Crane
Crane
Crane
EIO0000000620 09/2016
SoMachine
Hoisting Application Functions
Hoisting Library Guide
09/2016
EIO0000000620.09
www.schneider-electric.com
The information provided in this documentation contains general descriptions and/or technical
characteristics of the performance of the products contained herein. This documentation is not
intended as a substitute for and is not to be used for determining suitability or reliability of these
products for specific user applications. It is the duty of any such user or integrator to perform the
appropriate and complete risk analysis, evaluation and testing of the products with respect to the
relevant specific application or use thereof. Neither Schneider Electric nor any of its affiliates or
subsidiaries shall be responsible or liable for misuse of the information contained herein. If you
have any suggestions for improvements or amendments or have found errors in this publication,
please notify us.
No part of this document may be reproduced in any form or by any means, electronic or
mechanical, including photocopying, without express written permission of Schneider Electric.
All pertinent state, regional, and local safety regulations must be observed when installing and
using this product. For reasons of safety and to help ensure compliance with documented system
data, only the manufacturer should perform repairs to components.
When devices are used for applications with technical safety requirements, the relevant
instructions must be followed.
Failure to use Schneider Electric software or approved software with our hardware products may
result in injury, harm, or improper operating results.
Failure to observe this information can result in injury or equipment damage.
2016 Schneider Electric. All rights reserved.
2 EIO0000000620 09/2016
Table of Contents
Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
About the Book . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Part I Hoisting Library System Requirements. . . . . . . . . . . 23
Chapter 1 System Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Hoisting System Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Function Block Location in the Hoisting Library . . . . . . . . . . . . . . . . . 29
Hoisting Segment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Chapter 2 Crane Environment and Architecture . . . . . . . . . . . . . . . 37
Construction Cranes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Industrial Cranes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Special Cranes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Hardware Architecture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Part II Advanced Positioning . . . . . . . . . . . . . . . . . . . . . . . . 47
Chapter 3 AdvancedPositioning: Position Control of Single Axis
Driven by a Variable Speed Drive. . . . . . . . . . . . . . . . . . 49
3.1 Functional Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Functional Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
3.2 Architecture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Architecture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
3.3 Function Block Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
AdvancedPositioning Function Block . . . . . . . . . . . . . . . . . . . . . . 54
3.4 Pin Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Input Pin Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Output Pin Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
3.5 Structured Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Structured Parameter - stMotPara . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Structured Parameter - stPosPara . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Structured Parameter - stJogPara . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Structured Parameter - stHmngPara . . . . . . . . . . . . . . . . . . . . . . . . . 78
Structured Parameter - stEncPara . . . . . . . . . . . . . . . . . . . . . . . . . . 84
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3.6 Quick Reference Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Function Block Visualization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Instantiation and Usage Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Commissioning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Part III Anti-Crab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Chapter 4 AntiCrab: Correction of Bridge Movement to Solve Wear
of Rail and Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
4.1 Functional and Machine Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Functional Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Machine Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
4.2 Architecture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Hardware Architecture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Software Architecture. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
4.3 Function Block Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
AntiCrab Function Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
4.4 Pin Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Input Pin Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Output Pin Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
4.5 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Chapter 5 AntiCrab_2: Correction of Bridge Movement to Solve
Wear of Rail and Wheels . . . . . . . . . . . . . . . . . . . . . . . . . 125
5.1 Functional and Machine Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Functional Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Machine Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
5.2 Architecture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Hardware Architecture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Software Architecture. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
5.3 Function Block Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
AntiCrab_2 Function Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
5.4 Pin Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Input Pin Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Output Pin Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
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5.5 Quick Reference Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Visualization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Instantiation and Usage Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Commissioning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
Part IV Anti-Sway . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Chapter 6 AntiSwayOpenLoop: Correction of Sway in Horizontal
Movements without Sensor . . . . . . . . . . . . . . . . . . . . . . 159
6.1 Functional and Machine Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
Functional Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Machine Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
6.2 Architecture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
Hardware Architecture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
Software Architecture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
6.3 Function Block Description - Speed Reference . . . . . . . . . . . . . . . . . . 169
Speed Reference - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
SpeedRef_2 Function Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
Input Pin Description - SpeedRef_2. . . . . . . . . . . . . . . . . . . . . . . . . . 172
SpeedRef_4 Function Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
Input Pin Description - SpeedRef_4. . . . . . . . . . . . . . . . . . . . . . . . . . 176
SpeedRef_AI Function Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
Input Pin Description - SpeedRef_AI. . . . . . . . . . . . . . . . . . . . . . . . . 180
Output Pin Description - SpeedRef_2, SpeedRef_4 and
SpeedRef_Al . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
6.4 Function Block Description - Cable Length . . . . . . . . . . . . . . . . . . . . . 186
Cable Length - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
CableLength_2Pos Function Block . . . . . . . . . . . . . . . . . . . . . . . . . 189
Input Pin Description - CableLength_2Pos . . . . . . . . . . . . . . . . . . . 190
Output Pin Description - CableLength_2Pos . . . . . . . . . . . . . . . . . . 192
CableLength_3Pos Function Block . . . . . . . . . . . . . . . . . . . . . . . . . 194
Input Pin Description - CableLength_3Pos . . . . . . . . . . . . . . . . . . . 195
Output Pin Description - CableLength_3Pos . . . . . . . . . . . . . . . . . . 197
CableLength_Enc Function Block . . . . . . . . . . . . . . . . . . . . . . . . . . 199
Input Pin Description - CableLength_Enc . . . . . . . . . . . . . . . . . . . . 200
Output Pin Description - CableLength_Enc . . . . . . . . . . . . . . . . . . . 202
Calibration Procedure for the CableLength_Enc Function Block. . . 205
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CableLength_Enc_2 Function Block . . . . . . . . . . . . . . . . . . . . . . . . 207
Input Pin Description - CableLength_Enc_2 . . . . . . . . . . . . . . . . . . 209
Output Pin Description - CableLength_Enc_2 . . . . . . . . . . . . . . . . . 212
Instantiation and Usage Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
6.5 Function Block Description - AntiSwayOpenLoop . . . . . . . . . . . . . . . . 214
Anti-Sway - Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
AntiSwayOpenLoop Function Block . . . . . . . . . . . . . . . . . . . . . . . . . 216
Input Pin Description - AntiSwayOpenLoop . . . . . . . . . . . . . . . . . . . 217
Structure Parameter - AntiSwayOpenLoop . . . . . . . . . . . . . . . . . . . . 219
Output Pin Description - AntiSwayOpenLoop . . . . . . . . . . . . . . . . . . 222
AntiSwayOpenLoop Main Parameters . . . . . . . . . . . . . . . . . . . . . . . . . 224
6.6 Function Block Description - AntiSwayOpenLoop_2 . . . . . . . . . . . . . . 231
AntiSwayOpenLoop_2 - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . 232
AntiSwayOpenLoop_2 Function Block . . . . . . . . . . . . . . . . . . . . . . . 234
Input Pin Description - AntiSwayOpenLoop_2 . . . . . . . . . . . . . . . . . 235
Structure Parameter - AntiSwayOpenLoop_2. . . . . . . . . . . . . . . . . . 240
Output Pin Description - AntiSwayOpenLoop_2 . . . . . . . . . . . . . . . . 245
Instantiation and Usage Example - AntiSwayOpenLoop_2 . . . . . . . 248
Commissioning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
6.7 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
Part V Diagnostic Coverage . . . . . . . . . . . . . . . . . . . . . . . . 255
Chapter 7 DiagnosticCoverage: Increase Diagnostic Coverage of
Used Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
7.1 Functional Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
Functional Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
7.2 Architecture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260
Architecture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260
7.3 Function Block Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
DiagnosticCoverage Function Block . . . . . . . . . . . . . . . . . . . . . . . 262
7.4 Pin Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
Input/Output Pin Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
Input Pin Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
Output Pin Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
7.5 Quick Reference Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
Instantiation and Usage Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
Commissioning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
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Part VI Electronic Potentiometer. . . . . . . . . . . . . . . . . . . . . . 275
Chapter 8 ElectronicPotentiometer: Set Speed and Direction of a
Movement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
8.1 Functional Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278
Functional Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278
8.2 Architecture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279
Hardware Architecture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
Software Architecture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
8.3 Function Block Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
ElectronicPotentiometer Function Block . . . . . . . . . . . . . . . . . 282
8.4 Pin Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
Input Pin Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287
Output Pin Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290
8.5 Quick Reference Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
Instantiation and Usage Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293
Commissioning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295
Part VII Grab Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297
Chapter 9 GrabControl: Control of a Four Cable Grab . . . . . . . . . . 299
9.1 Functional Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300
Functional Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300
9.2 Architecture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
Architecture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
9.3 Function Block Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304
GrabControl Function Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304
9.4 Pin Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309
Input Pin Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310
Structured Variable Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316
Output Pin Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321
9.5 Quick Reference Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325
Instantiation and Usage Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326
Commissioning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334
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Part VIII Hoisting Position Synchronization . . . . . . . . . . . . . . 335
Chapter 10 HoistPositionSync: Synchronization of Two Identical Axes
for Hoist or Trolley Movement with Encoder. . . . . . . . . . . 337
10.1 Functional and Machine Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338
Functional Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339
Machine Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341
10.2 Architecture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 342
Hardware Architecture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343
Software Architecture. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344
10.3 Function Block Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345
HoistPositionSync Function Block . . . . . . . . . . . . . . . . . . . . . . . . 345
10.4 Pin Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346
Input Pin Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 347
Acceleration and Deceleration Parameter . . . . . . . . . . . . . . . . . . . . . . 352
Output Pin Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 353
10.5 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 356
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 356
Chapter 11 HoistPositionSync_2: Position Synchronization of Two
Crane Axes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 359
11.1 Functional Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 360
Functional Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 360
11.2 Architecture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 362
Software Architecture. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 362
11.3 Function Block Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363
HoistPositionSync_2 Function Block . . . . . . . . . . . . . . . . . . . . . . 363
11.4 Pin Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 364
Input Pin Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 365
Structured Variable Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 370
Output Pin Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 373
11.5 Commissioning Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 375
Commissioning Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 375
11.6 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 376
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 376
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Part IX Limit Switch Management. . . . . . . . . . . . . . . . . . . . . 377
Chapter 12 LimitSwitch: Surveillance of the Used Limit Switches of a
Crane with Fast/Slow Zone Identification . . . . . . . . . . . . 379
12.1 Functional and Machine Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . 380
Functional Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 381
Machine Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 383
12.2 Architecture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 384
Hardware Architecture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 385
Software Architecture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 387
12.3 Function Block Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 388
LimitSwitch Function Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 389
Configuration of the Movement Positions . . . . . . . . . . . . . . . . . . . . . . 390
Timing Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 394
12.4 Pin Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 396
Input Pin Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 397
Output Pin Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 399
12.5 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
Chapter 13 LimitSwitch_AR: Monitoring of the Limit Switches of a
Crane with Adaptive Speed Reference in Slow Zone . . . 403
13.1 Functional Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
Functional Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
13.2 Architecture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
Hardware Architecture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407
Software Architecture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
13.3 Function Block Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409
LimitSwitch_AR Function Block . . . . . . . . . . . . . . . . . . . . . . . . . . . 409
13.4 Pin Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413
Input Pin Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 414
Output Pin Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 418
13.5 Quick Reference Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 420
Instantiation and Usage Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . 421
Commissioning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 422
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 423
Chapter 14 DoubleLimitSwitch_AR: Administers Two Devices in
Synchronous Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 425
14.1 Functional Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 426
Functional Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 426
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14.2 Architecture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 428
Hardware Architecture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 429
Software Architecture. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 430
14.3 Function Block Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 431
DoubleLimitSwitch_AR Function Block . . . . . . . . . . . . . . . . . . . . . 431
14.4 Pin Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 436
Input Pin Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 437
Structured Variable Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 440
Output Pin Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 442
14.5 Quick Reference Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 445
Instantiation and Usage Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . 446
Commissioning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 447
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 448
Chapter 15 DoubleLimitSwitch_AR_2: Administers Two Devices in
Synchronous Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 449
15.1 Functional Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 450
Functional Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 450
15.2 Architecture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 453
Hardware Architecture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 454
Software Architecture. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 455
15.3 Function Block Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 456
DoubleLimitSwitch_AR_2 Function Block . . . . . . . . . . . . . . . . . . . 456
15.4 Pin Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 462
Input Pin Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 463
Structured Variable Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 466
Output Pin Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 468
15.5 Quick Reference Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 471
Instantiation and Usage Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . 472
Commissioning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 473
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 474
Part X Load Overspeed Control . . . . . . . . . . . . . . . . . . . . . 475
Chapter 16 LoadOverspeedCtrl: Detects Load Overspeed, Brake
Wear and Sensor Feedback on Hoist. . . . . . . . . . . . . . . . 477
16.1 Functional and Machine Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . 478
Functional Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 479
Machine Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 481
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16.2 Architecture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 482
Hardware Architecture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 483
Software Architecture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 484
16.3 Function Block Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 485
LoadOverspeedCtrl Function Block . . . . . . . . . . . . . . . . . . . . . . . . 486
Load Overspeed Detection and Sensor Feedback Alarm Detection . . 488
Brake Wear Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 491
16.4 Pin Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 493
Input Pin Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 494
Output Pin Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 498
16.5 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500
Chapter 17 LoadOverspeedCtrl_2: Detects Load Overspeed, Brake
Wear and Sensor Feedback on Hoist. . . . . . . . . . . . . . . 501
17.1 Functional and Machine Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . 502
Functional Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 503
Machine Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 505
17.2 Architecture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 507
Hardware Architecture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 508
Software Architecture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 509
17.3 Function Block Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 510
LoadOverspeedCtrl_2 Function Block . . . . . . . . . . . . . . . . . . . . . . 511
Load Overspeed Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 512
Brake Wear Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 514
17.4 Pin Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 515
Input Pin Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 516
Output Pin Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 519
17.5 Quick Reference Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 521
Instantiation and Usage Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . 522
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 523
Part XI Monitoring Data Storage . . . . . . . . . . . . . . . . . . . . . . 525
Chapter 18 Monitoring Data Storage Function: Collect and Monitor
the Operational Data of Cranes . . . . . . . . . . . . . . . . . . . 527
18.1 Functional and Machine Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . 528
Functional Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 529
Machine Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 533
18.2 Architecture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 534
Hardware Architecture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 534
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18.3 Function Block Description - StatisticDataStorage . . . . . . . . . . 535
StatisticDataStorage Function Block . . . . . . . . . . . . . . . . . . . . . 536
Pin Description - StatisticDataStorage. . . . . . . . . . . . . . . . . . . . 539
18.4 Function Block Description - StatisticDataStorage_2 . . . . . . . . 544
StatisticDataStorage_2 Function Block . . . . . . . . . . . . . . . . . . . 545
Pin Description - StatisticDataStorage_2 . . . . . . . . . . . . . . . . . 546
18.5 Function Block Description - AlarmDataStorage . . . . . . . . . . . . . . . 549
AlarmDataStorage Function Block . . . . . . . . . . . . . . . . . . . . . . . . . 550
Pin Description - AlarmDataStorage . . . . . . . . . . . . . . . . . . . . . . . . 551
18.6 Function Block Description - AlarmDataStorage_2. . . . . . . . . . . . . 553
AlarmDataStorage_2 Function Block . . . . . . . . . . . . . . . . . . . . . . . 554
Pin Description - AlarmDataStorage_2 . . . . . . . . . . . . . . . . . . . . . . 555
18.7 Function Block Description - OvldAlarmDataStorage . . . . . . . . . . 557
OvldAlarmDataStorage Function Block . . . . . . . . . . . . . . . . . . . . . 558
Pin Description - OvldAlarmDataStorage. . . . . . . . . . . . . . . . . . . . 559
18.8 Function Block Description - OvtqAlarmDataStorage . . . . . . . . . . 561
OvtqAlarmDataStorage Function Block . . . . . . . . . . . . . . . . . . . . . 562
Pin Description - OvtqAlarmDataStorage. . . . . . . . . . . . . . . . . . . . 563
18.9 Function Block Description - OvspAlarmDataStorage . . . . . . . . . . 565
OvspAlarmDataStorage Function Block . . . . . . . . . . . . . . . . . . . . . 566
Pin Description - OvspAlarmDataStorage. . . . . . . . . . . . . . . . . . . . 567
18.10 Function Block Description - LdslAlarmDataStorage . . . . . . . . . . 569
LdslAlarmDataStorage Function Block . . . . . . . . . . . . . . . . . . . . . 570
Pin Description - LdslAlarmDataStorage. . . . . . . . . . . . . . . . . . . . 571
18.11 Function Block Description - EncAlarmDataStorage . . . . . . . . . . . 573
EncAlarmDataStorage Function Block . . . . . . . . . . . . . . . . . . . . . . 574
Pin Description - EncAlarmDataStorage. . . . . . . . . . . . . . . . . . . . . 575
18.12 Function Block Description - MaintenanceDataStorage . . . . . . . . 577
MaintenanceDataStorage Function Block . . . . . . . . . . . . . . . . . . . 578
Pin Description - MaintenanceDataStorage . . . . . . . . . . . . . . . . . 582
Commissioning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 585
18.13 Function Block Description - MaintenanceDataStorage_2 . . . . . . 587
MaintenanceDataStorage_2 Function Block. . . . . . . . . . . . . . . . . 588
Pin Description - MaintenanceDataStorage_2 . . . . . . . . . . . . . . . 590
Commissioning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 595
18.14 Function Block Description - PasswordDataStorage . . . . . . . . . . . 597
PasswordDataStorage Function Block . . . . . . . . . . . . . . . . . . . . . . 598
Pin Description - PasswordDataStorage. . . . . . . . . . . . . . . . . . . . . 600
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18.15 Quick Reference Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
Instantiation and Usage Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 603
Part XII Overload Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . 605
Chapter 19 Overload Control Function: Detect Mechanical Overload
on Hoisting Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . 607
19.1 Functional and Machine Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . 608
Functional Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 609
Machine Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 615
19.2 Architecture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 616
Hardware Architecture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 617
Software Architecture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 618
19.3 Function Block Description - OverloadCtrlTrq . . . . . . . . . . . . . . . 620
OverloadCtrlTrq Function Block . . . . . . . . . . . . . . . . . . . . . . . . . . 621
Pin Description - OverloadCtrlTrq . . . . . . . . . . . . . . . . . . . . . . . . . 623
19.4 Function Block Description - OverloadCtrlDist . . . . . . . . . . . . . . 625
OverloadCtrlDist Function Block . . . . . . . . . . . . . . . . . . . . . . . . . 626
Pin Description - OverloadCtrlDist. . . . . . . . . . . . . . . . . . . . . . . . 628
19.5 Function Block Description - OverloadCtrlEnc . . . . . . . . . . . . . . . 630
OverloadCtrlEnc Function Block . . . . . . . . . . . . . . . . . . . . . . . . . . 631
Pin Description - OverloadCtrlEnc . . . . . . . . . . . . . . . . . . . . . . . . . 633
19.6 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 635
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 635
Chapter 20 Overload_EN15011: Overload Calibration With the
Requirements of EN15011 . . . . . . . . . . . . . . . . . . . . . . . 637
20.1 Functional Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 638
Functional Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 638
20.2 Architecture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 640
Hardware Architecture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 641
Software Architecture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 642
20.3 Function Block Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 643
Overload_EN15011 Function Block . . . . . . . . . . . . . . . . . . . . . . . . . 643
20.4 Pin Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 644
Input Pin Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 645
Structured Variable Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 646
Output Pin Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 651
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20.5 Quick Reference Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 654
Instantiation and Usage Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . 655
Commissioning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 656
Calibration Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 657
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 658
Part XIII Scale Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 659
Chapter 21 ScaleInput: Change Incoming Input to a Scaled Value . . 661
21.1 Functional Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 662
Functional Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 662
21.2 Architecture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 663
Software Architecture. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 663
21.3 Function Block Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 665
ScaleInput Function Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 665
21.4 Pin Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 666
Input Pin Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 667
Output Pin Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 669
21.5 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 670
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 670
Part XIV Smooth Slewing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 671
Chapter 22 Smooth Slewing Function: Stepwise Smooth Crane
Movement Based on Speed or Torque Value of the
Slewing Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 673
22.1 Functional and Machine Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . 674
Functional Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 675
Machine Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 677
22.2 Architecture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 678
Hardware Architecture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 679
Software Architecture. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 680
22.3 Function Block Description - SmoothSlewingSpd . . . . . . . . . . . . . . . 682
SmoothSlewingSpd Function Block . . . . . . . . . . . . . . . . . . . . . . . . . 683
Input Pin Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 686
Output Pin Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 687
22.4 Function Block Description - SmoothSlewingTrq . . . . . . . . . . . . . . . 688
SmoothSlewingTrq Function Block . . . . . . . . . . . . . . . . . . . . . . . . . 689
Input Pin Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 692
Output Pin Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 694
22.5 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 695
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 695
14 EIO0000000620 09/2016
Part XV Speed Optimization and Rope Slack . . . . . . . . . . . . 697
Chapter 23 SpeedOptRopeSlack: Reduces Work Cycle Time and
Avoid Start Up with Slack on the Rope. . . . . . . . . . . . . . 699
23.1 Functional and Machine Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . 700
Functional Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 701
Machine Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 703
23.2 Architecture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 704
Hardware Architecture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 705
Software Architecture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 706
23.3 Function Block Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 708
SpeedOptRopeSlack Function Block . . . . . . . . . . . . . . . . . . . . . . . . 709
Timing Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 712
23.4 Pin Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 716
Input Pin Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 717
Output Pin Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 721
23.5 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 723
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 723
Part XVI Speed Select . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 725
Chapter 24 SpeedSelect: Provides the Option to Choose between 8
Predefined and one Analog Speed. . . . . . . . . . . . . . . . . 727
24.1 Functional Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 728
Functional Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 728
24.2 Architecture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 729
Software Architecture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 729
24.3 Function Block Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 730
SpeedSelect Function Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 730
24.4 Pin Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 731
Input Pin Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 732
Output Pin Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 734
24.5 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 735
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 735
Part XVII Wind Speed Control . . . . . . . . . . . . . . . . . . . . . . . . . 737
Chapter 25 WindSpeedCtrl: Monitors and Provides Alarms for High
Wind Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 739
25.1 Functional and Machine Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . 740
Functional Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 741
Machine Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 742
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25.2 Architecture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 743
Hardware Architecture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 744
Software Architecture. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 745
25.3 Function Block Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 746
WindSpeedCtrl Function Block. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 746
25.4 Pin Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 748
Input Pin Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 749
Output Pin Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 751
Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 753
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 759
16 EIO0000000620 09/2016
Safety Information
Important Information
NOTICE
Read these instructions carefully, and look at the equipment to become familiar with the device
before trying to install, operate, service, or maintain it. The following special messages may appear
throughout this documentation or on the equipment to warn of potential hazards or to call attention
to information that clarifies or simplifies a procedure.
EIO0000000620 09/2016 17
PLEASE NOTE
Electrical equipment should be installed, operated, serviced, and maintained only by qualified
personnel. No responsibility is assumed by Schneider Electric for any consequences arising out of
the use of this material.
A qualified person is one who has skills and knowledge related to the construction and operation
of electrical equipment and its installation, and has received safety training to recognize and avoid
the hazards involved.
WARNING
UNGUARDED EQUIPMENT
Do not use this software and related automation equipment on equipment which does not have
point-of-operation protection.
Do not reach into machinery during operation.
Failure to follow these instructions can result in death, serious injury, or equipment damage.
This automation equipment and related software is used to control a variety of industrial processes.
The type or model of automation equipment suitable for each application will vary depending on
factors such as the control function required, degree of protection required, production methods,
unusual conditions, government regulations, etc. In some applications, more than one processor
may be required, as when backup redundancy is needed.
Only you, the user, machine builder or system integrator can be aware of all the conditions and
factors present during setup, operation, and maintenance of the machine and, therefore, can
determine the automation equipment and the related safeties and interlocks which can be properly
used. When selecting automation and control equipment and related software for a particular
application, you should refer to the applicable local and national standards and regulations. The
National Safety Council's Accident Prevention Manual (nationally recognized in the United States
of America) also provides much useful information.
In some applications, such as packaging machinery, additional operator protection such as point-
of-operation guarding must be provided. This is necessary if the operator's hands and other parts
of the body are free to enter the pinch points or other hazardous areas and serious injury can occur.
Software products alone cannot protect an operator from injury. For this reason the software
cannot be substituted for or take the place of point-of-operation protection.
Ensure that appropriate safeties and mechanical/electrical interlocks related to point-of-operation
protection have been installed and are operational before placing the equipment into service. All
interlocks and safeties related to point-of-operation protection must be coordinated with the related
automation equipment and software programming.
18 EIO0000000620 09/2016
NOTE: Coordination of safeties and mechanical/electrical interlocks for point-of-operation
protection is outside the scope of the Function Block Library, System User Guide, or other
implementation referenced in this documentation.
CAUTION
EQUIPMENT OPERATION HAZARD
Verify that all installation and set up procedures have been completed.
Before operational tests are performed, remove all blocks or other temporary holding means
used for shipment from all component devices.
Remove tools, meters, and debris from equipment.
Failure to follow these instructions can result in injury or equipment damage.
Follow all start-up tests recommended in the equipment documentation. Store all equipment
documentation for future references.
Software testing must be done in both simulated and real environments.
Verify that the completed system is free from all short circuits and temporary grounds that are not
installed according to local regulations (according to the National Electrical Code in the U.S.A, for
instance). If high-potential voltage testing is necessary, follow recommendations in equipment
documentation to prevent accidental equipment damage.
Before energizing equipment:
Remove tools, meters, and debris from equipment.
Close the equipment enclosure door.
Remove all temporary grounds from incoming power lines.
Perform all start-up tests recommended by the manufacturer.
EIO0000000620 09/2016 19
OPERATION AND ADJUSTMENTS
The following precautions are from the NEMA Standards Publication ICS 7.1-1995 (English
version prevails):
Regardless of the care exercised in the design and manufacture of equipment or in the selection
and ratings of components, there are hazards that can be encountered if such equipment is
improperly operated.
It is sometimes possible to misadjust the equipment and thus produce unsatisfactory or unsafe
operation. Always use the manufacturers instructions as a guide for functional adjustments.
Personnel who have access to these adjustments should be familiar with the equipment
manufacturers instructions and the machinery used with the electrical equipment.
Only those operational adjustments actually required by the operator should be accessible to
the operator. Access to other controls should be restricted to prevent unauthorized changes in
operating characteristics.
20 EIO0000000620 09/2016
About the Book
At a Glance
Document Scope
This document describes the functions of the SoMachine Hoisting Library.
Validity Note
This document has been updated with the release of SoMachine 4.2.
WARNING
LOSS OF CONTROL
The designer of any control scheme must consider the potential failure modes of control paths
and, for certain critical control functions, provide a means to achieve a safe state during and
after a path failure. Examples of critical control functions are emergency stop and overtravel
stop, power outage and restart.
Separate or redundant control paths must be provided for critical control functions.
System control paths may include communication links. Consideration must be given to the
implications of unanticipated transmission delays or failures of the link.
Observe all accident prevention regulations and local safety guidelines.1
Each implementation of this equipment must be individually and thoroughly tested for proper
operation before being placed into service.
Failure to follow these instructions can result in death, serious injury, or equipment damage.
1
For additional information, refer to NEMA ICS 1.1 (latest edition), "Safety Guidelines for the
Application, Installation, and Maintenance of Solid State Control" and to NEMA ICS 7.1 (latest
edition), "Safety Standards for Construction and Guide for Selection, Installation and Operation of
Adjustable-Speed Drive Systems" or their equivalent governing your particular location.
WARNING
UNINTENDED EQUIPMENT OPERATION
Only use software approved by Schneider Electric for use with this equipment.
Update your application program every time you change the physical hardware configuration.
Failure to follow these instructions can result in death, serious injury, or equipment damage.
EIO0000000620 09/2016 21
22 EIO0000000620 09/2016
SoMachine
System Requirements
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Part I
Hoisting Library System Requirements
Overview
This part describes the system requirements for the Hoisting Library function blocks.
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System Requirements
24 EIO0000000620 09/2016
SoMachine
System Requirements
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Chapter 1
System Requirements
System Requirements
EIO0000000620 09/2016 25
System Requirements
Overview
This section describes the 2 library versions, hardware and software requirements, and user
interface compatibility for Hoisting Library functions.
The Hoisting_Basic Library is part of the SoMachine software delivery, but needs to be registered
without any additional charge inside SoMachine.
The advanced Hoisting Library contains all available function blocks from the Hoisting_Basic
Library plus the following ones:
SpeedRef_2
SpeedRef4
SpeedRef_AI
CableLength_2Pos
CableLength_3Pos
CableLength_Enc
CableLength_Enc_2
AntiSwayOpenLoop
AntiSwayOpenLoop_2
Overload_EN15011
AntiCrab
AntiCrab_2
26 EIO0000000620 09/2016
System Requirements
AdvancedPositioning
DiagnosticCoverage
HoistingPositionSync
HoistingPositionSync_2
GrabControl
The advanced Hoisting Library needs to be registered inside SoMachine.
NOTE: Both libraries cannot be installed at the same time. When upgrading from the basic to the
advanced version, the Hoisting_Basic Library needs to be uninstalled.
System Requirements
The targeted controller for the segment Hoisting are:
Modicon M241 Logic controller
Modicon M258 Logic controller
Modicon LMC058 Motion controller
Altivar ATV IMC Drive controller
NOTE: All function blocks work with internally created information. Only the controller is needed.
Altivar ATV IMC Drive controller is associated with ATV71.
NOTE: Modicon LMC058 Motion controller can be used with 2 CANopen fieldbusses. In this case
the CANmotion bus is configured as a CANopen fieldbus.
WARNING
UNINTENDED EQUIPMENT OPERATION
Verify the SoMachine libraries contained in your program are the correct version after updating
SoMachine software.
Verify that the library versions updated are consistent with your application specifications.
Failure to follow these instructions can result in death, serious injury, or equipment damage.
EIO0000000620 09/2016 27
System Requirements
The EN/ENO inputs and outputs as defined by IEC 61131-3 are maladapted to, and therefore
inappropriate for, the targeted application of these functions. Suddenly disabling one function by a
falling edge on the EN input would require all outputs of the function block to immediately fall to
their default states, and such an unanticipated action would cause in abrupt change to the entire
process. The implication is that such an event would have deleterious results that may invoke
undesirable consequences. Therefore, the EN/ENO inputs/outputs as defined by IEC 61131-3 are
incompatible with the functions contained within this library.
WARNING
UNINTENDED MACHINE OPERATION
Do not use the EN/ENO functionality defined by IEC 61131-3 to control the behavior of the
Application Function blocks.
Failure to follow these instructions can result in death, serious injury, or equipment damage.
NOTE: Verify that the EN/ENO option is disabled in the compiler options menu of SoMachine.
28 EIO0000000620 09/2016
System Requirements
EIO0000000620 09/2016 29
System Requirements
30 EIO0000000620 09/2016
System Requirements
Hoisting Segment
Overview
The Hoisting segment is separated into 3 targeted areas:
Construction cranes
Industrial cranes
Special cranes
Construction Cranes
Construction cranes are cranes for construction sites, such as tower cranes, hammerhead cranes,
self erecting cranes etc.
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System Requirements
Construction cranes are used mainly external to buildings and used for constructing buildings.
Industrial Cranes
Industrial cranes are cranes used for production, such as bridge cranes, etc.
32 EIO0000000620 09/2016
System Requirements
Industrial cranes are mainly used inside buildings or production halls and used to support the
production work. However, they can also be used externally, for example in storage areas, loading
or unloading processes, etc.
EIO0000000620 09/2016 33
System Requirements
Special Cranes
Special cranes are defined as being neither industrial nor construction cranes. A special crane
could be a Grab crane to load/unload bulk goods or an Rubber Tire Crane (RTC) used in a harbor
to move containers, etc.
34 EIO0000000620 09/2016
System Requirements
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System Requirements
36 EIO0000000620 09/2016
SoMachine
Crane Environment and Architecture
EIO0000000620 09/2016
Chapter 2
Crane Environment and Architecture
EIO0000000620 09/2016 37
Crane Environment and Architecture
Construction Cranes
Overview
Simple construction crane with 1 drive per movement and a Schneider Electric controller:
38 EIO0000000620 09/2016
Crane Environment and Architecture
EIO0000000620 09/2016 39
Crane Environment and Architecture
Industrial Cranes
Overview
Simple industrial crane with 1 drive per movement and a Schneider Electric controller:
40 EIO0000000620 09/2016
Crane Environment and Architecture
Industrial crane with 2 hoists and 2 trolleys, 1 drive on each side for the translation and a Schneider
Electric controller with an I/O Expansion (OTB Island):
EIO0000000620 09/2016 41
Crane Environment and Architecture
42 EIO0000000620 09/2016
Crane Environment and Architecture
Special Cranes
Overview
These are cranes with specialized features such as a Grab crane or a crane to move liquids.
The architecture of this type of crane can be similar to the Tower/Bridge cranes but may be
completely different.
As an example here is the architecture for a Grab crane:
EIO0000000620 09/2016 43
Crane Environment and Architecture
44 EIO0000000620 09/2016
Crane Environment and Architecture
Hardware Architecture
Overview
These 2 following architectures are preferred for Hoisting Library hardware environment :
Optimized CANopen ATV IMC
Optimized CANopen M238
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Crane Environment and Architecture
46 EIO0000000620 09/2016
SoMachine
AdvancedPositioning
EIO0000000620 09/2016
Part II
Advanced Positioning
Advanced Positioning
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AdvancedPositioning
48 EIO0000000620 09/2016
SoMachine
AdvancedPositioning
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Chapter 3
AdvancedPositioning: Position Control of Single Axis Driven by a Variable Speed Drive
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AdvancedPositioning
Section 3.1
Functional Overview
Functional Overview
Functional Overview
WARNING
UNINTENDED EQUIPMENT OPERATION
Validate all function block input values before and while the function block is enabled.
Failure to follow these instructions can result in death, serious injury, or equipment damage.
50 EIO0000000620 09/2016
AdvancedPositioning
Functional View
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AdvancedPositioning
Section 3.2
Architecture
Architecture
Architecture
52 EIO0000000620 09/2016
AdvancedPositioning
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AdvancedPositioning
Section 3.3
Function Block Description
Pin Diagram
Functional Description
The function block (FB) calculates a speed reference for variable speed drive. It contains a
trapezoid speed profile generator and a position controller. Both ramping and speed reference
calculations are handled by the FB. The variable speed drive must be configured to follow the
speed reference given by the FB precisely. The FB supports absolute and relative movements.
Positioning is started by rising edge on i_xPosExe input.
Absolute movement:
Movement to a pre-determined, fixed position of the axis.
Supports change of the target position during execution (to prevent loss of position).
54 EIO0000000620 09/2016
AdvancedPositioning
Relative movement:
Relative change of axis position by a given distance.
Does not support change of travel distance during execution (to prevent loss of position).
Modulo Axis
The FB supports positioning of modulo axis.
This feature allows the following:
Positioning of the axis in one direction without risk of overflow of internal position value. This is
useful, for example, for positioning of conveyors.
Positioning of rotational axis in positive, negative and shortest distance directions.
Absolute and relative positioning within one modulo range or across multiple modulo ranges.
Position Controller
Position controller modifies the speed reference given to the drive in order to decrease the
difference between the target position and the actual position. It corrects position difference both
during movement and while the axis is at a standstill.
Position controller is active when the
variable speed drive is in RUN state,
system is ready, and
the FB is not in an alarm state.
Unit Scaling
Unit scaling allows scaling of the internal position value to user units. The absolute position of an
axis is internally stored as a 32 bit integer value. For detailed description of unit scaling, refer to
the description of the i_stEncPara structure.
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AdvancedPositioning
Position Feedback
An encoder or another device dedicated to position measurement is necessary for correct
functioning of the FB. It supports both incremental and absolute encoders.
The FB works internally with a 32 bit position value. If the resolution of the position measurement
device interface is less than 32 bit (16 bit for the internal encoder interface of Altivar 71, usually
25 bit for absolute CANopen encoders), the FB compensates for overflow of the encoder interface
value up to the range of the internal 32 bit position.
WARNING
UNINTENDED EQUIPMENT OPERATION
Always verify that the value of the encoder position increases in a positive direction and
decreases in a negative direction before putting the machine or process into operational service.
Failure to follow these instructions can result in death, serious injury, or equipment damage.
Homing
The FB supports various homing methods. It uses positive and negative limit switches or an
optional reference position limit switch to define a home position.
For detailed description of homing methods, refer to the description of the i_stHmngPara
structure. Homing is performed automatically (without movement of the axis) after the first
download and after a change between linear and modulo mode.
Jog Movement
Jog movement is designed to manually change a position of the axis. If configured
(i_stJogPara.diJogDist>0), the axis performs a defined distance movement at a defined
speed after a rising edge on a Jog command input (for example, one motor revolution). After this
movement, the FB waits for a defined period (i_stJogPara.wJogDelay) and then, if the Jog
command is still present, starts a continuous movement until the Jog command is set to FALSE or
a limit switch is reached.
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AdvancedPositioning
Limits of Movement
The FB supports limit switch signals for the definition of an operating area. It supports Normally
Closed (N/C) limit switches. It does not support impulse limit switches, i.e., when the axis enters
the area of the limit switch and beyond, the signal of the limit switch must remain FALSE.
Do not use positioning of linear axis without position limit switches.
WARNING
UNINTENDED EQUIPMENT OPERATION
Do not use impulse or normally open contact switches in association with the function blocks.
Only use Normally Closed contact switches with the function blocks.
Failure to follow these instructions can result in death, serious injury, or equipment damage.
NOTE: Limit switches are ignored in modulo mode (see page 55).
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AdvancedPositioning
Section 3.4
Pin Description
Pin Description
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AdvancedPositioning
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AdvancedPositioning
60 EIO0000000620 09/2016
AdvancedPositioning
i_xEn
When TRUE, this input activates the Advanced positioning function.
When FALSE, the FB enters a fallback state. In fallback state, speed reference outputs, status and
alarm outputs are reset to zero (FALSE). Information about current position is retained. Any
movement of the axis while the FB is disabled can lead to position information loss.
When i_xEn is set to FALSE while the axis is in motion, the currently active movement will
continue until it is finished before entering disabled/fallback status.
WARNING
UNINTENDED EQUIPMENT OPERATION
Do not use the i_xEn input to attempt to stop an active movement.
Failure to follow these instructions can result in death, serious injury, or equipment damage.
i_xPosExe
A rising edge on this input executes a positioning task if the following conditions are fulfilled:
FB enabled
no alarm
drive in RUN state (i_xDrvRun=TRUE)
machine is ready to start (i_xSysRdy=TRUE)
Execution of positioning has a higher priority than an execution of jog or a homing movement if
multiple executions are performed at the same time. If a homing or jog movement has already
started, it must first finish the movement before the positioning task may start.
i_xJogFwd
A rising edge on this input starts a jog movement if the following conditions are fulfilled:
drive in RUN state
system is ready
no alarm
no movement in progress
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AdvancedPositioning
i_xJogRev
A rising edge on this input starts a jog movement if the following conditions are fulfilled:
drive in RUN state
system is ready
no alarm
no movement in progress
i_xHmngExe
A rising edge on this input starts homing operation if the following conditions are fulfilled:
drive in RUN state
system is ready
no alarm
no movement in progress
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As an exception, the homing method 35 (see page 78) (immediate homing) does not require the
drive to be in RUN state since homing method 35 does not require axis movement for successful
homing.
i_xLsFwd
The input must be TRUE to allow movement in forward direction. The function block does not
support impulse limit switches. If the limit switch is reached in relative positioning mode, a rising
edge on the i_xRst input is necessary to cancel active motion task before starting another
movement.
WARNING
UNINTENDED EQUIPMENT OPERATION
Do not use impulse or normally open contact switches in association with the function blocks.
Only use Normally Closed contact switches with the function blocks.
Failure to follow these instructions can result in death, serious injury, or equipment damage.
i_xLsRev
The input must be TRUE to allow movement in reverse direction. The function block does not
support impulse limit switches. If the limit switch is reached in relative positioning mode, a rising
edge on the i_xRst input is necessary to cancel active motion task before starting another
movement.
WARNING
UNINTENDED EQUIPMENT OPERATION
Do not use impulse or normally open contact switches in association with the function blocks.
Only use Normally Closed contact switches with the function blocks.
Failure to follow these instructions can result in death, serious injury, or equipment damage.
i_xRef
This input defines the normally open (N/O) reference switch signal used in homing methods
23...30. Usage of this input is not mandatory when homing methods 23...30 are not used. For
details, refer to the description of the structure (see page 78) stHmngPara.
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i_xDrvRun
This input gives the FB information about the RUN status of the drive.
TRUE authorizes the start of the movement and must stay TRUE through the duration of the whole
movement.
FALSE during the movement triggers an alarm state and stops the movement using Quick stop.
For Altivar 71, 32 and 312, and other drives complying to CiA402/Drivecom standard, the
information about RUN state is stored in bit 2 of the status word.
i_xSysRdy
This input gives information about status of relevant parts of the machine. The most important
information is if the signal on the encoder value input i_diEncVal is valid.
The input i_xSysRdy must be TRUE to start the movement and must stay TRUE through the
duration of the whole movement.
When this input is set to FALSE during movement, the FB enters an alarm state and stops the
movement using Quick stop.
When the internal encoder interface of Altivar 71 is used, set the signal to TRUE when
the drive is in operational state (while controlling the drive through CANopen), or
the internal communication between ATV IMC and Altivar 71 is working (while controlling the
drive through backplane bus).
NOTE: To best determine the communication status between the ATV IMC and the Altivar drive
(while controlling the drive through backplane bus), use the bError output of
MANDATORY_AT_EACH_CYCLE program.
When an external encoder is used (for example, absolute encoder on CANopen), this input needs
to be TRUE only when the encoder is in an operational state and providing a position value.
i_wPosSpdRef
The speed reference is accepted at rising edge of i_xPosExe input. When there is a movement
in progress, the change of i_wPosSpdRef is taken into account only at a rising edge of
i_xPosExe input. This is possible only for absolute positioning (additive movement/position
blending).
i_wJogSpdRef
The speed reference is accepted immediately even if it changes during movement.
i_wHmngSpdRef
The speed reference is used for reference/limit switch search. When the reference/limit switch is
found, the axis continues with movement to homing edge at 1/4 of i_wHmngSpdRef.
When the speed is too high it would lead to overshooting of homing position or decreased accuracy
of homing. Therefore, the FB detects this case and triggers a homing alarm.
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i_diPosTarg
In absolute positioning mode (i_xPosMode=FALSE), this input defines the target position in user
units.
In relative positioning mode (i_xPosMode=TRUE), this input defines length of relative movement
from actual planned position.
NOTE: A planned position does not necessary equal the actual position. It is normal that after
stopping of the axis there is a certain difference between the planned position and the actual
position. This is acceptable as long as the difference is within a defined deadband. However, these
slight position differences could cause position loss when performing repetitive relative
movements. The FB accounts for the discrepancies by calculating the relative movements based
on planned position instead of actual position. For more information, refer to the description of
xMoveInDsbl parameter (see page 86) inside i_stEncPara input structure.
i_diEncVal
This value can be taken either from the encoder interface of Altivar 71 with encoder card or an
alternative source (CANopen absolute encoder or other position sensor).
WARNING
UNINTENDED EQUIPMENT OPERATION
Always verify that the value of the encoder position increases in a positive direction and
decreases in a negative direction before putting the machine or process into operational service.
Failure to follow these instructions can result in death, serious injury, or equipment damage.
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q_iSpdRef
This output contains the signed speed reference for a variable speed drive. Using a negatively
signed speed reference allows you to move the motor in reverse direction with forward command
on the drive. This method allows for a simple change of direction while the command to the drive
is controlled by user application outside of the FB.
For detailed information, refer to the Quick Reference Guide (see page 93).
q_iSpdRefFull
This output contains the signed speed reference for a variable speed drive in high resolution. The
maximum and minimum values correspond to maximum and minimum speed reference/frequency
configured in the FB. The output is intended for usage with a variable speed drive in high resolution
frequency reference mode.
Altivar variable speed drives can be switched to high resolution frequency reference mode using
bit 9 of extended command word (CMI).
For detailed information, refer to the documentation of your variable speed drive.
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q_diPosPlanInc
This output contains the planned position of the axis in encoder increments. Ideally, this value
should be equal to q_diPosActlInc. In reality, there is almost always deviation between these
values. The deviation can increase during periods of acceleration and deceleration, and may
trigger an alarm. If the deviation becomes too great, you need to review the configuration of the
application/machine.
q_diPosDiffInc
This output contains the difference between the planned and the actual position in encoder
increments. The lower the value, the greater is the accuracy of positioning. When this value
exceeds the maximum allowed position difference defined in i_stPosPara.diPosDiffMax, a
position following alarm is triggered and the axis stops using Quick stop.
q_dwStat
This output contains the status of the FB.
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q_dwAlrmId
This output identifies the detected alarm(s) indicated by the FB. A value of zero indicates no alarms
detected.
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Section 3.5
Structured Parameters
Structured Parameters
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Structure: stMotPara
Structure of parameters related to the motor configuration
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Structure: stPosPara
Structure of parameters related to positioning
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diPosDiffMax
The parameter is defined in encoder pulses. Drive running in closed loop motor control mode will
allow for lower value of i_stPosPara.diPosDiffMax because it can follow the target speed
more accurately. When the drive is running in open loop motor control mode, it is necessary to
increase the value to help preventing alarms.
diInPosWdow
This parameter defines the required accuracy of positioning.
Positioning is considered successfully finished when the difference between the actual and target
position of the axis is lower than i_stPosPara.diInPosWdow for the time defined by
i_stPosPara.wInPosTime. The parameter i_stPosPara.diInPosWdow is defined in
encoder pulses.
Excessively low value will cause reports of detected error on positioning.
Zero value disables the in-position window function. Target position is considered reached
immediately after profile generator reaches the target position.
winPosTime
Positioning is considered successfully finished when the axis is inside
i_stPosPara.diInPosWdow for at least the time defined by i_stPosPara.wInPosTime.
wPosFailTime
This parameter detects unsuccessfully positioning. The time starts running when the internal
position/speed profile generator reaches the target position. If the positioning does not finish
successfully within this time, an alarm is raised.
The time must be long enough to allow for finishing of the positioning under normal conditions.
rKpPos
A higher value of this input will proportionally increase the output of the internal position controller.
The parameter influences the reactivity of the axis and also the accuracy of positioning.
Start the commissioning with a low value (for example 5) and slowly increase to find the optimal
setting. If the response of the axis is too slow and the position deviation is too great, the value of
rKpPos is too low. If the axis starts to oscillate, the value is too high.
The value of proportional gain is internally compensated for encoder resolution (pulses per
revolution). It is not necessary to change this value if an encoder with different resolution is used.
The value of applicable proportional gain depends also on the accuracy (lag) of position
measurement and accuracy of the speed loop of used variable speed drive.
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To allow setting considerably higher value of i_stPosPara.rKpPos and achieving a higher level
of accuracy, proceed as follows:
Run the positioning in a task without short execution period.
Transfer information about axis position via backplane communication of Altivar 71 or a high
speed CANopen connection.
Configure the variable speed drive closed loop motor control mode.
rKpFeedFwd
This parameter defines the direct influence of internally generated speed profile on speed
reference for the drive. Higher value will make the axis more reactive. Too high value will cause
oscillations of the axis.
Setting of this value is optional. The default value is 0. Find an optimal setting of
i_stPosPara.rKpPos before increasing i_stPosPara.rKpFeedFwd.
Changes of the parameter value are taken into account immediately.
Excessive value of proportional gain of position controller and feed forward gain of the position
controller may lead to oscillations of controlled axis.
WARNING
UNINTENDED EQUIPMENT OPERATION
Always start with low values of position controller gains and increase them gradually.
Failure to follow these instructions can result in death, serious injury, or equipment damage.
diLsPosFwdSw
This parameter defines the position of optional software limit switch in positive direction. The
software limit switch function stops movement of the axis when actual position of the axis is higher
than position of the software limit switch.
NOTE: This function is active in Positioning and Jog modes. It is not active in Homing mode.
The software limit switch function is active when homing has been done (q_wStat.9 is TRUE)
and i_stPosPara.diLsPosFwdSw does not equal 0.
Software limit switch function is not active in Modulo mode.
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diLsPosRevSw
This parameter defines the position of optional software limit switch in negative direction. The
software limit switch function stops movement of the axis when actual position of the axis is lower
than position of the software limit switch.
NOTE: This function is active in Positioning and Jog modes. It is not active in Homing mode.
The software limit switch function is active when homing has been done (q_wStat.9 is TRUE)
and i_stPosPara.diLsPosRevSw does not equal 0.
Software limit switch function is not active in Modulo mode.
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Structure: stJogPara
Structure of parameters related to jog movement.
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Structure: stHmngPara
Structure of parameters related to jog movement.
wHmngMeth
The FB implements homing methods using forward and reverse limit switches (homing method
17,18), methods using reference position switch (homing method 23...30) and immediate homing
at current position (homing method 35).
Homing method overview:
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NOTE: Homing methods 17 and 18 are using limit switches and therefore are applicable only on
linear axis. They are not supported in Modulo mode.
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The following figure shows various kinds of possible behavior of an axis during homing with homing
method 27.
The examples under A) show possible behavior when homing starts between the reference switch
and the forward limit switch. Examples under B) describe behavior for homing with axis starting
between the reference switch and reverse limit switch.
Behavior of the axis may differ for various values of homing speed i_wHmngSpdRef, various
breadths of reference switch area and various execution times of the task calling AdvancedPo-
sitioning FB.
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Similar behavior can be expected from homing methods using a reference position switch (homing
method 23...30).
Possible behavior during homing for methods 23...30:
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2 Movement to homing edge at 1/4 of homing speed. The homing is performed at the rising edge of reference
switch signal.
3 Excessive speed (i_wHmngSpdRef) causing overshoot of the reference switch.
4 Return movement after overshoot at 1/4 of homing speed reference.
5 Clearance movement at 1/4 of homing speed reference. The clearance distance is defined in
i_stHmngPara.diHmngDistOut.
6 The movement at reduced speed 1/4 of homing speed is still to fast and causes an overshoot of reference
switch position.
Position of the axis after successful homing.
x Position of the axis after Unsuccessful homing.
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Structure: stEncPara
Structure of parameters related to encoder interface.
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wIntfResol
This parameter defines the bit resolution of used encoder interface:
16 bit resolution for the internal encoder interface of Altivar 71
25 bit resolution for the interface of absolute CANopen encoders of the XCC range
32 bit resolution for interfaces of integer type (-2147483648...2147483647)
NOTE: 32 bit interfaces of unsigned type (0 to 4294967296) are not supported.
Change of these parameter is possible only when i_xDrvRun = FALSE.
xEncType
FALSE selects an incremental encoder. Incremental encoder in this context means, that after
power cycle of the machine, the value of encoder position on the input i_diEncVal is reset to 0.
TRUE selects an absolute encoder which retains its position value through a power cycle.
This information is important for correct function of the FB which calculates the internal position of
the axis based on information from the encoder interface.
WARNING
UNINTENDED EQUIPMENT OPERATION
Remove the power of the incremental encoder interface every time the controller is switched off.
Failure to follow these instructions can result in death, serious injury, or equipment damage.
For example, when using the internal encoder interface of Altivar 71, it is necessary to switch the
drive off and let the encoder value of the drive reset to zero every time the controller is restarted.
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xPosIncSave
This parameter is only taken into account if an incremental encoder is used
(i_stEncPara.xEncType=FALSE).
It configures whether the FB retains the internal absolute position during a power cycle or not.
When i_stEncPara.xPosIncSave is FALSE, the internal absolute position is not retained and
you need to perform homing after every start of the machine.
NOTE: If the drive remains under power while power is removed from the controller, the
incremental encoder interface within the drive will retain its value. Once the controller is restarted,
and if the parameter i_stEncPara.xEncType=TRUE, you can use the incremental encoder
interface as a pseudo-absolute encoder.
In this case, the FB does not store the value of encoder interface when the controller is powered
down. It stores only the information about number of overflows of the encoder interface of the drive
and establishes the internal absolute position using the position information from incremental
encoder interface of the drive. If the drive had been reset (either through power cycled or product
reset) and the encoder position is reset (equal to zero), you must perform a new homing.
xMoveInDsbl
If the axis can move while the drive or FB is disabled or while the machine is powered off, set this
parameter to TRUE. This parameter makes the planned position of the FB follow its actual position
while the drive is not in RUN state. This helps preventing excessive acceleration applied to the
axis.
If the axis position is fixed by a brake in disabled state or if the axis cannot move on its own, set
this input to FALSE.
diScalNumer / diScalDenom
These parameters are the numerator and denominator values used for position value scaling.
These values are used to calculate the scaling factor. The scaling factor defines the relationship
between the number of motor revolutions and the corresponding distance in user units.
For example, when the axis movement by 10 mm corresponds to 7 motor revolutions, set
i_stEncPara.diScalNumer=7 and
i_stEncPara.diScalDenom=10.
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Numerator and denominator that are not relatively prime can be divided by their greatest common
divisor.
In this case it is 5. That results in:
You can change these parameters only when i_xDrvRun = FALSE. When the axis is in Modulo
mode, homing using homing method 35 is automatically performed on change of
i_stEncPara.diScalNumer or i_stEncPara.diScalDenom.
xModulo
With this parameter you can select between positioning of linear (FALSE) and rotary (TRUE) axis.
In Modulo mode is the position of the axis defined on a range between 0 and
i_stEncPara.diModRng.
Modulo mode is very useful for positioning of axes turning in one direction because it prevents
uncontrolled overflow of internal position.
Limit switch function (both, hardware and software) is disabled in Modulo mode.
Modulo movement is supported in both, absolute and relative modes, depending on setting of input
i_xPosMode.
Following images show movement with
i_diPosTarg = 900 and
wModDir = 1.
The left image shows positioning in absolute mode, the right image positioning in relative
mode.You can change this parameter only when i_xDrvRun = FALSE. When the axis is in
Modulo mode, homing using homing method 35 is automatically performed on change of
i_stEncPara. xModulo.
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diModRng
The value must be higher than 0 when i_stEncPara.xModulo = TRUE.
For example, the modulo range can be 3600 for a modulo axis with 360 rotation range. This gives
the axis a resolution of 0.1.
Following figure depicts change of position in time of modulo movement with
i_stEncPara.diModRng = 3600.
You can change this parameter only when i_xDrvRun = FALSE. Homing using homing method
35 is automatically performed on change of i_stEncPara.diModRng.
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wModDir
This parameter defines direction of rotation of a modulo axis. Supported values are:
0 shortest distance
1 positive direction (forward)
2 negative direction (reverse)
The left figure shows movement in modulo directions 0 and 1, the right one movement in direction
2.
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Modulo direction
xModMultiRng
With this parameter you can select between positioning within one revolution of the modulo axis
(i_stEncPara.xModMultiRng = FALSE) and positioning over multiple modulo ranges
(i_stEncPara.xModMultiRng = TRUE).
It can be used to perform positioning tasks ending at the same position as the starting position
(whole-number multiples of modulo range) or tasks exceeding modulo range.
The following example describes a positioning task with
target position i_diPosTarg = 3600,
on modulo range i_stEncPara.diModRng = 3600,
with wModDir = 1,
starting in position 0.
The diagram on the left side shows behavior in multiple-range mode and the one on the right
behavior in the single range mode. In single range mode is the target position equal to the actual
position and therefore the axis does not move.
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The left figure shows positioning within one modulo range and the right one positioning over
multiple modulo ranges.
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Multiple range mode is supported only in modulo directions 1 (positive) and 2 (negative). Mode 0
(shortest distance) is not supported.
Single and multiple-range mode positioning tasks are supported in both, absolute and relative
positioning modes.
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Section 3.6
Quick Reference Guide
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Visualization
This figure shows a visualization for the AdvancedPositioning function block:
The visualization of the AdvancedPositioning FB displays status and alarm words of the FB.
Its purpose is to help with the commissioning of the FB.
It is available inside the library and can be selected in the configuration of frame visualization object
under SE_HOIST.Visu_AdvancedPositioning.
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Commissioning Procedure
WARNING
UNINTENDED EQUIPMENT OPERATION
Verify that all equipment is secured to prevent harm to personnel and equipment damage.
Failure to follow these instructions can result in death, serious injury, or equipment damage.
1. Set the drive to factory settings. In drive menu application functions disable, preset speeds. Set
command and reference channel to controller card or CANopen depending on the preferred
communication channel.
2. Configure the Altivar variable speed drive (VSD) with correct motor control parameters.
3. Configure the following parameters in the settings menu of Altivar 71:
K speed loop filter (SFC) = 100
IR compensation (UFR) = 100
Low speed (LSP) = 0 (or as close to 0 as possible)
Slip compensation (SLP) = 100
Motor control mode (CTT) depending on machine configuration (FVC is preferred).
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9. Connect the speed reference output to input communication channel of the drive (typically
CANopen or internal bus of Altivar 71 when used with ATV IMC). The value is signed and
therefore the drive always gets only forward direction command. This simplifies the command
control of the drive, since the command control is performed by user application and not by the
AdvancedPositioning FB.
See the FB instantiation example (see page 95) for visual description of the program.
NOTE: When using the internal communication between Altivar 71 and ATV IMC to transfer the
speed reference to Altivar (function DriveTargetVelocitySet()), the speed reference needs to be
converted to an integer value with 0.1 Hz resolution.
For example 1500 RPM on 4 pole motor will result in 500 (50 Hz / 0.1).
NOTICE
POOR PERFORMANCE OR IRREGULAR PERFORMANCE OF EQUIPMENT
Verify that all speed references are properly converted with a 0.1 Hz resolution.
Failure to follow these instructions can result in equipment damage.
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12.Start the controller. The axis must be In position after the first start of the controller. If it is in
Positioning failed state or if there is a following error alarm detected it suggests that the
i_xSysRdy input was set to TRUE before the actual encoder value was present on the
i_diEncVal input.
WARNING
UNINTENDED EQUIPMENT OPERATION
Verify that the actual encoder value is present before the i_xSysRdy input is set to TRUE.
Failure to follow these instructions can result in death, serious injury, or equipment damage.
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Troubleshooting
Troubleshooting
Part III
Anti-Crab
Anti-Crab
Overview
This part explains the functionality and implementation of AntiCrab function block.
Chapter 4
AntiCrab: Correction of Bridge Movement to Solve Wear of Rail and Wheels
Notice
This function block has become obsolete, but has been retained to maintain compatibility for older
applications. We recommend using the new function block AntiCrab_2. The new function block
is not pin-compatible with the obsolete function block.
Section 4.1
Functional and Machine Overview
Functional Overview
Functional Description
The Anti-crab function is designed to correct the skew and the drift of the bridge in industrial cranes.
NOTE: The Anti-crab solution is frequently referred to as the Anti-skew solution. The Anti-crab
solution is not compatible with the AntiSwayOpenLoop function block on the same axis.
The Anti-crab solution uses 2 analog inductive sensors fixed onto either end of the bogie of the
crane. These analog sensor outputs are wired to the analog input channels of the SoMachine
controller. Alternatively, any other analog input of the crane system can be used.
The 2 sensors measure the distance of the bogie to the rail. If both sensors measure the same
distance, the bridge is parallel to the rail. If the sensors measure different values, the bridge is no
longer parallel to the rail. This is called skewing. The function calculates different speeds for the 2
motors (one faster, one slower) to bring the bridge back into a proper parallel position.
Besides skewing, the bridge drifts on rails to one side or another with both sensors measuring
increasing (or decreasing) values over a period of time. In this case, the function also calculates
different motor speed offsets to realign the bridge.
The principle is illustrated in the following figure.
Symbol Meaning
Sensor mounting position 1
Symbol Meaning
Sensor mounting position 2
This function block is intended to have significant influence on the physical movement of the crane
and its load. The application of this function block requires accurate and correct input parameters
in order to make its movement calculations valid and to avoid hazardous situations. If invalid or
otherwise incorrect input information is provided by the application, the results may be undesirable.
WARNING
UNINTENDED EQUIPMENT OPERATION
Validate all function block input values before and while the function block is enabled.
Failure to follow these instructions can result in death, serious injury, or equipment damage.
Functional View
Machine Overview
Machine View
The following figure is the Machine View of Anti-crab in an industrial crane using two motors to
move the bridge.
NOTE: The function Anti-crab works with ATV312 or ATV71. However, both drives used in the
application must be of the same model type. The graphic shows a pair of ATV312 drives, an
alternative option would be to use a pair of ATV71 drives.
Section 4.2
Architecture
Architecture
Hardware Architecture
A configuration with 2 drives and 2 motors is the most commonly used configuration. It uses 1 drive
and 1 motor for each of the bogies in the system.
NOTE: The function Anti-crab works with ATV312 or ATV71. However, both drives used in the
application must be of the same model type. The graphic shows a pair of ATV312 drives, an
alternative option would be to use a pair of ATV71 drives.
Software Architecture
Calibration Sub-Function
If i_xCalb is TRUE, the function block is storing the actual sensor values at every cycle.
To find the middle point of the sensor-range, the function is checking,
if the actual sensor value is bigger than the biggest stored value and
if the actual sensor value is smaller than the smallest stored value.
NOTE: You should either use the manual override of the sensors (i_wSenAvge1, i_wSenAvge2),
or enable calibration by setting i_xCalb to TRUE and leave it TRUE.
The calibration is intended to stay TRUE and it will get more accurate the longer it is running.
NOTE: If i_xCalb is FALSE and input i_wSenAvge1 > 0 and i_wSenAvge2 > 0 then offset is
calculated as below:
Offset1:= 12000 - i_wSenAvge1.
Offset2:= 12000 - i_wSenAvge2.
If i_xCalb is TRUE (*calculation of middle points*) then offset is calculated as below:
rCalbSenAvg1:= (wSen1Min + ((wSen1Max - wSen1Min) / 2))
rCalbSenAvg2:= (wSen2Min + ((wSen2Max - wSen2Min) / 2))
Section 4.3
Function Block Description
Pin Diagram
Section 4.4
Pin Description
Pin Description
i_xEn
By setting the i_xEn input to FALSE the output states will be overwritten by a defined fallback
state which is specific for each function block.
As soon as the function block gets enabled again the output states will be updated corresponding
to the function block behavior as described above. There is no additional action required from you
to re-establish the enabled state.
The fallback states of AntiCrab are given in the table below.
Outputs that are not listed will retain their current values.
i_xCalb
Calibration is needed if the sensors do not give the same value when the bridge is aligned properly.
Calibration can also take into account that the rails are uneven over the entire
movement.Calibration samples the input values of both sensors and stores the absolute minimums
and absolute maximums of all values during active calibration. The respective middle points are
always calculated following this formula:
Middle point = Minimum + (( Maximum - Minimum) / 2)
For more detailed information about the calibration process, refer to the Calibration Sub-Function
(see page 112) description.
i_xDrvRdyStat1, i_xDrvRdyStat2
The input need to be logical connected with the CANopen status of the controlled drive. This could
be found in the CANopen status word bit 1 / Ready state.
i_wSen1, i_wSen2
These are the sensor inputs for measuring the distance between the bogie and the rail. These
values have to be scaled by the Scale Input function block to a 4000 to 20000 range (representing
4...20 mA) before using them with the AntiCrab function block. For example, if a 0...10 V sensor
is used, the input to the function needs to be scaled to represent a range of 4000... 20000. The
sensors have to be mounted in a way that they show values of 12000 for a properly aligned bridge.
As seen in the diagram below, depending on the mounting position of the sensor set, they need to
be connected to these inputs according to the picture (only 2 sensors are required).
The following figure represents the 2 sensor mounting positions for AntiCrab function block.
Symbol Meaning
Sensor mounting position 1
i_wSkewMax
This is the maximum allowed difference in sensor readings (skew). If ((sensor 1 + offset 1) - (sensor
2 + offset 2)) > SkewMax an alarm is generated, bit 2 of q_wAlrmId is set high, the speed output
to the drives is 0, and the crane stops.
i_wDrftMax
This is the maximum allowed sensor averaged value of sensor 1 and sensor 2. This is the
maximum distance the bridge is allowed to drift away from the rail. If ((sensor 1 + offset 1) + (sensor
2 + offset 2))/2 > DrftMax, an alarm is generated, bit 0 of q_wAlrmId is set high, the speed output
to the drives is 0, and the crane stops.
i_wDrftMin
This is the minimum allowed sensor averaged value of sensor 1 and sensor 2. This is the minimum
distance the bridge is allowed to drift towards the rail. If (sensor 1 + offset 1 + sensor 2 + offset 2)/2
< DrftMin, an alarm is generated, bit 1 of q_wAlrmId is set to high, the speed output to the drives
is 0, and the crane stops.
i_wSenAvge1, i_wSenAvge2
These values are used to manually override the calculated middle points of both sensors during
calibration. The default of these inputs is 0. If any of the values is non-zero, manual override
becomes active and the input value is used as the middle point reference for all internal
calculations. Once reset to 0, the calibration value is used again.
q_rCalbSenAvge1, q_rCalbSenAvge2
This is the output of the actual active middle points of sensor 1 and sensor 2 either calculated by
the calibration process or manually overridden by the i_wSenAvge1, i_wSenAvge2 inputs. From
these values, the offsets are calculated:
Sensor average1 = 12000 offset1. Sensor average2 = 12000 offset2
NOTE: On detection of Alarm in Calibration state, the q_rCalbSenAvge1 and q_rCalbSe-
nAvge2 output are set to 0.
Notifications
Section 4.5
Troubleshooting
Troubleshooting
Troubleshooting
Troubleshooting
Chapter 5
AntiCrab_2: Correction of Bridge Movement to Solve Wear of Rail and Wheels
Section 5.1
Functional and Machine Overview
Functional Overview
This function block is intended to have significant influence on the physical movement of the crane
and its load. The application of this function block requires accurate and correct input parameters
in order to make its movement calculations valid and to avoid hazardous situations. If invalid or
otherwise incorrect input information is provided by the application, the results may be undesirable.
WARNING
UNINTENDED EQUIPMENT OPERATION
Validate all function block input values before and while the function block is enabled.
Failure to follow these instructions can result in death, serious injury, or equipment damage.
Functional View
Machine Overview
Machine View
The following figure is the Machine View of Anti-crab in an industrial crane using two motors to
move the bridge.
NOTE: The function Anti-crab works with ATV312, ATV32 or ATV71. However, both drives used
in the application must be of the same model type. The graphic shows a pair of ATV312 drives, an
alternative option would be to use a pair of ATV71 drives.
Section 5.2
Architecture
Architecture
Hardware Architecture
A configuration with 2 drives and 2 motors is the most commonly used configuration. It uses 1 drive
and 1 motor for each of the bogies in the system.
NOTE: The function Anti-crab works with ATV312, ATV32 or ATV71. However, both drives used
in the application must be of the same model type. The graphic shows a pair of ATV312 drives, an
alternative option would be to use a pair of ATV71 drives.
WARNING
UNINTENDED EQUIPMENT OPERATION
Equip the bridge in industrial cranes with mechanical safeguards protecting the crane against
de-railing and other damage.
Do not use the FB without the proper mechanical safeguard integrated into the crane
application.
Failure to follow these instructions can result in death, serious injury, or equipment damage.
Software Architecture
Section 5.3
Function Block Description
Pin Diagram
Functional Description
The Anti-crab function is designed to correct the skew and the drift of the bridge in industrial cranes.
Anti-crab function uses 2 analog sensors to measure distance from a crane runway rail or another
surface parallel to the rail. Both sensors are placed on one side of one of the bogies. They can be
placed in any of the positions corresponding to a) through d) in the following figure. The FB has to
be aware of placement of the sensors to operate correctly. The information is given to the FB via
i_xSenPos input.
i_xSenPos must be
FALSE if sensors are mounted in positions a) or c) on the left side of the rail in forward direction,
and
TRUE if they are in positions b) or d) on the right side of the rail in forward direction.
The actual skew is calculated from the reading of the 2 sensors and the center positions of the
sensors. Center positions are input values that help to compensate for an imperfect mechanical
alignment of the sensors. The values are configured during commissioning.
The formula for calculation of actual skew:
The actual drift is calculated from the reading of the 2 sensors and the center positions of the
sensors. Center positions are input values that help to compensate for an imperfect mechanical
alignment of the sensors. The values are configured during commissioning.
The formula for calculation of actual drift:
WARNING
UNINTENDED EQUIPMENT OPERATION
Do not use direction command provided by the AntiSwayOpenLoop_2 function block when the
AntiSwayOpenLoop_2 is disabled.
Failure to follow these instructions can result in death, serious injury, or equipment damage.
When using the combination of AntiCrab_2 and AntiSwayOpenLoop_2 FBs, set the ramp of
the used variable speed drives steep enough not to interfere with the speed profile generated in
the application. The FB sets its ramp outputs automatically to a shortest possible value when the
i_xAsw input is TRUE.
Section 5.4
Pin Description
Pin Description
i_xEn
When TRUE, this input enables function of AntiCrab_2 FB. When FALSE, the FB enters a
fallback state. In fallback state, the FB channels the target speeds, ramps and direction commands
to outputs for both drives.
i_xAsw
When TRUE, the FB is in a mode for concurrent operation of Anti-crab and Anti-sway. When
FALSE, the FB is in a standalone operation mode.
In standalone mode is the ramping of target speed performed by variable speed drives, the
AntiCrab_2 FB writes target speeds and ramp values to both drives via communication in every
cycle.
In combined operation of Anti-Crab and Anti-sway is the ramping of speed reference performed by
the AntiCrab_2 and AntiSwayOpenLoop_2 FBs. The ramp parameters of both bridge travel
drives must be set to a low value. The FB sets its ramp outputs automatically to a shortest possible
value when the i_xAsw input is TRUE. The drives then follow directly the speed reference
calculated by the application.
The FB does not prevent switching modes while the drives are running. Be sure that the value of
i_xAsw is not modified while the drives are running.
NOTE: Modifying the i_xAsw parameter of the AntiSwayOpenLoop_2 function block while the
drive(s) are running will result in a considerable delay of stopping performance of the bridge in the
industrial crane.
WARNING
UNINTENDED EQUIPMENT OPERATION
Do not modify the i_xAsw parameter while the drive is running.
Failure to follow these instructions can result in death, serious injury, or equipment damage.
i_xSenPos
Selects between 2 possible positions of sensors. When FALSE, the FB is configured for sensors
on the left side of the rail in direction of movement, positions a) and c) in the following figure. And
when TRUE, the FB is configured for sensors on the right side of the rail, positions b) and d) in the
following figure:
i_wDrvAcc
Requested acceleration ramp time of bridge travel motors. The value is used as a base for
calculated output acceleration ramp times to both drives. When the FB is used in combination with
Anti-sway, this ramp time is used for separate ramping of Anti-crab correction.
i_wDrvDec
Requested deceleration ramp time of bridge travel motors. The value is used as a base for
calculated output deceleration ramp times to both drives. When the FB is used in combination with
Anti-sway, this ramp time is used for separate ramping of Anti-crab correction.
i_xDrv1RdyStat, i_xDrv2RdyStat
Inputs of ready status of both drives. The information can be obtained from bit 1 of status word of
Altivar drives. This information has to be interlocked (logical AND) with an information that the drive
is communicating on CANopen and is in operational state.
If the communication with any of the 2 drives is interrupted, the FB has to get the information in
order to stop the movement.
WARNING
UNINTENDED EQUIPMENT OPERATION
Ensure that, in your application, the status of CANopen communication of both drives is
interlocked (logical AND) with both drives status (drives are ready and CANopen is in an
operational state).
Failure to follow these instructions can result in death, serious injury, or equipment damage.
The FB needs to have information about status of both drives. If one of the drives is not ready, the
FB does not authorize start of the movement. If one of the ready bits turns FALSE during
movement, both drives are stopped.
i_wSen1, i_wSen2
Scaled values of sensor outputs. The FB expects values scaled between 4000 and 20000.
Corresponding to an usual 4...20 mA output of distance sensor. 4 mA being the position of sensor
being closest to the rail, and 20 mA the position farthest from the rail.
The ScaleInput FB can be used to scale sensor values. See the Function Block Instantiation
Example (see page 151).
i_wSen1Centr, i_wSen2Centr
These parameters correspond to values of sensors 1 and 2 when the crane is centered on the
runway and both wheels of the bogie where the sensors are mounted are in the middle of the rail.
In an ideal state both of the sensors should output a value that results in a value of 12000 after
scaling.
However, it is not always possible eliminate deviation in the alignment of the sensors.
Using these inputs, it is possible to tell the FB that the centered position of either or both sensors
deviate from the ideal.
The internal skew and drift controllers use these values as a regulation setpoint.
If the value of i_wSen1Centr / i_wSen2Centr is zero, the FB takes 12000 as the centered
position of the related sensor, assuming there is no correction necessary.
i_wDrvSpdHsp
The parameter contains the maximum allowed speed the FB is allowed to write to target speed
outputs. The value must not exceed the value defined as the high speed in the variable speed
drives.
i_wDrvSpdLsp
The parameter contains the minimum allowed speed the FB is allowed to write to target speed
outputs. The value must not be lower than the value defined as the low speed in the variable speed
drives. If the mechanics and motor configuration allow it, use i_wDrvSpdLsp = 0
i_wMotSpdNom
The parameter contains the nominal speed of the applied motors. This parameter is used for
ramping of skew and drift correction when the FB is used together with Anti-sway. In standalone
operation it is not necessary to configure this parameter.
The synchronous value of the motor speed is optimal for working with this FB. For example, for 4-
pole motor @ 50 Hz, use 1500 RPM. Using the speed from the motor nameplate which is including
the motor slip is possible, but not necessarily optimal.
i_rKpDrft
The parameter contains the proportional gain of the drift controller. Optimal value depends on the
crane mechanics. Set this value after the i_rKpSkew has been configured. Setting this input to 0
disables the drift correction, but leaves the skew correction active.
For more information on configuration of controller gains, check the Commissioning Procedure
(see page 153) section.
i_rKpSkew
The parameter contains the proportional gain of the skew controller. Optimal value depends on the
crane mechanics. Set this value first before i_rKpDrft. Setting this input to 0 disables both skew
and drift correction.
For more information on configuration of controller gains, check the Commissioning Procedure
(see page 153) section.
i_wRegOputMax
The parameter defines the maximum output of the drift and skew controller. It corresponds to a
maximum allowed difference in target speeds for drives 1 and 2. When left to 0, the output of the
controller is limited only by the difference of i_wDrvSpdHsp and i_wDrvSpdLsp. The input can
help reducing a stress to the runway and building structure in case of problems with the mechanics
of the crane or sensor signals.
i_wSkewMax
The parameter contains the maximum allowed value of the bridge skew. If the actual value of skew
exceeds this value for longer than defined by the i_wFltrTime, an alarm is raised. Setting this
value to 0 disables the excessive skew detection.
i_wDrftMax
The parameter contains the maximum allowed value of the bridge drift. If the actual value of drift
exceeds this value for longer than defined by the i_wFltrTime, an alarm is raised. Setting this
value to 0 disables the excessive drift detection.
q_xEn
Enable status of the FB. While the FB is enabled, it modifies target speeds and ramp times of both
drives based on actual sensor readings. In disabled state it channels the input commands, speed
reference and ramp times to its outputs. Alarm outputs are set to zero (FALSE).
Transition between disabled and enabled state of the FB and vice versa while the crane is running
is not restricted but it is not recommended.
q_wDrv1Acc, q_wDrv2Acc
Acceleration times for drives 1 and 2. The acceleration times are calculated along with the target
speeds in order to optimize the skew and drift control. These values must be written to acceleration
time parameters of the drives.
When the FB is used together with Anti-sway, both outputs are written to 1 and the ramping is
handled by the FBs.
q_wDrv1Dec, q_wDrv2Dec
Deceleration times for drives 1 and 2. The deceleration times are calculated along with the target
speeds in order to optimize the skew and drift control. These values must be written to deceleration
time parameters of the drives.
When the FB is used together with Anti-sway, both outputs are written to 1 and the ramping is
handled by the FBs.
Notifications
Section 5.5
Quick Reference Guide
Visualization
Overview
actual displacement of sensors 1 and 2 compensated with center positions i_wSen1Centr and
i_wSen2Centr (horizontal green rectangles)
actual values of sensor positions, skew, drift, target and actual speeds and ramp times
It is available inside the library and can be selected in the configuration of frame visualization object
under SEAD_HOIST.Visu_AntiCrab_2.
Commissioning Procedure
5. Verify that the CANopen communication is functioning correctly between both drives.
6. Instantiate the FB and integrate it in your application.
7. Add scaling functions in order to scale the sensor output values.
8. Move the bridge in industrial cranes in manual mode in order to center the wheels of the bogie
with attached sensors on the rail. The crane may be moved by controlling the drives
independently, moving sides of the crane at slow speed.
The crane may be also centered on the rail by moving it against the buffer at the end of the
runway.
When both wheels are centered on the rail, note down the scaled values of both sensors. Write
these values as center positions on inputs i_wSen1Centr and i_wSen2Centr.
Once the wheels are centered, verify also the other side of the crane. The wheels on the other
side of the bridge should be centered as well. If they are too far from the center, it could signal
problems with the geometry of the crane or crane runway.
9. Set both drift and skew controllers gain to 0 and move the crane without Anti-crab to get familiar
with its behavior.
10.Leave the drift control gain at 0. Increase the value of proportional gain of skew controller
gradually while moving the crane and trace the value of actual skew and actual speeds. Find an
optimum value of skew controller. The skew should be reduced to a low value without causing
oscillations of the motor speeds on both sides of the bridge.
Watch the drift of the bridge in industrial cranes during the movement. If the bridge tends to drift
to the left in one direction of movement and to the right in the other direction of movement, it is
possible that the center positions are not set correctly and the skew controller does not keep the
bridge in industrial cranes straight. In this case, modify the i_wSen1Centr and
i_wSen2Centr values.
11.Keep the setting of the skew controller and start to increase the gain of the drift controller. Find
an optimum value of the drift controller.
12.Watch the torque of both drives during the tuning. The purpose of Anti-crab is not keeping the
crane dead centered at all cost. It should prevent the wheels from grinding the rails. It is
necessary to find an optimal compromise between centering of the bridge and balance of the
torques.
13.When the independent configuration has successfully been done, the outputs of the
AntiSwayOpenLoop_2 FB may be connected to inputs of the AntiCrab_2 FB.
Troubleshooting
Troubleshooting
Part IV
Anti-Sway
Anti-Sway
Chapter 6
AntiSwayOpenLoop: Correction of Sway in Horizontal Movements without Sensor
WARNING
UNCOMPENSATED INITIAL SWAY
Do not start the movement until the load is at rest and motionless.
Do not engage the Anti-sway function until all initial load movement has ceased.
Failure to follow these instructions can result in death, serious injury, or equipment damage.
Section 6.1
Functional and Machine Overview
Functional Overview
Functional Description
The Anti-sway function is designed for industrial cranes to correct the sway of the bridge or trolley
movement.
NOTE: The Anti-sway solution is not compatible with the AntiCrab function block on the same
axis.
The Anti-sway function is implemented and designed to be used to control ATV31/312 and ATV71
drives.
The following table shows the 3 main features provided by the solution:
WARNING
UNCOMPENSATED WIND SPEED AND DIRECTION
Do not use the AntiSwayOpenLoop or AntiSwayOpenLoop_2 function block to control
equipment that is in an outdoor environment, nor any environment subject to high velocity air
movement sufficient to sway the load.
Failure to follow these instructions can result in death, serious injury, or equipment damage.
This function block is intended to have significant influence on the physical movement of the crane
and its load. The application of this function block requires accurate and correct input parameters
in order to make its movement calculations valid and to avoid hazardous situations. If invalid or
otherwise incorrect input information is provided by the application, the results may be undesirable.
WARNING
UNINTENDED EQUIPMENT OPERATION
Validate all function block input values before and while the function block is enabled.
Failure to follow these instructions can result in death, serious injury, or equipment damage.
Functional View
Machine Overview
Machine View
The following figure is the machine view of Anti-sway in an overhead traveling crane.
Section 6.2
Architecture
Architecture
Hardware Architecture
Software Architecture
Section 6.3
Function Block Description - Speed Reference
Pin Diagram
Speed Selection
Pin Diagram
Speed Selection
Pin Diagram
i_iAnaVal
NOTE: The resolution range for the input i_iAnaVal changes depending on the maximum speed
value:
8192 = resolution of i_rDrvSpdHigh when the slow down sensor is not reached.
8192 = resolution of i_rDrvSpdSlowFwd or i_rDrvSpdSlowRev while within the slow down
area.
Deadband View
The graph below shows the deadband view with the analog input above the i_iAnaValDbnd
value.
Speed Selection
NOTE: q_rDrvSpd = i_iAnaVal and NOT i_rDrvSpdSlowRev only when the value
i_iAnaVal < i_rDrvSpdSlowRev.
The same case applies for i_rDrvSpdSlowFwd and i_iAnaVal.
Notifications
Status Notifications
Section 6.4
Function Block Description - Cable Length
Notice
The function block CableLength_Enc has become obsolete, but has been retained to maintain
compatibility for older applications. We recommend using the new function block
CableLength_Enc_2. The new function block is not pin-compatible with the obsolete function
block.
Pin Diagram
WARNING
UNINTENDED EQUIPMENT OPERATION
You must convert imperial units to metric units in meters before being used as inputs for this
function (1 meter equals 3.28 feet).
Failure to follow these instructions can result in death, serious injury, or equipment damage.
Example:
Low position = 10 m
Mid position = 8 m
High position = 6 m (less angle effect)
Best performance is reached with Low position = 10 m.
Maximum value for Low position (maximum cable length) is 40 m.
Selection Priority
NOTE: The screw selection of i_xSel2 = 0 and i_xSel1 = 1 is invalid and has to be avoided. It
will be interpreted as i_rPosLow.
Notifications
Status Notifications
Pin Diagram
WARNING
UNINTENDED EQUIPMENT OPERATION
You must convert imperial units to metric units in meters before being used as inputs for this
function (1 meter equals 3.28 feet).
Failure to follow these instructions can result in death, serious injury, or equipment damage.
Example:
Low position = 10 m
Mid position = 8 m
High position = 6 m (less angle effect)
Best performance is reached with Low position = 10 m.
Maximum value for Low position (maximum cable length) is 40 m.
Selection Priority
Notifications
Status Notifications
Pin Diagram
WARNING
UNINTENDED EQUIPMENT OPERATION
You must convert imperial units to metric units in meters before being used as inputs for this
function (1 meter equals 3.28 feet).
Failure to follow these instructions can result in death, serious injury, or equipment damage.
NOTE: CableLength_Enc is an automatic function that does not require input from the operator.
i_xHighLim
In this configuration, a Normally Close contact is mandatory at the top position. The Homing
function is used to establish the cable length and to allow for stretching.
On top position = FALSE; else = TRUE.
Notifications
Status Notifications
Procedure Example
Example
Parameter Description
i_xEn LI51 (ATV IMC)
i_xCalbMode LI52 (ATV IMC)
i_rCbleLenMax 40.0 m (131.23 ft)
i_rCbleLenMin 2.00 m (6.56 ft)
i_rCalbCbleLen 0.00 m
i_wPulsEnc The PUC parameter register of the encoder ATV71 drive
is used.
i_xHighLim LI54 (ATV IMC)
i_rLoadLen 0.00 m
i_xLoadSel FALSE
Procedure
Steps Description
1 i_xEn = TRUE
2 i_xCalbMode = TRUE
a. Signal calibration not done changes to TRUE q_wStat. bit5
b. Signal calibration mode changes to TRUE q_wStat. bit9
3 Run forward until reaching the i_xHighLim signal. The signal changes to
FALSE. This is Up movement.
4 Run reverse and leave i_xHighLim signal. The output signals change in this
way. this is Down movement.
a. i_xHighLim changes to TRUE
b. Calibration in process changes to TRUE q_wStat. bit6
c. Calibration mode remains TRUE value q_wStat. bit9
d. Down movement changes to TRUE q_wStat. bit13
e. Calibration not done changes to FALSE q_wStat. bit5
5 Stop the reverse command and introduce the value into i_rCalbCbleLen.
(The Anti-sway correction is better if the precision of the value is better. The
accuracy is 0.01 m. The distance can be measured with a laser telemeter).
Steps Description
6 Change i_xCalbMode = FALSE
a. Calibration in process changes to FALSE q_wStat. bit6
b. Calibration mode changes to FALSE q_wStat. bit9
c. Calibration done changes to TRUE q_wStat. bit7
d. Running mode changes to TRUE q_wStat. bit10
NOTE: Cable length movements are not recognized if the CableLength_Enc function block has
not been calibrated. For example, start of a movement when the slave on CANopen is not ready.
A new calibration procedure must be performed.
Pin Diagram
i_xEn
NOTE: If the information of the limit switch input i_xHighLim is transferred via CANopen, we
strongly recommend connecting the status of the CANopen bus to this i_xEn input, because
during the boot-up phase of the controller, the CANopen bus will get operational later than the
program of the controller. This could lead to a wrong cable length output of the function block.
The following figure shows an example of obtaining the CANopen network status of the hoisting
drive, assuming that the drive has been assigned a Node ID of 3:
By setting the i_xEn input to FALSE the output states will be overwritten by a defined fallback
state. As soon as the function block gets enabled again the output states will be updated
corresponding to the function block behavior as described above. There is no additional action
required from you to re-establish the enabled state.
WARNING
UNINTENDED EQUIPMENT OPERATION
Ensure that the status of CANopen communication is used to enable the function block.
Failure to follow these instructions can result in death, serious injury, or equipment damage.
i_xCalbMode
This is the input to enter into calibration mode of the FB. The calibration is conducted as followed:
1. It is mandatory to use a limit switch which is normally closed (NC contact).
2. Lift the hoist up to its highest limit, so the i_xHighLim is getting FALSE.
3. Set the i_xCalbMode input to TRUE.
4. Lower the hoist down to the ground.
5. Enter the distance from the top position down to the ground into the i_stCLE.rCalbCbleLen
input, scaling is 1.0 meter.
6. Set the i_xCalbMode input to FALSE.
Notifications
The alarm ID when q_xAlrm is TRUE. The ID is indicated by a bit set in this output.
The bit values have the following meaning:
Section 6.5
Function Block Description - AntiSwayOpenLoop
Notice
This function block has become obsolete, but has been retained to maintain compatibility for older
applications. We recommend using the new function block AntiSwayOpenLoop_2. The new
function block is not pin-compatible with the obsolete function block.
Anti-Sway - Overview
This function block is intended to have significant influence on the physical movement of the crane
and its load. The application of this function block requires accurate and correct input parameters
in order to make its movement calculations valid and to avoid hazardous situations. If invalid or
otherwise incorrect input information is provided by the application, the results may be undesirable.
WARNING
UNINTENDED EQUIPMENT OPERATION
Validate all function block input values before and while the function block is enabled.
Failure to follow these instructions can result in death, serious injury, or equipment damage.
Pin Diagram
i_strAswConf
This parameter is a structure for the following configuration parameters. The parameters inside the
structure are normally changed only during the commissioning phase.
NOTE: The syntax for structure declaration is as follows:
TYPE <Structurename>:
STRUCT
<Declaration of identifier Variables 1>
<Declaration of identifier Variables n>
END_STRUCT
END_TYPE
rAswCorr
The Anti-sway correction is for smooth action. 100% correction is very fast and normally used when
the crane has no occupied operator cabin. The setting should be applied in steps of 1%. When the
crane has an operator the setting must start at 80% (to reduce the vibration and the stress for the
machine).
rAswCorrRamp
This command is used to adapt the reaction time of the AntiSwayOpenLoop during a movement
when AntiSwayOpenLoop is active (% of acceleration and deceleration value). A setting of 100%
speed is used for the acceleration and the deceleration. When the setting is 50% only half of the
acceleration and deceleration value is used. Example:
rAswCorrRamp = 50%
rAcc= 3 s
rDec = 3 s
The ramp applied on the crane are Acceleration = 1.5 s and
Deceleration = 1.5 s
Notifications
Status Notifications
Overview
The following main parameters are described:
Speed Profile (see page 224)
Scan Time Effect (see page 226)
Slow Down Sensor (see page 227)
Stop Sensor (see page 227)
Start and Stop the Anti-Sway Correction (see page 228)
Speed End and Time Delay (see page 228) (rAswSpdEnd and rAswTimeEnd)
Speed Activation Anti-Sway (see page 228) (rAswJogSpd)
ATV71 Configuration (see page 229)
ATV31/312 Configuration (see page 230)
Speed Profile
When the Anti-sway function is not activated, a specific non linear speed profile is followed. This
profile is set up in real time by the AntiSwayOpenLoop function block, according to the following
main parameters:
Acceleration and deceleration
Set point speeds
Start and stop commands
The following figure represents the speed profile when the Anti-sway function is not activated.
When the Anti-sway function is activated a specific non linear profile is followed. This profile is set
up in real time by the AntiSwayOpenLoop according to the following main parameters:
Acceleration and deceleration
Set point speeds
The ramp profile does not have enough value to correct the sway if the cycle time is too high. The
value cannot exceed 100 ms for the parameter rSmplRate.
The cycle time must be measured during implementation. Validate that the setting has the correct
value.
When the Slow down sensor switch is open, the speed reference is equal to i_rDrvSpdFwdMax
or i_rDrvSpdRevMax depending on the RUN command.
Forward Order i_rDrvSpdFwdMax
Reverse Order i_rDrvSpdRevMax
NOTE: In some cases, it may be necessary to change the position of the sensor due to the Anti-
sway correction.
Stop Sensor
The following figure represents the graph depicting the reaction on the Anti-sway stop sensor.
When the Stop sensor is open, the drive must stop as fast as possible.
NOTE: The stop command must be run outside the function block.
ATV71 Configuration
The following table contains typical ATV71 configuration settings:
ATV31/312 Configuration
The following table contains typical ATV31/312 configuration settings:
Section 6.6
Function Block Description - AntiSwayOpenLoop_2
AntiSwayOpenLoop_2 - Overview
WARNING
UNINTENDED EQUIPMENT OPERATION
Validate all function block input values before and while the function block is enabled.
Failure to follow these instructions can result in death, serious injury, or equipment damage.
Functional View
Pin Diagram
i_xEn
This input activates the Anti-sway function.
Activation is possible only when the output speed of the Anti-sway FB equals zero. If the output
speed is higher than zero, the Anti-sway function is only activated once it reaches zero.
The Anti-sway function can be de-activated regardless of the actual speed reference value.
If the FB is disabled it generates a speed profile using linear acceleration and deceleration ramps
defined by wAswAccDsbl and wAswDecDsbl. This profile can be used to control the motor speed
without changing the setting of acceleration and deceleration ramps in the drive (e.g. when there
is no more place in rPDOs to write the parameters).
However it is preferable to use the ramping of the drive, if it is possible.
NOTE: It is not possible to activate Anti-sway during the movement because the calculation of the
pendulum position is only active when the Anti-sway function is enabled. If a movement with
activated Anti-sway function starts while the load sways, this initial sway is not suppressed by the
function.
WARNING
UNCOMPENSATED INITIAL SWAY
Do not start the movement until the load is at rest and motionless.
Do not engage the Anti-sway function until all initial load movement has ceased.
Failure to follow these instructions can result in death, serious injury, or equipment damage.
i_xLsFwdSlow
This signal is used to assist the slow down at the slow down limit switch in a forward direction. This
input does not modify the speed reference. It sets shorter ramps in order to slow the movement
down in a shorter distance while still using the Anti-sway function. The speed reference required
in the slow area must be given to the input i_wDrvSpdRef from an external source (e.g.
SpeedSelect function block).
i_xLsRevSlow
This signal is used to assist the slow down at the slow down limit switch in the reverse direction.
This input does not modify the speed reference. It sets shorter ramps in order to slow the
movement down in a shorter distance while still using the Anti-sway function. The speed reference
required in the slow area must be given to the input i_wDrvSpdRef from an external source (e.g.
SpeedSelect function block).
i_xBrakFbck
This is the feedback brake status. A TRUE value indicates the brake is released. The feedback is
needed to start the movement without the brake engaged.
If there is a command to run present (i_xDrvFwd or i_xDrvRev) and other conditions to start the
movement are fulfilled, the corresponding direction output command (q_xDrvFwd or q_xDrvRev)
is set to TRUE immediately. (in order to switch the drive to RUN state) Ramp generation starts after
i_xBrakFbck becomes TRUE.
The input is important for smoothness of movement. The internal ramp generator starts the ramp
only after this input is set to TRUE. If it is TRUE all the time, ramping begins before the motor is
fluxed and brake is open, which in combination with a 0.1 s ramp on the drive results in a steep
ramp at the beginning of movement. This is especially important for motors with a longer fluxing
time.
Using the contact of the brake contactor is acceptable but not optimal, especially for brakes which
take a long time to open. (If the brake needs 200 ms to release and the task time is 50 ms, the
ramp runs for 4 cycles before the brake releases).
Alternatively, if there is no information on the state of the brake, see i_stPAS.wBrakDly
parameter.
i_rCbleLenActl
This is the actual cable length from the point where the rope is attached to the drum (or the average
position for complex systems) to the approximate center of gravity of the system (the system
consists of the hook, load and also rope, but the rope can usually be neglected) in meters (coming
from the CableLength function block or similar). The load length must be added to the cable
length beforehand.
Correct setting of i_rCbleLenActl input:
i_stPAS
A structure of the data type PAS containing configuration parameters.
For example, a declaration of structure variable with initial values:
VAR
struct_instance: data_type := (element1 := XX, ement2 := YY);
END_VAR
NOTE: Unlike the acceleration and deceleration time parameters on the Altivar that are between
zero and nominal speed, the ramp time values of Anti-sway FB are calculated between zero and
maximum speed. Therefore the ramp times need to be set accordingly when the maximum speed
does not equal the nominal speed of the drive to maintain the required ramp slope.
wAswRampLim
This parameter defines the steepest ramp the Anti-sway function is allowed to use in order to
correct the sway. Lower values of this parameter makes the correction more aggressive and allow
shortening of the acceleration and deceleration phase which improves load handling for the
operator (it is easier to estimate a 2 m stop distance than a 4 m and therefore it is possible to arrive
to a target position with much higher precision).
The disadvantage is that the stress of the crane structure is increased.
It is essential to find the right compromise during commissioning.
q_wStat bit 6 indicates whether an additional stop distance optimization is possible with the
current combination of i_stPAS.wAswRampLim and i_rCbleLenActl. If it is not possible, the
i_stPAS.wAswRampLim value can be lowered in order to allow for the optimization.
Stop distance optimization is beneficial mainly with longer cable lengths that approach or exceed
10 m. For shorter cable lengths, the effect is not that significant and the normal stopping distances
are acceptable without optimization.
wBrakDly
This is an alternative to the feedback signal from a brake (i_xBrakFbck). If the brake feedback
signal is not available and the i_stPAS.wBrakDly value is not zero, an internal timer is used to
enable the speed profile generation instead.
If there is a command to run present (i_xDrvFwd or i_xDrvRev) and other conditions to start the
movement are fulfilled, the corresponding direction output command (q_xDrvFwd or q_xDrvRev)
is set to TRUE immediately. (in order to switch the drive to RUN state) Ramp generation starts after
the time specified by i_stPAS.wBrakDly has elapsed.
rCoefFrct
This is the friction coefficient during the movement which is used to adjust the mathematical model
to be closer to the behavior of the real crane. A high value for the friction coefficient results in higher
damping of the calculated sway in the mathematical model. Use a low value for a hoist with a
simple pulley block and a higher value for complex pulley blocks.
Example: set 0.1 for a single rope hoist without much friction, 0.9 for a hoist with a very complex
pulley block, 12 thick ropes and a high friction.
rAswSpdStrt
This is the speed threshold for activation of the Anti-sway function (given in % of maximum speed).
When set to zero, Anti-sway is active from the beginning of a movement. As it corrects the sway
continuously, this results in a less predictable behavior during short movements.
An alternative is to set this threshold higher than the lowest speed of the crane. This allows for
short, accurate movements without Anti-sway.
wCalcDistTime
This defines how much time the FB is allowed to spend on recursive calculation of the required
stop distance for one cycle. A zero value disables the calculation completely.
The calculation can run over several controller cycles. A low value for i_stPAS.wCalcDistTime
saves processing time, but increases the number of controller cycles needed to finish the
calculation. This decreases accuracy in the result especially during acceleration and deceleration.
xOptimRampDecEn
This parameter enables additional stop distance optimization. It allows a considerable shortening
of a stop distance. Performance of this function depends on the maximum allowed steepness of
acceleration and deceleration ramp (see description of i_stPAS.wAswRampLim. Sharper
acceleration and deceleration ramps results in shorter stop distances and less time but at the cost
of possibly higher mechanical stress to the crane structure.
q_xBrakCtrl
This is a brake control output. Normally the brake is controlled by the brake logic of the drive. If this
is so, leave this output unconnected. If an accurate Anti-sway control is also required for short
movements, it is possible to let the Anti-sway FB control the brake directly. The output goes TRUE
as soon as a command in the forward/reverse direction is given, the output is set to FALSE when
the movement finishes.
NOTE: When brake logic is used on an ATV31, ATV312 or ATV71 running in open loop motor
control, the drive closes the brake when the actual speed drops to/below the brake engage
frequency. Since Anti-sway has to lower the speed to zero on short movements before applying
the sway correction, closing of the brake interferes with the Anti-sway action.
WARNING
UNINTENDED EQUIPMENT OPERATION
Do not use parameter Brake engage delay (TBE) inside the Brake logic control menu of the
Altivar drive.
Failure to follow these instructions can result in death, serious injury, or equipment damage.
Setting of the Brake engage delay to value higher than 0 may cause the drive to lock up in DCB
state during reversing of direction of movement. If you need to delay closing of the brake, use
q_xBrakCtrl instead.
q_rDistStop
This is the calculated distance necessary to stop the movement using the Anti-sway function.
When this function is enabled, in setting i_stPAS.wCalcDistTime to a value higher than zero,
the function block continuously calculates the necessary stopping distance. The calculation is
spread over several controller cycles.
This function is used on automatic cranes to determine the point where the stopping ramp has to
start in order to arrive at the target position.
q_wStat
Notifications
This output indicates what alarm has been reported.
Alarm resets automatically after the cause of the alarm is removed.
Commissioning Procedure
Pre-requisites
1. The drives must be set to follow the speed reference accurately. When possible, use the vector
control. Set slip compensation to 100%.
Set the acceleration and deceleration parameters in the drive to 0.1 s.
2. A compromise setting must often be made when setting the system for usage with Anti-sway.
Anti-sway requires a smooth speed profile, especially during the stopping phase, to achieve the
highest possible quality of sway control. Because most motors used on trolleys and bridges are
run in an open loop, the engineer commissioning the crane must decide whether to set the LSP
and brake engage frequency to the value of motors slip or to 0 Hz.
Setting the LSP to 0 Hz improves smoothness of the movement but increases the risk of losing
control over the axis when the motor cannot apply sufficient torque on low or zero speed. This
must be kept in mind during the commissioning.
3. If a high precision Anti-sway function is required, set the LSP to 0 Hz to prevent LSP from
interfering with the Anti-sway profile.
4. Configure the behavior of the brake. The brake logic of the drive can interfere with Anti-sway
movements when the speed profile reaches the brake engage frequency before the end of the
movement. This can happen during short movements or when the acceleration of the crane
movement is higher than the acceleration of the pendulum (the cable is long and acceleration
time of trolley/bridge is short).
In this case disable the brake logic and let the Anti-sway FB control the brake directly using the
q_xBrakCtrl output.
WARNING
UNINTENDED EQUIPMENT OPERATION
Do not use parameter Brake engage delay (TBE) inside the Brake logic control menu of the
Altivar drive.
Failure to follow these instructions can result in death, serious injury, or equipment damage.
Setting of the Brake engage delay to value higher than 0 may cause the drive to lock up in DCB
state during reversing of direction of movement. If you need to delay closing of the brake, use
q_xBrakCtrl instead.
5. If there is a risk of the load moving when the trolley/bridge is at or close to zero speed, use DC
braking to hold the motor in position.
6. Calculate or measure linear speed of movement for each axis. Make sure that you receive a
correct value of cable length as explained for the i_rCbleLenActl description (a laser range
finder is a very useful tool when commissioning the Anti-sway FB). A correct value of load length
and linear speed are essential for the precision of the Anti-sway function especially when
moving at high speeds and accelerating/decelerating on steep ramps.
3. i_stPAS.wAswRampLim. Defines the steepest ramp the Anti-sway function is allowed to use
in order to correct the sway. Low values for this parameter makes the correction more
aggressive and allows shortening of the acceleration and deceleration phase, which improves
the load handling for the operator (it is easier to estimate a 2 m stop distance than a 4 m and
therefore it is possible to arrive at the target position more precisely). The disadvantage is that
the stress on the crane structure increases. It is essential to find the right compromise during
commissioning.
q_wStat. Bit 6 gives information on whether an additional stop distance optimization is possible
with the current combination of i_stPAS.wAswRampLim and i_rCbleLenActl. If it is not
possible, the i_stPAS.wAswRampLim value can be lowered in order to allow for the
optimization.
The stop distance optimization is beneficial mainly with longer cable lengths close to or over
10 m. For shorter cable lengths the effect is not that significant and the stopping distances are
acceptable without optimization.
4. i_stPAS.wDrvDecEmgy. The value of this parameter must be small enough to stop the crane
safely when a stop limit switch is reached or a contact signal from a brake is lost. (Default value:
5)
The following figures show an optimized (red) and non-optimized (blue, rounder form) Anti-sway
speed profile for a crane with 8 m cable length moving at 1 m/s with various acceleration and
deceleration ramps:
6. i_stPAS.rAswSpdStrt. Defines the speed threshold at which Anti-sway starts to correct the
sway (% of maximum speed). Micro movements are often a concern when commissioning an
Anti-sway function. The majority of operators request Anti-sway to be disabled during short
movements. If this is the case, set the i_stPAS.rAswSpdStrt threshold above the micro/jog
speed.
8. i_stPAS.rAswSpdEnd. Defines the speed threshold to stop the Anti-sway correction at the
end of a movement (% of maximum speed). Setting this value too high stops the movement
earlier but decreases the performance. Setting it too low increases the stopping time. (Default
value: 1)
9. i_stPAS.wAswTimeEnd. Defines how long must be the speed output reference below
i_stPAS.rAswSpdEnd to consider the movement finished.
10.Be aware that an Anti-sway speed profile is generally longer (in both time and distance) than a
linear acceleration speed profile. Therefore you must have in place limit switches on the crane
adjusted to allow safe stopping/slowdown with all possible speeds and cable lengths.
11.As a safeguard, the application should check the difference between speed reference and
actual speed and stop the movement if the difference is too great. This is not implemented in
the FB since it is application dependent.
Section 6.7
Troubleshooting
Troubleshooting
Troubleshooting
Troubleshooting
Part V
Diagnostic Coverage
Diagnostic Coverage
Chapter 7
DiagnosticCoverage: Increase Diagnostic Coverage of Used Control System
Section 7.1
Functional Overview
Functional Overview
Functional Overview
WARNING
UNINTENDED EQUIPMENT OPERATION
Validate all function block input values before and while the function block is enabled.
Failure to follow these instructions can result in death, serious injury, or equipment damage.
Functional View
Section 7.2
Architecture
Architecture
Architecture
System Requirements
For any details of the system requirements, refer to the chapter System Requirements
(see page 25).
Data Flow
Internal structure of the DiagnosticCoverage FB
Section 7.3
Function Block Description
Pin Diagram
Section 7.4
Pin Description
Pin Description
i_xEn
When TRUE, enables the FB. When FALSE, the FB enters a fallback state:
q_xEn FALSE
q_xAppOK FALSE
q_xCrossCheckPuls FALSE
q_wStat 0
I_wExeCntCfg
This input contains a value corresponding to the number of execution of all programs and sub-
programs in the main cyclic task. The FB monitors the number of executions on the pin
iq_wExeCntActl. If the number of executions (increments of the value connected to
iq_wExeCntActl) is not equal to i_wExeCntCfg, the q_xAppOk output is set to FALSE.
i_dwAppliSignature1...4
These inputs are used for testing of application signature. Each application has a unique
application signature consisting of four 32 bit DWORD values. Connect retained DWORD
variables to these inputs and after downloading the application, write values found in
PLC_R.i_dwAppliSignature1..4 to these retained variables.
NOTE: Do not write hard-coded values to the application; each change of the application changes
also its signature.
i_bFirmVers0...3
These inputs are used for checking of controller firmware version. The firmware version consists
of 4 byte values. The actual firmware version can be found in the PLC_R structure in an array of
BYTE.PLC_R.i_bFirmVers[0..3].
Location of controller firmware version information
i_wTaskJittLim
This input contains the maximum allowed value of execution time jitter. If the cyclic task execution
time exceeds the sum of i_wTaskTime and i_wTaskJittLim, q_xAppOk output is set to
FALSE. The protection only checks if the actual execution period is longer than configured, it will
not react if the actual cycle time is shorter than configured.
i_xCrossChkEn
TRUE on this input enables cross checking function for mutual checking of 2 controllers. The FB
generates a pulse train with 400 ms period and 50% duty cycle at q_xCrossChkPuls and expects
a pulse train on the input i_xCrossChkPuls. The output of the FB should be connected to a
physical (solid state) output of the controller and the input of the FB to an input of the controller.
Two controllers running an instance of the FB with mutually connected inputs and outputs are
necessary for cross checking.
i_xCrossChkPuls
Input for the pulse train coming from a second controller. The function is enabled when
i_xCrossChkEn is TRUE and gets activated after the first rising edge on this input. Activation of
the function on the first rising edge prevents false alarms when one of the controllers involved in
cross checking is switched on with a delay.
Before activation is the q_xAppOk FALSE. Once activated the q_xAppOk becomes TRUE and
reverts to FALSE state only after 500 ms without incoming pulses.
i_xTest
TRUE on this input bypasses checking of application signature, firmware version information,
execution count, cycle time test and mutual cross checking of 2 controllers. Boolean operation test
and floating point operation test remain active. It allows for a simple way of keeping the q_xAppOk
TRUE during commissioning period.
The input keeps its effect for 5 hours, if it stays TRUE for more than 5 hours, it is ignored.
q_wStat
This output contains the status of the FB.
Section 7.5
Quick Reference Guide
Commissioning Procedure
Then do the same on the other controller and connect them both input to output.
8. If variable speed drives are not used, then interlock (logical AND) the output q_xAppOk with free
wheel or Quick stop inputs of device functions of variable speed drives or direction commands.
9. Download the application, read the application signature from PLC_R structure and write the
values of 4 DWORD variables to the retained variables in your application.
10.Power-cycle the controller or use the i_xRst input.
11.The q_xAppOk output should be TRUE at this point. If it is not, than verify the q_wStat output
to find out why it is not TRUE.
12.During commissioning you can set the input i_xTest to TRUE to bypass checking of
application signature, firmware version information, execution count, cycle time test and mutual
cross checking of 2 controllers. TRUE on this input will suppress the checking for 5 hours.
Troubleshooting
Troubleshooting
Part VI
Electronic Potentiometer
Electronic Potentiometer
Chapter 8
ElectronicPotentiometer: Set Speed and Direction of a Movement
Section 8.1
Functional Overview
Functional Overview
Functional Overview
Functional Description
The ElectronicPotentiometer FB offers an effective approach to setting an arbitrary analog
speed reference and direction of movement of a variable speed drive using 3 or 4 digital inputs.
Functional View
Section 8.2
Architecture
Architecture
Hardware Architecture
Software Architecture
Section 8.3
Function Block Description
Pin Diagram
Profile Generation
The FB generates an output speed profile based on configuration parameters and control inputs.
Direction command in either forward i_xDrvFwd or reverse i_xDrvRev direction causes the
output speed reference to ramp to low speed i_wDrvSpdLsp. Low speed can equal zero for
drives running in full vector control. If the drive is not running in a full vector control, the value of
i_wDrvSpdLsp should be set to the same value as the LSP parameter inside the drive.
There are 2 modes of operation supported by the FB:
three-wire control (uses 3 inputs i_xDrvFwd, i_xDrvRev and i_xDrvAcc)
four-wire control (uses the 3 inputs plus i_xDrvSpdMntn in addition)
Both modes
There are 2 speed output reference outputs.
The unsigned q_wDrvSpdRef is positive for both directions.
The signed q_iDrvSpdRef is positive in forward and negative in reverse direction.
NOTE: Use the unsigned q_wDrvSpdRef output when working with Altivar71_Control,
Altivar32_Control and Altivar31_Control device FBs.
Section 8.4
Pin Description
Pin Description
i_xDrvFwd
When the output q_wDrvSpdRef is zero and i_xDrvFwd is set TRUE, the q_wDrvSpdRef ramps
up to the value of i_wDrvSpdLsp.
When the speed reference in forward direction is higher than i_wDrvSpdLsp, i_xDrvFwd is
TRUE and i_xDrvAcc is FALSE, q_wDrvSpdRef is held.
When i_xDrvFwd is FALSE, q_wDrvSpdRef decreases towards zero using deceleration ramp
defined by i_wDrvDec.
See the timing diagram for three-wire mode (see page 284) and for four-wire mode (see page 285)
for a visual depiction of the function.
i_xDrvRev
When the output q_wDrvSpdRef is zero and i_xDrvRev is set TRUE, the q_wDrvSpdRef ramps
up to the value of i_wDrvSpdLsp.
When the absolute value of speed reference in the reverse direction is higher than
i_wDrvSpdLsp, i_xDrvRev is TRUE and i_xDrvAcc is FALSE, q_wDrvSpdRef is held.
When i_xDrvRev is FALSE, q_wDrvSpdRef decreases towards zero using deceleration ramp
defined by i_wDrvDec.
See the timing diagram for three-wire mode (see page 284) and for four-wire mode (see page 285)
for a visual depiction of the function.
i_xDrvSpdMntn
Command to maintain the actual speed reference. This input is used in four-wire mode. In three-
wire mode it does not have any effect.
If this input is TRUE together with i_xDrvAcc and a direction command, the FB is ramping up the
speed reference in requested direction.
If this input is TRUE but i_xDrvAcc is FALSE and direction command in actual direction of
movement is present, the FB keeps the speed reference.
If this input is FALSE and direction command in actual direction of movement is present, the FB
ramps the speed reference towards i_wDrvSpdLsp.
i_xDrvSlow
If this input is TRUE, the FB forces a slow speed reference defined by i_wDrvSpdRefSlow.
If the current value of q_wDrvSpdRef is higher than that, the output speed reference gets ramped
down using a deceleration ramp defined by i_wDrvDec.
This input can be used with a slow-down signal from a limit switch.
i_wDrvAcc
This input sets the acceleration ramp time between zero and nominal motor speed defined by
i_wDrvSpdNom. The resolution of this parameter is 0.1 s. The acceleration ramp time should be
equal to or longer than the ramp configured in the Altivar variable speed drive.
i_wDrvDec
This input sets the deceleration ramp time between nominal motor speed defined by
i_wDrvSpdNom and zero. The resolution of this parameter is 0.1 s. The deceleration ramp time
should be equal to or longer than the ramp configured in the Altivar variable speed drive.
q_xDrvFwd / q_xDrvRev
Usage of this output is optional. It is not necessary if a command to the drive is handled by other
FB (HoistPositionSync, AntiCrab) or if the deceleration time parameter set in the drive is
higher or equal to i_wDrvDec.
Notifications
Identification of the alarm, if q_xAlrm is TRUE.
Section 8.5
Quick Reference Guide
Commissioning Procedure
2. Connect the direction and acceleration commands (and speed maintain command in four-wire
connection).
3. Connect the i_xDrvSlow input to a signal from a limit switch. It is possible to leave this input
unconnected if a slow-down limit switch is not used in the system.
4. Nominal speed value given to the FB should match the nominal speed of the drive
(compensated for slip if slip compensation is used)
For example, 1500 RPM for 2 pole pair motor, 3000 RPM for 1 pole pair motor.
7. There are 2 speed reference outputs on the function block. q_wDrvSpdRef is an unsigned
output which should be used with Altivar71_Control or Altivar31_Control device
function blocks and q_iDrvSpdRef that can be used wherever a signed speed reference value
is needed.
Troubleshooting
Troubleshooting
Part VII
Grab Control
Grab Control
Chapter 9
GrabControl: Control of a Four Cable Grab
Section 9.1
Functional Overview
Functional Overview
Functional Overview
WARNING
UNINTENDED EQUIPMENT OPERATION
Validate all function block input values before and while the function block is enabled.
Failure to follow these instructions can result in death, serious injury, or equipment damage.
Functional View
Section 9.2
Architecture
Architecture
Architecture
System Requirements
GrabControl requires two Altivar 71 variable speed drives. One of the drives controlling hold axis
and the other one controlling the close axis.
Both hold and close axes must be equipped with encoders and both Altivar 71 drives must be
configured to run in flux vector control motor control mode. The FB works with incremental
encoders. The positions of both axes are stored in non-volatile memory.
The hold and close axes must have identical linear speeds and encoder resolutions.
Vertical movement must be limited in upwards direction by an emergency limit switch.
Environment
The following equipment are required to use GrabControl function block:
SoMachine controller
Two Altivar 71 variable speed drives
Two encoder interface cards for Altivar 71
Two incremental encoders, typically 1024 PPR (Pulses Per Revolution)
CANopen cabling
The following equipment is typically used in conjunction with GrabControl function block:
A two-axis joystick for control of close and hold axes.
NOTE: The function block supports analog and digital joysticks.
Three buttons for resetting the calibration values and setting calibration of open and closed grab
positions (can be done via HMI).
Additional button(s) on the joystick for extended functions like scraping and rapid opening.
Two buttons, selector or potentiometer for direct modification of hold torque during closing on
stack. These buttons are useful when materials of various densities are transported.
Optional strain gauge weighing system for enabling automatic closing on stack only when the
grab is on the stack.
The hold motor is working in a torque limited mode during automatic closing on stack. If activation
of the automatic closing on stack function must be suppressed while the grab is mid-air, the user
application must take into account the enabling and disabling of the automatic closing on stack
function. The situation often results in a detected over speed fault reported by the Altivar 71 drive.
NOTICE
GRAB MECHANISM DAMAGE
Only use the automatic closing on stack function when the grab mechanism is in contact with the
material to be moved.
Failure to follow these instructions can result in equipment damage.
Section 9.3
Function Block Description
Pin Diagram
The pin diagram of function block GrabControl:
Targeted Cranes
The function block is suitable for control of four cable grabs. It supports both clamshell and spider
grabs and can be used on bridge cranes, gantry cranes, luffing jib cranes and floating grab cranes.
Control Interface
The function block is designed for use with a two-axis joystick. It requires one additional button on
the joystick for optional functions of rapid opening and/or scraping.
Top-down view of a two-axis joystick :
Alternative control interface may be used as long as the FB receives control commands in the
supported form.
During closing, the close axis moves in forward direction closing the grab. The hold axis must
provide enough torque to keep hold cables straight. It must also allow the grab to sink in the
transported material in order to fill it properly. The amount of sinking can be influenced by
configuration parameters.
The hold drive torque is limited during automatic closing on stack which can lead to hold drive
losing the load.
The hold motor is working in a torque limited mode during automatic closing on stack. If activation
of the automatic closing on stack function must be suppressed while the grab is mid-air, the user
application must take into account the enabling and disabling of the automatic closing on stack
function. The situation often results in a detected over speed fault reported by the Altivar 71 drive.
NOTICE
GRAB MECHANISM DAMAGE
Only use the automatic closing on stack function when the grab mechanism is in contact with the
material to be moved.
Failure to follow these instructions can result in equipment damage.
Scraping
Scraping is a special case of closing on stack usable with clamshell grabs. Its purpose is to gather
remaining material from a flat surface. The grab closes while the jaws stay in contact with the
surface.
When the grab is fully closed, the function starts upwards movement of the grab.
The command to activate scraping is as follows:
The function is optional and does not need to be configured and used if it is not needed.
An additional modifier button, preferably on the joystick, is needed. The same button may be also
used for rapid opening function.
Rapid Opening
This function allows fast opening of the grab in order to release the load as quickly as possible. It
is typically used when the grab is emptied while it is in a swing. The feature is usually used on
pontoon cranes with a luffing jib.
The following figure is the command to activate rapid opening:
The function is optional and does not need to be configured and used if it is not needed.
An additional modifier button, preferably on the joystick, is needed. The same button can also be
used for scraping function.
Hook Mode
Hook mode is an alternative to grab function. While in hook mode, the FB synchronizes the hold
and close axes either based on actual relative positions of both axes or modifies speeds of both
axes in order to share the load. The FB can be configured to do one or the other.
NOTE: Only the raise and lower commands are available in hook mode. Commands to close or
open the grab are ignored.
Maintenance Mode
Use maintenance mode during changing of the cables and other maintenance tasks. Disabling the
FB to activate the maintanence mode. In this mode the FB just channels the direction commands,
speed references and ramp values through without changing them. Open and closed software limit
switch positions are not active.
Section 9.4
Pin Description
Pin Description
i_xEn
When TRUE, enables the function block. When FALSE, the FB enters a fallback state. In fallback
state, the function block uses the configuration parameters, target speeds, ramps and direction
commands to provide output for both drives. Torque limitation of hold drive is set to 300% (is
disabled). Internal position calculation of both axes stays active.
Transition between disabled and enabled state of the FB and vice versa while the crane is running
is not restricted but is not recommended.
Disabling the FB can be used as a switch to maintenance mode for changing of cables.
i_xDrvFwdHold
Command for forward (upwards) movement of the hold axis. When there is no command for
movement of close axis present at the same time, the forward command for the hold axis is used
to move both, hold and close axes synchronously.
i_xDrvRevHold
Command for reverse (downwards) movement of the hold axis. When there is no command for
movement of close axis present at the same time, the reverse command for the hold axis is used
to move both, hold and close axes synchronously.
i_xDrvRdyStatHold, i_xDrvRdyStatClose
Inputs of ready status of both hold and close drives. The information can be obtained from bit 1 of
status word of Altivar drives. This information has to be interlocked (logical AND) with an
information that the drive is communicating on CANopen and is in operational state.
The following figure shows an example of CANopen status check for node3:
If the communication with any of the two drives is interrupted, the FB has to get the information in
order to stop the movement.
Failing to interlock the CANopen communication status with the ready status of the drive may result
in a dangerous situation when one of the motors stops because of communication interruption
between the controller and drive. When the FB does not receive information about the loss of
communication, the other motor stays in motion.
WARNING
UNINTENDED EQUIPMENT OPERATION
Interlock the CANopen communication status with the ready status of the drive.
Failure to follow these instructions can result in death, serious injury, or equipment damage.
The FB needs to have information about status of both drives. If one of the drives is not ready, the
FB does not authorize start of the movement. If one of the ready bits turns FALSE during
movement, both motors are stopped.
i_wDrvSpdRefHold, i_wDrvSpdRefClose
Speed reference for hold and close drives. [rpm]
i_iDrvSpdActlHold, i_iDrvSpdActlClose
Actual speed of hold and close motors read from the drives. [rpm]
i_iDrvTrqActlHold, i_iDrvTrqActlClose
Actual torque of hold and close motors read from the drives.
Use the Motor torque scope object (SOTR). CANopen index 2002:1B.
The value must be either scaled in the user application to the range -3000...3000 corresponding to
-300...300% of nominal motor torque or internally in the GrabControl FB.
To scale the value in your application, divide it by 4.096 and convert it to integer.
To let it scale automatically within the GrabControl FB, connect the un-scaled values and set
the i_stPGC.xTrqScopeScale parameter to TRUE.
The values are automatically filtered by a low-pass filter inside the function block. The filtered
values are available at the outputs q_iTrqFltrHold and q_iTrqFltrClose.
i_wEncPosHold, i_wEncPosClose
Encoder positions of hold and close axes. The FB is designed to work with position information
read out of Altivar 71 drives running in closed loop. Use the Encoder position object (PUC) in the
Altivar 71, CANopen index 201 A:0C.
Encoder value must increase when motor is moving in positive direction.
i_xGrabCalbOpen
Rising edge on this input calibrates position difference corresponding to open state of the grab.
You must perform calibration for the soft limit switch function to work. You can perform a new
calibration without re-setting the previously calibrated value. If desired position cannot be reached
because of previous calibration, you can reset the calibration values by rising edge on input
i_xGrabCalbRst.
i_xGrabCalbClosed
Rising edge on this input calibrates position difference corresponding to closed state of the grab.
Perform calibration for the soft limit switch function to work. You can perform a new calibration
without re-setting the previously calibrated value. If desired position cannot be reached because
of previous calibration, you can reset the calibration values by rising edge on input
i_xGrabCalbRst.
i_xGrabCalbRst
Rising edge on this input resets calibration values for open and closed grab positions.
i_xClsOnStackEn
TRUE on this input enables automatic closing on stack. Activate this function by applying
commands to close and raise the grab simultaneously. When the input is FALSE, automatic closing
on stack is disabled and the commands to close and raise are acting on their respective axes.
The input must be TRUE to start the automatic closing on stack. It does not need to stay TRUE for
the whole duration of closing.
You can set this input continuously to TRUE. Automatic closing on the stack is only to be used
while the grab is on the material.
A load cell detecting that the grab is on the ground may be used to enable automatic closing on
stack.
The hold motor is working in a torque limited mode during automatic closing on stack. If activation
of the automatic closing on stack function must be suppressed while the grab is mid-air, the user
application must take into account the enabling and disabling of the automatic closing on stack
function. The situation often results in a detected over speed fault reported by the Altivar 71 drive.
NOTICE
GRAB MECHANISM DAMAGE
Only use the automatic closing on stack function when the grab mechanism is in contact with the
material to be moved.
Failure to follow these instructions can result in equipment damage.
i_xTrqShareEn
TRUE on this input enables sharing of the load between hold and close axes when the grab is
closed. When it is FALSE, the axes are position synchronized.
Use torque sharing and switch to position synchronization only when the torque values are too low
or unstable for load sharing.
You can configure a torque offset in order to have more torque on the close motor to keep the filled
grab closed. See parameter i_stPGC.wTrqAddOnClose.
NOTE: Switching between load sharing and position synchronization while the axes are moving is
possible when the position with balanced load is similar to the target position of position
synchronization.
Example: In hook mode,when the hook is empty and the torque of one or both axes is too low for
effective load sharing, set i_xTrqShareEn to FALSE. And set it to TRUE once the torque
increases.
In grab mode, you should set i_xTrqShareEn to TRUE.
i_xScrapEn
TRUE on this input enables the scraping function. Scraping is active only during automatic closing
on stack. Ideally it is directly controlled by a modifier button on the joystick. It can share the button
with the function of rapid opening. When the button gets released during scraping, the FB
automatically changes to standard closing on stack.
i_xHookModeEn
TRUE on this input enables the hook mode. Commands to close drive are ignored in the hook
mode. The axes operate either in load sharing or position synchronization mode, based on the
state of i_xTrqShareEn input.
NOTE: Switching between hook mode and standard grab operation while the axes are running is
possible but not recommended.
i_xRapidOpenEn
The function is active when commands to raise and open and the i_xRapidOpenEn are active at
the same time. It enables a fast opening of the grab by moving hold and close axes in opposite
directions.
i_xRst
Resets alarms on rising edge, if the cause of the alarm is no longer present.
i_stPGC
The following table describes the parameter structure of the data type i_stPGC
wDrvAcc
Acceleration ramp used for hold and close axes. The value is used by the FB in position synchroni-
zation and load sharing as a base for output acceleration values q_wDrvAccHold and
q_wDrvAccClose.
wDrvDec
Deceleration ramp used for hold and close axes. The value is used by the FB in position synchroni-
zation and load sharing as a base for output deceleration values q_wDrvDecHold and
q_wDrvDecClose.
wDrvSpdHsp
High speed value used for hold and close axes. Defines the maximum speed reference that the FB
is allowed to use for both axes.
wEncPulsPerRevo
Number of encoder pulses per motor revolution. Must be identical for both axes.
wDrvSpdNom
Nominal (synchronous, without slip) speed of the motor. Must be identical for both axes.
50 Hz:
1pole pair: 3000 RPM
2pole pairs: 1500 RPM
3pole pairs: 1000 RPM
4pole pairs: 750 RPM
60 Hz:
1pole pair: 3600 RPM
2pole pairs: 1800 RPM
3pole pairs: 1200 RPM
4pole pairs: 900 RPM
rKpPosSync
Proportional gain of position controller used during position synchronization. It defines the
difference of speed references of hold and close axes based on their actual position deviation. The
default value is 0.01. It is internally normalized by encoder pulses per motor revolution
i_stPGC.wEncPulsPerRevo and does not need to be changed when encoder type changes.
Decrease the value if motor speeds or torques are oscillating during position synchronization.
Increase the value if the correction is not sufficient to reduce the position deviation to an acceptable
value.
rKpTrqShr
Proportional gain of torque controller used during load sharing. It defines the difference of speed
references of hold and close axes based on the actual difference of torques of both motors. Default
value is 0.1. Decrease the value if motor speeds or torques are oscillating during load sharing.
Increase the value if the correction is not sufficient to keep the motor torques at similar values.
wTrqAddOnClose
A torque offset for close axis. The FB allows for a torque difference between close and hold axes
during load sharing when the grab is closed. This difference with higher torque on the close axis
helps to keep the filled grab closed and prevent spillage of material. The default value is 50 [0.1%].
This parameter does not have any influence in hook mode.
wLowTrqDecRamp
An alternative short deceleration ramp used in downwards direction when a grab is on the ground.
The ramp reduces the rope slack. It is used when the difference of torques of hold and close is
below i_stPGC.wLowTrqDecRampThsh.
wLowTrqDecRampThsh
Torque threshold for switching between normal and alternative short deceleration ramp. [0.1%].
The function block switches the deceleration ramp to a short ramp defined in
i_stPGC.wLowTrqDecRamp when the difference between hold and close motor torques gets
below the value defined by i_stPGC.wLowTrqDecRampThsh. You can disable the function by
setting i_stPGC.wLowTrqDecRampThsh to zero. The function is active when hold and close
are moving synchronously. It is not active when the grab is opening or closing during downwards
movement.
wClsHoldTrqLim
Torque limitation of hold motor during closing on stack. The value must be high enough to keep
hold cables straight, but low enough to allow sinking of the grab into material during closing on
stack. The usual value is between 10 and 15% of nominal torque. Default value: 100 [0.1%]
wClsHoldSpdRef
Speed reference for hold drive during closing on stack. The speed reference should be
approximately 10% of nominal motor speed.
wClsTrqCloseThsh
Torque threshold of close motor for considering the grab closed. The threshold is an alternative to
detecting closed state of the grab by relative position of hold and close axes. It is used when a full
grab does not close completely because of bulky material. Typical example is a cactus (spider)
grab used in scrap metal or waste handling. The right value of torque must be found during
commissioning, ideally using a trace in SoMachine. [0.1%]
wClsTrqCloseTimeFltr
Time filter used for detection of closed state of the grab based on torque. It defines for how long
must the torque of close motor stay above i_stPGC.wClsTrqCloseThsh to consider the grab
closed. [ms]
wClsClosedPosOfst
Offset of closed position for closing on stack. This parameter allows exceeding the closed position
during closing on stack. When controlling clamshell grabs, it is usually required to exceed the
closed position during closing on stack to prevent spillage of material during lifting. Start with a zero
value and increase it if the grab spills during lifting. Spider (orange peel) grabs do not close fully
when they are filled with material and therefore it is not necessary to use this parameter. Set this
value to zero when controlling a spider grab.
wScrapHoldTrqLim
Torque limitation of hold motor during scraping. The value is slightly higher than
i_stPGC.wClsHoldTrqLim. The torque must be low enough for the jaws to stay in contact with
the surface, but high enough to prevent the grab from scraping too hard. [0.1%]
wBrakTimeDelay
Estimation of the time brakes of hold and close axes need to open. This parameter is used to
prevent one of the axes moving while the other one is opening its brake. [ms]
xTrqScopeScale
When TRUE, the values of actual torque are divided by 4.096 internally by the FB for scaling of the
Motor torque scope object (SOTR). CANopen index 2002:1B to the standard -3000 to 3000 range
with 0.1% resolution. If it is FALSE, input torque values must be scaled to this range outside of the
FB.
q_xEn
Enable status of the FB.
q_diEncPosDiff
Encoder position difference between hold and close axes.
q_diEncPosDev
Deviation of actual position difference between hold and close axes from the target position
difference. This value is written only during synchronized movement and load sharing.
When position synchronization is active this value should be close to zero if the proportional
position controller is configured correctly.
During torque sharing it shows the difference between closed position and the position
corresponding to actual torque difference.
q_xDrvFwdHold, q_xDrvRevHold
Forward and reverse command for hold drive.
q_wDrvSpdTargHold
Target speed for hold drive.
q_wDrvAccHold, q_wDrvDecHold
Acceleration and deceleration ramps for hold drive.
q_wDrvTrqLimHold
Torque limitation for hold drive. Torque limitation is used during closing on stack. Torque limitation
must be enabled in configuration of the hold drive. [0.1%]
q_xDrvFwdClose, q_xDrvRevClose
Forward and reverse command for close drive.
q_wDrvSpdTargClose
Target speed for close drive.
q_wDrvAccClose, q_wDrvDecClose
Acceleration and deceleration ramps for close drive.
q_xGrabOpen
TRUE when the grab is fully open. The open position must be calibrated in order for open position
detection to work.
q_xGrabClosed
TRUE when the grab is fully closed or if it is considered closed based on torque of the close motor
during closing on stack. The closed position must be calibrated in order for closed position
detection to work.
q_wGrabPos
Actual position of the grab. The range of this output is 0 to 100%. 0% corresponds to a fully closed
and 100% to a fully open grab. Both closed and open positions must be calibrated for this output
to work.
q_iTrqFltrHold, q_iTrqFltrClose
Actual torque scope values of hold and close drives filtered by the FB. These values can be used
for tracing during commissioning.
q_wStat
Status word of the FB:
q_xAlrm
In case of an alarm the FB removes run commands from both drives and does not allow any further
movement until the cause of the alarm has been cleared.
q_dwAlrmId
This output identifies the detected alarm.
Section 9.5
Quick Reference Guide
Commissioning Procedure
Step Action
1 Set hold and close drives to factory settings.
2 Configure correct motor control parameters.
3 Configure brake logic control.
4 Perform motor tuning and encoder test.
5 Set the motor control mode to FVC.
6 In drive menu application functions disable preset speeds. Set command and reference channel
to CANopen.
7 Configure CANopen addresses and bus speed, drive power cycle is needed after change of
CANopen configuration.
8 In settings menu set the K speed loop filter to 100. This parameter influences how accurately
the actual speed follows the target speed. The higher the value the more accurately Altivar 71
responds to changing target speed. If motor speeds or torque tend to oscillate, it is possible to
lower the value at a cost of lowering precision of virtual limit switch function during opening and
closing.
9 Enable torque limitation on the hold drive and set it to 0.1% resolution. The hold drive is torque
limited during closing on stack.
10 Disable detection of load slipping in encoder fault configuration in fault management. If load
slipping fault detection is enabled during closing on stack, hold drive reports a load slipping fault.
Step Action
1 Without moving the motors verify that all commands and target speeds are being received
correctly from the operator interface.
2 Add two Altivars 71 to CANopen configuration.
Configure the PDOs:
Receive PDOs
Both drives: Command word, Target speed, Acceleration, Deceleration
Hold drive only: Motor torque limitation, Generator torque limitation
Transmit PDOs
Both drives: Status word, Actual speed (Control effort), Encoder position value (PUC), Torque
scope value, Motor current
3 Instantiate the GrabControl FB in your program and parameterize it with initial parameters.
Step Action
4 If the torque scope values of both motors are connected to the FB directly, set the
i_stPGC.xTrqScopeScale parameter to TRUE. Otherwise the torque values need to be
scaled in the application by dividing it by 4.096 and the i_stPGC.xTrqScopeScale parameter
must be set to FALSE.
5 Instantiate it in a program executed in a cyclic task. Preferably in the Master task. The same task
should be a parent task for CANopen communication. Master task is the parent task by default.
6 Configure the execution period of the corresponding task to a value in the range between 20 and
50 ms.
7 Download the application, put it to run and verify status of CANopen communication.
8 Calibrate open and closed positions of the grab. Following two steps describing calibration of
closed and open positions may be performed in an arbitrary order. Incorrect calibration may be
reset by rising edge on i_xGrabCalbRst input.
9 Close the grab fully and calibrate the closed position by rising edge on i_xGrabCalbClosed.
NOTE: When the grab is in good mechanical condition (no space between jaws when it softly
closes), calibrate it in a state when the jaws are closed, but both hold and close cables are still
fully tensioned.
When the mechanics of the grab is not aligned perfectly, you may want to calibrate it in a little
overclosed position (more load on close cables).
10 Open the grab fully and calibrate the open position by rising edge on i_xGrabCalbOpen.
11 Close the grab at slow speed and verify that it stops automatically when it reaches closed state.
If it functions correctly, repeat this step at nominal speed. The grab should close softly without
an impact of the jaws and jerk of the crane. If the grab was calibrated in a slightly over-closed
position as described earlier, certain impact when the grab closes is acceptable and even
desirable.
12 Repeat the test for open position. The grab must open softly. Both, hold and close cables should
be straight without slack in open position.
13 Set the proportional gain for position synchronization i_stPGC.rKpPosSync. The default gain
is 0.01 and the FB internally compensates for resolution of the encoder. Therefore it is not
necessary to change the value when encoder with different resolution is used.
14 Test the behavior of position synchronization. Set the i_xTrqShareEn input to FALSE or move
the grab to a non-closed position to activate position synchronization q_wStat.5 = TRUE.
Move the grab up and down by giving command to the hold drive without giving command to the
close drive. Take a trace of actual torque, speeds of both motors and the position deviation
output q_diEncPosDev.
When the position deviation is higher than required and if the motor speeds and torques do not
oscillate, increase the value of i_stPGC.rKpPosSync. If motor speeds and torques are
oscillating, decrease the value of i_stPGC.rKpPosSync.
15 Set the proportional gain for load sharing i_stPGC.rKpTrqShr. The default gain is 0.1.
Step Action
16 Test the behavior in load sharing. Close the grab and set the i_xTrqShareEn input to TRUE to
activate load sharing q_wStat.6 = TRUE. Set the i_stPGC.wTrqAddOnClose parameter to
0. Move the grab up and down by giving command to the hold drive without giving command to
the close drive. Take a trace of actual torque of both motors. Both torques should converge to
the same value. When the torques do not converge fast enough, increase the value of
i_stPGC.rKpTrqShr. If the torques are oscillating around a common average value, decrease
the value of i_stPGC.rKpTrqShr.
17 Set a value of i_stPGC.wTrqAddOnClose to a value of ~50 (5%) if it is required to keep higher
torque on the close motor in order to keep the grab closed. The value may be modified later
during tests with filled grab. Take a trace to test that the torque of close motor is higher than the
torque of the hold motor by defined value and that the motor torques are stable.
18 Configure a trace object in SoMachine containing actual speed, speed reference and actual
torque of both motors and commands from the joystick. Add also bits from status word.
(1,2,5,6,7) The trace is very useful during commissioning and for troubleshooting.
19 Configure the closing on stack function.
Set the value of i_stPGC.wClsHoldTrqLim to ~100 (10%). The FB will limit torque of the hold
drive to this value during closing on stack. The value must be high enough to keep the hold
cables straight and support the grab in upright position, but must be low enough to allow sinking
of the grab to the material during closing.
Set the i_stPGC.wClsHoldSpdRef to ~10% of the nominal speed of the motor. The speed
may be increased if slack of the hold cables is not compensated for fast enough and decreased
if straightening of hold cables lifts the closing grab.
Configure the wClsClosedPosOfst parameter to 0, it may be increased later to help keeping
the filled grab closed during vertical movement.
Test the automatic closing on stack by laying an open grab on the stack and giving and keeping
the command to activate closing on stack. Speed of the close motor can be modified during
closing on stack. Speed of the hold motor is given by i_stPGC.wClsHoldSpdRef and
i_stPGC.wClsHoldTrqLim.
The grab must close fully and when the command is still being held it must softly lift the closed
grab up.
Step Action
20 Following figure depicts speeds and torques of both drives and describes phases of the
procedure:
Phase 1
Close axis accelerates in forward direction, closing the grab
Hold axis has also a positive speed reference, but is torque limited, which prevents it from
lifting the whole grab. Therefore it only straightens the slack cables and then stops.
Phase 2
Close axis continues to close the grab.
Hold axis is pulled down by the weight of the grab because of its torque limitation. This allows
for a proper filling of the grab. The amount of sinking of the grab is influenced by the
parameter i_stPGC.wClsHoldTrqLim.
Phase 3
The grab is approaching the closed position. Close axis decelerates and the torque limitation
of hold axis is gradually lifted. The hold axis accelerates and reaches the same speed as the
close axis in the moment when the grab is fully closed
Phase 4
Both axes move in load sharing or position synchronization depending on setting of the
parameter i_xTrqShareEn. The torques are equalizing and lifting of the filled grab
continues
21 If the grab is spilling when its lifted from the stack, increase the value of
i_stPGC.wClsClosedPosOfst by 2 and repeat the closing on stack. Increase the value some
more if necessary. The parameter causes a slight over-closing of the grab and helps to contain
the material in a grab with less than optimal mechanical precision. When controlling a spider
grab, leave this value at 0.
When you are controlling a spider grab or any grabbing application where a grab might not close
fully because of objects between the jaws, configure the i_stPGC.wClsTrqCloseThsh and
i_stPGC.wClsTrqCloseTimeFltr parameters. Trace the torque value of close motor during
opening and select an appropriate torque level for considering the grab closed. Configure a filter
time to filter out torque peaks.
Step Action
22 Move the closed and filled grab upwards and downwards and trace actual torques of both
motors. The torques should stabilize and the close torque should be higher than the hold torque
by the value specified in i_stPGC.wTrqAddOnClose. If the torques do not converge fast
enough, increase the value of i_stPGC.rKpTrqShr, if they oscillate, decrease it. If the grab
spills its content, increase the value of i_stPGC.wTrqAddOnClose.
23 Configure quick deceleration ramp. It helps reducing rope slack by allowing fast stop ramp in
downwards direction when the grab is laid on the stack. Measure the torque of hold drive during
downwards movement with open grab and the difference it makes when grab lands on the
ground/stack and the movement continues with slack cables. Set the i_stPGC
.wLowTrqDecRampThsh parameter lower than absolute value of torque with grab hanging on
the cables and moving down. Test that the short ramp is used only when the grab lies on the
stack. This function is not active while the grab is opening or closing during movement.
24 If required, configure the optional scraping function. It allows scraping of rests of transported
material from a hard flat surface. The function is similar to closing on stack, but it keeps contact
with the surface until the grab is fully closed. The parameter i_stPGC.wScrapHoldTrqLim
defines torque limitation of the hold drive during scraping. It defines how much force is applied
on the surface. Set the value higher to apply less force on the surface during scraping. The value
must be low enough to keep contact between jaws of the grab and the surface for the whole
duration of scraping.
25 If required, enable and test the optional rapid opening function.
26 If the brakes on hold and close axes need a long time to open, it may lead to slack cables. This
usually happens when a downward movement command is given right after the grab fully
opened. The brake of the close motor is still open because it just finished the opening movement,
but the brake of the hold drive is closed. Therefore the close drive starts to move immediately,
but the hold drive waits until its brake opens. This delay causes more or less significant slack of
close cables. The function block uses the parameter i_stPGC.wBrakTimeDelay to
compensate for the brake delay. Set the value to the brake opening time in milliseconds.
Step Action
27 If required, test the hook mode. Hook mode allows usage of a hook on a four cable system. There
are several hook types. Two of them are described here.
The following figure is a hook type with two variants of hooks for four cable grabs:
The following figure is a hook type with two variants of hooks with position difference between
hold and close axes:
The left hook uses a lever principle to distribute load depending on position difference between
hold and close axes and the right one distributes the load evenly independent of the position
difference.
The left hook uses the shape of triangular connection blocks and the resulting variable lever arm
length ratio to apply more load on close cables than on hold cables in the depicted position. The
right hook applies the same load on both cables because the lever arm length ratio stays the
same regardless of the position difference as long as both cables are straight. This makes the
left hook well suited for operation in load sharing and the right one for position synchronization.
When moving an unloaded hook, the torque may be too low for efficient load sharing. In this case
it is possible to switch from position synchronization using the input i_xTrqShareEn when the
torque value exceeds certain value.
Switching between load sharing and positioning on the fly is possible as long as the synchronized
positions are not far from positions in which the loads are in balance.
Troubleshooting
Troubleshooting
Part VIII
Hoisting Position Synchronization
Overview
This part explains the functionality and implementation of HoistPositionSync function block in
the Hoisting Library.
Chapter 10
HoistPositionSync: Synchronization of Two Identical Axes for Hoist or Trolley Movement with Encoder
Section 10.1
Functional and Machine Overview
Functional Overview
Functional Description
The HoistPositionSync function block for industrial cranes is designed to synchronize the
position of 2 axes for simultaneous handling of large objects. The block provides a relative
synchronization. This means that the difference in position of 2 motors is kept constant in
synchronized state and the absolute position of hoists is not taken in account.
WARNING
UNINTENDED EQUIPMENT OPERATION
Validate all function block input values before and while the function block is enabled.
Failure to follow these instructions can result in death, serious injury, or equipment damage.
Functional View
Machine Overview
Machine View
Section 10.2
Architecture
Architecture
Hardware Architecture
Software Architecture
DataFlow Overview
The function block is used to synchronize 2 motors. It uses 2 drives:
Master
Slave
The motors are equipped with encoders for the position feedback. The function block uses these
encoder feedbacks in synchronization mode. The encoder position difference is fed as process
detected error to the P controller. The P controller generates manipulated value to correct the
speed of the slave drive to minimize the process error.
In non-synchronized mode, user can operate the drives independently.
Section 10.3
Function Block Description
Pin Diagram
Section 10.4
Pin Description
Pin Description
i_xEn
By setting the i_xEn input to FALSE the output states will be overwritten by a defined fallback
state which is specific for each function block.
When the i_xEn input is set back to TRUE, the function block resumes its normal operation. If
synchronization command is present at the time of enabling of the function block and all conditions
for synchronization are fulfilled, the axes enter synchronous mode at their current positions.
The fallback states of HoistPositionSync are given in the table below.
Outputs that are not listed will retain their current values.
i_xDrvRdyStatMstr, i_xDrvRdyStatSlav
The input needs to be logically connected with the CANopen status of the controlled drive. This
could be found in the CANopen status word bit 1 / ready state.
i_xSync
Command to enter or leave the synchronized state. Both drives must be ready and stopped to
enter the Synchronous mode and must be stopped to exit it.
In Synchronous mode (i_xSync is TRUE), the master and the slave are controlled from the
command inputs of the master. For example, i_xDrvFwdMstr starts the master and slave drive
in forward direction. The input for the slave, for example, i_xDrvFwdSlav is ignored. The speed
reference for both drives is given at i_wDrvSpdRefMstr; both speed reference are recalculated
internally by the P control.
The master and slave is controlled individually in Asynchronous mode (i_xSync is FALSE). That
is, the master is controlled by the master command (i_xDrvFwdMstr), the slave is controlled by
the slave command (i_xDrvFwdSlav). The reference speeds are given by i_wDrvSpdRefMstr
for the master and i_wDrvSpdRefSlav for the slave.
Description
The following are the acceleration and deceleration parameters of the master and slave drive,
when the synchronization is active:
i_wDrvAccSlav
i_wDrvDecSlav
i_wDrvAccMstr
i_wDrvDecMstr
Active synchronization:
When synchronization is active, these values are used to recalculate output acceleration and
deceleration ramps to reach required target speed simultaneously. The block calculates internally
the required ramp time values.
Inactive synchronization (or the function block disabled):
q_wDrvAccSlav = i_wDrvAccSlav
q_wDrvDecSlav = i_wDrvDecSlav
q_wDrvAccMstr = i_wDrvAccMstr
q_wDrvDecMstr = i_wDrvDecMstr
NOTE: The following commands, target speed and ramp value outputs must be connected to the
corresponding ATV function block input pins of the master to allow operation:
q_xDrvFwdMstr
q_xDrvRevMstr
q_wDrvSpdTargMstr
q_wDrvAccMstr
q_wDrvDecMstr
The following commands, target speed and ramp value outputs must be connected to the
corresponding ATV function block input pins of the master to allow operation:
q_xDrvFwdSlav
q_xDrvRevSlav
q_wDrvSpdTargSlav
q_wDrvAccSlav
q_wDrvDecSlav
Notifications
NOTE: If an alarm based on q_diEncPosDiff > i_dwSynchMax arises, the movement will be
stopped automatically and you need to turn off the Synchronization function (i_xSync=FALSE).
Bring 1 of the 2 drives back into the correct position for the synchronization manually. When your
load is back in the desired position, restart the synchronization (i_xSync=TRUE).
If the alarm arises again, verify your configuration for correctly set parameters or your hardware for
defective parts.
Section 10.5
Troubleshooting
Troubleshooting
Troubleshooting
Troubleshooting
Chapter 11
HoistPositionSync_2: Position Synchronization of Two Crane Axes
Section 11.1
Functional Overview
Functional Overview
Functional Overview
Functional Description
The HoistPositionSync_2 function block for industrial cranes is designed to synchronize
positions of 2 axes for simultaneous handling of large objects. It can synchronize axes with
identical or different motors, gears, and encoders. The block retains information about positions of
both axes and synchronization status when the crane is switched off. This means that the
synchronization can continue after a power cycle of the crane.
WARNING
UNINTENDED EQUIPMENT OPERATION
Validate all function block input values before and while the function block is enabled.
Failure to follow these instructions can result in death, serious injury, or equipment damage.
Functional View
Section 11.2
Architecture
Architecture
Software Architecture
DataFlow Overview
The motors are equipped with encoders for the position feedback. The function block uses these
encoder feedbacks in synchronous mode. The encoder position deviation is given to the
proportional position controller. The controller corrects speeds, acceleration, and deceleration
ramps of both motors to minimize the position deviation.
In non-synchronous mode, the user can operate the drives independently.
Section 11.3
Function Block Description
Pin Diagram
Section 11.4
Pin Description
Pin Description
i_xEn
By setting the i_xEn input to FALSE, the output states will be overwritten by a defined fallback
state.
When the i_xEn input is set back to TRUE, the function block resumes its normal operation. If
Synchronization command is present at the time of enabling of the function block and all conditions
for synchronization are fulfilled, the axes enter synchronous mode at their current positions.
The fallback states of HoistPositionSync_2 are given in the table below.
i_xSync
This is the command to enter or leave the synchronized state. Both drives must be ready and
stopped (i_iDrv1SpdActl and i_iDrv1SpdActl equal 0) and both encoder values must be
valid to enter the Synchronous mode.
In Synchronous mode (i_xSync is TRUE), both axes are controlled from the command inputs of
the drive 1. For example, i_xDrv1Fwd starts both drives in forward direction. The input for the
drive 2, for example, i_xDrv2Fwd is ignored. The speed reference for both drives is given at
i_wDrv1SpdRef; output target speeds are calculated by the FB based on the speed reference
and relative position of both axes.
The FB can leave Synchronous mode only when both axes are stopped.
Drives 1 and 2 are controlled individually in Asynchronous mode (q_xSync is FALSE). That is, the
drive 1 is controlled by the commands i_xDrv1Fwd and i_xDrv1Rev and the drive 2 is controlled
by the commands i_xDrv2Fwd and i_xDrv2Rev. The reference speeds are given by
i_wDrv1SpdRef for the drive 1 and i_wDrv2SpdRef for the drive 2.
i_xDrv1RdyStat, i_xDrv2RdyStat
These inputs correspond to ready status of both drives. The information can be obtained from bit
1 of status word of Altivar drives. This information has to be interlocked (logical AND) with an
information that the drive is communicating on CANopen and is in operational state.
The following figure shows an example of obtaining the CANopen network status of the hoisting
drive, assuming that the drive has been assigned a Node ID of 3:
WARNING
UNINTENDED EQUIPMENT OPERATION
Ensure that the status of CANopen communication of both drives is interlocked with the ready
status of respective drive.
Failure to follow these instructions can result in death, serious injury, or equipment damage.
If the communication with any of the 2 drives is interrupted, the FB has to get the information in
order to stop the movement.
The FB needs to have information about status of both drives. If one of the drives is not ready, the
FB does not authorize start of the movement. If one of the ready bits turns FALSE during
movement, both drives are stopped.
i_xEnc1RdyStat, i_xEnc2RdyStat
These inputs correspond to ready status of both encoder interfaces. These inputs must be set to
TRUE when values connected to inputs i_wDrv2EncPos and i_wDrv2EncPos are valid. Both of
these inputs must be TRUE for the whole duration of movement in Synchronous mode.
When using the internal encoder interface of Altivar 71 and communicating with the drive via
CANopen, set the corresponding input to TRUE when the drive is in an operational state (refer to
description of i_xDrv1RdyStat and i_xDrv2RdyStat).
When using an external encoder interface, set the corresponding input to TRUE when this encoder
interface delivers valid position value.
WARNING
UNINTENDED EQUIPMENT OPERATION
Ensure that both encoder interfaces deliver valid position data.
Failure to follow these instructions can result in death, serious injury, or equipment damage.
i_wDrv1EncPos, i_wDrv2EncPos
These inputs correspond to encoder positions of axes 1 and 2. The values may come from various
sources such as the internal encoder interface of Altivar 71, absolute encoder connected through
CANopen, value of bi-directional counter or others. The resolution of the encoder interface must
be at least 16 bits. If the resolution is higher than 16 bits, the FB uses the lowest 16 bits of both
encoder interfaces for position synchronization.
i_stPHPS
The following table describes the structure of parameters of data type PHPS:
wSyncMaxThsh
If the actual position difference exceeds this value, the FB raises an alarm and stops the movement
of both axes.
When 2 axes are not identical, actual position of the second axis is re-calculated to fit the scaling
of the first axis.
Example:
If wDrv1EncPuls = 1024 and wDrv2EncPuls = 4096, and the alarm should be raised when
position difference exceeds 2 motor revolutions, set wSyncMaxThsh to 2048.
rKpPosSync
This parameter corresponds to proportional gain of position controller. Start with a low gain (for
example, 0.01) and increase it slowly.
When the gain is too low, position controller cannot compensate for position difference. When the
gain is too high, the position controller over-compensates and causes oscillations of speeds of both
drives and the position difference.
The proportional gain of position controller is internally normalized and is therefore independent of
the number of encoder pulses per revolution. It is not necessary to find a new value when a
different encoder is used.
wDrv1SpdNom, wDrv2SpdNom
These parameters corresponds to nominal speed of both axes in RPM. Enter the synchronous
values. (for example, 1500 for 4-pole motor at 50 Hz and 1800 for 4-pole motor at 60 Hz). These
values are used for calculation of gear ratio when the synchronized axes are not identical. When
the axes are identical, leave these inputs unconnected.
rDrv1SpdLin, rDrv2SpdLin
These parameters corresponds to linear speed of both axes in m/s. These values are used for
calculation of gear ratio when the synchronized axes are not identical. When the axes are identical,
leave these inputs unconnected.
wDrv1EncPuls, wDrv2EncPuls
These parameters corresponds to number of encoder pulses per revolution of motors 1 and 2.
These values are used for calculation of encoder positions of both axes when the used encoders
are not identical. When the axes are identical, leave these inputs unconnected.
xDrv1EncType, xDrv2EncType
These parameters are TRUE when the connected encoder is absolute and FALSE when it is
incremental type. When an incremental encoder is used, the FB stores actual position of the axis
when the crane is power cycled. When an absolute encoder is used, the actual position is retained
by the encoder.
It is necessary to select correct encoder type for both encoders. The FB supports mixed encoder
types on axes 1 and 2.
Incremental encoder does not register movement of the axis while the encoder interface is
powered Off. If the axis can move while the encoder interface is not powered, use a multi turn
absolute encoder.
wDrv1SpdHsp, wDrv2SpdHsp
These parameters define the maximum allowed speed of both motors in RPM. The values are used
in both Asynchronous and Synchronous modes. In Synchronous mode, the speed of synchronous
movement is limited by the slower axis. Gear ratios are considered when the axes are not identical.
wDrv1SpdLsp, wDrv2SpdLsp
These parameters define the minimum allowed speed of both motors in RPM. The values are used
in both Asynchronous and Synchronous modes. In Synchronous mode, the speed of synchronous
movement is limited by the faster axis. Gear ratios are considered when the axes are not identical.
If possible, keep both of these values at 0. If one or both of the values need to be higher than 0 (for
example, because of using other than closed loop motor control mode), set the values as low as
possible.
wDrv1Acc, wDrv2Acc
These parameters correspond to acceleration ramp times for both axes. In Synchronous mode,
acceleration time value for drive 1 is used to calculate acceleration time values for both axes. The
values are calculated in every cycle and must be written to both drives. Correction of acceleration
time is important part of the position synchronization process.
wDrv1Dec, wDrv2Dec
These parameters correspond to deceleration ramp times for both axes. In Synchronous mode,
deceleration time value for drive 1 is used to calculate deceleration time values for both axes. The
values are calculated in every cycle and must be written to both drives. Correction of deceleration
time is important part of the position synchronization process.
q_diEncPosDiff
This is the actual difference of encoder positions in the Synchronous mode. The output is reset to
0 in Asynchronous mode.
q_wDrv1Acc, q_wDrv2Acc
These parameters correspond to acceleration ramp times for both drives. In Synchronous mode,
these values must be written to acceleration time parameters of both drives in every cycle.
Correction of acceleration time is important part of the position synchronization process.
q_wDrv1Dec, q_wDrv2Dec
These parameters correspond to deceleration ramp times for both drives. In Synchronous mode,
these values must be written to deceleration time parameters of both drives in every cycle.
Correction of deceleration time is important part of the position synchronization process.
q_xAlrm
This output corresponds to the alarm output of the FB. TRUE indicates an detected alarm state.
FALSE indicates an no alarm detected state.
q_wAlrmId
Alarm identification output contains information about actually present alarms.
The actual position difference detected alarm (bit 0) is reset by re-synchronizing the axes.
Other detected alarms are reset by rising edge on the i_xRst input.
Section 11.5
Commissioning Guide
Commissioning Guide
Commissioning Guide
Section 11.6
Troubleshooting
Troubleshooting
Troubleshooting
Part IX
Limit Switch Management
Overview
This part explains the functionality and implementation of LimitSwitch function block.
Chapter 12
LimitSwitch: Surveillance of the Used Limit Switches of a Crane with Fast/Slow Zone Identification
Section 12.1
Functional and Machine Overview
Functional Overview
Functional Description
The LimitSwitch function block is applicable to the following types of cranes:
Industrial Cranes (trolley, bridge and hoisting movement)
Construction Cranes (trolley, slewing and hoisting movement)
The LimitSwitch function block reads limit switch inputs from the field. It checks the limit switch
status and generates the control outputs which are used to control the movements of the crane.
The function block is designed for use with cross and screw limit switches using Normally Closed
(NC) contacts. The contacts indicate the specific status, for example, the stop position.
WARNING
UNINTENDED EQUIPMENT OPERATION
Validate all function block input values before and while the function block is enabled.
Failure to follow these instructions can result in death, serious injury, or equipment damage.
WARNING
UNINTENDED EQUIPMENT OPERATION
Do not use impulse or normally open contact switches in association with the function blocks.
Only use Normally Closed contact switches with the function blocks.
Failure to follow these instructions can result in death, serious injury, or equipment damage.
Functional View
Machine Overview
Machine View
The following figure illustrates a machine view of Limit switch management being used in a tower
crane.
Section 12.2
Architecture
Architecture
Hardware Architecture
Software Architecture
Section 12.3
Function Block Description
Pin Diagram
NOTE: If a Stop on Distance is executed while in the non-working zone, movement towards the
slow switch is possible, but movement in the opposite direction is blocked until the slow limit switch
is passed.
Remark
If any of the limit switch positions are not used, the related input on the function block must be set
to TRUE, as the LimitSwitch function block is designed for N.C. configuration.
Normal Cycle
When the system is moving in the forward direction, and Forward Slow position
(i_xLsFwdSlow)is initiated, the function block enables the Forward Slow signal
(q_xDrvFwdSlow). When the Forward Stop position (i_xLsFwdStop)is initiated, the function
block turns off the Forward Allow signal(q_xDrvFwd).
When the system is moving in the reverse direction and Reverse Slow position
(i_xLsRevSlow)is initiated, the function block enables the Reverse Slow signal
(q_xDrvRevSlow). When the Reverse Stop position (i_xLsRevStop)is initiated, the function
block turns off the Reverse Run signal (q_xDrvRev).
Stop on Distance
The function block has the functionality to stop the trolley/bridge on distance after passing the Slow
Forward or Slow Reverse position. To enable this functionality, enter any value greater than zero
at i_wDistStop. If the input is equal to zero, the Stop on Distance function is disabled.
The function block converts the actual RPM from the drive to the equivalent actual linear speed in
m/s. From this conversion, the function block calculates the traveled distance. When the traveled
distance is greater than the configured stop distance, the Forward Run signal(q_xDrvFwd)or the
Reverse Run signal(q_xDrvRev)is turned off (depending on which way the crane is moving).
Example:
Stop distance: 3 m
Nominal speed of the drive: 1500 RPM
Nominal linear speed: 1 m/s
If the actual speed of the drive = 600 RPM, the actual linear speed (m/s) =
1 m/s * 600 RPM /1500 RPM = 0.4 m/s
Distance traveled in meters during one sample time = ((0.4 m/s * Sample Rate in ms)/1000)
When the distance traveled is greater than the stop distance, the drive stops and further
movement in the same direction is not allowed.
The following figure represents the speed time curve of LimitSwitch function block.
Timing Chart
Section 12.4
Pin Description
Pin Description
The linear speed of movement is entered at this pin in m/s when the motor is at nominal motor
speed (i_wDrvSpdNom). This is used in the distance calculation.
Example:
Nominal speed of motor in RPM: 1500
Nominal linear speed in m/s: 1.00
When the motor runs at 1500 RPM, the nominal speed of trolley/bridge is 1.0 m/s.
i_xEn
By setting the i_xEn input to FALSE the output states will be overwritten by a defined fallback
state which is specific for each function block.
As soon as the function block gets enabled again the output states will be updated corresponding
to the function block behavior as described above. There is no additional action required from you
to re-establish the enabled state.
The fallback states of LimitSwitch are given in the table below.
Outputs that are not listed will retain their current values.
q_wLsStat
Indicates the status of the LimitSwitch function block where:
0: trolley/bridge in the working area
1: trolley/bridge between the Slow Forward and Stop Forward positions
2: trolley/bridge beyond the Slow Forward and Stop Forward positions
3: trolley/bridge between the Slow Reverse and Stop Reverse positions
4: trolley/bridge beyond the Slow Reverse and Stop Reverse positions
Notifications
Section 12.5
Troubleshooting
Troubleshooting
Troubleshooting
Troubleshooting
Chapter 13
LimitSwitch_AR: Monitoring of the Limit Switches of a Crane with Adaptive Speed Reference in Slow Zone
Section 13.1
Functional Overview
Functional Overview
Functional Overview
Functional Description
The LimitSwitch_AR function block interprets the information received from limit switch sensors
in the system, so that the information can be easily exploited by the user application in a controller.
WARNING
UNINTENDED EQUIPMENT OPERATION
Validate all function block input values before and while the function block is enabled.
Failure to follow these instructions can result in death, serious injury, or equipment damage.
WARNING
UNINTENDED EQUIPMENT OPERATION
Do not use impulse or normally open contact switches in association with the function blocks.
Only use Normally Closed contact switches with the function blocks.
Failure to follow these instructions can result in death, serious injury, or equipment damage.
An arbitrary configuration of inputs is supported. Inputs that are not used must be set to TRUE.
The adaptive ramp function calculates the maximum speed the axis can move in a slow-down area
depending on the calculated position (without using a position sensor). This solves the problem of
a standard limit switch which limits the speed to a pre-defined slow speed directly after entering
the slow-down area and significantly increases performance of cranes which have to enter the
slow-down area regularly.
Functional View
Section 13.2
Architecture
Architecture
Hardware Architecture
Software Architecture
Section 13.3
Function Block Description
Pin Diagram
Remark
If any of the limit switch positions are not used, the related input on the function block must be set
to TRUE, as the limit switch management function is designed for NC configuration.
Example:
When the system moves in the forward direction and the Forward slow position i_xLsFwdSlow is
reached, the function block enables the Forward slow signal q_xDrvFwdSlow. When the Forward
stop position i_xLsFwdStop is reached, the function block turns OFF the Forward command
output signal q_xDrvFwd. .
When the system moves in the reverse direction and the Reverse slow position i_xLsRevSlow
is reached, the function block enables the Reverse slow signal q_xDrvRevSlow. When the
Reverse stop position i_xLsRevStop is reached, the function block turns OFF the reverse
command output signal q_xLsRevStop.
The first chart shows the behavior when entering a properly configured slow-down area at nominal
speed:
The second chart describes entering the slow-down area at a speed that is approximately half of
the nominal speed with an adaptive ramp function:
The third chart shows the behavior without the adaptive ramp function. The shaded area
corresponds to the distance traveled in slow-down area at a given speed:
The function block can work in 2 modes depending on the value of the i_rDistStop input:
Mode Meaning
Adaptive ramp The FB removes the direction command after the preset stop distance
has been traveled.
Slow-down only After the Slow switch became FALSE, the q_xDrvFwdSlow or
q_xDrvRevSlow is set to TRUE, until the Hardware Stop Limit switch
is reached.
Section 13.4
Pin Description
Pin Description
i_rDistStop
Distance between slow-down limit switch and a desired stop position.
i_rDistStop > 0 enables adaptive ramp function
i_xDisLsAlrm
Disables the plausibility check of the sequence of limit switch inputs.
NOTE: Set this parameter to TRUE only if disabling of plausibility check is needed for correct
function of the application.
i_wScalFact
A scaling factor of 0...200% used to adjust the calculated distance traveled to the real distance.
The overall distance calculation is as follows:
Traveled distance = Scaling Factor * (Actual Speed * Time)
= Scaling Factor * (Linear Speed * Sample Rate * Actual Speed / Nominal Speed)=
i_wSclFct[%] / 100 * (i_wMotSpdLin[m/s] * i_wSmplRate[ms] /1000) *
i_iDrvSpdActl[RPM] / i_wDrvSpdNom[RPM])
Example:
Distance in current cycle = 100 %/ 100 * (1 m/s* 40 ms/ 1000 * 750 RPM/ 1500 RPM) = 0.02 m
i_wRampDrv
This input corresponds to the deceleration ramp time of the drive.
For example:
NOTE: The parameter Ramp increment assumes a drive default ramp increment configuration
of 0.1 seconds. The unit-base used for this parameter must be the same as that configured in the
drive. Further, the drive deceleration ramp time must be the same as for this parameter as it is
configured in the drive.
This means that the time needed to reach the zero speed from the nominal speed of 1500 RPM is
5 seconds.
q_wLsStat
q_xAlrm
Is TRUE if the FB is in an alarm state. Drive direction commands are set to FALSE if an alarm is
present. The alarm must be reset using the i_xRst input after the cause of the alarm was
removed.
See the alarm description list in Notifications.
Notifications
The alarm ID when q_xAlrm is TRUE. The ID is indicated by a bit set in this output.
The bit values have the following meaning:
Section 13.5
Quick Reference Guide
Commissioning Procedure
Troubleshooting
Troubleshooting
Chapter 14
DoubleLimitSwitch_AR: Administers Two Devices in Synchronous Mode
Notice
This function block has become obsolete, but has been retained to maintain compatibility for older
applications. We recommend using the new function block DoubleLimitSwitch_AR_2. The
new function block is not pin-compatible with the obsolete function block.
Section 14.1
Functional Overview
Functional Overview
Functional Overview
Functional Description
The function reads limit switch inputs from the field. It checks the limit switch status on 2 limit
switches and generates the control outputs which are used to control the cranes movements. The
function block is designed for use with cross and screw limit switches using Normally Closed (NC)
contacts. The contacts retain the current status, for example, the stop position.
WARNING
UNINTENDED EQUIPMENT OPERATION
Do not use impulse or normally open contact switches in association with the function blocks.
Only use Normally Closed contact switches with the function blocks.
Failure to follow these instructions can result in death, serious injury, or equipment damage.
Unlike the single limit switch management function block (LimitSwitch_AR), the double limit
switch management function block administers 2 devices in Synchronous mode which are
intended to be used with the HoistPositionSync function block.
NOTE: The function block is constructed by combining 2 LimitSwitch_AR function blocks into one.
The behavior of the FB in the Asynchronous mode is similar to 2 separate LimitSwitch_AR
function blocks.
This function block is intended to have significant influence on the physical movement of the crane
and its load. The application of this function block requires accurate and correct input parameters
in order to make its movement calculations valid and to avoid hazardous situations. If invalid or
otherwise incorrect input information is provided by the application, the results may be undesirable.
WARNING
UNINTENDED EQUIPMENT OPERATION
Validate all function block input values before and while the function block is enabled.
Failure to follow these instructions can result in death, serious injury, or equipment damage.
Functional View
Section 14.2
Architecture
Architecture
Hardware Architecture
Software Architecture
Section 14.3
Function Block Description
Pin Diagram
Remark
If any of the limit switch stop positions is not used, or the slow position is only used in one direction,
the related input on the function block must be set to TRUE, as the limit switch management
function is designed for N.C. configuration. If using the adaptive ramp function of the block the
corresponding slow limit switch for the desired direction must be present.
When the distance traveled is equal to i_rDistStop, the FB turns OFF the Forward command
signal (q_xDrvFwdMstr or q_xDrvFwdSlav). When the Forward stop position ( i_xLsFwd-
StopMstr or i_xLsFwdStopSlav) is initiated, the function block turns OFF the Forward allow
signal (q_xDrvFwdMstr or q_xDrvFwdSlav). The logic is the same for the reverse direction.
If i_xSync is TRUE, the signal information of both connected limit switches is analyzed
simultaneously and the result is written to both, the master and the slave outputs. If either one of
the Forward or Reverse slow signals is FALSE, the output is set to slow movement. If either one
of the Forward or Reverse stop signals is FALSE, the output disables the movement in that
direction.
Example
Stop distance: 3 m
Nominal speed of the drive: 1500 RPM
Nominal linear speed: 1 m/s
If the actual speed of the drive = 600 RPM, the actual linear speed (m/s) =
1/ms * 600 RPM / 1500 RPM = 0.4 m/s
Distance traveled in meters = ((0.4 m/s * internal calculated cycle time) / 1000)
When the distance traveled is greater than the stop distance, the drive stops and further
movement in the same direction is not allowed.
NOTE: The following chart shows the actual speed of the drive.
The following figure represents the speed time curve of DoubleLimitSwitch_AR function block:
The following figures describe the benefit of using an adaptive ramp function.
The first chart shows the behavior when entering a property configured slow-down area at nominal
speed:
The second chart describes entering a slow-down area at a speed that is approximately half of the
nominal speed with an adaptive ramp function:
The third chart shows the behavior without the adaptive ramp function. The shaded area
corresponds to the distance traveled in a slow-down area at a given speed.
Section 14.4
Pin Description
Pin Description
SODAR (i_stSodAR)
wScalFactMstr, wScalFactSlav
A scaling factor of 0...200% used to adjust the calculated distance traveled to the real distance.
The overall distance calculation is as follows:
D = Scaling Factor * (Actual Speed * Time)
= Scaling Factor * (Linear Speed * Actual Speed * Sample Rate / Nominal Speed)=
i_wSclFct[%] * (i_wLinSpd[m/s] * i_iActSpd[RPM] * i_wSmplRate[ms] /
i_wNomSpd[RPM])
Example:
Distance in current cycle = 100% * 1 m/s * 750 RPM * 40 ms / 1500 RPM = 0.02 m
wRampDrvMstr, wRampDrvSlav
This input corresponds to the deceleration ramp time of the drive.
Example:
NOTE: The parameter assumes a drive default ramp increment configuration of 0.1 seconds. The
unit-base used for this parameter must be the same as that configured in the drive. Further, the
drive deceleration ramp time must be the same as for this parameter as it is configured in the drive.
This means that the time needed to reach the zero speed from the nominal speed of 1500 RPM is
5 seconds.
q_wLsStatMstr, q_sLsStatSlav
q_xAlrm
An alarm signal is generated in the cases of incorrect limit switch configuration or improper
operation of a limit switch.
The function block detects any incorrect signaling of the position with respect to the movement, i.e.
during movement, the signaling of any limit switch position located in the opposite direction of the
movement generates an alarm.
Notifications
Section 14.5
Quick Reference Guide
Commissioning Procedure
q_xDrvFwdMstr :=False;
q_xDrvRevMstr :=False;
q_xDrvFwdSlowMstr :=False;
q_xDrvRevSlowMstr :=False;
q_xDrvFwdSlav :=False;
q_xDrvRevSlav :=False;
q_xDrvFwdSlowSlav :=False;
q_xDrvRevSlowSlav :=False;
Troubleshooting
Troubleshooting
Chapter 15
DoubleLimitSwitch_AR_2: Administers Two Devices in Synchronous Mode
Section 15.1
Functional Overview
Functional Overview
Functional Overview
Functional Description
The function reads limit switch inputs from the field. It checks the status on 2 limit switches and
generates the control outputs which are used to control the cranes movements. The function block
is designed for use with cross and screw limit switches using Normally Closed (NC) contacts and
a photoelectric sensor. The contacts retain the current status, for example, the stop position.
WARNING
UNINTENDED EQUIPMENT OPERATION
Do not use impulse or normally open contact switches in association with the function blocks.
Only use Normally Closed contact switches with the function blocks.
Failure to follow these instructions can result in death, serious injury, or equipment damage.
NOTE: The function block is constructed by combining 2 LimitSwitch_AR function blocks into
one. The behavior of the FB in the Asynchronous mode is similar to 2 separate LimitSwitch_AR
function blocks.
WARNING
UNINTENDED EQUIPMENT OPERATION
Validate all function block input values before and while the function block is enabled.
Failure to follow these instructions can result in death, serious injury, or equipment damage.
Functional View
Section 15.2
Architecture
Architecture
Hardware Architecture
Software Architecture
Section 15.3
Function Block Description
Pin Diagram
Remark
If any of the limit switch stop positions is not used, or the slow position is only used in one direction,
set the related input on the function block to TRUE, as the limit switch management function is
designed for N.C. configuration. If using the adaptive ramp function of the block, the corresponding
slow limit switch for the desired direction must be present.
By using the DoubleLimitSwitch_AR_2 FB for managing the movement of 2 bridges or 2
trolleys on industrial crane, extra protection is required to be provided when they approach each
other.
WARNING
COLLISION OF TWO BRIDGES/TROLLEYS
Use proximity sensors to avoid collisions between bridges/trolleys.
Failure to follow these instructions can result in death, serious injury, or equipment damage.
No Synchronization
Synchronization
the system moves in the reverse direction and the the function block enables the Reverse slow signal of
reverse slow position (i_xLsRevSlowDrv1 or both drives q_xRevSlowDrv1 and
i_xLsRevSlowDrv2) is reached and the both q_xRevSlowDrv2.
parameters (i_rDistStopDrv1,
i_rDistStopDrv2) are zero,
the Reverse stop position (i_xLsRevStopDrv1 or the function block turns OFF the Reverse command
i_xLRevdStopDrv2) is reached, output signals q_xRevDrv1 and q_xRevDrv2.
the system is moving in the forward direction and the the function block enables the internal calculation of
Forward slow position i_xLsFwdSlowDrv1 or the remaining distance according to the actual speed.
i_xLsFwdSlowDrv2 is initiated while the
parameters i_rDistStopDrv1 and
i_rDistStopDrv2 are not equal zero,
the calculated distance is greater than lower of the the function block turn OFF the Forward command
two stop distance values (i_rDistStopDrv1 or output signals q_xFwdDrv1 and q_xFwdDrv2.
i_rDistStopDrv2),
the system is moving in the reverse direction and the the function block enables the internal calculation of
reverse slow position (i_xLsRevSlowDrv1 or the remaining distance according to the actual speed.
i_xLsRevSlowDrv2) is initiated while the
parameters i_rDistStopDrv1 and
i_rDistStopDrv2 are not equal zero,
the calculated distance is greater than lower of the the function block turn OFF the Forward command
two stop distance values (i_rDistStopDrv1 or output signals q_xFwdDrv1 and q_xFwdDrv2.
i_rDistStopDrv2),
The function block calculates the traveled distance by integrating actual speed of the drive over
time.
The adaptive ramp function allows the FB to calculate the highest available speed while the axis
is in a slow-down area.
Example
Stop distance: 3 m
Nominal speed of the drive: 1500 RPM
Nominal linear speed: 1 m/s
If the actual speed of the drive = 600 RPM, the actual linear speed (m/s) =
1/ms * 600 RPM / 1500 RPM = 0.4 m/s
Distance traveled in meters = ((0.4 m/s * internal calculated cycle time) / 1000)
When the distance traveled is greater than the stop distance, the drive stops and further
movement in the same direction is not allowed.
NOTE: The following chart shows the actual speed of the drive.
The following figure represents the speed time curve of DoubleLimitSwitch_AR_2 function
block:
The following figures describe the benefit of using an adaptive ramp function.
The first chart shows the behavior when entering a property configured slow-down area at nominal
speed:
The second chart describes entering a slow-down area at a speed that is approximately half of the
nominal speed with an adaptive ramp function:
The third chart shows the behavior without the adaptive ramp function. The shaded area
corresponds to the distance traveled in a slow-down area at a given speed.
By using the DoubleLimitSwitch_AR_2 for 2 cranes (bridges or trolleys) moving on the same
rail, the input i_xDisLsAlrm has to set to TRUE to disable alarms based on combination of limit
switch states.
WARNING
COLLISION OF TWO BRIDGES/TROLLEYS
Use proximity sensors to avoid collisions between bridges/trolleys.
Failure to follow these instructions can result in death, serious injury, or equipment damage.
When 2 cranes approach each other, the sensor head receives signal a reflected from the reflector.
With this, presence of another crane is sensed and movement of approaching crane is stopped in
that particular direction. The crane can move in any other direction (away from another crane) any
time. Likewise, another unit is fixed on another crane and its reflector is fixed on the first crane.
Therefore, each time the cranes approach each other within a specified distance, movement is
stopped and collision of the cranes is avoided.
Section 15.4
Pin Description
Pin Description
SODAR_2 (i_stSodAR)
wScalFactDrv1, wScalFactDrv2
A scaling factor of 0...200% used to adjust the calculated distance traveled to the real distance.
The overall distance calculation is as follows:
D = Scaling Factor * (Actual Speed * Time)
= Scaling Factor * (Linear Speed * Actual Speed * Sample Rate / Nominal Speed)=
i_wSclFct[%] * (i_wLinSpd[m/s] * i_iActSpd[RPM] * i_wSmplRate[ms] /
i_wNomSpd[RPM])
Example:
Distance in current cycle = 100% * 1 m/s * 750 RPM * 40 ms / 1500 RPM = 0.02 m
wRampDrv1, wRampDrv2
This input corresponds to the deceleration ramp time of the drive.
Example:
NOTE: The parameter assumes a drive default ramp increment configuration of 0.1 seconds. The
unit-base used for this parameter must be the same as that configured in the drive. Further, the
drive deceleration ramp time must be the same as for this parameter as it is configured in the drive.
This means that the time needed to reach the zero speed from the nominal speed of 1500 RPM is
5 seconds.
q_wLsStatDrv1, q_sLsStatDrv2
q_xAlrm
An alarm signal is generated in the cases of incorrect limit switch configuration or improper
operation of a limit switch.
The function block detects any incorrect signalling of the position with respect to the movement,
i.e. during movement, the signalling of any limit switch position located in the opposite direction of
the movement generates an alarm.
When the FB is applied for 2 bridges/trolleys moving on the same rail and if the input
i_xDisLsAlrm is set to TRUE the function block disables the plausibility check of the limit switch
inputs which detects a wrong order of limit switch signals.
q_wAlrmId
Section 15.5
Quick Reference Guide
Commissioning Procedure
q_xFwdDrv1 :=False;
q_xRevDrv1 :=False;
q_xFwdSlowDrv1 :=False;
q_xRevSlowDrv1 :=False;
q_xFwdDrv2 :=False;
q_xRevDrv2 :=False;
q_xFwdSlowDrv2 :=False;
q_xRevSlowDrv2 :=False;
Troubleshooting
Troubleshooting
Part X
Load Overspeed Control
Overview
This part explains the functionality and implementation of LoadOverspeedCtrl function block in
the Hoisting Library.
Chapter 16
LoadOverspeedCtrl: Detects Load Overspeed, Brake Wear and Sensor Feedback on Hoist
Notice
This function block has become obsolete, but has been retained to maintain compatibility for older
applications. We recommend using the new function block LoadOverspeedCtrl_2. The new
function block is not pin-compatible with the obsolete function block.
Section 16.1
Functional and Machine Overview
Functional Overview
Functional Description
The Load Overspeed Control function block (LoadOverspeedCtrl) is used to detect overspeed,
brake wear, alarm and sensor feedback alarms.
The Load Overspeed Control function (LoadOverspeedCtrl) is a function which helps to
protect hoisting against load overspeed and detects brake wear. The Load Overspeed Control
function detects a load overspeed by monitoring the pulse input of the controller. The brake wear
function checks the wear and tear of the hoist brake. This function detects any movement on the
load when the drive is not running.
The function is used to detect:
Load overspeed
Brake wear
Sensor feedback
The LoadOverspeedCtrl function bock is designed to be used on the ATV71 and ATV312
drives.
The function block monitors the drive movement and a reference point, which is usually a simple
proximity sensor linked to a cog behind the gear box. The sensor must be connected to the high
speed input of the controller.
The function compares the drive movement information with the maximum speed of the drive and
generates an alarm, if a higher speed than the specified is detected.
For the brake wear detection, the function block generates an alarm, if the sensor signal indicates
movement when the drive is not in RUN mode.
A sensor feedback alarm is generated if the speed sensor does not deliver any signal although the
drive is in RUN mode.
NOTE: A sensor feedback alarm is detected when the actual speed from the drive is higher than
the threshold speed.
Functional View
Machine Overview
Machine View
The following figure represents the machine view of the function block with an industrial crane.
The following figure represents the machine view of the function block with a tower crane.
Section 16.2
Architecture
Architecture
Hardware Architecture
NOTE: The high speed pulses from the proximity sensor must be connected to a high speed input.
Software Architecture
Section 16.3
Function Block Description
Pin Diagram
Step Action
1 The frequency threshold value above which a load overspeed alarm generated
is defined with the i_wFreqOvsp input of the function block.
2 If the value of the calculated frequency exceeds the frequency defined at
i_wFreqOvsp input of the function block, then a timer is started. (The duration
of this time period is defined at the i_wOvspFltrTime input of the function
block.)
3 The frequency calculation for the load overspeed detection is done by using the
number of pulses over a number of controller scans defined at
i_wPlcOvspCyclNb.
Step Action
4 If the calculated frequency continues to exceed the defined frequency at
i_wFreqOvsp, even after the load overspeed alarm timer has timed out, then
a load overspeed alarm is generated at the output pin (Bit 0 of q_wAlrmId) of
the function block.
The following figure represents the timing diagram for Load overspeed alarm.
Step Action
1 The RPM value above which a Sensor feedback alarm must be generated is
defined at the i_wSenFbckAlrm input of the function block.
2 If the actual speed of the drive read at i_iDrvSpdActl exceeds the value
defined at i_wSenFbckAlrm, then a timer is started. (The duration of this time
period is defined at the i_wSenFbckFltrTime input of the function block.)
Step Action
3 If the actual speed of the drive continues to exceed the user defined value at
i_wSenFbckAlrm, even after the sensor feedback alarm timer has timed out
and no pulses are registered, then a Sensor feedback alarm is generated at the
output pin (Bit 2 of q_wAlrmId) of the function block.
The following figure represents the timing diagram for Sensor feedback alarm.
Step Action
1 The frequency value above which a brake wear alarm is generated is defined
at the i_wFreqBrakWearMax input of the function block.
2 If the value of the calculated frequency exceeds the brake wear frequency
defined at the i_wFreqBrakWearMax input of the function block, then a timer
is started. (The duration of this time period is defined at the
i_wBrakWearFltrTime input of the function block.)
3 The frequency calculation for the brake wear detection is done using the
number of pulses over a time period and number of controller scans defined at
i_wPlcBrakWearCyclNb.
4 If the calculated frequency continues to exceed the user defined frequency at
i_wFreqBrakWearMax even after the brake wear alarm timer has timed out,
then a brake wear alarm is generated at the output pin (Bit 1 of q_wAlrmId)
of the function block.
The following figure represent the timing diagram for Brake wear alarm.
Section 16.4
Pin Description
Pin Description
i_xEn
By setting the i_xEn input to FALSE the output states will be overwritten by a defined fallback
state which is specific for each function block.
As soon as the function block gets enabled again the output states will be updated corresponding
to the function block behavior as described above. There is no additional action required from you
to re-establish the enabled state.
The fallback states of LoadOverspeedCtrl are given in the table below.
Outputs that are not listed will retain their current values.
i_rPulsGdnt
The LoadOverspeedCtrl function block calculates the pulse frequency of incoming pulses from
the cog in Hz. This frequency and the pulse gradient are used to calculate the speed of the motor.
The condition for overspeed is as follows:
Pulse Frequency * Pulse Gradient = Motor Frequency.
The pulse gradient needs to take into account the geometry of the gear box (ratio) as well as
geometry of the cog wheel (number of teeth on the cog).
Example
Nominal motor speed = 1500 RPM
Nominal speed at the tooth wheel end = 750 RPM
Gearing ratio = 1500 / 750 = 2
Number of teeth on the tooth wheel = 50
The pulse gradient is equal to:
Pulse gradient= Gear ratio / Number of tooth = 2 / 50 = 0.04.
So, if pulses arrive with a frequency of 750 Hz, the shaft of the motor turns with 750 Hz * 0.04 =
30 Hz. The overspeed frequency can be directly set as a maximum allowed frequency.
The following figure represents the motor with gear box.
q_rMotFreq
This output gives information about the (mechanical) motor frequency based on the received
pulses from the sensor.
Example:
1. 1 rotation of the drum causes 4 pulses on the sensor.
2. 1 rotation of the drum needs 10 rotations of the motor axis.
==> 4 pulses per second (4 Hz as pulse frequency) in 10 rotations of the motor axis per second is
10 Hz. So the pulse gradient is 10 / 4 = 2.5
Motor Frequency = Pulse Gradient * Pulse frequency
The function block detects overspeed if the motor frequency is higher than the overspeed
frequency.
Brake wear is detected if the motor frequency is higher than the brake wear frequency.
Calculated frequency is the rotation of the shaft of the motor and not the output frequency of the
Variable Speed Drive.
Notifications
NOTE: The individual bits of the alarm status output need to be extracted using the '.' (DOT) and
interlocked suitably with the crane operation program. The function does not have direct control of
the drive.
Section 16.5
Troubleshooting
Troubleshooting
Troubleshooting
Troubleshooting
Chapter 17
LoadOverspeedCtrl_2: Detects Load Overspeed, Brake Wear and Sensor Feedback on Hoist
Section 17.1
Functional and Machine Overview
Functional Overview
Functional Description
The Load Overspeed Control 2 function block (LoadOverspeedCtrl_2) is used to detect load
overspeed and brake wear. If the hoist moves at a speed faster than configured overspeed
threshold the function block raises an overspeed alarm. The function block also detects movement
of the hoist when the drive is not in RUN mode. The sensor feedback function tests the connection
between the sensor and the controller input and generates an alarm if the sensor does not deliver
any signal although the motor is running.
The function is used to detect:
Load overspeed
Brake wear
Sensor feedback loss
Functional View
Machine Overview
Machine View
The following figure represents the machine view of the function block with an industrial crane.
The following figure represents the machine view of the function block with a tower crane.
Section 17.2
Architecture
Architecture
Hardware Architecture
NOTE: The high speed pulses from the proximity sensor must be connected to a high speed input
of the controller.
Software Architecture
Section 17.3
Function Block Description
Pin Diagram
The function block calculates the pulse frequency of incoming pulses from the cogwheel. These
pulses and the motor gear box ratio (numerator factor / denominator factor) are used to calculate
the speed of the motor.
In case that only the gear box ratio is given on the nameplate of the gear box, the numerator factor
is set to the gear box ratio and the denominator to 1.
If the sensor is not attached directly on the drum behind the gear box but further on the cogwheel,
the ratio between drum and the cogwheel must be taken into account.
Section 17.4
Pin Description
Pin Description
i_xEn
By setting the i_xEn input to FALSE the output states will be overwritten by a defined fallback
state which is specific for each function block.
As soon as the function block gets enabled again the output states will be updated corresponding
to the function block behavior as described above. There is no additional action required from you
to re-establish the enabled state.
The fallback states of LoadOverspeedCtrl_2 are given in the table below.
Outputs that are not listed will retain their current values.
i_wSpdOvsp
The i_wSpdOvsp is the threshold speed above which the overspeed alarm is raised. The TRUE
value must be higher than the maximum allowed speed. The difference should be at least a value
defined by i_wSpdCalcToler (percent of i_wSpdOvsp).
i_rRevoBrakWearMax
This is the user-defined value of rotations of the motor. The hoist is not allowed to move while the
drive is not running before the brake wear alarm is raised. If the drive is not in RUN state, but the
movement is still registered by the sensor wheel and the number of rotations of the motor shaft is
greater than i_rRevoBrakWearMax, the function indicates that the mechanical brakes are
slipping or inoperative.
i_wSpdCalcToler
This input defines the requested accuracy of motor speed measurement. The value can be set
between 1 and 10, meaning 1...10% of tolerance. Higher tolerance will result in lower accuracy of
the measurement, but faster reaction time. Tolerance around 5% is considered as a compromise
between accuracy of the measurement and reaction time. The estimated reaction time is available
at the output q_tOvspReactTime.
q_tOvspReactTime
This output gives an estimated worst case reaction time of overspeed detection.
The value depends on
combination the overspeed threshold value,
gear ratio given by the nominator and denominator,
number of pulses on the cogwheel,
configured tolerance for speed measurement and
execution period of the function block.
Notifications
Section 17.5
Quick Reference Guide
Troubleshooting
Troubleshooting
Part XI
Monitoring Data Storage
Chapter 18
Monitoring Data Storage Function: Collect and Monitor the Operational Data of Cranes
Section 18.1
Functional and Machine Overview
Functional Overview
Functional Description
All cranes are constructed based on a theoretical lifetime. This lifetime is calculated using the
nominal load, nominal use and a theoretical usage concentration. Once this lifetime is up, the crane
is recommended to be refurbished and critical components have to be replaced.
With an accurate record of all movements and loads, the function block assists the user in choosing
the right time for maintenance. In the case of many movements with a high load, it is possible to
plan maintenance work before a component breaks down and eliminate long down times. When
loading is occasional it is possible to postpone maintenance, leading to a longer lifecycle and
effective maintenance costs.
NOTE: The function block retains the recorded data despite shut down or power cut to the
controller. For a proper retention of values, a working battery in the controller is required for those
platforms which have battery backed memory.
Monitoring data storage is a function for collecting and monitoring the crane's operational data to
improve handling efficiency:
It allows monitoring of the machine usage under normal and abnormal conditions. All
movements of the crane are monitored.
Usage rates are tallied and an alarm is raised when the system or individual components require
maintenance.
Abnormal conditions such as detected alarms are stored individually.
The Monitoring data storage consist of set of a function blocks for SoMachine controller which is
dedicated to collect operational and detected alarm data from the crane. Following are the function
blocks of Monitoring data storage:
StatisticDataStorage
StatisticDataStorage_2
AlarmDataStorage
AlarmDataStorage_2
MaintenanceDataStorage
MaintenanceDataStorage_2
These function blocks are using an internal function to get the system cycle time for recording the
events.
NOTE: The function blocks StatisticDataStorage, AlarmDataStorage and
MaintenanceDataStorage have become obsolete, but are retained to maintain compatibility for
older applications. We recommend using the following new function blocks in your projects:
StatisticDataStorage_2, AlarmDataStorage_2 and MaintenanceDataStorage_2.
The new function blocks are not pin-compatible with the obsolete function blocks.
Hours 300 class of hoist (amount of hours with more than 300 operations per hour)
Hours 600 class of hoist (amount of hours with more than 600 operations per hour)
Functional View
Machine Overview
Machine View
The Monitoring data storage function is a software function and although hardware independent,
it requires the monitored hardware that provides the information to be logged and collected.
Section 18.2
Architecture
Architecture
Hardware Architecture
Section 18.3
Function Block Description - StatisticDataStorage
Notice
This function block has become obsolete, but has been retained to maintain compatibility for older
applications. We recommend using the new function block StatisticDataStorage_2. The
new function block is not pin-compatible with the obsolete function block.
Pin Diagram
Hoist movement
This block records the number of up or down movements, the number of hoist operational hours
in Up or Down movements and the number of backtracking and pulsating operations carried out
during the hoisting operations.
NOTE: The reset of the hoisting operations (up, down movements and the number of
backtracking and pulsating) can only be carried out when the i_xHstDrvUp, i_xHstDrvDown
is FALSE and the i_xHstDrvEn enabled.
Slew movement
This block records the number of Right or Left movements, the number of slew operational
hours during Right or Left movements and the number of backtracking and pulsating operations
carried out during the slewing operations.
NOTE: The reset of the slewing operations (Right, Left movements and the number of
backtracking and pulsating) can only be carried out when the i_xSlewDrvCw,
i_xSlewDrvCcw is FALSE and the i_xSlewDrvEn enabled.
Trolley movement
This block records the number of Forward or Reverse movements, the number of trolley
operational hours during Forward or Reverse movements and the number of backtracking and
pulsating operations carried out during the trolley movement.
NOTE: The reset of the trolley operations (Forward, Reverse movements and the number of
backtracking and pulsating) can only be carried out when the i_xTrolDrvFwd,
i_xTrolDrvRev is FALSE and the i_xTrolDrvEn enabled.
Traveling movement
This block records the number of Traveling Forward or Traveling Reverse movements, the
number of traveling operational hours during Traveling Forward or Traveling Reverse
movements, and the number of backtracking and pulsating operations carried out during the
traveling movement.
NOTE: All outputs of this block are retained after each expected (switch Off) and unexpected
power shutdown as long as there is sufficient battery power available.
NOTE: The reset of the traveling operations (Forward, Reverse movements and the number of
backtracking and pulsating) can only be carried out when the i_xTrvlDrvFwd,
i_xTrvlDrvRev is FALSE and the i_xTrvlDrvEn enabled.
i_xEn
By setting the i_xEn input to FALSE the output states will be overwritten by a defined fallback
state which is specific for each function block.
As soon as the function block gets enabled again the output states will be updated corresponding
to the function block behavior as described above. There is no additional action required from you
to re-establish the enabled state.
The fallback states of StatisticDataStorage are given in the table below.
Outputs that are not listed will retain their current values.
Section 18.4
Function Block Description - StatisticDataStorage_2
Pin Diagram
TRUE: Active
FALSE: Inactive
i_xEn
By setting the i_xEn input to FALSE the output states will be overwritten by a defined fallback
state which is specific for each function block.
As soon as the function block gets enabled again the output states will be updated corresponding
to the function block behavior as described above. There is no additional action required from you
to re-establish the enabled state.
q_dwPlsNb
A pulsating incident is defined as followed:
A falling edge on a forward command followed by a rising edge of a forward command within 2
seconds.
A falling edge on a reverse command followed by a rising edge of a reverse command within 2
seconds.
q_dwBtrkNb
A backtracking incident is defined as followed:
A falling edge on a forward command followed by a rising edge of a reverse command within 2
seconds.
A falling edge on a reverse command followed by a rising edge of a forward command within 2
seconds.
Section 18.5
Function Block Description - AlarmDataStorage
Notice
This function block has become obsolete, but has been retained to maintain compatibility for older
applications. We recommend using the new function block AlarmDataStorage_2. The new
function block is not pin-compatible with the obsolete function block.
Pin Diagram
NOTE: When the value entered at i_wAlrmNb < 1, the alarm value is 1.
i_xEn
By setting the i_xEn input to FALSE the output states will be overwritten by a defined fallback
state which is specific for each function block.
As soon as the function block gets enabled again the output states will be updated corresponding
to the function block behavior as described above. There is no additional action required from you
to re-establish the enabled state.
The fallback states of AlarmDataStorage are given in the table below.
Outputs that are not listed will retain their current values.
Output Description
Section 18.6
Function Block Description - AlarmDataStorage_2
Pin Diagram
i_xEn
By setting the i_xEn input to FALSE the output states will be overwritten by a defined fallback
state.
As soon as the function block gets enabled again the output states will be updated corresponding
to the function block behavior as described above. There is no additional action required from you
to re-establish the enabled state.
The fallback states of AlarmDataStorage_2 are given in the table below.
i_wAlrmNb
The input is the selector for the alarm event to be displayed at the corresponding outputs
q_dtAlrm and q_wAlrmDur. The FB is able to store 20 alarm incidents with time stamp and
duration. The most recent alarm is always stored in position [1] and therefore the oldest recorded
event at position [20].
Output Description
Section 18.7
Function Block Description - OvldAlarmDataStorage
Notice
This function block has become obsolete, but has been retained to maintain compatibility for older
applications. We recommend using the new function block AlarmDataStorage_2. The new
function block is not pin-compatible with the obsolete function block.
Pin Diagram
NOTE: When the value entered at i_wAlrmNb < 1, the alarm value is 1.
i_xEn
By setting the i_xEn input to FALSE the output states will be overwritten by a defined fallback
state which is specific for each function block.
As soon as the function block gets enabled again the output states will be updated corresponding
to the function block behavior as described above. There is no additional action required from you
to re-establish the enabled state.
The fallback states of AlarmDataStorage are given in the table below.
Outputs that are not listed will retain their current values.
The fallback states of AlarmDataStorage_2 are given in the table below.
NOTE: The function block AlarmDataStorage has become obsolete, but has been retained to
maintain compatibility for older applications. We recommend using the new function block
AlarmDataStorage_2 in your project. However, the new function block is not pin-compatible
with the obsolete function block.
Section 18.8
Function Block Description - OvtqAlarmDataStorage
Notice
This function block has become obsolete, but has been retained to maintain compatibility for older
applications. We recommend using the new function block AlarmDataStorage_2. The new
function block is not pin-compatible with the obsolete function block.
Pin Diagram
NOTE: When the value entered at i_wAlrmNb < 1, the alarm value is 1.
i_xEn
By setting the i_xEn input to FALSE the output states will be overwritten by a defined fallback
state which is specific for each function block.
As soon as the function block gets enabled again the output states will be updated corresponding
to the function block behavior as described above. There is no additional action required from you
to re-establish the enabled state.
The fallback states of AlarmDataStorage are given in the table below.
Outputs that are not listed will retain their current values.
The fallback states of AlarmDataStorage_2 are given in the table below.
NOTE: The function block AlarmDataStorage has become obsolete, but has been retained to
maintain compatibility for older applications. We recommend using the new function block
AlarmDataStorage_2 in your project. However, the new function block is not pin-compatible
with the obsolete function block.
Section 18.9
Function Block Description - OvspAlarmDataStorage
Notice
This function block has become obsolete, but has been retained to maintain compatibility for older
applications. We recommend using the new function block AlarmDataStorage_2. The new
function block is not pin-compatible with the obsolete function block.
Pin Diagram
NOTE: When the value entered at i_wAlrmNb < 1, the alarm value is 1.
i_xEn
By setting the i_xEn input to FALSE the output states will be overwritten by a defined fallback
state which is specific for each function block.
As soon as the function block gets enabled again the output states will be updated corresponding
to the function block behavior as described above. There is no additional action required from you
to re-establish the enabled state.
The fallback states of AlarmDataStorage are given in the table below.
Outputs that are not listed will retain their current values.
The fallback states of AlarmDataStorage_2 are given in the table below.
NOTE: The function block AlarmDataStorage has become obsolete, but has been retained to
maintain compatibility for older applications. We recommend using the new function block
AlarmDataStorage_2 in your project. However, the new function block is not pin-compatible
with the obsolete function block.
Section 18.10
Function Block Description - LdslAlarmDataStorage
Notice
This function block has become obsolete, but has been retained to maintain compatibility for older
applications. We recommend using the new function block AlarmDataStorage_2. The new
function block is not pin-compatible with the obsolete function block.
Pin Diagram
NOTE: When the value entered at i_wAlrmNb < 1, the alarm value is 1.
i_xEn
By setting the i_xEn input to FALSE the output states will be overwritten by a defined fallback
state which is specific for each function block.
As soon as the function block gets enabled again the output states will be updated corresponding
to the function block behavior as described above. There is no additional action required from you
to re-establish the enabled state.
The fallback states of AlarmDataStorage are given in the table below.
Outputs that are not listed will retain their current values.
The fallback states of AlarmDataStorage_2 are given in the table below.
NOTE: The function block AlarmDataStorage has become obsolete, but has been retained to
maintain compatibility for older applications. We recommend using the new function block
AlarmDataStorage_2 in your project. However, the new function block is not pin-compatible
with the obsolete function block.
Section 18.11
Function Block Description - EncAlarmDataStorage
Notice
This function block has become obsolete, but has been retained to maintain compatibility for older
applications. We recommend using the new function block AlarmDataStorage_2. The new
function block is not pin-compatible with the obsolete function block.
Pin Diagram
NOTE: When the value entered at i_wAlrmNb < 1, the alarm value is 1.
i_xEn
By setting the i_xEn input to FALSE the output states will be overwritten by a defined fallback
state which is specific for each function block.
As soon as the function block gets enabled again the output states will be updated corresponding
to the function block behavior as described above. There is no additional action required from you
to re-establish the enabled state.
The fallback states of AlarmDataStorage are given in the table below.
Outputs that are not listed will retain their current values.
The fallback states of AlarmDataStorage_2 are given in the table below.
NOTE: The function block AlarmDataStorage has become obsolete, but has been retained to
maintain compatibility for older applications. We recommend using the new function block
AlarmDataStorage_2 in your project. However, the new function block is not pin-compatible
with the obsolete function block.
Section 18.12
Function Block Description - MaintenanceDataStorage
Notice
This function block has become obsolete, but has been retained to maintain compatibility for older
applications. We recommend using the new function block MaintenanceDataStorage_2. The
new function block is not pin-compatible with the obsolete function block.
Pin Diagram
Where:
LNOM = Nominal value of the load entered by you.
LACT = Analog output from the load cell (to be scaled using scaling block).
T= Total time since movement started up until movement stops. This time is calculated internally.
LdAct = Actual torque of the drive.
LdNom = Nominal torque of the drive.
K (i_wCnst) is in % and is the relationship between the nominal crane load and nominal motor
torque, usually 100%.
C (i_iDrvTrqAct) is in % and is the nominal torque on the crane for stationary movement
(acceleration zero, constant speed). You must configure this input to read the actual torque from
the hoist drive.
Example:
T = 10 s, K = 100%, C = 20%
(KC) = (1*0.2) = 0.008
T = 10/3600 h
WPFS = 2.22e-5
(Since both K and C are in %, while calculating WPFS, both K and C are divided by 100).
T is the total time since movement started up until movement stops. This time is calculated
internally.
NOTE: If the actual load is being measured by a load cell, then you must verify that the load cell
data acquisition (i_xLcEn) input is enabled otherwise this input remains disabled by default.
WPFS Calculation
The figure above explains, whenever a hoist operation (up or down) is carried out, the time T for
WPFS calculation is taken into consideration only after a RUN command is given, speed reference
is reached and the RUN status becomes FALSE.
NOTE:
WPFS is updated with the following sequence of operations:
1. RUN command is TRUE.
2. Speed reference reached.
3. RUN command is FALSE.
i_xEn
By setting the i_xEn input to FALSE the output states will be overwritten by a defined fallback
state which is specific for each function block.
As soon as the function block gets enabled again the output states will be updated corresponding
to the function block behavior as described above. There is no additional action required from you
to re-establish the enabled state.
The fallback states of MaintenanceDataStorage are given in the table below.
Outputs that are not listed will retain their current values.
NOTE:
If over a period of 1 hour, the number of hoist operations carried out exceeds 600, then only the
q_wHst600Ophr output will get updated but q_wHst300Ophr will not get updated.
Similarly, if over a period of 1 hour, the number of hoist is greater than 300 and less than 600,
then only q_wHst300Ophr output will get updated but q_wHst600Ophr will not get updated.
Commissioning Procedure
5. Look at the trace and stop it once the torque curve is constant.
6. Determine the average torque during the phase of running at nominal frequency.
Example:
7. Enter the value (here in the example: 30.0%) at the input i_stMDS.rTrqLoadNom.
8. Connect all other pins and make sure i_stMDS.xLcEn is FALSE.
Section 18.13
Function Block Description - MaintenanceDataStorage_2
Pin Diagram
Where:
T= Actual cycle time. This time is calculated internally.
LdAct = Actual load of the drive.
LdNom = Nominal load of the drive.
Where:
T= Actual cycle time. This time is calculated internally.
TrqAct = Actual torque of the drive.
TrqNom = Nominal torque of the drive.
Overview
You will find the following pin descriptions:
Input pin description (see page 590)
Sub-structure description (see page 591)
Output pin description (see page 592)
i_xEn
By setting the i_xEn input to FALSE the output states will be overwritten by a defined fallback
state.
As soon as the function block gets enabled again the output states will be updated corresponding
to the function block behavior as described above. There is no additional action required from you
to re-establish the enabled state.
The fallback states of MaintenanceDataStorage_2 are given in the table below.
i_diCranLoadActl
This is the sensor input of the load cell or the actual torque of the drive.
If the FB is used with a load cell, the xLcEn parameter of the MDS structure needs to be set to
TRUE. Incoming load value must be scaled to 1.0 kilogram.
If the FB is used with the torque value of the drive, the xLcEn parameter of the MDS structure needs
to be set to FALSE (default). Incoming torque values must be scaled to 1.0 percent of torque.
Notifications
Identification of the alarm, if q_xAlrm is TRUE.
Commissioning Procedure
5. Look at the trace and stop it once the torque curve is constant.
6. Determine the average torque during the phase of running at nominal frequency.
Example:
7. Enter the value (here in the example: 30.0%) at the input i_stMDS.rTrqLoadNom.
8. Connect all other pins and make sure i_stMDS.xLcEn is FALSE.
Section 18.14
Function Block Description - PasswordDataStorage
Pin Diagram
The new function blocks are not pin-compatible with the obsolete function blocks.
Procedure Example
You have to create an instance of the PasswordDataStorage function block as shown in the
figure below:
The output variable must be connected bitwise to the reset input (i_xRst) of the function blocks
that should be reset by the PasswordDataStorage function block.
The connection between a Magelis XBTGT display and controller is supported with the SoMachine
protocol. The password coming from the Magelis uses a variable in the Global Variables List
(GVL).
After one cycle, the function block sets the incoming password back to zero.
i_xEn
By setting the i_xEn input to FALSE the output states will be overwritten by a defined fallback
state which is specific for each function block.
As soon as the function block gets enabled again the output states will be updated corresponding
to the function block behavior as described above. There is no additional action required from you
to re-establish the enabled state.
The fallback states of PasswordDataStorage are given in the table below.
Outputs that are not listed will retain their current values.
Section 18.15
Quick Reference Guide
Troubleshooting
Troubleshooting
Part XII
Overload Control
Overload Control
Overview
This part explains the functionality and implementation of the Overload control functions in the
Hoisting Library.
Chapter 19
Overload Control Function: Detect Mechanical Overload on Hoisting Devices
Section 19.1
Functional and Machine Overview
Functional Overview
Functional Description
The Overload control function helps to protect the hoisting equipment from mechanical overload.
The function uses the actual torque to detect an overload. In the case of an overload, it stops any
ascending motion of the hoist and only allows descent.
The Overload control function is applicable to:
Industrial cranes (Hoisting movement)
Construction cranes (Hoisting movement)
The Overload control function is designed to be used on ATV71 and ATV312 drives.
Legend:
Symbol Meaning
Intended movement
Symbol Meaning
Movement done
1. The operator wants to move a load from a higher position to the ground.
2. After lifting the load up, the Overload alarm is raised. A continued up movement is no longer
possible.
3. The load is set back on the starting position and the Overload alarm is reset.
Scenario B: Movement with moving the load to the side and attempting to the ground.
Legend:
Symbol Meaning
Intended movement
Movement done
1. The operator wants to move a load from a higher position to the ground.
2. After lifting the load up, the Overload alarm is raised. A continued up movement is no longer
possible.
3. The load is moved to the side to lower it down to the ground.
4. The load is lowered beneath the starting level. The AFB still maintains the alarm and does not
allow an up movement.
If the Hook reaches the Limit switch for the down movement, before lowering the load onto the
ground, the operator can not move the load either up or down. The AFB limits upward movement
of the load due to the Overload alarm, and the Limit switch does not allow further downward
movement. The load, which is overloading the crane, is suspended and the operator can not move
it.
To prevent this condition, you must make sure that the load length is greater than the distance
imposed by the Limit Switch Down Stop:
5. A high limit switch position for the Hook down stop movement could block either upward or
downward movement of the load.
6. To prevent this condition, the load length must be greater than the limit switch for down stop
movement level.
WARNING
PROLONGED SUSPENSION OF AN OVERLOAD
Ensure that the configuration of the mechanical limit switch down stop does not prevent any load
from being positioned on the ground.
Failure to follow these instructions can result in death, serious injury, or equipment damage.
WARNING
UNINTENDED EQUIPMENT OPERATION
Validate all function block input values before and while the function block is enabled.
Failure to follow these instructions can result in death, serious injury, or equipment damage.
Functional View
Machine Overview
Machine View
The following figure is the machine overview of the Overload control in the industrial crane.
The following figure is the machine overview of the Overload control in the tower crane.
Section 19.2
Architecture
Architecture
Hardware Architecture
Software Architecture
In this overload control torque method, when the actual torque is greater than or equal to the
maximum torque for a period of time defined by the user an overload alarm is generated. The
overload alarm will only reset when the actual torque is less than the hook torque and the hoist is
moving down.
In this overload control distance method, when the actual torque is greater than the maximum
torque for a period of time defined, an overload alarm is generated.
Distance traveled = Distance traveled + Actual speed (RPM) * (Controller scan time (ms) /60000)
The overload alarm will only reset when the actual torque is less than the maximum torque and the
distance traveled under overload is less than or equal to zero.
In this overload control encoder method, the encoder connected to the hoist motor is used as a
feedback to store the distance traveled under overload condition. When the actual torque is greater
than the maximum torque for a period of time defined, an overload alarm is generated.
The overload alarm will only reset when the actual torque is less than the maximum torque, and
the distance traveled under overload is less than or equal to zero.
Section 19.3
Function Block Description - OverloadCtrlTrq
Notice
This function block has become obsolete, but has been retained to maintain compatibility for older
applications. We recommend using the new function block Overload_EN15011. The new
function block is not pin-compatible with the obsolete function block.
Pin Diagram
Timing Chart
i_xEn
By setting the i_xEn input to FALSE the output states will be overwritten by a defined fallback
state which is specific for each function block.
As soon as the function block gets enabled again the output states will be updated corresponding
to the function block behavior as described above. There is no additional action required from you
to re-establish the enabled state.
Outputs that are not listed will retain their current values.
i_DrvTrqActl
This input i_iDrvTrqActl is read in through the CANopen interface directly from the drive. It is
a mandatory input for the function.
The range of the torque is 300% to 300%.
i_wHookTrq
You must run the drive without a load on the hook and note the percentage (0.1%/unit) load from
the monitoring menu on the drive or by monitoring the corresponding CANopen parameters. This
value should then be applied to this parameter. This is mandatory for Overload control torque.
q_xOvldAlrm
If any drive operation needs to be restricted during an overload condition, the application designer
must interlock this particular output to the crane program.
NOTE: The Overload alarm q_xOvldAlrm is retained after warm start.
Section 19.4
Function Block Description - OverloadCtrlDist
Notice
This function block has become obsolete, but has been retained to maintain compatibility for older
applications. We recommend using the new function block Overload_EN15011. The new
function block is not pin-compatible with the obsolete function block.
Pin Diagram
Timing Chart
NOTE: This timing chart does not describe the real behavior of the movement.
i_xEn
By setting the i_xEn input to FALSE the output states will be overwritten by a defined fallback
state which is specific for each function block.
As soon as the function block gets enabled again the output states will be updated corresponding
to the function block behavior as described above. There is no additional action required from you
to re-establish the enabled state.
The fallback states of OverloadCtrlDist are given in the table below.
Outputs that are not listed will retain their current values.
i_iDrvTrqActl
This input is read in through the CANopen interface directly from the drive. It is a mandatory input
for the function. The range of the torque is 300% to 300%.
i_iDrvSpdActl
The actual speed i_iDrvSpdActl is used to calculate the distance traveled.
Example:
Actual speed = 1500 RPM
Controller scan time = 200 ms (internal measurement)
Then traveled distance by the hoist for this scan (revolutions) = (1500) * (200/ (1000* 60))
Then traveled distance by the hoist for this scan = 5 (revolutions).
The distance traveled by the hoist is calculated by integrating the travel distance in each scan.
q_xOvldAlrm
This is the overload alarm output. If the upward movement of the hoist needs to be restricted during
an overload condition, the application designer must interlock this particular output to the crane
program.
q_rDistOvld
When an overload condition is detected during an upward movement, the distance traveled until
the stop is recorded. The load must be lowered back the position where the overload was first
detected to be able to reset the overload alarm.
NOTE: The overload alarm q_xOvldAlrm and the distance traveled q_rDistOvld under
overload are retained after warm start.
Section 19.5
Function Block Description - OverloadCtrlEnc
Notice
This function block has become obsolete, but has been retained to maintain compatibility for older
applications. We recommend using the new function block Overload_EN15011. The new
function block is not pin-compatible with the obsolete function block.
Pin Diagram
Timing Chart
NOTE: This timing chart does not describe the real behavior of the movement.
i_xEn
By setting the i_xEn input to FALSE the output states will be overwritten by a defined fallback
state which is specific for each function block.
As soon as the function block gets enabled again the output states will be updated corresponding
to the function block behavior as described above. There is no additional action required from you
to re-establish the enabled state.
The fallback states of OverloadCtrlEnc are given in the table below.
Outputs that are not listed will retain their current values.
i_iDrvTrqActl
The input i_iDrvTrqActl is read in through the CANopen interface directly from the drive. It is
a mandatory input for the function.
The range of the torque is 300% to 300%.
i_wEncPos
This is used as the feedback to calculate the distance traveled under overload.
NOTE: The 16 bit encoder resolution of WORD type is converted to 32 bit resolution DINT internally
by the function block.
q_xOvldAlrm
If the upward movement of the hoist needs to be restricted during an overload condition, the
application designer must interlock this particular output to the crane program.
NOTE: The overload alarm q_xOvldAlrm and the position are retained after warm start.
Section 19.6
Troubleshooting
Troubleshooting
Troubleshooting
Troubleshooting
Chapter 20
Overload_EN15011: Overload Calibration With the Requirements of EN15011
Section 20.1
Functional Overview
Functional Overview
Functional Overview
Functional Description
The Overload_EN15011 function block is applicable to the following types of cranes:
Industry Cranes (hoisting movement)
Construction Cranes
The function reads the torque inputs from the hoist drive. It detects an overload situation according
to the calibrated torque threshold and gives an alarm indication by lights and horn as well as
stopping the upwards movement of the hoist. Additionally an alert indication by lights and horn at
90% of the nominal calibrated load is generated.
The function also shows the actual mass of the load with an accuracy of +/- 5%, depending on the
setting of the speed loop of the drive.
The FB is conforms with the requirements of EN15011. Furthermore, it is possible to connect a
load cell instead of the drive torque value.
An internal calibration procedure (see page 657) allows easy commissioning of the thresholds and
the weight output.
This function block is intended to have significant influence on the physical movement of the crane
and its load. The application of this function block requires accurate and correct input parameters
in order to make its movement calculations valid and to avoid hazardous situations. If invalid or
otherwise incorrect input information is provided by the application, the results may be undesirable.
WARNING
UNINTENDED EQUIPMENT OPERATION
Validate all function block input values before and while the function block is enabled.
Failure to follow these instructions can result in death, serious injury, or equipment damage.
Section 20.2
Architecture
Architecture
Hardware Architecture
Software Architecture
Section 20.3
Function Block Description
Pin Diagram
Section 20.4
Pin Description
Pin Description
i_rSenIputActl
This is either the actual torque input from the drive, or the input from the load cell sensor scaled to
1 kg.
We recommend using the 4Q-Torque output of the drive scaled to 0.01% accuracy.
i_rDrvTrqMax
This is the torque threshold input that will trigger an overload alarm. It represents the torque of the
drive at 100% of the nominal load of the crane. If the measurement state of the
Overload_EN15011 FB calculates an actual torque above this value the upwards movement is
stopped and the overload alarm indicators q_xLampRed, q_xHorn are enabled.
If using a load cell this input is not used.
OVLD (i_stOVLD)
A structure of the data type OVLD containing configuration parameters.
wSpdDbnd
To be able to measure the actual torque correctly, constant speed is needed. Therefore the FB is
only starting to engage into the torque sampling, once the measurement frequency is reached.
Depending on the settings of the speed loop of the drive the actual speed is oscillating around the
target speed. To compensate this irregularity a dead band around the target speed is needed.
The FB defines target speed attainment as:
actual speed > ( target speed wSpdDbnd )
and
actual speed < ( target speed + wSpdDbnd )
wTrqBndCnt
During starting and acceleration the torque of the drive is oscillating. To measure the actual torque
correctly, the FB is waiting until the torque has settled and becomes relatively constant. This
parameter is the number of cycles the torque values from the drive need to be inside the torque
dead band defined by wTrqBndWdth to start the measurement.
wTrqBndWdth
Depending on the settings of the speed loop of the drive, the actual speed is oscillating around the
target speed. To compensate this irregularity a dead band for the torque is needed. The FB starts
counting values to fulfill wTrqBndCnt if the actual torque values are:
actual torque > ( actual torque of the last cycle * ( 1.0 wTrqBndWdth ))
and
actual torque < ( actual torque of the last cycle * ( 1.0 + wTrqBndWdth ))
wSmple
This is the number of samples (equaling controller cycles) that are taken during the torque
measurement. The resulting value is the average of all samples.
dwLoadNom
This is the nominal load of the hoist. If the nominal load is variable (e.g. changing based on the
position of the trolley on a jib of a tower crane) this value must be updated continuously to reflect
the actual nominal load.
wMeasFreq
This is the frequency in RPM at which the torque measurement is conducted. It must be bigger or
equal to the LSP setting of the drive. The smaller the value chosen, the earlier the measurement
will result in overload detection. We recommend setting this frequency higher than the slip of the
motor, even when running in closed loop.
wTrqThres
This is a percentage of torque to detect a change in load after the torque measurement. If the actual
value of the torque rises beyond this value, the drive is decelerated to measurement frequency
again and the torque is measured one more time. Make sure to set the value above the normal rise
of the torque during acceleration with a constant 100% load.
wAntiTip
From the start of the upwards movement of the hoist the distance is monitored. After a successful
measurement of the torque the monitoring is disabled. The FB will compare the actual distance
with the desired number of turns entered into this parameter. This is necessary to help prevent the
user from inching the load upwards without performing a load measurement, and thereby allowing
an excessive load to be lifted without triggering an alarm. If wAntiTip is engaged, it will stop the
upwards movement by setting the overload alarm output to TRUE.
If i_stOVLD.wAntiTip is at 55 turns and i_stOVLD.wEncPuls is at 1024, the maximum
distance available to measure the load is 55 x 1024 = 56320.
It is helpful to look at the q_wStat output of the FB during commissioning.
wNoTrq
This is a threshold of torque in percent.
Below this threshold value the measurement procedure is disabled.
If the motor is running with very little load, the actual torque value of the drive has high oscillations.
Therefore any torque measurement in this range would be too inconsistent to use in application.
rOvldThres
This is the tolerance adjustment of the overload detection. It can be set between 0% to 20%
tolerance.
If the maximum torque at 100% load is set to 10000, and rOvldThres is set to 1.1, a measured
torque of 11000 must be exceeded to detect overload.
xEnLdCell
To enable the usage of a load cell instead of using the torque of the drive, this bit must be set
TRUE. The signal of the sensor must be scaled to 1 kg. The measurement run at lifting up will be
disabled. All signaling, the overload alarm, the 90% alert, the lamps and the horn remain active.
The input pin i_rDrvTrqMax does not need to be connected.
rAcuWght
This is an optional dividing factor to the q_ wActWght output. By default it is set to 1.0 which puts
the weight output to a scaling of 1 kg.
rAcuWght q_wActWght
1.0 1 equals 1 kg
10.0 1 equals 10 kg
100.0 1 equals 100 kg
1000.0 1 equals 1 metric ton
This value is helpful for a display. A value of 123 with a scaling of 10 can be used to show the actual
weight in tons with 2 decimal places, i.e. on an ATV71 display.
wActWghtThres
If the hoist is used with no load or little load, the torque value of the drive is not always reproducible
and steady. Therefore it is possible to disable the actual weight output below a certain load, it will
then always be zero. If you put a value of 1000.0 to this input, all loads below 1000 kg are
represented as 0 kg. Depending on the mechanical circumstances of the crane the threshold for
reproducible and steady results is at around 30% of the available torque of the drive.
dwCalbWght
This is the weight value in kilogram used during the calibration, that means, the calibration bit
i_stOVLD.xCalb is TRUE. All internal calculations of the 100% load threshold are based on this
value, therefore it is very important to measure the weight used precisely. If calibration is inactive
this input does not have any effect.
xCalb
This is the switch to enable calibration. If the input i_rDrvTrqMax is left at zero the result of the
calibration is used to analyze the load. If any value unequal to zero is entered at the
i_rDrvTrqMax input, it will override the calibrated result.
Refer to the calibration procedure description (see page 657).
xOvld
This is the switch to enable the overload test during the acceptance test for a new crane.
If set to TRUE, it enables to lift loads with up to 300% torque. It can only be active for a maximum
of 5 hours of movement. If left active for longer than 5 hours an overload alarm will be triggered
preventing the upwards movement of the hoisting axis.
DANGER
CRANE OVERLOAD
You must provide the necessary security in the application of the xOvld input and restrict its use
to commission and test.
Failure to follow these instructions will result in death or serious injury.
q_xOvldAlrm
Indicates an overload incidence if TRUE. That means, during the measurement process stage of
the FB a torque value was calculated higher than i_rDrvTrqMax. The distance run since the start
of the movement was memorized and the load has to be brought down to the same position where
it was moved from to reset the alarm. The alarm is indicated by a constant horn and a flashing red
light 1 s on and off.
If using a load cell the input value of i_rSenIputActl is compared to i_stOVLD.dwLoadNom.
q_xOvldWrn
The calculated torque value of the measurement process stage of the FB is higher than 90% of
i_rDrvTrqMax. A advisory is given by the yellow light and the horn by being activated for 1 s on
and off. The advisory is reset by a new movement/measurement resulting in a lower torque value
than 90% of i_rDrvTrqMax. If using a load cell the input value of i_rSenIputActl is compared
to 90% of i_stOVLD.dwLoadNom.
q_wDrvSpdRef
This is the speed reference to the hoist drive. It is mandatory to transfer the target speed by this
block to get proper functionality of the torque measurement. See the instantiation example
(see page 655).
q_wStat
q_xAlrm
An alarm signal is generated in cases of incorrect parameterization of input values. Refer to the
q_wAlrmId table below. In case of an alarm the yellow light and the horn are flashing 1 s on and off.
q_wAlrmId
Identification of the alarm, if q_xAlrm is TRUE.
Section 20.5
Quick Reference Guide
Commissioning Procedure
Calibration Procedure
Troubleshooting
Troubleshooting
Part XIII
Scale Input
Scale Input
Chapter 21
ScaleInput: Change Incoming Input to a Scaled Value
Section 21.1
Functional Overview
Functional Overview
Functional Overview
Functional Description
The Scale input function scales an analog or counter input from a device to a desired output range.
Section 21.2
Architecture
Architecture
Software Architecture
DataFlow Overview
Section 21.3
Function Block Description
Pin Diagram
Section 21.4
Pin Description
Pin Description
i_xEn
By setting the i_xEn input to FALSE the output states will be overwritten by a defined fallback
state which is specific for each function block.
As soon as the function block gets enabled again the output states will be updated corresponding
to the function block behavior as described above. There is no additional action required from you
to re-establish the enabled state.
The fallback states of ScaleInput are given in the table below.
Outputs that are not listed will retain their current values.
Notifications
NOTE: An alarm does not stop the scaling. The input or output values are restricted to the given
limits.
Section 21.5
Troubleshooting
Troubleshooting
Troubleshooting
Troubleshooting
Part XIV
Smooth Slewing
Smooth Slewing
Chapter 22
Smooth Slewing Function: Stepwise Smooth Crane Movement Based on Speed or Torque Value of the Slewing Drive
Section 22.1
Functional and Machine Overview
Functional Overview
Functional Description
This function allows to turn construction cranes with different acceleration and deceleration levels.
As a result, it helps ensure a soft movement without creating a high force against the construction
of the crane.
When starting a slewing (rotation) movement of the jib on a tower or self-erecting crane, it is
necessary to overcome the inertia of the jib. There is always a chance of an over-torque (during
start) or over-speed (during stop) condition. To help prevent this over-torque or over-speed
condition, it is necessary to control the acceleration and deceleration ramps.
This specification explains two different solutions for smooth slewing:
Type 1 : Speed based
Type 2 : Torque based
WARNING
UNINTENDED EQUIPMENT OPERATION
Validate all function block input values before and while the function block is enabled.
Failure to follow these instructions can result in death, serious injury, or equipment damage.
Functional View
Machine Overview
Machine View
The following figure shows a tower crane with jib where the function blocks can be used to achieve
smooth slewing movement.
Section 22.2
Architecture
Architecture
Hardware Architecture
Software Architecture
Section 22.3
Function Block Description - SmoothSlewingSpd
Pin Diagram
Acceleration Parameter
During acceleration, the acceleration parameter is selected from 4 pre-defined acceleration values
(ACC1, ACC2, ACC3 and ACC4) as the actual speed reaches the threshold (speed1, speed2 and
speed3 respectively).
Example:
If Spd1 = 500 RPM, Spd2 = 1000 RPM, Spd3 = 1500 RPM (that is, Spd1 < Spd2 < Spd3) then:
NOTE: You must set speed levels such that Spd1< Spd2< Spd3 to give a four slope acceleration
curve. If less than four levels of acceleration are required, the values for ACC2, ACC3 and ACC4
should be set to the same value.
Deceleration Parameter
During deceleration, the deceleration parameter is selected from four pre-defined deceleration
values (DEC1, DEC2, DEC3 and DEC4), as the actual speed reaches threshold (speed4, speed5
and speed6 respectively).
Example:
If Spd4 = 1500 RPM, Spd5 = 1000 RPM, and Spd6 = 500 RPM (that is, Spd4 > Spd5 > Spd6) then:
NOTE: You must set Speed levels such that Spd4>Spd5>Spd6 to get a three slope deceleration
curve. If less than four levels of deceleration are required, the values for DEC2, DEC3 and DEC4
should be set the same.
i_xEn
By setting the i_xEn input to FALSE the output states will be overwritten by a defined fallback
state which is specific for each function block.
As soon as the function block gets enabled again the output states will be updated corresponding
to the function block behavior as described above. There is no additional action required from you
to re-establish the enabled state.
The fallback states of SmoothSlewingSpd are given in the table below.
Outputs that are not listed will retain their current values.
Notifications
NOTE:
On detection of alarm:
q_wDrvAcc is set to the i_wDrvAccLvl4.
q_wDrvDec is set to the i_wDrvDecLvl4.
Section 22.4
Function Block Description - SmoothSlewingTrq
Pin Diagram
Acceleration Parameter
During acceleration, the acceleration parameter is selected from 4 pre-defined acceleration values
(ACC1, ACC2, ACC3 and ACC4) as the actual torque reaches the threshold (Trq1, Trq2 and Trq3
respectively).
Example:
If Trq1 = 10%, Trq2 = 20%, Trq3 = 30% (that is, Trq1<Trq2<Trq3) then,
NOTE: You must set torque levels such that Trq1<Trq2 <Trq3 to give a four slope acceleration
curve. If less than 4 levels of acceleration are required, the values for ACC2, ACC3 and ACC4
should be set to the same value.
Deceleration Parameter
During deceleration, the deceleration parameter is selected from 4 pre-defined deceleration values
(DEC1, DEC2, DEC3 and DEC4), as the actual torque reaches threshold Trq4, Trq5 and Trq6
respectively.
Example:
If Trq4 = 30%, Trq5 = 20%, and Trq6 = 10% (that is, Trq4>Trq5>Trq6) then,
NOTE: You must to set torque levels such that Trq4>Trq5>Trq6 to get a three slope deceleration
curve. If less than four levels of deceleration are required, the values for DEC2, DEC3 and DEC4
should be set the same.
i_xEn
By setting the i_xEn input to FALSE the output states will be overwritten by a defined fallback
state which is specific for each function block.
As soon as the function block gets enabled again the output states will be updated corresponding
to the function block behavior as described above. There is no additional action required from you
to re-establish the enabled state.
The fallback states of SmoothSlewingTrq are given in the table below.
Outputs that are not listed will retain their current values.
Notifications
NOTE:
On detection of alarm:
q_wDrvAcc is set to the i_wDrvAccLvl4.
q_wDrvDec is set to the i_wDrvDecLvl4.
It is mandatory to have acceleration parameter i_wDrvAccLvl4 and deceleration parameter
i_wDrvDecLvl4
Section 22.5
Troubleshooting
Troubleshooting
Troubleshooting
Troubleshooting
Part XV
Speed Optimization and Rope Slack
Chapter 23
SpeedOptRopeSlack: Reduces Work Cycle Time and Avoid Start Up with Slack on the Rope
Section 23.1
Functional and Machine Overview
Functional Overview
Functional Description
The Speed optimization and rope slack function is designed to:
Optimize the utilization of power based on the actual torque of the drive.
Correct any rope-slack commonly found at the start or end of any hoisting operation.
WARNING
UNINTENDED EQUIPMENT OPERATION
Validate all function block input values before and while the function block is enabled.
Failure to follow these instructions can result in death, serious injury, or equipment damage.
NOTE: The load on the motor at hook level must be at minimum 10% of the nominal load.
Otherwise, the function can not work correctly due, at least in part, to the inefficiency of the gear
box. If the load torque is below the minimum 10%, the further reduction by the gear box creates a
scenario in which the ATV71 or ATV312 is not able to determine between generator and motor
mode. The result is a non optimized movement with limited speed.
Functional View
NOTE: The function Speed optimization and rope slack works with ATV312 or ATV71. In the
graphic, only ATV71 is shown, but ATV312 could also be used.
Machine Overview
Machine View
The following figure represents the machine view of tower crane using the Speed optimization and
rope slack function.
The following figure represents the machine view of an industrial crane with Speed optimization
and rope slack function.
NOTE: The function Speed optimization and rope slack works with ATV312 or ATV71. In the
graphic, only ATV71 is shown, but ATV312 could also be used.
Section 23.2
Architecture
Architecture
Hardware Architecture
NOTE: The function Speed optimization and rope slack works with ATV312 or ATV71. In the
graphic, only ATV71 is shown, but ATV312 could also be used.
Software Architecture
The Rope slack function is used to avoid slack in the rope when the hoist is moved in a downward
direction. If the actual torque drops below the user-defined hook-torque (for down movement)
during any downward movement, any further movement is restricted to the minimum speed until
the actual torque reaches the hook-torque. The speed reference is sent to the ATV drive which is
connected to the motor and to the mechanical assembly.
The following figure represents the Rope slack function for up and down movement.
DataFlow Overview
Section 23.3
Function Block Description
Pin Diagram
NOTE:
The function block is defined with two distinct inputs for hook torque:
Hook torque up
Hook torque down
The hook torque up is considered when the hoist is moving up and hook torque down is considered
when the hoist is moving down.
The Rope slack function is activated when the actual torque goes below or equal to 70% of the
hook torque up value when the hoist is moving up.
The Rope slack function is activated when the actual torque goes below or equal to 70% of the
hook torque down value when the hoist is moving down.
Timing Chart
Hoist Moving Up
Hoist Moving Down-Response of Speed on the Change of Motor and Generator Coefficient
NOTE: The timing diagram does not depict the real performance of the hoist.
Section 23.4
Pin Description
Pin Description
i_xEn
By setting the i_xEn input to FALSE the output states will be overwritten by a defined fallback
state which is specific for each function block.
As soon as the function block gets enabled again the output states will be updated corresponding
to the function block behavior as described above. There is no additional action required from you
to re-establish the enabled state.
The fallback states of SpeedOptRopeSlack are given in the table below.
Outputs that are not listed will retain their current values.
i_iDrvTrqActl
Do not use Motor Torque or Motor Torque Scope as an input for the actual torque inputs of the
drive.
Use 4 Quadrant Torque instead. Because 4 Quadrant Torque cannot be read by CANopen directly,
use AO1 of the drive to be read and configure 4 Quadrant Torque to the AO1 output.
Verify the scaling of AO1, it should be set to 4...20 mA. A value of 12 000 represents zero (0)
torque, 4 000 is -300% torque and 20 000 is 300% torque.
i_wGenTrqTimeAvge
Average torque calculation is disabled when the value at the pin i_wGenTrqTimeAvge is set to
zero. In this case the optimized speed for downwards movement is calculated continuously. The
average torque is recalculated when the drive is stopped and started again or a change in the
direction is detected. Actual torque is averaged only when the actual speed is equal to or greater
than the 90% of the nominal speed.
i_wDrvSpdRef
When the speed reference (i_wDrvSpdRef) is less than nominal speed (i_wDrvSpdNom) of the
drive, then
q_wDrvSpdTarg = i_wDrvSpdRef
q_wSpdTargMax = i_wDrvSpdNom
When the speed reference (i_wDrvSpdRef) is greater than or equal to Nominal speed
i_wDrvSpdNom, optimized speed is calculated.
i_wHookTrqUp
You are advised to run the drive without a load on the hook and record the percentage (%) load
from the Monitoring Menu on the drive or by monitoring the corresponding CANopen parameters.
When the Hoist is moving up and if the actual torque (i_iDrvTrqActl) is less than or equal to
70% of the hook torque (i_wHookTrqUp), then the target speed (q_wDrvSpdTarg) is set to
minimum speed reference (i_wDrvSpdLsp) and (q_wSpdTargMax) is set to (i_wDrvSpdNom).
NOTE:
Following are the points to be respected while using this input:
The load on the motor at hook level must be at minimum 10% of the nominal load. Otherwise,
the function cannot work correctly due to the efficiency of the gear box. If the load torque is
below the minimum 10%, the further reduction by the gear box creates the scenario in which the
ATV71 is not able to determine between generator and motor mode. The result is a non-
optimized movement with limited speed.
When the i_wHookTrqUp input is set to zero, Rope slack detection and correction while
moving up is disabled.
When the i_wHookTrqDown input is set to zero, Rope slack detection and correction while
moving down is disabled.
i_wHookTrqDown
You are advised to run the drive without a load on the hook and record the percentage (%) load
from the Monitoring menu on the drive or by monitoring the corresponding CANopen parameters.
When the Hoist is moving down and if the actual torque (i_iDrvTrqActl) is less than or equal
to 70% of the hook torque (i_wHookTrqDown), then the target speed (q_wDrvSpdTarg) is set to
minimum speed reference (i_wDrvSpdLsp) and (q_wSpdTargMax) is set to (i_wDrvSpdNom).
q_wDrvSpdTargMax
The values of this input are calculated as follows:
q_wDrvSpdTarg = i_wDrvSpdNom if i_wDrvSpdRef < i_wDrvSpdRef < i_wDrvSpdNom
(normal mode) or
When i_iTrqact 70% of i_wHookTrqUp or i_wHookTrqUp, q_wDrvSpdTargMax =
optimized speed if i_wDrvSpdRef = i_wDrvSpdNom (speed optimized mode)
Notifications
NOTE: On detection of alarm, the target speed (q_wDrvSpdTarg ) and maximum speed reference
(q_wMaxSpdTarg) are set to zero.
Section 23.5
Troubleshooting
Troubleshooting
Troubleshooting
Troubleshooting
Part XVI
Speed Select
Speed Select
Chapter 24
SpeedSelect: Provides the Option to Choose between 8 Predefined and one Analog Speed
Section 24.1
Functional Overview
Functional Overview
Functional Overview
Functional Description
The SpeedSelect function block allows you to control the speed inside the application that is
communicated to the ATV71 or ATV312 drives using an analog input channel or selector switch.
You have the flexibility to select 8 pre-selectable speeds using the selector switch.
Section 24.2
Architecture
Architecture
Software Architecture
DataFlow Overview
Section 24.3
Function Block Description
Pin Diagram
Section 24.4
Pin Description
Pin Description
NOTE:
The Forward and Reverse command are allowed to pass through, even in the presence of a
detected alarm.
The input Forward Slow (i_xDrvFwdSlow) and Reverse Slow (i_xDrvRevSlow) has the
highest priority over the Speed Select input (i_xDrvSpdSel).
When the Forward Slow or Reverse Slow input is activated, the output Speed Reference is set
to i_wDrvSpdLsp.
i_xEn
By setting the i_xEn input to FALSE the output states will be overwritten by a defined fallback
state which is specific for each function block.
As soon as the function block gets enabled again the output states will be updated corresponding
to the function block behavior as described above. There is no additional action required from you
to re-establish the enabled state.
The fallback states of SpeedSelect are given in the table below.
Outputs that are not listed will retain their current values.
i_wDrvSpdRefAna
This input pin allows you to control the speed of the drive using an analog input channel. It is the
speed reference from analog input device like a joystick. i_wDrvSpdSel input must be set to zero
to select analog input as reference.
NOTE: You should scale the analog reference input to RPM units. The ScaleInput function block
can be used for this purpose.
Notifications
Bit Description
Number
0 i_DrvSpdHsp is less than or equal to i_wDrvSpdLsp.
1 One of the pre-selectable speeds ( 1-8 ) is lower than i_wDrvSpdLsp.
2 One of the pre-selectable speeds ( 1-8 ) is higher than i_wDrvSpdHsp.
Section 24.5
Troubleshooting
Troubleshooting
Troubleshooting
Troubleshooting
Part XVII
Wind Speed Control
Chapter 25
WindSpeedCtrl: Monitors and Provides Alarms for High Wind Conditions
Section 25.1
Functional and Machine Overview
Functional Overview
Functional Description
The Wind speed control function monitors the wind speed and generates an alert and/or alarm
when it exceeds a specified limit. It attracts the attention of the operator with yellow and red
indicator lamps and a horn.
This function is used to generate an alert when the wind speed is above the set alert threshold.
The WindSpeedCtrl function block is applicable to the following types of cranes:
Industrial Cranes (outdoor use)
Construction Cranes
Functional View
NOTE: The function works with ATV312 or ATV71. In the graphic, only ATV312 is shown, but
ATV71 could also be used.
Machine Overview
Machine View
The following illustrates wind speed control being used on a tower crane.
NOTE: The function works with ATV312 or ATV71. In the graphic, only ATV71 is shown, but
ATV312 could also be used.
Section 25.2
Architecture
Architecture
Hardware Architecture
Software Architecture
Section 25.3
Function Block Description
Pin Diagram
Timing Chart
The following figure represents the timing and signals diagram for WindSpeedCtrl function block.
Section 25.4
Pin Description
Pin Description
i_xEn
By setting the i_xEn input to FALSE the output states will be overwritten by a defined fallback
state which is specific for each function block.
As soon as the function block gets enabled again the output states will be updated corresponding
to the function block behavior as described above. There is no additional action required from you
to re-establish the enabled state.
The fallback states of WindSpeedCtrl are given in the table below.
Outputs that are not listed will retain their current values.
Notifications
Glossary
!
%
According to the IEC standard, % is a prefix that identifies internal memory addresses in the logic
controller to store the value of program variables, constants, I/O, and so on.
A
AFB
(application function block)
analog input
Converts received voltage or current levels into numerical values. You can store and process these
values within the logic controller.
analog output
Converts numerical values within the logic controller and sends out proportional voltage or current
levels.
application
A program including configuration data, symbols, and documentation.
ARRAY
The systematic arrangement of data objects of a single type in the form of a table defined in logic
controller memory. The syntax is as follows: ARRAY [<dimension>] OF <Type>
Example 1: ARRAY [1..2] OF BOOL is a 1-dimensional table with 2 elements of type BOOL.
Example 2: ARRAY [1..10, 1..20] OF INT is a 2-dimensional table with 10 x 20 elements of
type INT.
ATV
The model prefix for Altivar drives (for example, ATV312 refers to the Altivar 312 variable speed
drive).
C
calibration
The process of setting or maintaining the accuracy of a measuring device by comparing its value
to a known and correct standard.
CANmotion
A CANopen-based motion bus with an additional mechanism that provides synchronization
between the motion controller and the drives.
CANopen
An open industry-standard communication protocol and device profile specification (EN 50325-4).
closed loop
A closed loop control is a motion control system that used both positional feedback and velocity
feedback to generate a correction signal. It does this by comparing its position and velocity to the
values of specified parameters. The devices providing the feedback are typically encoders,
resolvers, LVTDs, and tachometers.
See also: open loop
closing on stack
process of filling the grab with bulk cargo
configuration
The arrangement and interconnection of hardware components within a system and the hardware
and software parameters that determine the operating characteristics of the system.
controller
Automates industrial processes (also known as programmable logic controller or programmable
controller).
D
derating
A reduction in an operating specification. For devices in general, it is usually a specified reduction
in nominal power to facilitate operation at increased ambient conditions like higher temperatures
or higher altitudes.
E
element
The short name of the ARRAY element.
encoder
A device for length or angular measurement (linear or rotary encoders).
equipment
A part of a machine including sub-assemblies such as conveyors, turntables, and so on.
expansion bus
An electronic communication bus between expansion I/O modules and a controller.
F
FB
(function block) A convenient programming mechanism that consolidates a group of programming
instructions to perform a specific and normalized action, such as speed control, interval control, or
counting. A function block may comprise configuration data, a set of internal or external operating
parameters and usually 1 or more data inputs and outputs.
function
A programming unit that has 1 input and returns 1 immediate result. However, unlike FBs, it is
directly called with its name (as opposed to through an instance), has no persistent state from one
call to the next and can be used as an operand in other programming expressions.
Examples: boolean (AND) operators, calculations, conversions (BYTE_TO_INT)
G
GVL
(global variable list) Manages global variables that can be passed between controllers on an
Ethernet TCP/IP Modbus network.
H
HSP
(high speed) The motor frequency at maximum reference of a drive.
I
I/O
(input/output)
ID
(identifier/identification)
L
LMC
(Lexium motion controller)
LMC058
Lexium motion controller A Modicon logic controller
LSP
The motor frequency at minimum reference of a drive.
M
M258
Modicon M258 logic controller
machine
Consists of several functions and/or equipment.
ms
(millisecond)
N
N/C
(normally closed) A contact pair that closes when the actuator is de-energized (no power is
applied) and opens when the actuator is energized (power is applied).
N/O
(normally open) A contact pair that opens when the actuator is de-energized (no power is applied)
and closes when the actuator is energized (power is applied).
node
An addressable device on a communication network.
O
open loop
Open loop control refers to a motion control system with no external sensors to provide position or
velocity correction signals.
See also: closed loop.
OTB
(optimized terminal block) Used in the context of STB I/O distributed modules.
P
PDO
(process data object) An unconfirmed broadcast message or sent from a producer device to a
consumer device in a CAN-based network. The transmit PDO from the producer device has a
specific identifier that corresponds to the receive PDO of the consumer devices.
PID
(proportional, integral, derivative) A generic control loop feedback mechanism (controller) widely
used in industrial control systems.
program
The component of an application that consists of compiled source code capable of being installed
in the memory of a logic controller.
project file
A project file contains information about the developer and purpose of a project, the configuration
of the targeted logic controller and associated expansion modules, the source code of a program,
symbols, comments, and all other related information.
protocol
A convention or standard definition that controls or enables the connection, communication, and
data transfer between 2 computing system and devices.
R
REAL
A data type that is defined as a floating-point number encoded in a 32-bit format.
RPDO
(receive process data object An unconfirmed broadcast message or sent from a producer device
to a consumer device in a CAN-based network. The transmit PDO from the producer device has a
specific identifier that corresponds to the receive PDO of the consumer devices.
RPM
(revolutions per minute)
run
A command that causes the controller to scan the application program, read the physical inputs,
and write to the physical outputs according to solution of the logic of the program.
S
scan
A function that includes:
reading inputs and placing the values in memory
executing the application program 1 instruction at a time and storing the results in memory
using the results to update outputs
setpoint
In a PID controller, the target value set by the user. The main objective of the PID controller is to
ensure that the process value reaches the setpoint.
See also process value.
STOP
A command that causes the controller to stop running an application program.
T
task
A group of sections and subroutines, executed cyclically or periodically for the MAST task or
periodically for the FAST task.
A task possesses a level of priority and is linked to inputs and outputs of the controller. These I/O
are refreshed in relation to the task.
A controller can have several tasks.
V
variable
A memory unit that is addressed and modified by a program.
W
WORD
A type encoded in a 16-bit format.
Index
A H
AdvancedPositioning, 49 Hoisting
AlarmDataStorage, 549 AdvancedPositioning, 49
AlarmDataStorage_2, 553 AlarmDataStorage, 549
anti sway function, 159 AlarmDataStorage_2, 553
AntiCrab, 103 anti sway function, 159
AntiCrab_2, 125 AntiCrab, 103
AntiSwayOpenLoop, 214 AntiCrab_2, 125
AntiSwayOpenLoop_2, 231 AntiSwayOpenLoop, 214
architecture AntiSwayOpenLoop_2, 231
hardware architecture, 45 CableLength_2Pos, 186
CableLength_3Pos, 186
CableLength_Enc, 186
C CableLength_Enc_2, 186
CableLength_2Pos, 186 cranes, 31
CableLength_3Pos, 186 DiagnosticCoverage, 257
CableLength_Enc, 186 DoubleLimitSwitch_AR, 425
CableLength_Enc_2, 186 DoubleLimitSwitch_AR_2, 449
ElectronicPotentiometer, 277
EncAlarmDataStorage, 573
D
DiagnosticCoverage, 257
DoubleLimitSwitch_AR, 425
DoubleLimitSwitch_AR_2, 449
E
ElectronicPotentiometer, 277
EncAlarmDataStorage, 573
G
GrabControl, 299