different parameterized message-conditions can be provided.

Sensors: - Anti-collision fore/ aft, Antivalent ( parameter-able )
Parameter: Delay time for buffering
Delayed-start after release
Slow-driving timer after release

- Light Switch (photo-eye) (parameter-able)

- Magnet Switch (parameter-able)

- Halt-mode push-button with signal-lamp (parameter-able)


Control: Half-wave + = V1 [mm/min] (Parameter)
Half-wave - = V2 [mm/min] (Parameter)
Full-wave = V3 [mm/min] (Parameter)
Over Control-rail S1
Messages: Fault message with negative half-wave
Presence message with positive half-wave Over Message-rail M




3.2. PCM - Control


3.2.1. Driving with different speeds up until 87 Hz.
(High Speed)
Driving with different speeds is selectable through using PCM drive-commands. The speeds from V0...Vn are able to be Parameterized.

The drive-speeds of the trolley (through an application of a light-switch) upon the approach to a fore-standing trolley are reduced to a value that allow it to be safely stopped through the activation and braking ramp of the Anti-collision sensor.
The Anti-collision sensor inputs are antivalent switched (EX-OR) for protection against broken wires.

A single channel Lighgt-switch is used to reduce the hi-speed from a parameterized value, the stopping is then possible through the braking ramp of the Anti-collision sensor.

A magnet switch can be configured to reduce the speed of the trolley when driving around corners to either a parameterized speed or the active speed-command reduced to half its value. These speeds are set in mm/ min.

A stopping switch for "halt-mode“can be installed on the trolley. Through the use of a message lamp, different parameterized message-conditions can be provided.

Sensors: - Anti-collision fore/ aft, Antivalent ( parameter-able )
Parameter: Delay time for buffering
Delayed-start after release
Slow-driving timer after release

- Light Switch (photo-eye) (parameter-able)

- Magnet Switch (parameter-able)

- Halt-mode push-button with signal-lamp (parameter-able)


Control: PCM = V1...Vn [mm/min] (Parameter)
Over Control-rail S1

Messages: Fault message with negative half-wave
Presence message with positive half-wave Over Message-rail M




3.2.2. Driving with different speeds up until 87 Hz. / Synchronized Driving
(High Speed)
Driving with different speeds is selectable through using PCM drive-commands. The speeds from V0...Vn are able to be Parameterized.

For synchronized driving (select modes) in assembly lines, Production-speeds
from 0,75...4,8 m / min with a higher resolution through selectable
PCM drive-commands is available.

The drive-speeds of the trolley (through an application of a light-switch) upon the approach to a fore-standing trolley are reduced to a value that allow it to be safely stopped through the activation and braking ramp of the Anti-collision sensor.
The Anti-collision sensor inputs are antivalent switched (EX-OR) for protection against broken wires.

A single channel Lighgt-switch is used to reduce the hi-speed from a parameterized value, the stopping is then possible through the braking ramp of the Anti-collision sensor.

A magnet switch can be configured to reduce the speed of the trolley when driving around corners to either a parameterized speed or the active speed-command reduced to half its value. These speeds are set in mm/ min.

A stopping switch for "halt-mode“can be installed on the trolley. Through the use of a message lamp, different parameterized message-conditions can be provided.

Sensors: - Anti-collision fore/ aft, Antivalent ( parameter-able )
Parameter: Delay time for buffering
Delayed-start after release
Slow-driving timer after release

- Light Switch (photo-eye) (parameter-able)

- Magnet Switch (parameter-able)

- Halt-mode push-button with signal-lamp (parameter-able)


Control: PCM = V1...Vn [mm/min] (Parameter)
Over Control-rail S1

Messages: Fault message with negative half-wave
Presence message with positive half-wave Over Message-rail M







4. MONITORING AND PROTECTION FUNCTIONS

The controller monitors all functions that are necessary for the problem-free operation of the trolley. In the event of a disturbance the trolley is immediately stopped

5. DISPLAY AND MESSAGING CONCEPTS

The presentation of the operation status- and fault messaging is arranged by a four-digit 7-segmented-display located in the housing cover.
Display Functions :
Through the use of the MU-700, various display functions can be selected:
Examples:
Standard setting: PCM Command eg.. . . 2
Selection: Drive-motor frequency eg.. . 2 1
Drive-motor current eg.. 1 1 0
(for project, refer to the corresponding Software description)
Display Modes :

-21 Phase Loss
-22 24VDC Protection on I/O Card
-23 Controller Over-voltage
-31 Anti-collision sensor inputs invalid
-32 Anti-collision sensor is activated
-41 Drive Motor over-temperature
-51 Drive Motor over-current
-53 Controller over-current
-71 Controller Output fault
-72 Controller over-temperature
-73 Chopper(DB) overload
-9- Parameter fault
-91 Controller is offline
-92 I/O card is offline
Par Control-box is not configured



Steady-light : Fault, by display of a steadily lit negative number, eg. ( - 21 ),
represents a fault ouside of the controller, that once the fault is
alleviated the condition automatically resets ( eg. Phase-loss,
short duration heavy overload of the motors)

Blink-light : Fault, by the blinking of a negative number it
it represents a internal or external fault condition ( eg. Defective
proximity switch, over-temperature / over-current and etc. )
After the correction of the failure cause, the fault must be acknowledged
by temporarily setting the controller in hand-mode (with IR-remote)
or cycling the power off/on.





6. BETRIEBSPARAMETER

All the necessary parameters required by the controller can be transmitted and stored through an infra-red interface utilized by the MU-700 hand-held programming device.
With this, can installation- or motor specific Parameters such as delay-times, drive- and braking ramps, current-limits, U/F curves, and etc. be modified and the controller be configured for varying applications (see corresponding Parameter sets)

The most important Parameters for controllers with integrated frequency controllers are :
(for project, refer to the corresponding Software description)

T0 => Delay after power-on [ms]
T1 => Waiting time after release of Anti-collision sensor [ms]
Ac => Motor Acceleration ramp [ms/Hz]
Dc => Motor Braking ramp [ms/Hz]
V0 => Speed 1, minimum driving speed [mm/min]
V1 => Speed 2 [mm/min]
V2 => Speed 3 [mm/min]
V3 => Speed 4, highest driving speed [mm/min]
V4 => minimum speed for regulated driving (synchronous –drive) [mm/min]
V5 => Resolution or incremented steps for regulated driving [mm/min]
V6 => Drive speed limited by Magnet switch [mm/min]
V7 => Drive speed limited by Light switch (Photo-eye) [mm/min]
GET => Speed at 50 Hz [mm/min]
AB1 => Drive-away distance [mm] – from Anti-collision switch activation
AB2 => Slipped distance [mm] – limit value for lost regulation by synchronous-drive
G => Servo gain [%/Inkr]
Gmn => minimum servo gain [%]
Geb => Encoder scaling [mm/Inkr]
M1 => I x R - Compensation ; [%]
M2 => Corner frequency [Hz]
In => Nominal Motor current – reference value for current limit [100mA]


The selected Parameter values are restricted between the default values contained in the MU-700 hand-held programming device.




















7. TECHNISCHE DATEN

- Housing: Powder-coated sheet steel RAL 7035,
with lid and screw-locks
- Dimensions: ( W x H x D ) 200 x 200 x 95 mm
- Weight 3,65.......4,3 kg corresponding to Power Class
- Environmental use : IP 54

- Operating Temperature : +10ºC bis +50°C

- Main Power Feed : 3 x 400 V / 50 Hz through EMF-class Filter


- Motor Protection Switch : 2,5 ..4 A externally accessible
Additional functions: - Operating Switch
- Failure Acknowledgement

- Sliding-contact Connections: X1 using Faston Block (8 pole)
1 L1
2 L2
3 L3
4 PE
5 S1
6 M1
7 (Option Z-Stop)
8 (Option Z-Stop)

- Drive Motor Plug details: X2 Connector Plug 10-pole (Han 10 E)
1 U
2 V 230V / 400V AC
3 W
7 Brake 180 V DC
8 Brake
9 Thermistor Motor-PTC 10 Thermistor
PE

- Motor Cable:

Length: max. 3m (triple shielded)

The motor cable is to be supplied with multiple shields.
The performace of the Thermistor and the motor temperature monitoring and for the brake-control are to be seperately shielded from one-another inside the shielded cable!
The Shields are to be terminated at both ends!

By using motor cables > 3m an external filter at the motor connection must be utilized!





- Power Module : IGBT-Modul (Short-circuit resistant)
Voltage restriction 1200 V
- protection switching : active
- DC bus monitoring

- Brake: 180V DC, 50 W
- Brake Control : with Transistor
- Protection mode : Varistor

Connected Sensors:

Magnetic Speed-switch
Anti-collision proximity sensor
Double Light Barrier encoder
Light Switch (Photo-eye)
Function-halt with indicator


Fault-message Output M1 Relay contact , 230V ( L3 ), max. 0,5 A
- protection : PTC thermistor, Varistor

- Control Input : S1 230V / 400V AC , 5 mA

- Power Supply : 24V DC , 500 mA
For internal and
external components

- Storage

Temperature -10  C bis + 50 C
Relative humidity < 80 % non-condensing




Subject to Technical Alteration !






LIMITED WARRANTY AND LIMITATION OF LIABILITY

LJU Industrieelektronik GmbH („LJU“) warrants to the original purchaser that the products manufactured by LJU is free from defects in material and workmanship under normal use and service.
The obligation of LJU under this warranty shall be limited to the repair or exchange of any part or parts which may prove defective under normal use and service within( 18 ) months from the date of manufacture or ( 1 ) year from the date of installation by the original purchaser whichever occurs first.

In no event, whether as a result of breach of contract, warranty, tort ( including negligence ) or otherwise, shall LJU or its suppliers be liable of any special, consequential, identical or penal damages including, but not limited to, loss of profit or revenues, loss of use of the products or any associated equipment, damage to associated equipment, cost of capital, cost of substitute products, facilities, services or replacement power, down time costs, or claims of the original purchaser`s customer for such damages.

For additional information please contact your sales representative.


LJU assumes no obligation of notice to holders of this document with respect to changes subsequently made !
 
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