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MOORING EQUIPMENT

- Instruction manual -

EQUIPMENT:

MW--T-EL-200/10/25-GDW-NLF Mooring Winch (Starboard side)


MW--T-ER-200/10/25-WDG-NLF Mooring Winch (Port side)
................................ Winch control box
................................ Electric control cabinets
................................ Portable joystick control station

SPLIT, 2013.
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Safety information - Important

SAFETY INFORMATION
- IMPORTANT -

Operators of the AdriaWinch deck machinery and mooring


systems shall be qualified and trained personnel.

The personnel shall have relevant knowledge to the system and


procedures involved.

The machinery shall be operated in accordance with the


procedures described in this manual.

Service work may only be carried out by specialists. This requires


knowledge of the machine’s functions, as well as safety technical
measures.

Failure to obey these warnings can lead to severe injuries or death,


or could cause damage to the ship's equipment or the ship's
environment.

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Contents

Contents
1. TECHNICAL DESCRIPTION.............................................................................................................................. 7
1.1. MOORING WINCH ................................................................................................................................................ 7
Tech. Spec. for Mooring Winch ..................................................................................................................... 10
Mooring Winch Driving Electromotor ........................................................................................................... 11
Driving Electric motor ................................................................................................................... 11
Voltage....................................................................................................................................................... 11
Design data ................................................................................................................................................................ 11
Other technical data ................................................................................................................................................... 11
Built-in equipment ..................................................................................................................................................... 11
Frequency inverter ..................................................................................................................................................... 11
Winch electric control cabinet ....................................................................................................................... 12
Portable joystick control station (radio control) ........................................................................................... 13
Control box .................................................................................................................................................... 13
2. INSTALLATION OF THE EQUIPMENT ........................................................................................................ 15
2.1. MOORING WINCH .............................................................................................................................................. 15
2.2. ELECTRIC INSTALLATION .................................................................................................................................. 16
3. OPERATING INSTRUCTIONS ......................................................................................................................... 19
3.1. PRECAUTIONS .................................................................................................................................................... 19
3.2. GENERAL ........................................................................................................................................................... 19
3.3. MOORING WINCH .............................................................................................................................................. 19
Mooring drum band brake ............................................................................................................................. 19
Mooring drum coupling ................................................................................................................................. 21
Control cabinet .............................................................................................................................................. 21
Winch operations – Control box .................................................................................................................... 22
Winch operations - Portable joystick control station (radio control) ............................................................ 24
Emergency stop button ................................................................................................................................... 25
Normal operating procedure ......................................................................................................................... 26
Motor overload condition .............................................................................................................................. 26
Automatic mooring ........................................................................................................................................ 27
Automatic Mooring Procedure................................................................................................................................... 27
Automatic mooring backup mode .................................................................................................................. 29
Working with Split Mooring Drum ................................................................................................................ 30
General....................................................................................................................................................................... 30
Split mooring drum .................................................................................................................................................... 30
Warping procedure ........................................................................................................................................ 32
4. MAINTENANCE .................................................................................................................................................. 33
4.1. REGULAR CHECKING ......................................................................................................................................... 33
4.2. MAINTENANCE OF THE CONTROL CABINET ........................................................................................................ 34
4.3. WINCH SENSORS REPLACING PROCEDURE.......................................................................................................... 34
4.4. LUBRICATION .................................................................................................................................................... 35
Recommended grease types ........................................................................................................................... 35
Recommended oils for the gear reducers ....................................................................................................... 36
Lubrication charts.......................................................................................................................................... 37
4.5. MAINTENANCE AND ADJUSTMENT OF THE BRAKE ............................................................................................. 39
Procedure for changing of brake linings ....................................................................................................... 39
Adjusting the brake ........................................................................................................................................ 40
4.6. LONG TIME PARKING MAINTENANCE ................................................................................................................. 41
5. TROUBLESHOOTING ....................................................................................................................................... 43
5.1. MOORING WINCH TROUBLESHOOTING GUIDE................................................................................................... 43
6. ALARMS LIST ..................................................................................................................................................... 45

7. SPARE PARTS ..................................................................................................................................................... 47

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7.1. ORDERING OF THE SPARE PARTS ....................................................................................................................... 47
7.2. SPECIFICATION: MOORING WINCH, MW-T-EL-200/10/25-GDW-NLF............................................................ 48
7.3. SPECIFICATION: MOORING WINCH, MW-E2R-100/14,7/30-GDW ................................................................... 49
7.4. SPECIFICATION: MOORING WINCH - 3-STAGE REDUCING GEAR......................................................................... 50
7.5. SPECIFICATION: BRAKE T800/120/15-336 ........................................................................................................ 54
7.6. SPECIFICATION: MOORING DRUM COUPLING ARRANGEMENT............................................................................ 56
7.7. SPECIFICATION: ELECTRIC SCHEMES................................................................................................................. 57
8. APPENDIX ........................................................................................................................................................... 59

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Technical description

1. Technical description

1.1. Mooring Winch


Mooring winch (one starboard and one port side) has one split mooring drum and warping end.
(Drawing No. 939-050-00 SB and 939-060-00 PS).
Working temperature range of all parts exposed on the deck is: from -15°C to +45°C at 75%
humidity.
Mooring winch consists of the following main groups:

• Reducing gear
• Main shaft
• Mooring drum with split flange
• Claw coupling
• Band brake (manual)
• Warping drum
• Bearing block
• Electromotor
• Control box
• Portable joystick control station with storage cabinet
• Inductive sensor – detection of position of the clutch handle
• Junction box (for inductive sensor)

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Reducing gear - is performed as three-stage reducer with spur gears.

Reducing gear housing - is designed as welded structural steel construction, fully enclosed.
Spur gears and shafts are made of heat-treated steel with high performance. Gearbox shafts
including main shaft are supported with self - adjusting roller bearings. Lubrication of parts is
done with oil bath.

Main shaft - is made of heat-treated steel tempered at tensile strength of 900 MPa, and is
capable to withstand brake holding load operating conditions.

Mooring drum with split flange – is performed as welded steel structure. Mooring drum
bearings are made of bronze lubricated with grease.

Claw coupling - for mooring drum is performed as welded steel structure from material GS-
42CrMo4. Coupling is lubricated with lubrication grease.

Mooring drum band brake - is designed to withstand loads of brake holding load 385 kN.

Warping drum - is made of cast iron EN – GJS – 500 - 7.

Bearing block - is made of structural steel as welded construction with coupling arrangement
base plates. Bearings are made of bronze and lubricated with grease.

Electromotor - is manufactured by "Končar MES",


Type: "7ABZKA 250M-8TAG IM B5". For detail technical information see Appendix.

Control box – is delivered with winch and is intended to be mounted on deck near the winch.
For details see chapter “Winch operations – Control box”.

Portable joystick control station – is manufactured by “Cavotec" and includes storage


cabinet that is intended to be mounted on deck near the winch, and remote control station base
unit with protection cabinet. For details see chapter “Winch operations – Portable joystick
control station (radio control)”.

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Technical description

9
Tech. Spec. for Mooring Winch

1x MOORING DRUM

Drum capacity 200 m synthetic rope φ 60 mm (stored in 6 layers)


Drum dimensions φ508 / φ1420 x (550+350) mm
Nominal pull at low
200 kN at 1st layer
speed range
st
Low pull at high speed 60 kN at 1 layer and speed 25 m/min
st
Rope low speed range 2,5÷10 m/min on 1 layer/
(f = 14 ÷ 60 Hz) 5÷21 m/min at full drum
High speed range 10 ÷ 25 m/min on 1st layer /
th
(f = 60 ÷ 140 Hz) 21 ÷ 50 m/min at 6 layer – full drum
Brake and clutch controls Locally manually operated

Brake holding force 385 kN

1x WARPING HEAD
180 kN at 11 m/min
Pull and speed
55 kN at 27 m/min
Performance Keyed to the shaft

Dimensions φ560 x 570 mm

GENERAL

Gear performance Oil bath – fully enclosed

Winch driving engine Electromotor with frequency inverter, see specification

Winch control Control box and portable joystick control station

Winch mass 3500 [kg]

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Technical description

Mooring Winch Driving Electromotor

- Manufacturer “Končar – MES”


- Type 7ABZKA 250M-8TAG IM B5
- Voltage 690V

Driving Electric
motor
Voltage 690 (V)

Rated output Rated speed Rated


U (V) f (Hz) current at Duty type
P (kW) n (rev/min) 690 V (A)
690 D 43 830 60 60 S2-30 min

Design data

Mounting arrangement IMB5


Protection by enclosure IP56
Terminal box enclosure IP56
Standard of shipping DNV
Cooling arrangement IC410
Direction of rotation BOTH
Ambient temperature +45 C
Class of insulation F
Temperature rise 90K
DE Bearing Rolling, grease lubricated
NDE Bearing Rolling, grease lubricated

Other technical data

Motor starting Direct on line


Overload 1.5-2min

Motor can withstand 15 sec with blocked rotor at 2p=8 (830 rev/min)

Built-in equipment

In winding 3 pcs PTC PT100


Space Heater 2x65W; 220V; 50Hz
Electromagnetic brake Uk = 190Vdc; Mk=900Nm

Frequency inverter

“Schneider” ATV71HD55Y 55 kW 690V 3P for electric motor stepless speed control.

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Winch electric control cabinet

Installation of the cabinet has to be done in accordance with the schemes included in
Appendix

Mooring winch has it's own control cabinet (mounted below deck – IP 55). Each cabinet inside
contains Main switch (Start/Stop), circuit breaker, frequency inverter, anti-condensation
heating, hour counter and all necessary components for control of the winch.

The schematic drawing with part specification is included in this manual – See specifications in
chapter "Spare Parts" and schemes in "Appendix").

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Technical description

Portable joystick control station (radio control)

There is one remote control station for starboard side winch and one for portside winch. Radio
control is equipped with stepless joystick for winch manipulation, emergency stop, control
activation switch, MAN/AUTO mooring selection switch, transmitter off/on switch, tension
setting potentiometer for automatic mooring mode, rope tension LCD display, indication lamps
and etc.

Remote control station is stored in storing cabinet IP66. Cabinet is equipped with remote
control station carrier, heater and battery charger for remote control station.

Remote control station base unit is stored in it’s cabinet. Cabinet is used for protection of base
unit.

For detailed description and using instructions see chapter "Operating Instructions – Winch
operations”.

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Control box

There is one control box for starboard side winch and one for port side winch. Control box
comes together with emergency stop push button and has potentiometer for speed control,
switch for winch manipulation, local-remote switch, automatic mode switch, auto-tension
potentiometer, el. motor current indicator, motor torque indicator, actual force indicator and
indicator lamps. Control box is mounted on deck near the winch (IP 56).

Emergency stop
pushbutton

For detailed description and using instructions see chapter "Operating Instructions - Winch
Operations".

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Installation of the equipment

2. Installation of the equipment

2.1. Mooring Winch


1. The winch is to be mounted on the specially prepared winch stand. The surrounding
structure must be strengthened to withstand the loads generated by the winch. The
drawing with foundations and mounting holes ("bore picture") for winch is provided in
obligatory documentation and also within Appendix-Drawings section, in this manual.
2. The winch foundation is to be welded to the deck structure, keeping the top level within
the tolerances of ±0,5 mm in any direction. Check by means of piano wire or similar.
3. Check that the “bore picture” of the winch foundation is within the tolerance of ±1,5 mm.
4. Place the winch on the foundation resting on the adjustment screws.
5. When the equipment is positioned on the foundation, check that foundation bolts slip
easily through bolt holes.
6. Slightly tighten the foundation bolts on the gear case base plates, and use this as the
master when aligning the main shaft through the bearing bracket.
7. Position the bearing bracket. Be sure that the main shaft rests properly in the bearing.
8. Adjustment is done by the adjustment screws in the foundations. Adjust with ± 0,1 mm
tolerance.
9. Tighten the bearing bracket bolts slightly when in position.
10. Place the brake support in accordance with the foundation and check the following:
• The brake fits properly around brake pulley
• Is vertically correct
• Foundation bolts must slip easily through the bolt holes. Then tighten the bolts
slightly. Or, if support is to be welded - place the support according to fundaments
drawing. Arc weld procedure using "DIN1913 - E 51 54 B 10" electrode or with
MAG procedure with shield gas SG2 or SG3 according to DIN 8559.
11. The winch is now ready for casting of the linear compound or making the final steel liners.

The thickness of the liner compounds must be in accordance with compound


maker’s recommendation.

12. All electric connections are to be made after the compound is properly hardened and
foundation bolts tightened.
13. As the final check of the alignment, winch will be rotated for 30 minutes in each direction
with bearing temperature monitored.

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2.2. Electric Installation

Installation of electric equipment has to be done by qualified and trained personnel and
according to schemes provided within this manual. Servicing of the electric equipment
has to be done by Adria winch approved service. Improper electric installation or
altering any part of electric circuit or software data can cause severe injuries or
damage.

Electric installation refers to:


• Winch electro control cabinets – every winch has it's own control cabinet containing
switches, frequency inverter, automation, measuring and other electric equipment
(Dimensional and Schematic drawings):

No. 939-651-00, 939-650-00 pages 1-14, 939-655-00 pages 1-4 - Starboard side and
Portside,

• Winch control box with separate emergency stop pushbutton – every winch has it's
own control box with separate emergency stop pushbutton mounted on deck near the
winch (Dimensional and Schematics drawing):
No. 939-653-00 - Starboard side and Portside,

• Portable joystick control station with storage cabinet - every winch has it’s own
portable joystick control station with storage cabinet and radio base unit with cabinet
for base unit. Storage cabinet is equipped with battery charger and heater
(Dimensional drawing):

No. 939-610-01, 939-610-02 - Remote control unit SB and PS


No. 939-651-01 - Cabinet for winch portable control station storing
No. 939-651-02 - Cabinet with radio base unit

Cabinet with Radio base unit should be placed in such manner that it provides
unobstructed communication between Remote control unit and Radio base unit.

Winch control box is intended to be mounted directly on deck. Mount it near the winch so the
winch operation is safe for the operator and with good overview of the situation.

Do not place the control box where the operator might be in danger eg. in line of
tensioned rope.

Scheme on next page represent global description of the mooring equipment electric system.
Detailed schemes are provided within Appendix.

16
Installation of the equipment

17
Control box

Emergency stop
pushbutton

Connection
cable

- Mount emergency stop near the control box in such manner that it provides easy access.

18
Operating instructions

3. Operating instructions

3.1. Precautions
• Before doing any operations with the mooring equipment take all necessary precautions needed
for safety of the equipment and personnel.
• Do not stand in the line of tight rope when the winch is operating.
• Do not touch rotating/moving parts.
• Never improvise or misuse the equipment for any operation that is not described in this manual.

3.2. General
• Main switch inside Control cabinet should be "ON".
• Check winch gear drive oil level
• Check electric systems – pilot lamps
Winch is controlled with portable joystick control station or with local control box installed near
the winch on deck.

Perform winch operations one by one. Never use winch for two or more operations
simultaneously e.g. warping and mooring at the same time etc. This leads to equipment
damage and possible accidents or injuries.

3.3. Mooring Winch

Mooring drum band brake

Winch is equipped with manually operated band brake.


Brake is activated (“On”) by turning handle in clockwise direction, and deactivated (“Off”) by
turning the handle in the opposite direction. Force on the handle is multiplied by thread spindle
and lever system (see picture below).

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The brake support screw has to be adjusted as the brake lining wears. It is necessary that the
gap between this screw and the brake band is approx. 3 mm (measured while the brake is
tighten). When the adjustment is done, set the counter nut to secure support screw in position.

Brake should be adjusted before test probe and Brake Mooring


adjustment should be checked at least every three months. handle drum
When the brake lining wears to the thickness of approx. 4-
Brake
5 mm, it is necessary to change it (new lining is 10 mm
band
thick). For changing of brake linings, see chapter
“Maintenance and adjustment of the brakes” of this
manual. Brake
lining
Before operating with winch brake should be prepared. For
safe and failure-free operation, the following should always
be done:
• Engage and disengage brake several times to
achieve full operating function of brake, and to
remove eventual corrosion attacks.
• Check that the brake adjustment is correct.
• Grease all grease nipples on the brake
mechanism if necessary Gap
• Check the brake lining wear. 3 mm

Adjustment
screw

The brake lining thickness and the brake adjustment is very important for safe
operation of the mooring drum brake performance.

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Operating instructions

Mooring drum coupling

Coupling is controlled with hand lever. It has two possible positions (Engaged & Disengaged).
The lever must be secured with safety pin when in proper position – meaning that the coupling
claw is completely engaged / disengaged. The lever must never be somewhere between those
2 positions because the coupling claw could get damaged or dangerous situation can develop if
the mooring drum starts to rotate free on shaft. Before uncoupling be sure to secure the
mooring drum with band brake. If the counter coupling claws are forced to each other, the
friction force does not allow moving the coupling lever. To move it then, do not apply force to
the lever, but slowly move the winch shaft in appropriate direction to free the claw. Operation
with coupling lever must be easy and smooth.

Control cabinet

Each winch is equipped with control cabinet located below deck. Lamps and instruments are
described on image below.

Motor fan
Hour
meter

Main switch “ON”


indication lamp

Heater “ON”
indication
lamp

Control cabinet is equipped with:


- Hour meter which is running hour counter
- Heather with indication lamp (white pilot lamp)
- Main switch “ON” indication lamp – control cabinet under voltage (blue pilot lamp)
- Main switch which is located inside cabinet. Set switch to position “1” when working
with equipment.

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Winch operations – Control box

Each mooring winch has control box mounted on deck near the winch. Buttons, lamps and
instruments are described on image below:
Actual force Motor torque Drum engaged
display display lamp
Automatic
mode lamp
Time-based
READY AUTOMATIC ACTUAL FORCE
automooring lamp
SPEED DRUM ENGAGED
Ready lamp
1 0 11 kN TIME-BASED
Overheating lamp
2 10
MOTOR TORQUE AUTOMOORING
3 9
Winch speed 4 8
Excessive force
OVERHEATING
potentiometer 5 6 7 (Overload) lamp
CABLE
PAYING-OUT 0 HAULING-IN Nm
FORCE>120%
MOTOR CURRENT Cable slack lamp
Drum rotating
direction switch CABLE SLACK
A Fault lamp
FAULT

MOORING AUTOMATIC MODE


REF. FORCE 200kN
LOCAL 0 REMOTE DRIVE 0 LOAD CELL Motor current
“Local-remote” 2
1 0 11
10 display
mooring switch 3 9
4 8
5 6 7 Tension force
potentiometer
Automatic mooring
mode switch
„EMERGENCY STOP“
button
To control winch via control box:

• Set main switch located in electric cabinet below deck to position “ON”
• Set “local-remote” switch on control box to position “local”
• Lamp “Ready” should lit up whit steady light indicating that winch is ready for operation
• If working with mooring drum, lamp “Drum engaged” should lit up indicating drum clutch
engaged, otherwise if working with warping drum, lamp “Drum engaged” is not lighting
indicating drum clutch disengaged
• Set drum rotating direction switch left for paying rope out or right for hauling rope in
• During paying-out or hauling-in, rotate “Winch speed potentiometer” to desired winch
speed (0 – refers to zero winch speed, thus 10 – refers to winch highest speed)
• For automatic mooring (auto-tension) mode, rotate “Tension force potentiometer” to
desired position (potentiometer dial is dived from 0 to 10, representing percentage 0 –
100% of nominal pulling force; 10 – refers to rope nominal pulling force of 200 kN;
divide between two numbers is 20 kN) and set “Automatic mooring mode” switch to
position “Load cell”. Winch should from now on self-maintain previously set force in the
rope.
• Use “Actual force” display for monitoring force in the rope.
• If automatic mooring, on “Load cell” mode, doesn’t work use “Drive” mode. “Drive”
mode is backup mode for auto-tension. “Load cell” – refers to obtaining rope force
using load cells readings, thus “drive” – refers to obtaining rope force using frequency
inverter electromotor moment readings. “Drive” mode of auto-tension leads to
overheating of frequency inverter and is not capable to read force in the rope, thus this
mode should be used only as backup. “Automatic mooring mode” switch should be
primarily set to “Load cell” mode for auto-tension, “Drive” mode should be used
only as backup mode for auto-tension.
• Lamp “Automatic” should lit up indicating that auto-tension mode is activated (winch is
self-maintaining desired force on the rope)

22
Operating instructions

Note: If “Fault” lamp lights up soon after the “Automatic mode” switch is engaged
(either on “Load cell” or “Drive” position) it indicates defective load cells. Replacement
of load cells needs to be done.

Control box is equipped with three switches:


- “Local-remote mooring” switch which is used for selecting local or remote winch
control,
- “Drum rotating direction” switch which is used for selecting drum rotating direction,
- “Automatic mooring mode” switch which is used for selecting winch automatic mooring
(auto-tension) mode.

There are two potentiometers:


- “Winch speed potentiometer” which is used for defining winch rotating speed,
- “Tension force potentiometer” which is used for defining pulling force in rope for winch
automatic mooring (auto-tension) mode.

There are three illuminated displays:


- “Actual force display” for monitoring actual force in rope,
- “Motor torque display” for monitoring electromotor torque,
- “Motor current display” for monitoring electromotor current.

There are eight indicating lamps:


- “Ready lamp” which indicates that the winch is ready for operation,
- “Automatic mode lamp” which indicates that winch automatic mooring (auto-tension)
mode is activated,
- “Drum engaged lamp” which indicates that the drum coupling is engaged.
- “Time-based auto mooring lamp” which indicates that winch is working in automatic
mooring mode using frequency inverter electromotor moment readings (“Automatic
mode” switch on position “Drive”).
- “Overheating lamp” which indicates that electromotor is overheated
- “Excessive force (Overload) lamp” which indicates excessive force in the rope
- “Cable slack lamp” (activates only during automatic mooring) which indicates
constantly unstable rope force, excessive rope tightening or releasing during automatic
mooring (>5 meters), load cell falling out due to bad connection or rope rupture (winch
is working in automatic mooring mode and is not registering any force in the rope for 2
minutes)
- “Fault lamp” which indicates that there is any failure in system.

Control box

„EMERGENCY STOP“
button

23
Winch operations - Portable joystick control station (radio control)

There is one radio control for Starboard side winch and one for Portside winch. Radio control
is usually stored in cabinet. Cabinet is equipped with heater and battery charger. Buttons,
lamps and instruments are described on image below:

Ready lamp Drum engaged lamp Fault lamp


Stepless
joystick

Rope tension
LCD display
Emergency
Stop button

Control activation
switch

Tension setting
Mooring selection potentiometer
switch

Transmitter
Display illumination „ON-OFF“
pushbutton Search wireless network switch
„Status“ indication lamp pushbutton

To control winch via radio control:

• Set main switch located in electric cabinet below deck to position “ON”
• Set local-remote switch on control box to position “remote”
• Set Transmitter “ON-OFF” switch to position “1”
• Set control activation switch on radio control to position “ON”
• Lamp “Status” should lit up indicating communication with equipment
• If working with mooring drum, lamp “Drum engaged” should lit up indicating drum
clutch engaged, otherwise if working with warping drum, lamp “Drum engaged” is not
lighting indicating drum clutch disengaged
• Lamp “Ready” on remote control should lit up indicating that winch is ready for
operation
• Set “mooring selection” switch to position “manual” for manual winch control using
stepless joystick
• Pushing joystick forwards causes winch to rotate in paying-out direction, and pulling it
causes the winch to rotate in hauling-in direction. Joystick lever is stepless and speed
range is automatically selected based on coupling levers
• For automatic mooring (auto-tension) mode, set “tension setting” potentiometer to
desired position (potentiometer dial is dived from 0 to 100 representing percentage of
nominal pulling force of 200 kN) and set “mooring selection” switch to position
“automatic”. Winch will from now on self-maintain desired force on the rope.
• Use “Rope tension LCD display” for monitoring force on the rope.

24
Operating instructions

Note: If “Fault” lamp lights up soon after the “Mooring selection” switch is set to
position “Automatic” it indicates defective load cells. Replacement of load cells needs to
be done.

Radio control is equipped with:


- Stepless joystick which is used to control speed and direction of rotation,
- Rope tension LCD display which is used to monitor load (force) on the rope,
- Emergency stop button.

There are three switches:


- “ON-OFF” switch which is used to turn transmitter wireless connection “ON” or “OFF”,
- “Control activation” switch which is used to turn winch radio control “ON” or “OFF”,
- “Mooring selection” switch which is used to select manual or automatic mooring mode.

There are two pushbuttons:


- Display illumination pushbutton for turning on LCD display,
- Search wireless network pushbutton which is used for finding wireless network
between receiver and transmitter.

There is one potentiometer:


- Tension setting potentiometer which is used to select percentage of nominal force that
will be obtained during automatic mooring mode (auto-tension mode).

There are four indicating lamps:


- Status lamp which indicates communication with equipment,
- Ready lamp which indicates that the winch is ready for operation,
- Drum engage lamp which indicates that the drum coupling is engaged,
- Fault lamp which indicates any failure in system.

Emergency stop button

“EMERGENCY STOP” pushbutton is located near the control box and on the front side of radio
control below stepless joystick. Use this button in any unpredicted situation when things start to
go wrong.

25
Normal operating procedure

Before operating the winch, be sure that the brake is released and coupling engaged for
the desired operation.

Set main switch located in electric cabinet to position “ON”. Set “Local-remote” switch on
control box to position “LOCAL” for winch control via control box, or to position “REMOTE” for
winch control via radio control. When winch control is via control box, pilot lamp “Ready” on
control box lights up indicating that the winch is ready for operation. Winch operations now can
be engaged using “drum rotating direction” switch and “winch speed potentiometer”.
By setting “Drum rotating direction switch” to position “Paying-out” causes winch to rotate in
rope paying-out direction, while setting switch to position “Hauling-in” causes winch to rotate in
rope hauling-in direction. Winch rotating speed in “Paying-out” or “Hauling-in” direction is
controlled using winch speed potentiometer (potentiometer dial is divided from 0 to 10), 0 –
refers to zero winch speed, thus 10 – refers to winch highest speed. During winch operations
with control box, electromotor current, pulling force and motor torque can be monitored on
illuminated instruments on control box.
When winch is controlled via radio control (“Local-remote” switch on control box set to position
“REMOTE”), set transmitter “ON-OFF” switch to position “1”, set “Control activation switch” to
position “ON” and set “Mooring selection switch” to position “Manual”. Pilot lamps “Status” and
“Ready” lights up (“Status” lamp indicates communication with equipment, thus “Ready” lamp
indicates that the winch is ready for operation). Winch operations now can be engaged using
stepless joystick on radio control. Pushing it forwards causes winch to rotate in paying-out
direction, and pulling it causes the winch to rotate in hauling-in direction. Lever is stepless and
speed range is automatically selected based on coupling levers. During winch operations via
radio control, pulling force can be monitored on radio control LCD display.
When operating with winch mooring drum via control box, lamp “Drum engaged” on control box
should lit up indicating that the mooring drum clutch is engaged, equally when operating with
winch mooring drum via radio control, lamp “Drum engaged” on radio control should lit up.

Motor overload condition


If the winch works with excessive force for a while, the motor will become overloaded.
Overheating of the motor occurs if the overloaded working condition continues. Thermal
protection activates (pilot lamp “Overheating” and “Fault” are lighting, "Ready" lamp is turned
off) and alarm sound is heard. Normal winch operations are not possible any more. For
continuing of the operations, the motor must cool down. When the motor is cooled, pilot lamp
"Ready" is lit with steady light again, and the alarm is turned off. The motor is declared to work
30 min with nominal load, or maximum load (1,5xnominal) for 2 minutes.

26
Operating instructions

Automatic mooring
Winches are equipped with load cells which are used for measuring winch pulling force. As the
winch pulls the rope / cable – the force is being measured with load cell mounted on the shaft
bearing. Signals from the strain gauges are directed through signal amplifier to the PLC device
where they are recalculated to represent real force values. Based on this information, PLC
device regulates the winch operation. Image below shows positions of load cell and strain
gauge amplifier.

Automatic Mooring Procedure


1. Release mooring drum band brake and engage mooring drum coupling
2. Set “local-remote” switch on control box to position “local” and turn “tension force”
potentiometer to desired position (potentiometer dial is divided from 0 to 10,
representing percentage 0-100% of nominal pulling force; 10 – refers to nominal rope
force of 200 kN). Now set “automatic mooring mode” switch to position “load cell”
(previously slightly tighten the rope, read chapter “normal operating procedure”). Pilot
lamps “Ready” and “Automatic” lights up with steady light (pilot lamp “Drum engaged”
must also light up indicating that the drum clutch is engaged).
3. For setting automatic mooring mode via radio control set “local-remote” switch to
position “remote”, set “Transmitter ON-OFF switch” to position “1”, set “Control
activation switch” to position “ON” and turn “Tension setting potentiometer” to desired
position (potentiometer dial is divided from 0 to 100 representing percentage of nominal

27
pulling force of 200 kN). Now set “mooring selection” switch to position “load cell”
(previously slightly tighten the rope, read chapter “normal operating procedure”). Pilot
lamps “Ready”, “Status” and “Drum engaged” should lit up (for lamps meanings read
chapter “Winch operation – Portable joystick control station (radio control)”)
4. The PLC device is continuously monitoring the rope tensioning force and compares it
to the desired mooring force previously set. In case that the rope force decreases or
increases over allowed tolerance limits (plus/minus 10% of previously set auto tension
force), the winch automatically corrects tensioning force by engaging the electromotor
and turning the winch until the desired force is reached again. During this time, when
control winch via control box, the lamp “Automatic” is blinking indicating that the winch
is adjusting tensioning force (when controlling via radio control nothing happens). The
lamp starts to light with steady light when the balance is obtained again.
5. During automatic mooring, rope length is been constantly measured. If rope length
during automatic hauling in or paying out outgrows 5 meters winch stops and ship
alarm sound is heard. If winch control is local lamps “Fault” and “Cable slack” on
control box lights up, while if winch control is remote, lamp “Fault” on radio control
lights up. Repeat the action after resetting the alarm (for alarm reset procedure read
paragraph 10 of this chapter).
6. If the force begins to increase fast and the rope becomes overloaded for a while (rope
force > 120% of nominal pulling force), electromagnetic brake holds the rope and alarm
sound is heard. If winch control is local via control box, “Actual force” display shows
unrealistic values of force in the rope and lamps “Cable force > 120%” and “Fault”
lights up, while if winch control is remote via radio control, “Rope tension LCD display”
shows zero value and lamp “Fault” lights up. Alarm resetting is needed in order to
continue working with winch (for alarm reset procedure read paragraph 10 of this
chapter).
7. If the force is being constantly unstable and the winch is trying to obtain desired force
longer than 2 minutes, the winch stops and sound alarm is activated (this process will
also occur if the load cells falls out due to bad connection). If the winch control is local
via control box, lamps “Cable slack” and “Fault” lights up, while if winch control is
remote via radio control, lamp “Fault” lights up. Repeat the action after the fault is
cleared. For alarm reset procedure read paragraph 10 of this chapter.
8. In case of broken rope the winch will try to tighten the rope. If the mooring drum rotates
more than 2 minutes without obtaining force, the winch stops, and alarm sound is
heard. If the winch control is local via control box, lamps “Cable slack” and “Fault” lights
up, while if winch control is remote via radio control, lamp “Fault” lights up. Check the
rope for a rupture and replace it if is necessary. Repeat the action after the fault is
cleared (for alarm reset procedure read paragraph 10 of this chapter).
9. When the motor is overheated, thermal sensor activates alarm. If the winch control is
local via control box, lamps “Overheating” and “Fault” lights up, while if winch control is
remote via radio control, lamp “Fault” light up. It is necessary to wait for the motor to
cool down in order to continue with winch operations.
10. To reset previously mentioned alarms and lamps set “local-remote mooring”
switch on control box to neutral position if the winch control is local via control
box, or set “mooring selection” switch on radio control to position “manual” if
the winch control is remote via radio control.
11. In automatic mooring mode winch rotating speed is always 5 m/min.

28
Operating instructions

Automatic mooring backup mode


If automatic mooring mode, when controlling winch local via control box or remote via radio
control, for any kind of reason, doesn’t work, use backup mode. Backup mode of automatic
mooring is only accessible when controlling the winch locally via control box. Turn “tension
force” potentiometer to desired position and set “Automatic mooring mode” switch to position
“Drive”. The PLC device recalculates previously set force on potentiometer to corresponding
motor torque and continuously monitors motor torque using frequency inverter electromotor
moment readings. In case that the motor torque decreases or increases over allowed tolerance
limits (plus/minus 10% of previously set motor torque), the winch automatically corrects
tensioning force by engaging the electromotor and turning the winch until the desired motor
torque is reached again. Backup mode of auto tension is constantly working on below
described time principle:
• PLC due to frequency inverter readings tensions rope to desired force for 10 seconds,
• After given time of 10 seconds, electromotor brake activates and holds the rope for
100 seconds.
When working with winch in automatic backup mode lamps “Automatic” and “Time-based
automooring” lights up.
During backup automatic mooring mode rope length is been constantly measured. If rope
length during automatic hauling in or paying out outgrows 5 meters winch stops and ship alarm
sound is heard. Lamps “Fault” and “Cable slack” will light up. To reset alarm and lamps set
“local-remote mooring” switch to neutral position.
When the motor is overheated, thermal sensor activates alarm. Lamps “Overheating” and
“Fault” will light up. It is necessary to wait for the motor to cool down in order to continue with
winch operations.
The winch in automatic mooring backup mode can’t register broken rope or overload
condition, if the measuring cells are defective. In case of defective load cells replace
them (contact AdriaWinch).

WARNING!

“Automatic mooring mode” switch on control box should be primarily set to “Load cell”
mode for automatic mooring, “Drive” mode should be used only as backup mode for
automatic mooring.

29
Working with Split Mooring Drum
General

• Engage the drum coupling by pushing the coupling lever. Lock the coupling lever
when in position.
• Release the drum band brake.
• To haul rope in when controlling winch via control box, set “Drum rotating direction”
switch to position “Hauling-in”. For increasing hauling-in speed, rotate “Winch speed”
potentiometer in clockwise direction. To haul rope in when controlling winch via radio
control, pull joystick backward. For increasing hauling-in speed pull lever more in
backward direction.
• To stop the winch when controlling via control box, set “Drum rotating direction”
switch in neutral position. To stop the winch when controlling via radio control, leave
the joystick in the neutral position.
• To pay out rope when controlling winch via control box, set “Drum rotating direction”
switch to position “Paying-out”. For increasing paying-out speed, rotate “Winch
speed” potentiometer in clockwise direction. To pay rope out when controlling winch
via radio control, push joystick forward. For increasing paying-out speed push joystick
more in forward direction.
• When the operation of the winch is completed, engage the drum brake and disengage
drum coupling.
• Lock the coupling lever when in position.

Split mooring drum

The main feature of the split mooring drum is to obtain maximum pulling force, independent of
how many layers there are left on the drum. The split drum is divided into two separate parts by
means of a split flange with a slot. Smaller part is used for tensioning, while the bigger is used
for storage.

Band brake Tension part


of the drum

Storage part
Split flange of the drum

30
Operating instructions

When used correctly, a split drum permits the operator always to use the first layer when
mooring, independent of how many layers there are left on the storage part. Hoisting and brake
holding load are specified on the first layer of a drum.
• Pay out the rope and fasten the rope to a pulley onshore or on a buoy. Instead of
hauling in immediately, a further 10 m or so of slack is to be paid out.
• Start to heave in the slack. Guide the rope manually into the slot the first or the
second time the slot comes round.
• Wind the remaining slack on to the tension part and make sure there is at least three
turns or more. In this case, there will be no tension transferred through the slot even
when operated at full load.
Sometimes the rope has to be transferred from the storage part to the tension part while the
rope is under tension. If this is the case do the following:
• Use a lever and manual power or a manual or air driven power block with a hook
fastened to the rope when guiding the rope through the slot.
• Haul the rope to desired load and apply the drum brake.
• Disconnect the drum coupling after the brake is applied to avoid damage to the gear
system.

Observe that manhandling the rope from the storage part to the tension part through
the split flange is dangerous. If the rope tension is too high to enter the tension part, the
rope tension must be reduced.

31
Warping procedure

Warping head rotates always when the winch drive is powered.

When warping, be sure that the rope is winded to the drum correctly. Rope enters the
warping head on the inner side.

MOORING DRUM
WARPING END

SLACK

TENSION

Wind the rope few times around the warping head and pull the joystick on the radio control to
"Hauling-in" direction or set “Drum rotating direction” switch to “Hauling-in” position when
controlling the winch via control box. While pulling the rope with the winch, one operator should
collect the slack rope.
The maximum electromotor speed can be operated at high speed range.

Warning! Do not stay near the rope under tension nor touch it while the winch is
working.

When using the warping head, never fix the mooring line as shown on the figure below. That
could cause bending and damage to the warping end shaft (winch main shaft). Always fix the
line on the warping bitt – not on the warping drum, nor after the warping drum. See the
illustration below.

CORRECT
TO FAIRLEAD

TO FAIRLEAD

UNCORRECT

32
Maintenance

4. Maintenance

4.1. Regular checking


Routine inspection of the winches is a very important form of preventive maintenance and will
result in considerable savings by detecting any major trouble that might be developing, and
allowing the necessary repairs to be made on a planned or normal shut down time e.g. at a
docking.
The frequency at which the inspection should be made is depending on the time and conditions
the winches have been in operations. However, it is recommended that the intervals listed
below be considered minimum for optimum performance of the winches. It is also
recommended that the inspections of the winches be made more frequently in the first period of
one year after the winches have been started up for the first time.

During mooring operations


• Listen to transmission for abnormal gear wheel noise.
• Listen to bearings for abnormal noise and check for overheating.
• Check electromotor overheating.

Once each week


• Check for leaking oil or grease seals and replace if necessary.

Once each 3 months


• Grease all lubrication nipples.
• Check brake lining.
• Check that coupling is working properly.
• Check all bolts and nuts for proper tightness.

Once each year


• Check the end stoppers and see that the winch is not moving.
• Tighten all terminals in control box.
Check entire winch for any kind of surface damage, and repaint those surfaces.
Change oil in side of gear housing periodically, according to manufacturer.

33
4.2. Maintenance of the control cabinet

Before any operation evolving touching or disassembling of electrical devices inside


control box, turn the power off.

Control box is made of steel plates and consists of support plate for built in devices, and steel
box with a door with pilot lamp onto it. Maintenance of the control box consists of:

• Occasional tightening of the bolts on devices and terminal blocks,

• Dusting, by blowing dust out,

• Control of functioning of the contactors. Occasionally check buzzing of contactors. In


case of buzzing clean the contact surfaces of the contactor’s yoke and armature from
rust and dirt, because increased clearance can cause overheating of the coil. Rough
and dark surface of the contacts doesn’t have any influence on properly functioning of
the contactor, as long as there is small coat of the silver present. It is recommended
to check contactors at least every two years and replace worn out by new one.

4.3. Winch sensors replacing procedure

Images shows the assembly of coupling handle sensor in its holder. Please check dwg. 939-
050-00, 939-060-00, 938-550-00 and 938-560-00.
DIN-912
Bolt M5x16 DIN-933 M10x55
DIN-934 M10
Coupling lever

Sensor
MM08-60
Magnetic ring
APS-ZUK
with holder
Bushing

Cable
protection

Sensor
holder

Sensor block

DIN-915
M5 Sensor replacing procedure:

• Unscrew bolts DIN 912 M5x16 and untighten set screw DIN-915 M5.
• Remove bushing with sensor then remove sensor from the bushing.
• Replace sensor and assemble everything back

34
Maintenance

4.4. Lubrication

Recommended grease types

Tempera- Penetration Drop


Manufacturer Grease type ture range 25 point
[°°C] [°°C] [°°C]
BP BP ENERGREASE MM –EP2 +120 265/295 175

CASTROL SPHEEROL AP2 -30 +105 280 175


SPHEEROL AP3 -25 +95 235 175
SPHEEROL EPL2 -20 +105 270 170
CHEVRON CH. DURA – LITH GREASE 2 -25 +125 280 185
CH. DURA –LITH GREASE EP2 -20 +125 280 185
CH. INDUSTR. GREASE MEDIUM -25 +165 295 260
CH. POLYUREA EP GREASE 2 -20 +160 280 260
ESSO MP GREASE/BEACON EP 2 -30 +125 275 185

FUCHS RENOLIT FWA 160 -25 +130 265/295 185


RENOLIT FEP 2 -20 +130 265/295 185
RENOLIT HLT 2 -50 +140 265/295 185
GULF GULFCROWN GREASE NO. 2 -20 +120 268 191
GULFCROWN GREASE EP NO.2 -20 +125 280 185
INA INA - LIS 1 -30 +100 310 180
INA – LIS 2 -30 +120 265 185
INA – LIS 3 -10 + 130 220 190
MOBIL MOBILPLEX 47 -30 +140 275/305 260
MOBILUX EP 2 -30 +110 265/295 180
MOBILTEMP SHC 100 -40 +180 265/295 260
MOLYKOTE LONGTERM 2 PLUS -50 +150 265/295 175

SHELL ALVANIA GREASE R 2 -35 +100 265/295 185


ALVANIA EP GREASE 2 -15 +100 265/295 185
TEXACO MULTIFAK EP 2 -30 +120 280 192

TOTAL TOTAL MULTIS EP 1 -20 +130 325 190


TOTAL MULTIS EP 22 -20 +140 260 190

35
Recommended oils for the gear reducers

In general: For –5°C or colder the viscosity at 40°C should be less than 220 cSt.

Flash Pour
Visc. cSt Visc.
Manufacturer Oil type point point
40 [°°C] index
[°°C] [°°C]
ELF EPONA Z 100 105 100 220 -27
EPONA Z 150 150 98 220 -21
EPONA Z 220 210 98 220 -21
BP BP ENERGOL GR-XP 150 140 96 196 -24
BP ENERGOL GR-XP 220 210 94 196 -21
BP ENERGOL GR-XP 320 305 92 199 -15
CASTROL ALPHA SP 150 150 97 198 -12
ALPHA SP 220 220 94 198 -9
ALPHA SP 320 320 94 195 -9
CHEVRON NL GEAR COMPOUND 150 150 98 250 -21
NL GEAR COMPOUND 220 220 98 260 -21
NL GEAR COMPOUND 320 320 98 260 -18
ESSO SPARTAN EP 150 149 96 238 -21
FUCHS RENEP COMPOUND 106 225 100 218 -21
142 105 216 -24
101 110 212 -27
GULF GULF EP LUBRICANT HD 150 146 98 231 -18
GULF EP LUBRICANT HD 220 219 97 237 -15
INA EPOL SP 100 100 100 220 -25
EPOL SP 150 150 99 220 -20
EPOL SP 220 220 99 220 -20
MOBIL MOBIL GEAR 629 142 93 228 -28
306 95 240 -19
143 135 238 -48
SHELL OMALA OIL 220 220 100 238 -18
OMALA OIL 100 150 100 232 -26
OMALA OIL 150 100 100 238 -21
TEXACO MEROPA 150 145 101 224 -28
MEROPA 220 209 92 232 -18
MEROPA 320 220 98 232 -18
TOTAL TOTAL CARTER EP 100N 100 100 -20
150 100 -15
220 96 -12
HESSOL OM –150 150 100 218 -20
GL 5 -

36
Maintenance

Lubrication charts

37
Gear reducer oil change for Mooring Winch
Gear housings of all winches are welded steel assembly, totally enclosed, and watertight.
Splashing of oil during rotation lubricates gears and bearings. Oil level can be checked on oil
level indicator.

After first start of the winch, gear oil should be changed after approx. 300 working
hours. Due to gears running in, small particles are created, which can cause wear, and
damage of the bearings. Therefore, first oil change is very important.

To change oil in the gear case unscrew the vent (oil inlet plug) placed on the top of the gear
case. After that unscrew the oil drain plug. Collect the old oil. Wait for oil to leak out.
Screw back oil drain plug. Pay attention if the plug sealing is damaged – change if necessary.
Fill the new oil through the vent hole (oil inlet). Quantity of the oil is controlled on the oil level
indicator. Fill until the oil is about to pour out of oil indicator bore. Use only recommended oil
types. (Approx. 25 litres of oil is needed).
Screw the vent plug (oil inlet) back.

38
Maintenance

4.5. Maintenance and adjustment of the brake

Brake is checked before every operation with the winch involving mooring drum, as described
in chapter "Operating instructions / Mooring Winch".
Brake linings wear in time and become thinner. Before any operation with the winch it is
necessary to check wearing of linings. When linings are worn out, they require changing.
For technical information about built-in brake linings see the Appendix.

Procedure for changing of brake linings

Before any disassembling of the equipment ensure that all safety requirements are
obtained.

1. Disassemble the brake from pulley.


2. Untighten nuts, and take out screws that are assembling brake lining and the band. (If the
lining is riveted to band, disassemble the rivets using appropriate tooling – do not
damage the brake band.)
3. On the new lining, drill holes according to holes on the old one. Pay attention to position
of the holes. Holes are to be counterbored as specified in the drawing.
4. Check the screws that are taken off from the linings for damage, and if necessary change
them. Use same type of the screws (or rivets).
5. Assemble the brake, and put it back on the pulley. Pay attention on leaning of the lining
against the pulley, and on placing of the brake in vertical direction.
6. It is recommended to tighten brake lightly and turn the winch on, with coupling engaged.
Brake should be engaged, but not to obtain full force, so the pulley can rotate. Leave the
winch running for 5 minutes, and pay attention on the heating of the brake. This way the
lining shall work a little and adopt to the drum.
7. Adjust the brake.

Usage of linings with lower mechanical characteristics can jeopardize reliability of the
winch, and bring to damage of the winch, as well as the vessel.

Brake lever bolts should be lubricated and checked for the corrosion attacks. Band
brake lining should be controlled periodically.

39
Adjusting the brake

Brake adjustment should be checked regularly every 3 months or more frequently, depending
on the exploitation conditions. Adjustment of the brake after assembling is done by tightening /
releasing adjustment screw (see the picture to the right) according to the following procedure:
1. Band brake should be engaged (tightened).
Brake Mooring
2. The gap between brake band and the adjustment
handle drum
screw head should be approx. 3 mm. When
adjusted, tighten the counter nut on the adjustment Brake
screw. band
3. To engage the brake, turn the brake handle in
clockwise direction, and to disengage the brake turn Brake
the handle in opposite direction. When disengaging lining
the brake, it should completely release the mooring
drum – it should easily turn on the main shaft when
the mooring drum clutch is disengaged.

Gap
3 mm

Adjustment
screw

40
Maintenance

4.6. Long time parking maintenance

Before long time parking


• Wash the equipment with fresh water.
• All to be fully lubricated. All open surfaces should be covered completely with grease.
For winches or open surfaces exposed to seaspray and icing, it should be considered
to cover these by means of protective cover.

During long time parking


Lubrication intervals for long time parking in lubrication charts should be maintained. Movable
parts should be moved/rotated during lubrication to ensure that grease gets into all corners.
Therefore the plant to be started. The equipment will then also be moved and it can be avoided
that components are rusted in. Check the equipment for corrosion attacks.

After long time parking


Before use, equipment should be cleaned, lubricated, moved and checked for corrosion
attacks.

41
42
Troubleshooting

5. Troubleshooting

5.1. Mooring Winch Troubleshooting Guide

Trouble Possible Cause Required Action


• Power ON the main switch inside
control cabinet
• System not powered
• Press start-control switch – lamp
“Ready” should lit
• Input voltage is not present on the
electric motor due to Malfunction of
• Service needed
the motor, thermal protection,
overcurrent protection,…
• Wait to motor to cool off
• Bridge the thermal protection and
• Motor thermal protection activated.
Electric motor does not rotate. continue with work (WARNING – SEE
THE USAGE INSTRUCTIONS)
• Electric motor fuse lowered • Raise lowered electric motor fuse

• “EMERGENCY STOP” button • Release “EMERGENCY STOP“


pressed button.

• Electric contacts inside control box • Check electric contacts inside control
disconnected. cabinet

Motor is turning in unexpected • Phases of the electric motor • Switch phases of the electric motor
direction switched. inside electric cabinet.
• Check if the dimension and the • Install winch following manufacturers
Main shaft is turning with
tolerances of the winch after recommendation
explicit vibrations, noises or
installing onto the deck are meeting • Some component of the gear case
with overheating the bearings
manufacturers requests. damaged. Service needed.
Main shaft is turning, but the • mooring drum coupling disengaged • Engage appropriate coupling.
mooring drum stands still. • Coupling gripped • See if the coupling is damaged.
• There is too much oil inside gear • Reduce the amount of oil to the
case. required level.
Oil inside gear case is foamed • Oil is not of correct type • Substitute oil with correct type
• There is leakage present on one of • Seal the leaking surface if it is not
the sealing surfaces. damaged.
Trying to heave but nothing • Brake is engaged • Disengage the brake
happens. • Electrical problem •

43
Trouble Possible Cause Required Action

• Thread spindle is not greased • Add grease to all grease nipples


• Pin of the handle boss is broken • Replace broken pin
Brake thread spindle is not • Remove the rust or dirt that is
turning, or turning very hard. • Spindle is jammed
blocking movement
• Due to improper use, thread spindle
is bended, and permanently • Repair thread spindle.
damaged
• Brake lining is worn out • Change brake lining
• Band brake support is not adjusted • Adjust band brake support
• Wrong type of the brake lining • Replace brake lining with correct type
Brake doesn’t operate properly
• Degrease lining - grind the lining if
• Brake lining or pulley is greased
necessary
• After service, brake is not
• Check assembly of the brake
assembled properly

Required pulling force couldn’t


• Trying to haul rope in using higher
be obtained on the mooring • Use rope low speed range
speed range
drum

• Check wiring
• Load cell in short circuit
• Check if connectors/wires are moist
• Load cell disconnected
• Check load cell response
• Load cell wrongly connected
• Check power supply (24 VDC),
• Load cell malfunctioning, readings
Load cell not working or wrong circuit breaker F24
out of range
readings • Calibrate load cell in software
• Load cell power supply problem
• Check PLC input A5, wiring
• Load cell not calibrated
• Check if other power supply cables
• PLC error
cause noise or interference
• Interferences, noise
Lamp “Fault” lights during
automatic mooring backup • Defective load cells • Replace load cells
mode

44
Alarms List

6. Alarms list

Alarm Activates Required Action


• Stop the operations and wait for the
frequency inverter to cool down
Variable frequency drive error • When frequency inverter overheats • Reset the alarm (read paragraph 10
of chapter “Operating instructions –
Automatic Mooring Procedure”)
• Stop the operations and wait for the
motor to cool down
Motor temperature above
0 • When motor overheats • Reset the alarm (read paragraph 10
130 C (PT100 sensor)
of chapter “Operating instructions –
Automatic Mooring Procedure”)
• Stop the operations with winch
Excessive force in the rope • During automatic mooring mode • Reset the alarm (read paragraph 10
(lamp “Cable force > 120%” when force in the rope outgrows of chapter “Operating instructions –
lights) 120% of nominal pulling force Automatic Mooring Procedure”)
• Repeat the action
Rope haul in or pay out length • Reset the alarm (read paragraph 10
• During automatic mooring mode
in automatic mooring mode of chapter “Operating instructions –
when rope length during hauling in
reached (lamp “Cable slack” Automatic Mooring Procedure”)
or paying out outgrows 5 meters
lights) • Repeat the action
• Check load cells wiring
• When load cells falls out due to • Check if connectors/wires are moist
bad connection • Check the rope for rupture and
Requested force in the rope • During automatic mooring mode if replace it if is necessary
can’t be reached in the time of the force in the rope is been • Reset the alarm (read paragraph 10
2 minutes constantly unstable of chapter “Operating instructions –
• During automatic mooring mode in Automatic Mooring Procedure”)
case of the broken rope • Repeat the action after the fault is
cleared

45
46
Spare parts

7. Spare parts

7.1. Ordering of the spare parts

Spare parts order should contain following information:

NO. INFORMATION TYPE WHERE TO FIND INFORMATION


1 Ship name and building yard On the contract
2 Equipment type On the marking plates / Manual
3 Serial number of the actual unit On the marking plates / Appendix
4 Drawing number Specification Sheets / Drawings
5 Part number Specification Sheets / Drawings
6 Description Specification Sheets / Drawings
7 Quantity Specification Sheets / Drawings

47
7.2. Specification: Mooring Winch, MW-T-EL-200/10/25-GDW-NLF

Reference Dwg. No. 939-050-00 SB.

Drawing No. /
Pos. Part description Material Dimensions Pcs.
Standard
Red. Gearbox - RG-R 4/6/10-148;
1 939-100-00 1
(i=148,2) - SB
2 Main shaft 939-050-02 1
3 Mooring drum 938-200-00 1
4 Warping end 938-050-10 1
5 Bearing block SB 939-400-00 1
6 Coupling arrangement SB 938-550-00 1
7 Claw coupling 938-050-09 1
8 Band Brake T 800/120/15-336 939-350-00 1
9 Brake band support 024-214-00 1
10 Cover plate no.1 938-050-11 1
11 Parallel key 40x24x282 938-050-19 2
12 Distance ring No.1 938-050-12 1
13 Distance ring No.2 938-050-13 2
14 Sensor block support 939-050-14 1
15 Double sensor block 894-050-41 1
16 Sensor bushing 939-050-16 3
17 Magnet housing 939-050-17 6
18 Coupling sensor block 894-050-50 1
19 Marking Plate 939-050-19 1
Standard parts
g1 Hexagonal head screw DIN 933 A2 (AISI 304) M20x45 2
g2 Spring washer DIN 127 A2 (AISI 304) A20 2
g3 Hexagonal socket head screw DIN 912 A2 (AISI 304) M10x25 4
g4 Hexagonal head screw DIN 933 A2 (AISI 304) M12x45 4
g5 Spring washer DIN 127 A2 (AISI 304) A12 4
g6 Hexagonal nut DIN 934 A2 (AISI 304) M12 4
g7 Hexagon head screw DIN 933 8.8 M24x70 2
g8 Hexagonal socket set screw DIN 915 A2 (AISI 304) M12x25 12
g9 Sensor MM08-60APS-ZUK "SICK" 3
g10 Hexagonal socket set screw DIN 915 A2 (AISI 304) M8x12 1
g11 Hexagonal socket head screw DIN 912 A2 (AISI 304) M8x22 2
g12 Spring washer DIN 127 A2 (AISI 304) A8 8
g13 Hexagonal socket head screw DIN 912 A2 (AISI 304) M6x12 4
g14 Electric bronze box NRK bronze 80x80x50 2
g15 Hexagonal head screw DIN 933 A2 (AISI 304) M8x14 4
g16 Hexagonal nut DIN 934 A4 (AISI 316) M8 2
g17 Grease nipple SNF DIN 3404 M10x1 2
g18 Hexagonal socket set screw DIN 915 A2 (AISI 304) M8x10 2
g19 Hexagonal socket head screw DIN 912 A2 (AISI 304) M8x55 2
g20 Hexagonal nut 0.5d M8 DIN 439 A2 (AISI 304) M8 2
g21 Hexagon socket head screw DIN 7991 A2 (AISI 304) M8x18 12
g22 Neomidium magnet "ARTAS" N35/Ni 40x20x5 6

48
Spare parts

7.3. Specification: Mooring Winch, MW-E2R-100/14,7/30-GDW

Reference Dwg. No. 939-060-00 PS.

Drawing No. /
Pos. Part description Material Dimensions Pcs.
Standard
Red. Gearbox - RG-L 4/6/10-148;
1 939-110-00 1
(i=148,2) - PS
2 Main shaft 939-050-02 1
3 Mooring drum 938-200-00 1
4 Warping end 938-050-10 1
5 Bearing block PS 939-410-00 1
6 Coupling arrangement PS 938-560-00 1
7 Claw coupling 938-050-09 1
8 Band Brake T 800/120/15-336 939-350-00 1
9 Brake band support 025-214-00 1
10 Cover plate no.1 938-050-11 1
11 Parallel key 40x24x282 938-050-19 2
12 Distance ring No.1 938-050-12 1
13 Distance ring No.2 938-050-13 2
14 Sensor block support 939-050-14 1
15 Double sensor block 894-050-41 1
16 Sensor bushing 939-050-16 3
17 Magnet housing 939-050-17 6
18 Coupling sensor block 894-050-50 1
19 Marking Plate 939-060-19 1
Standard parts
g1 Hexagonal head screw DIN 933 A2 (AISI 304) M20x45 2
g2 Spring washer DIN 127 A2 (AISI 304) A20 2
g3 Hexagonal socket head screw DIN 912 A2 (AISI 304) M10x25 4
g4 Hexagonal head screw DIN 933 A2 (AISI 304) M12x45 4
g5 Spring washer DIN 127 A2 (AISI 304) A12 4
g6 Hexagonal nut DIN 934 A2 (AISI 304) M12 4
g7 Hexagon head screw DIN 933 8.8 M24x70 2
g8 Hexagonal socket set screw DIN 915 A2 (AISI 304) M12x25 12
g9 Sensor MM08-60APS-ZUK "SICK" 3
g10 Hexagonal socket set screw DIN 915 A2 (AISI 304) M8x12 1
g11 Hexagonal socket head screw DIN 912 A2 (AISI 304) M8x22 2
g12 Spring washer DIN 127 A2 (AISI 304) A8 8
g13 Hexagonal socket head screw DIN 912 A2 (AISI 304) M6x12 4
g14 Electric bronze box NRK bronze 80x80x50 2
g15 Hexagonal head screw DIN 933 A2 (AISI 304) M8x14 4
g16 Hexagonal nut DIN 934 A4 (AISI 316) M8 2
g17 Grease nipple SNF M10x1.00 DIN 3404 M10x1 2
g18 Hexagonal socket set screw DIN 915 A2 (AISI 304) M8x10 2
g19 Hexagonal socket head screw DIN 912 A2 (AISI 304) M8x55 2
g20 Hexagonal nut 0.5d M8 DIN 439 A2 (AISI 304) M8 2
g21 Hexagon socket head screw DIN 7991 A2 (AISI 304) M8x18 12
g22 Neomidium magnet 40x20x5 "ARTAS" N35/Ni 40x20x5 6

49
7.4. Specification: Mooring Winch - 3-stage reducing gear

Reference Dwg. No. 939-100-00 SB.

Drawing No. /
Pos. Part description Material Dimensions Pcs.
Standard
1 Reducing gear housing SB 939-101-00 1
2 Housing cover SB 939-102-00 1
Spur gear mn=4; z=19; β=15°;
3 939-100-01 1
right handed
Gearwheel mn=4; z=115; β=15°;
4 938-104-00 1
left handed
Spur gear mn=6; z=17; β=15°; left
5 939-100-03 1
handed
Gearwheel mn=6; z=90; β=15°;
6 938-105-00 1
right handed
Spur gear mn=10; z=16; β=15°;
7 939-100-05 1
right handed
Gearwheel mn=10; z=74; β=15°;
8 939-106-00 1
left handed
9 Cover no.1 939-100-09 1
10 Distance ring no.1 939-100-10 2
11 Distance ring no.2 939-100-11 1
12 Cover no.2 939-100-12 1
13 Bearing housing no.1 939-100-13 1
14 Plain parallel key 25x14 938-100-14 1
15 Distance ring no.3 939-100-15 1
16 Distance ring no.4 939-100-16 1
17 Cover no.3 939-100-17 1
18 Bearing cover no.2 938-100-22 1
19 Plain parallel key 28x16 938-100-20 1
20 Distance ring no.5 939-100-20 1
21 Bearing cover no.1 938-100-18 1
22 Strain gauge 939-107-00 1
23 Cover no.4 938-100-26 1
24 Bearing cover no.3 938-100-25 1
25 Distance ring no.6 939-100-25 1
26 Plain parallel key 40x22 939-100-26 1
27 Distance ring no.7 939-100-27 1
28 Cover no.5 938-100-28 1
29 Cover no.6 938-100-29 1
30 Bearing housing no.3 938-100-30 1
31 Oil pump 349-106-00 1
32 Polyamide pump washer 673-050-39 1
33 Oil pump support 939-100-33 1
34 "Oil inlet/vent" marking plate 938-100-46 1
35 "Oil level" marking plate 778-100-33 1
36 "Oil drain" marking plate 778-100-34 1
37 Stud bolt M30x265 939-100-37 2
38 Stud bolt M30x235 939-100-38 2
Standard parts
Electromotor, 43 kW; 830 o/min; 7ABZKA 250M-
g1 1
3x690 V / 60 Hz 8ZAG IM B5

50
Spare parts

Drawing No. /
Pos. Part description Material Dimensions Pcs.
Standard
g2 Hexagon head screw DIN 933 8.8 M18x45 8
g3 Spring washer DIN 127 A18 8
g4 Deep groove ball bearing 6219-2Z DIN 625 Ø95 / Ø170 x 32 1
g5 Deep groove ball bearing 6214 DIN 625 Ø70 / Ø125 x 24 2
g6 Spherical roller bearing 22212-E1 DIN 635 Ø60 / Ø110 x 28 1
g7 Spherical roller bearing 22216 DIN 635 Ø80 / Ø140 x 33 1
g8 Spherical roller bearing 22219 DIN 635 Ø95 / Ø170 x 43 1
g9 Spherical roller bearing 22224 DIN 635 Ø120 /Ø215 x 58 1
g10 Spherical roller bearing 23036 DIN 635 Ø180/ Ø280 x 74 1
g11 Spring retaining ring DIN 471 Ø95x3 1
g12 Spring retaining ring DIN 472 Ø170x4 1
g13 Spring retaining ring DIN 471 Ø70x2.5 2
g14 Spring retaining ring DIN 471 Ø60x2 1
g15 Lock nut KM36 DIN 981 M180x3 1
g16 Lock washer MB 36 DIN 5406 1
g17 Radial shaft seal A DIN 3760 NBR φ95xφ120x12 1
g18 Radial shaft seal A DIN 3760 NBR φ95xφ120x12 2
g19 Hexagon head screw DIN 933 A4 M8x18 8
g20 Spring washer DIN 127 A8 12
g21 Hexagon socket head cap screw DIN 912 A4 M10x25 2
g22 Hexagon socket head cap screw DIN 912 A4 M10x30 6
g23 Spring washer DIN 7980 A10 12
g24 Hexagon socket head set screw DIN 913 A2 M8x25 1
g25 Hexagon head screw DIN 933 A4 M12x25 16
g26 Spring washer DIN 127 A12 54
g27 Hexagon socket head cap screw DIN 912 8.8 M10x20 4
g28 Hexagon head screw DIN 933 A4 M12x30 26
g29 Hexagon head screw DIN 933 A2 M12x14 2
g30 Parallel pin DIN 7979 D φ6x16 1
g31 Hexagon head screw DIN 933 A2 M5x12 8
g32 Spring washer DIN 127 A5 8
g33 Hexagon head screw DIN 933 A4 M12x35 8
g34 Hexagon socket head cap screw DIN 912 8.8 M12x25 2
g35 Spring washer DIN 7980 A12 2
g36 Parallel pin DIN 7979 D φ30x60 2
g37 Parallel pin DIN 7979 D φ20x50 2
g38 Hexagonal socket head screw DIN 913 A2 M6x25 1
g39 Washer DIN 125 / A6 1
g40 Hexagon nut DIN 934 8 M30 4
g41 Hexagon nut 0.5d M30 DIN 439 8 M30 4
g42 Hexagon head screw DIN 933 A2 M12x12 4
g43 Hexagon socket head cap screw DIN 912 8.8 M8x30 2
g44 Hexagon nut DIN 934 8 M8 2
g45 Tube clamp RAP2-106 RAP2-106 4
g46 Hydraulic pipe AISI 316 φ6 1
g47 Hexagon socket head cap screw DIN 912 8.8 M6x40 2
g48 Spring washer DIN 127 A6 3
g49 Hexagon nut DIN 934 8 M6 3
g50 Hexagon head screw DIN 933 8.8 M24x70 4
g51 Plug VHR 90-3/4 ED 2
g52 Reducing adapter 1"-3/8" RIK NW 25 10 ED Galvanized steel G1" - G3/8" 1

51
Drawing No. /
Pos. Part description Material Dimensions Pcs.
Standard
g53 Breather plug 3/8" 31A-13030009 CuSn G3/8" 1
g54 T union tee with EO-2 nut T06LL 1
g55 Male stud connector GE-R-ED GE06LREDCF 1

Reference Dwg. No. 939-110-00 PS.

Drawing No. /
Pos. Part description Material Dimensions Pcs.
Standard
1 Reducing gear housing PS 939-111-00 1
2 Housing cover PS 939-112-00 1
Spur gear mn=4; z=19; β=15°;
3 939-100-01 1
right handed
Gearwheel mn=4; z=115; β=15°;
4 938-104-00 1
left handed
Spur gear mn=6; z=17; β=15°; left
5 939-100-03 1
handed
Gearwheel mn=6; z=90; β=15°;
6 938-105-00 1
right handed
Spur gear mn=10; z=16; β=15°;
7 939-100-05 1
right handed
Gearwheel mn=10; z=74; β=15°;
8 939-106-00 1
left handed
9 Cover no.1 939-100-09 1
10 Distance ring no.1 939-100-10 2
11 Distance ring no.2 939-100-11 1
12 Cover no.2 939-100-12 1
13 Bearing housing no.1 939-100-13 1
14 Plain parallel key 25x14 938-100-14 1
15 Distance ring no.3 939-100-15 1
16 Distance ring no.4 939-100-16 1
17 Cover no.3 939-100-17 1
18 Bearing cover no.2 938-100-22 1
19 Plain parallel key 28x16 938-100-20 1
20 Distance ring no.5 939-100-20 1
21 Bearing cover no.1 938-100-18 1
22 Strain gauge 939-107-00 1
23 Cover no.4 938-100-26 1
24 Bearing cover no.3 938-100-25 1
25 Distance ring no.6 939-100-25 1
26 Plain parallel key 40x22 939-100-26 1
27 Distance ring no.7 939-100-27 1
28 Cover no.5 938-100-28 1
29 Cover no.6 938-100-29 1
30 Bearing housing no.3 938-100-30 1
31 Oil pump 349-106-00 1
32 Polyamide pump washer 673-050-39 1
33 Oil pump support 939-100-33 1
34 "Oil inlet/vent" marking plate 938-100-46 1
35 "Oil level" marking plate 778-100-33 1
36 "Oil drain" marking plate 778-100-34 1
37 Stud bolt M30x265 939-100-37 2

52
Spare parts

Drawing No. /
Pos. Part description Material Dimensions Pcs.
Standard
38 Stud bolt M30x235 939-100-38 2
Standard parts
Electromotor, 43 kW; 830 o/min; 7ABZKA 250M-
g1 1
3x690 V / 60 Hz 8ZAG IM B5
g2 Hexagon head screw DIN 933 8.8 M18x45 8
g3 Spring washer DIN 127 A18 8
g4 Deep groove ball bearing 6219-2Z DIN 625 Ø95 / Ø170 x 32 1
g5 Deep groove ball bearing 6214 DIN 625 Ø70 / Ø125 x 24 2
g6 Spherical roller bearing 22212-E1 DIN 635 Ø60 / Ø110 x 28 1
g7 Spherical roller bearing 22216 DIN 635 Ø80 / Ø140 x 33 1
g8 Spherical roller bearing 22219 DIN 635 Ø95 / Ø170 x 43 1
g9 Spherical roller bearing 22224 DIN 635 Ø120/ Ø215 x 58 1
g10 Spherical roller bearing 23036 DIN 635 Ø180/ Ø280 x 74 1
g11 Spring retaining ring DIN 471 Ø95x3 1
g12 Spring retaining ring DIN 472 Ø170x4 1
g13 Spring retaining ring DIN 471 Ø70x2.5 2
g14 Spring retaining ring DIN 471 Ø60x2 1
g15 Lock nut KM36 DIN 981 M180x3 1
g16 Lock washer MB 36 DIN 5406 1
g17 Radial shaft seal A DIN 3760 NBR φ95xφ120x12 1
g18 Radial shaft seal A DIN 3760 NBR φ95xφ120x12 2
g19 Hexagon head screw DIN 933 A4 M8x18 8
g20 Spring washer DIN 127 A8 12
g21 Hexagon socket head cap screw DIN 912 A4 M10x25 2
g22 Hexagon socket head cap screw DIN 912 A4 M10x30 6
g23 Spring washer DIN 7980 A10 12
g24 Hexagon socket head set screw DIN 913 A2 M8x25 1
g25 Hexagon head screw DIN 933 A4 M12x25 16
g26 Spring washer DIN 127 A12 54
g27 Hexagon socket head cap screw DIN 912 8.8 M10x20 4
g28 Hexagon head screw DIN 933 A4 M12x30 26
g29 Hexagon head screw DIN 933 A2 M12x14 2
g30 Parallel pin DIN 7979 D φ6x16 1
g31 Hexagon head screw DIN 933 A2 M5x12 8
g32 Spring washer DIN 127 A5 8
g33 Hexagon head screw DIN 933 A4 M12x35 8
g34 Hexagon socket head cap screw DIN 912 8.8 M12x25 2
g35 Spring washer DIN 7980 A12 2
g36 Parallel pin DIN 7979 D φ30x60 2
g37 Parallel pin DIN 7979 D φ20x50 2
g38 Hexagonal socket head screw DIN 913 A2 M6x25 1
g39 Washer DIN 125 / A6 1
g40 Hexagon nut DIN 934 8 M30 4
g41 Hexagon nut 0.5d M30 DIN 439 8 M30 4
g42 Hexagon head screw DIN 933 A2 M12x12 4
g43 Hexagon socket head cap screw DIN 912 8.8 M8x30 2
g44 Hexagon nut DIN 934 8 M8 2
g45 Tube clamp RAP2-106 RAP2-106 4
g46 Hydraulic pipe AISI 316 φ6 1
g47 Hexagon socket head cap screw DIN 912 8.8 M6x40 2
g48 Spring washer DIN 127 A6 3

53
Drawing No. /
Pos. Part description Material Dimensions Pcs.
Standard
g49 Hexagon nut DIN 934 8 M6 3
g50 Hexagon head screw DIN 933 8.8 M24x70 4
g51 Plug VHR 90-3/4 ED 2
g52 Reducing adapter 1"-3/8" RIK NW 25 10 ED Galvanized steel G1" - G3/8" 1
g53 Breather plug 3/8" 31A-13030009 CuSn G3/8" 1
g54 T union tee with EO-2 nut T06LL 1
g55 Male stud connector GE-R-ED GE06LREDCF 1

7.5. Specification: Brake T800/120/15-336

Reference Dwg. No. 939-350-00.

Drawing No. /
Pos. Part description Material Dimensions Pcs.
Standard
1 Upper band with links 939-351-00 1
2 Lower band with links 486-132-00 1
3 Brake Link 939-350-03 2
4 Thread spindle 939-353-00 1
5 Brake lever 486-130-05 2
6 Brake handle 486-134-00 1
7 Support ring housing 853-355-00 1
8 Cover 349-350-08 1
9 Thread spindle nut 853-350-09 1
10 Securing plate 853-350-10 1
11 Securing ring 349-350-11 1
12 Bolt Ø34 349-350-12 1
13 Bolt washer Ø34 349-350-13 2
14 Distance bushing No.1 349-350-14 1
15 Distance bushing No.2 349-350-15 1
16 Washer 349-350-16 4
17 Bolt Ø50 349-350-17 2
18 Bolt washer Ø50 349-350-18 4
19 Bolt Ø58 349-350-19 1
20 Bushing 349-350-20 1
21 Stud bolt M20 349-350-21 1
22 Bolt Ø40 349-350-22 1
23 Bolt washer Ø40 349-350-23 2
24 Extended Flat bar 939-356-00 1
Standard parts
g1 Parallel pin Ø10x55 DIN 7 Ø10x55 2
g2 Hexagonal head screw M8x25 DIN 933 M8x25 6
g3 Spring washer A8 DIN 127 A8 10
g4 Grease nipple M10x1 straight Ø10 DIN 3404 M10x1-Ø16 2
g5 Split pin Ø8x71 DIN 94 Ø8x71 2
g6 Spring straight pin Ø5x40 DIN 1481 Ø5x40 2
g7 Hexagon nut M20 DIN 934 M20 2
g8 Split pin Ø10x80 DIN 94 Ø10x80 2
g9 Hexagonal head screw M16x120 DIN 931 M16x120 1

54
Spare parts

Drawing No. /
Pos. Part description Material Dimensions Pcs.
Standard
g10 Hexagonal head screw M16x90 DIN 931 M16x90 1
g11 Hexagon nut M16 DIN 934 M16 2
g12 Spring washer A16 DIN 127 A16 2
g13 Hexagonal head screw M8x20 DIN 933 M8x20 4
Upper band with links 939-351-00
1 Flat bar 486-131-01 1
2 Link No.1 486-131-02 1
3 Link No.2 939-351-03 2
4 Connecting link 486-131-04 1
5 Brake lining Khüne-Intertech M9020 10x120x1700 1
6 Rivet Ø8x25 DIN 7338 Cu Ø8x25 38
Lower band with links 486-132-00
1 Flat bar 486-132-01 1
2 Link No.1 349-352-02 2
3 Link No.2 486-132-03 2
4 Brake lining Khüne-Intertech M9020 10x120x1100 1
5 Rivet Ø8x25 DIN 7338 Cu Ø8x25 21
Thread spindle 939-353-00
1 Spindle 939-353-01 1
2 Support ring 349-353-02 1
Brake handle 486-134-00
1 Handle 486-134-01 2
2 Hub 486-134-02 1
Support ring housing 853-355-00
1 Housing 853-355-01 1
2 Bushing 349-355-02 1
Extended Flat bar 939-356-00
1 Flat bar 939-356-01 1
2 Bushing for extended Flat bar 939-356-02 1

55
7.6. Specification: Mooring drum coupling arrangement

Reference Dwg. No. 956-550-00 / 056-560-00.

Drawing No. /
Pos. Part description Material Dimensions Pcs.
Standard
938-551-00 /
1 Coupling handle 938-561-00 1
2 Bolt 485-140-02 1
3 Support part 858-180-03 1
4 Support part 938-550-04 1
5 Pipe 769-260-05 2
6 Plate 769-260-06 2
7 Pipe 485-140-07 1
8 Stone 349-213-05 2
9 Bolt 349-213-06-A 2
Standard parts
g1 Spring type straight pin DIN 1481 φ4x25 2
g2 Bearing INA PAF 30260 P11 INA ∅30/x∅34x26 1
g3 Bearing INA PAF 20115 P11 INA ∅20/x∅23x11,5 4
g4 Hexagonal head screw DIN 933 M10x55 2
g5 Hexagonal nut DIN 934 M10 2
g6 Washer DIN 125 A10 2
g7 Hexagonal head screw DIN 933 M20x70 1
g8 Hexagonal nut DIN 934 M20 1
g9 Washer DIN 125 A20 1
g10 Hexagonal nut DIN 934 M16 2
g11 Spring washer DIN 127 A16 2
938-551-00 /
Coupling handle
938-561-00
938-551-01 /
1 Handle 938-561-01 1
2 Fork 938-551-02 1
3 Hub 485-141-03 1
4 Bushing 485-141-04 1

56
Spare parts

7.7. Specification: Electric schemes

Dwgs. No: 939-650-00 pages 1-14 (circuit diagram), 939-655-00 pages 1-4 (cabling diagram), 853-
650-03 (circuit diagram), 853-650-04 (circuit diagram), 939-651-00 (electric cabinet), 939-653-00
(control box), 939-651-01 (radio control storage cabinet).

Pos. Description Type Qty. Manufacturer


Frequency inverter for
ATV71 HD30Y 690V 1 Schneider
electromotor, 690V, 43kW,
Brake resistance 12 ohm, 4kW 1 EL-GRI
Housing 1200x1000x400 IP55 CRNG-1210/400 1 Himel-Schneider
Metal plain chassis 1200x1000 MM-1210 1 Himel-Schneider
Wall mounting accessories PFCR 1 Himel-Schneider
Door holder A 2 Himel-Schneider
PLC FX3U-48MT/ESS 1 MITSUBISHI
Current transformer ASR 14.3
TA1 1 DEIF
75/1 A kl1 75/1A kl.1 VA1
TA1 Mounting accessories on DIN rail No 1213990005 1 DEIF
FM1 Fuse carriers 3-pole GK1-FF (22x58) 1 Schneider
FM1 Cartridge (22x58) 80A 690V 3 ETI
F1 Fuse carriers 2-pole 14X51 MGN15710 2 Schneider
F12 Cartridge (14x51) 4A 2630003 4 ETI
Module for PT100 RMP T53BD 1 Schneider
Modular power supply
ABL8MEM24006 1 Schneider
230VAC/24VDC 15W
AC Current converter RMC A61BD 1 Schneider
H1 Pilot lamp, white 230V AC XB4-BVM1 1 Schneider
H2 Pilot lamp, blue 230V AC XB4 BVM6 1 Schneider
INS 100
SM Disconnector switch -3 pol 1 Schneider
No 28908
TMUE 690/
TC1 Transformer 230/24V,60Hz 1
400/400/100 VA
TMUE 690/ 230V,60Hz
TC2 Transformer 1
400 VA
G1 Brake module SGL 1 Pintsch Bubenzer
C60N 2p 4A C
F2-5 Circuit breaker 4 Schneider
A9F74204
FA1 Thermistor protection unit 230V
LT3SA00M 2 Schneider
FA2 AC
Contactor 3 pol 95A AC3
KM1 LC1D95P7 1 Schneider
LC1-D95P7, 230V 60Hz
Contactor 3 pol 12A AC3
KB1 LC1D12P7 1 Schneider
LC1-D12P7, 230V 60Hz
Hour counter
P1 HC 36/24, 230V 60Hz 1 DEIF
HC 36/24, 230V 60Hz
Fan
MF VF300 1 Schneider
HC 36/24, 230V 60Hz
Outlet grilles
MF FS165 2 Schneider
HC 36/24, 230V 60Hz
MF Thermostat TS141 1 Schneider
KA12-16 Relay 4CO, 24VDCz RXM4AB1BD 5 Schneider
Socket RXM RXZE2M114M 20 Schneider
Holding clamps RXZ400 20 Schneider

57
Pos. Description Type Qty. Manufacturer
KM1 Contactor auxiliary contact LAD-N11 2 Schneider
KA1-4
KA6
KA7-A
KA8 Relay 4CO, 24V,50Hz RXM4AB1B7 15 Schneider
KA9
KA10,A,B
KA11,A,B
R Heater 230V 40W CG 40W 1 EL-GRI
SVP1,2 Magnetic sensor MM08-60APS-ZUK 3 SICK
Neodymium magnet 20X12X5 N35 Ni 3 ARTAS
SP1,2 Enclosure NRKM 2 ALUMEN
SB1 Pushbutton XB4-BA21 1 Schneider
SB1 Boot, transparent ZBP A 1 Schneider
Mechanical protection against
4 DS
SB1 accidental pushbutton activation ZBP A
JC2/1
Enclosure 3 ALUMEN
JC2/2 NRKM
FX3U-48MT/ESS (26 ULAZA I
1
26 IZLAZA) MITSUBISHI
FX2N-4AD 1 MITSUBISHI
FX2N-4DA 1 MITSUBISHI
FX2N-2DA 1 MITSUBISHI
FX2N-2AD 1 MITSUBISHI
CONTROL BOX 250x180x200 1
S1,3 Selector switch XB4 BD33 2 Schneider
S1,3 Selector switch XB4 BD21 1 Schneider
S0 Pushbutton operator XB4 BT42 1 Schneider
Digital instrument 4-20ma,
P DPM A 3 RISHABH Instruments
24x48mm, 24VDC
R1 Heater 230V 40W CG 20W 1 EL-GRI
Potentiometer SZ1 RV 1202 2 Schneider
Silicon hat ZBZ 48 1 Schneider
Silicon hat ZBPA 4 Schneider
Pilot lamp fi 8mm 24V Green XVL A233 3 Schneider
Pilot lamp fi 8mm 24V Red XVL A334 4 Schneider
Pilot lamp fi 8mm 24V Yellow XVL A235 1 Schneider
RADIO CONTROL CABINET
Radio control carrier 1
Heater protection cover 1
STAINLESS STEL BOX
"R" SBOX4.5-250V2 1 ELSTEEL
400x500x250, AISI 316
"R" Wall mounting brackets AISI316 SWB 1 ELSTEEL
"R" Cabinet door closer AISI 316 SSKL 2 ELSTEEL
R Heater 220V, 50Hz 20W 20W,220V ELGRI 1 EL-GRI
TH Thermostat NSYCCOTHC 1 Schneider

58
Appendix

8. Appendix

DRAWINGS
1. Electric Mooring Winch, Starboard side - Assembly Dwg No. 939-050-00 SB
2. Electric Mooring Winch, Port side - Assembly Dwg No. 939-060-00 PS
3. Starboard side winch - Fundaments Dwg No. 939-003-01
4. Port side winch - Fundaments Dwg No. 939-003-02
5. Reducing Gear, Starboard side - Assembly Dwg No. 939-100-00 SB
6. Reducing Gear, Port side - Assembly Dwg No. 939-110-00 PS
7. Brake T800/120/15-336 - Assembly Dwg No. 939-350-00
8. Upper band with links Dwg No. 486-131-01
9. Lower band with links Dwg No. 486-132-01
10. Mooring drum coupling arrangement SB-assembly Dwg No. 956-550-00
11. Mooring drum coupling arrangement PS-assembly Dwg No. 956-560-00
12. Electric Mooring Winch - Marking Plates SB Dwg No. 939-050-19
13. Electric Mooring Winch - Marking Plates PS Dwg No. 939-060-19
14. Control Cabinets - Marking Plates /
15. Control box - Marking Plates /
16. Storing cabinet for control station /
ELECTRIC SCHEMES
1. Electric Mooring Winch – Circuit diagram (SB&PS) Dwg No. 939-650-00 (Pages 1-14)
Electric Mooring Winch – Cabling diagram
2.
(SB&PS) Dwg No. 939-655-00 (Pages 1-4)
3. Electric Mooring Winch – Electric cabinet Dwg No. 939-651-00
Electric Mooring Winch – Radio control storage
4.
cabinet Dwg No. 939-651-01
5. Electric Mooring Winch - Control box Dwg No. 939-653-00
6. Electric Mooring Winch – Radio control SB Dwg No. 939-610-01
7. Electric Mooring Winch – Radio control PS Dwg No. 939-610-02
BUILT-IN COMPONENTS
MC-3 Series radio remote control – Instruction
1. “Cavotec S.A.”
manual
2. Sensor MM08-60 APS-ZUK – Catalogue pages “Sick”
Electric motor 7ABZKA 250M-8TAG IM B5 +
3. “Končar”
Encoder HTL
“Schneider” – variable speed drive ATV71-55kW –
4. Catalog pages
690 V
5. Brake lining GBC - Specification “Trimat Ltd.”
6. Brake lining M9020 - Specification “Khune-Intertech GMBH”
Frequency inverter Altivar 71 – Faults
7. “Schneider”
Troubleshooter
8. PLC FX3U- 48MT/ESS – Hardware Manual “Mitsubishi”
FACTORY TESTING APPLICATIONS
Factory Testing Application - Electric Mooring
1. /
Winch

59
60
APPENDIX
DRAWINGS
www.adriawinch.com
21000 Split, CROATIA
OIL INLET and VENT
(-20°... +5°C) - ISO VG 100
( +5°...+40°C) - ISO VG 150
(+30°...+65°C) - ISO VG 220
(+40°...+65°C) - ISO VG 320
M 1:2
View "A"
M 1:2
View "B"
"B"
Rope direction
"B"
"B"

Rope direction
"B"

View "B"
M 1:2
View "A"
M 1:2

OIL INLET and VENT

21000 Split, CROATIA


www.adriawinch.com
Supports built by
NOTE:
shipyard
+ tension
- pressure

+130 kN
Supports built by
shipyard

Gearbox centre line


+240 kN

Main shaft Centre line


-130 kN

+130 kN

M30 bolts, 18 pcs.


Tightening torque:
Tk=1300 Nm, 8.8 class
Supports built by
shipyard

Supports built by
shipyard
Rope direction

21000 Split, CROATIA


www.adriawinch.com
Supports built by
NOTE:
shipyard
+ tension
- pressure

+130 kN
Supports built by
shipyard

Gearbox centre line


+240 kN

Rope direction
Main shaft Centre line
-130 kN

+130 kN

M30 bolts, 18 pcs.


Tightening torque:
Tk=1300 Nm, 8.8 class
Supports built by
shipyard
Supports built by
shipyard

21000 Split, CROATIA


www.adriawinch.com
OIL LEVEL

OIL DRAIN
OIL INLET and VENT

21000 Split, CROATIA


www.adriawinch.com
OIL LEVEL

OIL DRAIN

OIL INLET and VENT


21000 Split, CROATIA
www.adriawinch.com
21000 Split, CROATIA
www.adriawinch.com
21000 Split, CROATIA
www.adriawinch.com
125
118

TM

Autotension Mooring Winch: MW-T-ER-200/10/25-GDW-NLF


Serial No : Year : 2013
Synthetic rope: Drum capacity:

73
80
Rope min. BL : 480 kN Nominal Pull : 200 kN
Brake Hold : 385 kN Low Speed range: 2.5-10 m/min
E-motor Power: 43 kW High Speed range: 10-25 m/min
Electric supply: 3x690V-60Hz Winch mass : 4050 kg
Reg No :

R2

Napomene:
- debljina lima t=1 mm
- AISI 316
- polirano
- gravura i font bojano u crno.

21000 Split, CROATIA


www.adriawinch.com
125
118

TM

Autotension Mooring Winch: MW-T-EL-200/10/25-WDG-NLF


Serial No : Year : 2013
Synthetic rope: Drum capacity:

73
80
Rope min. BL : 480 kN Nominal Pull : 200 kN
Brake Hold : 385 kN Low Speed range: 2.5-10 m/min
E-motor Power: 43 kW High Speed range: 10-25 m/min
Electric supply: 3x690V-60Hz Winch mass : 4050 kg
Reg No :

R2

Napomene:
- debljina lima t=1 mm
- AISI 316
- polirano
- gravura i font bojano u crno.

21000 Split, CROATIA


www.adriawinch.com
TM

SEAONICS
SEAONICS Serial no:
SEAONICS Drawing no:
ELECTRIC CONTROL CABINET
For : MW-T-EL-200/10/25-GDW-SB
Serial No : Year :

TM

SEAONICS
SEAONICS Serial no:
SEAONICS Drawing no:
ELECTRIC CONTROL CABINET
For : MW-T-ER-200/10/25-WDG-PS
Serial No : Year :
TM

SEAONICS
SEAONICS Serial no:
SEAONICS Drawing no:
WINCH CONTROL BOX
For : MW-T-EL-200/10/25-GDW-SB
Serial No : Year :

TM

SEAONICS
SEAONICS Serial no:
SEAONICS Drawing no:
WINCH CONTROL BOX
For : MW-T-ER-200/10/25-WDG-PS
Serial No : Year :
TM

SEAONICS
SEAONICS Serial no:
SEAONICS Drawing no:
STORING CABINET FOR
CONTROL STATION
For : MW-T-EL-200/10/25-GDW-SB
MW-T-ER-200/10/25-WDG-PS
Serial No : Year :
ELECTRIC SCHEMES
21000 Split, CROATIA
www.adriawinch.com
21000 Split, CROATIA
www.adriawinch.com
21000 Split, CROATIA
www.adriawinch.com
21000 Split, CROATIA
www.adriawinch.com
21000 Split, CROATIA
www.adriawinch.com
21000 Split, CROATIA
www.adriawinch.com
21000 Split, CROATIA
www.adriawinch.com
21000 Split, CROATIA
www.adriawinch.com
21000 Split, CROATIA
www.adriawinch.com
21000 Split, CROATIA
www.adriawinch.com
21000 Split, CROATIA
www.adriawinch.com
21000 Split, CROATIA
www.adriawinch.com
21000 Split, CROATIA
www.adriawinch.com
21000 Split, CROATIA
www.adriawinch.com
21000 Split, CROATIA
www.adriawinch.com
21000 Split, CROATIA
www.adriawinch.com
21000 Split, CROATIA
www.adriawinch.com
21000 Split, CROATIA
www.adriawinch.com
BUILT IN COMPONENTS
 

Instruction Manual 
MC‐3 Series Radio remote control systems    
          

 
    MC‐3 Series instruction manual 

 
Contents
SAFETY NOTES ............................................................................................................................................. 3 
1  INTRODUCTION ................................................................................................................................... 4 

1.1  MARKING ................................................................................................................................................. 4 
2  SYSTEM DESCRIPTION .......................................................................................................................... 5 
2.1  TERMINAL ................................................................................................................................................. 5 
2.2  BASE UNIT ................................................................................................................................................ 6 
2.3  CABLE CONNECTION (OPTIONAL) ................................................................................................................... 6 
2.4  ANTENNA ................................................................................................................................................. 6 
2.5  CARRYING BELT/ NECK STRAP ........................................................................................................................ 6 

3  FUNCTIONAL DESCRIPTION .................................................................................................................. 7 
3.1  SYSTEM CONFIGURATION ............................................................................................................................. 7 
3.2  SIGNAL ENCODING ...................................................................................................................................... 7 
3.3  FEEDBACK ................................................................................................................................................. 7 
3.4  OPERATING RANGE ..................................................................................................................................... 7 
4  MAIN DATA ......................................................................................................................................... 8 

5  INSTALLATION ..................................................................................................................................... 9 
5.1  INSTALLING THE BASE UNIT .......................................................................................................................... 9 
5.2  INSTALLING THE ANTENNA ........................................................................................................................... 9 

6  COMMISSIONING ............................................................................................................................... 10 
7  OPERATION ....................................................................................................................................... 11 

7.1  OPERATION OF TERMINAL .......................................................................................................................... 11 
7.2  OPERATION OF BASE UNIT ......................................................................................................................... 14 

8  BATTERY CHARGER AND BATTERIES ................................................................................................... 17 
8.1  CHANGING THE BATTERY ............................................................................................................................ 17 
8.2  BATTERY CHARGER INSTALLATION AND USE .................................................................................................... 18 
8.3  CABLE MODE ........................................................................................................................................... 22 

9  MAINTENANCE .................................................................................................................................. 22 
9.1  SPARE/REPLACEMENT ............................................................................................................................... 22 
9.2  SERVICE .................................................................................................................................................. 22 
9.3  FAULT REPORTING .................................................................................................................................... 23 

10  WARRANTY ....................................................................................................................................... 23 

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    MC‐3 Series instruction manual 

Safety notes
 

Inspect the MC‐3 series equipment before using it. 

Check for any damage that may be incurred during shipping.  

Do not open the terminal unit. There are no user serviceable parts. 

Do not use the device if it appears to be damaged. 

Use only original batteries from CMC. 

Avoid mechanical shock and vibrations if possible.  

Do not use outside temperature range. 

Do not immerse in water. 

ENSURE THAT THE SUPPLY VOLTAGE IS CORRECT.  

INSTALLATION SHOULD ONLY BE CARRIED OUT BY QUALIFIED PERSONNEL. 

Cavotec Micro‐control AS reserves the right to make improvements and/or changes in the 
®  products and/or specifications described in this information at any time without notice. 

MAN‐07‐007‐08                                                                                                                                                    3  

 
    MC‐3 Series instruction manual 

1 Introduction
The MC‐3 series radio remote control is designed for use in harsh industrial environment to control 
machinery such as overhead cranes, hoists, recovery vehicles, concrete pumps, sludge trucks etc. 

As the different remote control models vary according to customer requirements, this manual 
describes only functions that are common for all MC‐3 series deliveries (including MC‐3 series EX). 
For customer‐specific systems please refer to project documentation. 

1.1 Marking
1.1.1 Terminal units
The serial number and other relevant data such as frequency, project number etc. is found on the 
backside of the respective unit.  

                 

                                            

1.1.2 Base unit


The serial number and other relevant data such as frequency, project number etc. is found on the 
right hand side of the respective unit.  

           

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    MC‐3 Series instruction manual 

2 System description
The system consists of  

 terminal (remote control unit), with a carrying 
belt or neck strap 

  base unit with antenna   

 (battery charger and batteries) 

The terminal and the base unit are communicates via 
a radio link. Some systems are also delivered with a 
cable for communication between terminal and base 
unit as the only way of communication or as a backup 
for the radio link. When the system communicates 
only by cable, battery charger and batteries are not part of delivery. 

As customer requirements vary greatly, the system comes in different models which differ in 
configuration, size and weight.  

2.1 Terminal
The terminal contains the Stop switch, pushbuttons, joysticks, toggle switches, LED indicator lamps 
and optionally a LCD display. The terminal is carried by the operator with a belt or a neck strap. 

All terminals are also available in EX proof versions. 

                              
MC‐3200   
MC‐3300 

                      
MC‐3‐5  MC‐3‐6   

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    MC‐3 Series instruction manual 

2.2 Base unit


The base unit is the part of the system that is connected to the customer’s machine or PLC. CMC 
delivers output signals to control the machinery from the remote control, based on the customer’s 
specification.  

The base unit can be delivered in EX or NON‐EX. 

CMC has no responsibility for control elements that are part of machinery. 

2.3 Cable connection (optional)


The cable connects the terminal with the base unit and serves both as power supply and 
communication line. Cable can be used as backup or instead of radio communication. When the 
cable is connected, the system will automatically communicate on cable, and the radio will be 
disabled. 

2.4 Antenna
Located on or connected to the base unit with a coaxial cable. The antenna can be of internal or 
external type. External antenna can be mounted on the base unit or some distance away with an 
extension cable supplied by Cavotec Micro‐control. 

  Depending of cable type, the recommended maximum length of the antenna extension cable is 
either 30 m or 50 m. 

2.5 Carrying belt/ neck strap


The carrying belt or strap should always be used whenever the terminal is operated to carry the 
terminal safely and keep the operator’s hands free.  

Failure to use the belt or strap may cause injury as you will not have proper control of the 
terminal. 

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    MC‐3 Series instruction manual 

3 Functional description
The terminal unit communicates by radio signals or by cable, with the base unit which is installed at 
the designated equipment.  

3.1 System configuration


The system may consist of more than one terminal/base unit operating together. Where several 
terminal units are used to control one base unit, it is customer’s responsibility to ensure that the 
operator always has control of which terminal unit is in operation, to avoid any dangerous 
uncontrolled movements.  

For tandem configurations, e.g. multiple cranes doing tandem lift of heavy equipment, please refer 
to the specification SP‐11‐015 CMC Tandem configurations.  

3.2 Signal encoding


Unique encoding of the radio signal prevents unintentional operation caused by interference from 
other radio systems. 

3.3 Feedback
If feedback is configured, the operator can read information from the machine at the terminal unit, 
via a display or LEDS. The information could include e.g. % of load, rpm, torque, speed, text 
instruction, etc. If the feedback is a direct input from the machinery, customer is responsible for the 
information being presented. 

3.4 Operating range


Depending on the installation the operating range can be from 100‐1000 m, typically 200 m line of 
sight. The range may change according to the surroundings and other equipment.  To achieve 
optimal range, care should be taken when installing the antenna (Chapter 5.2). 

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    MC‐3 Series instruction manual 

4 Main data
 

Terminal Base unit

Dimensions   MC-3-5 230x175x160 mm Physical size and weight of the housing


(L‐W‐H)  will vary for each delivery. Please refer
MC-3-6 330x220x200 mm to system specific drawings and order
specific documentation.
MC-3200 280x180x180 mm

MC-3300 340x230x185 mm

Weight 2-4 kg (the weight will vary with the terminal’s


equipment)

IP class IP 65, optional IP 66, depending on configuration.

Operating Temperature Between -20°C and +50°C for radio systems

Between -25°C and +60°C for cable systems without radio

Radio frequency CMC can provide systems for frequency bands in the range 335 Mhz – 870 MHz.
Contact CMC for guidance on correct radio frequency. 
Radio power <10 mW, according to regulations 

Operating range Approx 200 m line of sight 

Batteries Rechargeable Li-ion, 7.4 V, 1100-2030 mAh Power 12-24 V


supply
Use only MC-3-series batteries from Cavotec 110-230 V
base
unit

Operating time Typical 20 hours, depending on configuration and Input Refer to system specific data
temperature

Time out Adjustable, 0-99 min, 30 min. default Output Refer to system specific data

Time out is defined in SW, must be configured


before delivery of system

MAN‐07‐007‐08                                                                                                                                                    8  

 
    MC‐3 Series instruction manual 

5 Installation

INSTALLATION SHOULD ONLY BE CARRIED OUT BY QUALIFIED PERSONNEL.

ENSURE THE SUPPLY VOLTAGE IS CORRECT. 

 Consider the ambient temperature and IP rating. 

 If the installation is subject to harsh vibrations, use vibration dampers available from CMC. 

5.1 Installing the Base unit


1) Fasten the base unit securely onto a suitable part of the machine or equipment being controlled.  

a) Install the base unit in a mechanical protected area not being exposed to damage 

b) Make sure the base unit is not installed near high energy lines 

c) Ensure that the base unit is installed where it will not be conflicting with moving parts in 
operation 

2) Reserve space around the unit to ensure easy removal of the lid/opening of the door and easy 
access to the connectors and buttons in the base unit 

3) The system shall be installed/wired according to the wiring diagram and system description 
given in the project specific documentation. Control that the load (valves etc.) is connected 
correct and that the specification on the load is within the specified minimum/maximum load of 
the CMC output relays.  

5.2 Installing the Antenna


Mount the antenna so there is line of sight between the antenna on the base unit and the terminal 
carried by the operator. Large metal objects between the terminal and antenna on base unit may 
stop the signal and prevent operation.  

 Take care that the antenna will not be damaged by moving machinery. 

 Do not mount the antenna inside a metal enclosure. There should be no metal objects within a                       
radius of 1 m from the centre of the antenna 

Other wireless equipment may interfere with the radio remote system. Frequency planning is 
important to avoid this. Contact CMC for guidance 

If more than one antenna is mounted at the same site, particular care should be taken with 
regards to sufficient channel spacing and distance between antennas. Range may be degraded if 
these are not considered. Contact CMC for guidance. 

MAN‐07‐007‐08                                                                                                                                                    9  

 
    MC‐3 Series instruction manual 

6 Commissioning
The system has been through a 100 % test before leaving factory, ensuring that all outputs are 
controlled by the correct joystick/switch on the terminal unit, and that the output values are correct 
according to the specification from customer. 

When the system has been installed, customer is responsible for checking of all functions in a 
controlled and safe manner before the system is put in to normal operation: 

1) Check all control functions  
 Validate that each function controls the intended operation/movement on the 
machine, with minimum to maximum deflection/speed where relevant. 
 Where configured, validate that all interlocking functions works as intended.  
 Where configured, validate that all selector switches works as intended. 
 Where configured, validate that max/min programming of analogue functions works 
as intended. 
 Where feedback from machine(load cell , sensor etc) to terminal unit is configured, 
either to display or LED, validate that the input signal gives correct corresponding 
value in the terminal unit. 
2) Validate the Stop function: Press the Stop button and check that all movements/functionality 
connected in the Stop loop are deactivated.  
Start up after Stop: 
 For SIL certified systems the radio remote system is activated again by first releasing 
the Stop button, checking that terminal unit is ON and then pressing the Start 
button.  
 For systems with ON/OFF and Stop button the radio remote system is activated 
again by first powering OFF terminal unit, releasing the Stop button and powering 
ON terminal unit 
 For systems with ON/OFF, Start and Stop button the radio remote system is 
activated again by first powering OFF terminal unit, releasing the Stop button, 
powering ON terminal unit and then pressing Start. 
 For systems without ON/OFF and Start, only Stop, the radio remote system is 
activated again by releasing the Stop button. 

If modules have been replaced at service, or other modifications have been done on the system, 
commissioning must be done before the modified system is put in to operation again. 

MAN‐07‐007‐08                                                                                                                                                    10  

 
    MC‐3 Series instruction manual 

7 Operation
7.1 Operation of Terminal
MC‐3 series terminals are produced to control a variety of equipment, and each terminal unit is 
configured uniquely according to customer specification, for optimal integration with the customer’s 
machine. Specific instructions are found in the project specific documentation.  

It is important that the operator is familiar with the machine being controlled, and has been given 
the necessary training. 

7.1.1 Start
Check that a sufficient charged battery is in the terminal. Pull out/twist the Stop button and make 
sure the terminal is ON. Press the Start button if fitted. All SIL certified systems are equipped with a 
Start button, ON/OFF and Stop button.  

After a self test (approx. 1 sec.) the terminal will establish contact with the base unit. 

If the communication between terminal unit and base unit is broken, e.g due to radio loss, the Start 
button has to be activated to establish communication again. For some system configurations (all SIL 
certified systems) all safety related analogue functions and any selector functions enabling these, 
have to be deactivated before Start up is allowed.  

7.1.2 Stop
Press the Stop button to activate the Stop. Twist or pull to release.  

The system is default equipped with a grey Stop button placed on the right hand side of the 
terminal.

Stop button 

To start machinery again, after the Stop function has been activated, refer to chapter 6, point 3). 

7.1.3 Time out


If the system is not used for a time, it can be configured to go into power save mode to conserve the 
battery. Time out can be adjusted from 0‐99 minutes or turned off. Default time out is 30 min. 

7.1.4 Activity check


For safety reasons, activity check may be added for all, or for a range of functions. This will force the 
switch/joystick to be set in neutral position before the operator is allowed to start up terminal.  

As default, all functions have activity check. All SIL certified systems have activity check on all safety 
related functions. 

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    MC‐3 Series instruction manual 

7.1.5 Frequency selection


MC 3‐series systems can be delivered with automatic or manual frequency selection. 

If automatic, the system will scan a set of 2 to 8 predefined frequencies and find an available 
frequency (not occupied/with low noise). 

Some system types (depending on terminal electronics) have the possibility for manual frequency 
selection. There will be a frequency select button on the terminal or a rotary switch to select the 
next frequency programmed into the system. The base unit will automatically scan to find the 
frequency the terminal is set to. The function should be used if there is bad link to base unit, either 
no connection or often interrupted. When changing frequency, all outputs will go to neutral position 
for a short time. The system starts again as described in chapter 7.1.1. After power off and on, the 
system will either start with a predefined frequency or with the last selected one, depending on 
system setup. 

7.1.6 MIN / MAX programming (optionally)


Optionally there is an easy, quick and exact possibility to program analogue output from the 
terminal side. 
If so, you will find two buttons for min/max on the terminal.  

Adjustment procedure: 
1. Turn the terminal off. 

2. Press the PROGRAM buttons MIN and MAX at the same time. 

3. While pressing the MIN/MAX buttons, turn the terminal on.  

4. Release the PROGRAM buttons MIN and MAX. The terminal is now in programming mode, 
indicated with short flashes at the battery status LED. If the terminal has a LCD‐display, this 
will show A‐00, indicating programming mode. When a function is being programmed the 
display shows:  
A‐XX where XX shows which analog channel is being programmed, and is a number between 
01….13. 

5. Adjustment: 
Move the function at your choice to adjust until you get the wanted response. If this shall be 
your minimum response, press MIN. If this shall be your maximum response, press MAX. The 
terminal will then automatically adjust the increase of the response so that the whole area 
of the joystick output is between the two chosen points. 

6. Each function is adjusted separately for each direction (up/down/right/left). 

7. Reset: 
Move the function you select to reset out from the center. Press MIN and MAX at the same 
time.  
The function is now reset. 

8. When the programming is finished, the transmitter must be turned off and on again to start 
in normal mode. 

MAN‐07‐007‐08                                                                                                                                                    12  

 
    MC‐3 Series instruction manual 

7.1.7 Status indications on the terminal


The terminal is delivered with a LED for status indications; this is usually marked with STATUS or 
BAT. On systems delivered with LCD screen, error codes and explanations are also found there. 

LED flashing pattern  Description  Action 

Steady light  Normal condition. Terminal is  None 


turned on, battery voltage is 
OK, no fault is detected 
Slow flashing light without stop   Low battery voltage  Replace battery with a fully 
(1 flash/sec.)  charged one. 

Short flashes (2 flashes/sec.)  Programming mode  Turn terminal off and on again 


to start normal operation.  
1 flash with long stop (every  Processor fault or test mode.  Ensure that the processor 
2nd  sec.)  Indicates a processor module  module BOOT‐jumper is not 
fault and/or a processor fault.  turned on. Replace processor 
module and/or processor.  
2 flashes with a stop  Activity at start‐up. A joystick is  Set all switches/joysticks to 
out of centre position, or a  OFF‐position and/or neutral 
switch is in ON‐position.   position.  

3 flashes with a stop  Radio fault  Change/replace radio module. 

4 flashes with a stop  Shutdown due to low battery  Replace battery with a fully 


voltage  charged one. 

5 flashes with a stop  Keyboard fault. Terminal is not  There is a fault at the input 


able to ”read” switches,  module.  
joysticks etc. 

6 flashes with a stop  Shutdown due to inactivity. The  Turn terminal off and on again 


terminal will soon ”turn itself  to start normal operation.  
off” since no switches, joysticks 
etc. have been activated.  

7 flashes with a stop  Priority stop. Stop button or  Ensure stop button is out and 


shock detector have been  turn terminal OFF and ON again 
activated. Not relevant for SIL  to start normal operation. 
certified system. 

Short flashes at the battery  Terminal in programming mode  Min/Max programming of 


status LED  analog functions 

No LED  Terminal off  Ensure terminal contains a 


charged battery and is turned 
on. If the terminal has turned 
itself off due to inactivity, turn 
it off and on again to start 
normal operation.  

MAN‐07‐007‐08                                                                                                                                                    13  

 
    MC‐3 Series instruction manual 

7.2 Operation of Base unit


All the MC‐3‐series base units are produced according to customer specifications, the wiring diagram 
shows how the base unit is connected. 

Under normal conditions, no operation of the base unit is necessary. 

If the base unit does not operate correctly, check the display for messages. See info below, for 
your type of base unit. 

All repairs must be carried out by a representative from CMC.  

Your local representative is found at www.cavotec.com 

7.2.1 MC‐IRX‐LITE and MC‐IRX2 base units

Display on MC‐IRX‐LITE 

The display on MC‐IRX base units is a menu system allowing viewing of all operational parameters 
and service information. 

During normal operation, the display is divided into three fields: an upper line, and a bottom line 
with a status field and a timer field. The upper line may also indicate error codes. 

Indications in the upper line  Description 

[..3......0......]  Normal operation: Shows activated relays, in this case relays #3 
and #10. 

[Error: E003]  Failure in radio module. 

[Error: E010]  Aux port communication error. 

[Error: E011]  MUS bus communication error. 

[Micro‐control as]  No communication with a terminal and no onboard relays active. 

[fatal: ]  A fatal error has occurred. 
<msg> is a text in the status field describing the cause. Turn the 
supply Off and On. If the message reappears, contact CMC. 
 

MAN‐07‐007‐08                                                                                                                                                    14  

 
    MC‐3 Series instruction manual 

Indications in the status field  Description 

A4:‐30 %  Most active analog output. In this case channel 4 with output 
value of ‐30 %. 
Online  Normal operation, base unit communicates with a terminal. 

Passive  Base unit communicates with a terminal, but the Stop relay is de‐
energized. May be caused by too low supply voltage. It is not 
possible to operate equipment when in passive mode. 

Idle  Base unit does not communicate with a terminal. 

Locked  If several terminals are configured for one base unit, the base 
unit communicates with selected terminal and does not search 
for additional terminals (first come first serve mode). 

Blocked  Base unit communicates with a terminal, but is inactive due to 
softplc function (e.g. start button is not activated). 

The timer field shows the time elapsed since the last change of operational mode 
(online/passive/idle/locked/blocked) in hours, minutes and seconds:   01:43:12 

Base unit display when there is no communication with the 
terminal. 

Normal operation. Base unit communicates with terminal and 
relay 1 and 7 are activated. 

                           
                                    
A fatal (non recoverable) error has occurred. 
<msg> is a text describing the cause. Turn the supply Off and On. 
If the message reappears, contact CMC. 
 

MAN‐07‐007‐08                                                                                                                                                    15  

 
    MC‐3 Series instruction manual 

7.2.2 Field bus base units


Field bus base units are always delivered with a 4 digit segment display. The display may be stacked 
on the PCB or placed on the outside of the enclosure. The display indicates different fault statuses as 
well as what terminal is online at any given time. On start‐up the display also show the terminal IDs 
that is supported in this base unit.  

Indication in display  Description 
E001  CPU in PM faulty 
E003  Radio error or no radio present 
E010  No communication with PLC 
E011  No communication with slave PM 
 

7.2.3 MC‐LINK‐CAN base units

Display on MC‐LINK‐CAN 

 
The MC‐LINK‐CAN is equipped with a 3 digit segment display. This display indicates operation status 
and error messages. The display is found on the upper right corner of the module. 

Operation status 
During normal operation digit 1 will be off, and the display will indicate ‐ ‐ 
Digit 1 (from the left)  Description 
2  Remote status 
3  CanOpen status 
E  Error, the next two digit is an error code (see table below for 
error codes) 
F  Fatal error, the next two digit is an error code (see table below 
for error codes) 
 

MAN‐07‐007‐08                                                                                                                                                    16  

 
    MC‐3 Series instruction manual 

Digit 2 (from the left)  Description 
0  No terminal communication 
‐  Communicating with terminal 
E  Stop function is activated on the terminal 
 
Digit 3 (from the left)  Description 
P  Pre‐operational 
‐  operational 
S  Stopped 
U  Unknown state 

Possible error indications in display 

Display  Description 
F01  Waiting for setup file to be downloaded 
E03  Radio error or no radio present 
E10  No communication on CAN bus 
Fxx  Fatal error, power cycle is required to resume 
normal operation. If message reappears, contact 
CMC. 

8 Battery charger and batteries

8.1 Changing the battery


 

Use only batteries provided by CMC.  

1. Put the machine being controlled in to a safe position. 
2. Turn the terminal OFF. 
3. Remove the battery and insert a fully charged one.  
4. Turn the terminal ON. 
5. Hot swap 
 Terminals with 2 battery compartments can continue to operate without being switched 
off. Replace only one battery at a time. 
 

       
 
 
 

MAN‐07‐007‐08                                                                                                                                                    17  

 
    MC‐3 Series instruction manual 

8.2 Battery charger installation and use

Read these instructions before using the charger 
 

 Consult instructions for use, symbols on charger are meant to support, not replace, 
these operating instructions. 
 
 This charger applies to the essential requirement of the applicable EC directives. 
 
 The charger is designed for indoor use and should not be exposed to water or dust.  
 
 Do not cover up the charger when in use. 
 
 The charger is turned on by connecting it to mains socket (100 V to 230 V  )  
or to 12‐24 V.   Disconnecting turns it off.  
 
 Control that the power cord is not damaged. If the cord is damaged, the charger must not be 
used. 
 
 The mains socket should be easily accessible. If an operational error occurs, the plug 
should be immediately removed from the mains socket. 
 
 The charger is double isolated (insulation class II).  
 
 The charger contains dangerous voltages and the cover should not be removed. The 
charger is not serviceable. In case of not working it has to be replaced by a new 
charger. Contact nearest Cavotec sales representative (www.cavotec.com). 
 
 Avoid the charger from coming into contact with oils, grease etc., as most types of plastic can be 
broken down by chemicals and solvents. 
 
 Electrical and electronic equipment shall not be discarded with the municipal waste, 
but be disposed of using separate collection, treatment, recovery/recycling and 
environmentally sound disposal, according to local rules. 
 
 The charger is intended to charge MC‐3 series batteries from Cavotec Micro‐control AS, Cavotec 
Micro‐control AS have no responsibility for any injuries caused by other usage, not according to 
intended use. 

MAN‐07‐007‐08                                                                                                                                                    18  

 
    MC‐3 Series instruction manual 

Important
The charger is designed for indoor use only! 

The MC‐3 series charger is designed for horizontal or vertical mounting. Two key holes on the 
bottom of the unit support wall mounting in two directions. Check that the screws are going easy in 
the keyholes for easy removal from wall if necessary. 

8.2.1 Charger description and functionality


The MC‐3 series charger is designed for CMC battery packs, MC‐BAT3 and MC‐EX‐BAT3. The battery 
packs contain two 3,7 V Lithium Ion batteries connected in series. Charge end voltage is 8.4 V. 
Capacity of the battery pack is 1600‐2030 mAh for the MC‐BAT3 and 1100‐1230 mAh for the MC‐EX‐
BAT3.  

The MC‐3 series charger is an advanced charger for Li‐Ion batteries. It is developed for optimal 
performance and battery power conservation. 

The charger is equipped with one tri‐color LED (light emitting diode) at the front displaying charge 
status. The charger may be used for 100‐230 VAC/50 and 60Hz or for 12VDC‐24 VDC. (only AC or DC at a 
time, not both). The charger is designed for DC operation in vehicles. AC and DC has separate 
inputs.The battery compartment is on the top of the charger.  

The charger should not be used to charge other batteries than Micro‐control batteries!  

The MC‐3 series charger is a constant current charger during the main period of charging. When the 
battery voltage is below a certain level, the charger is in constant current mode, delivering close to 
1100 mA. Fast charge continues until voltage is close to 8.4 V, then the charger goes into constant 
voltage mode and charge current decreases. Charge termination occurs when charge current is 
about 100 mA. Typical charge time for MC‐BAT3 is 2,5 hours and for the MC‐EX‐BAT3 1,5 hours. The 
battery capacity will decrease during the battery lifecycle, when capacity is to low (to low 
operational time) then replace the batteries with new ones. 

8.2.2 Charger operating instructions

Normal charge cycle 
To charge a MC‐BAT3 or MC‐EX‐BAT3, simply place it into the MC‐3 series charger. Charging will start 
automatically when the battery is inserted. Red LED light indicates charging.  If the charger/battery is 
outside temperature limits, charging will not take place and the LED will indicate yellow. Green LED 
indicates a fully charged battery. The charger is not intended for continuous use, after a charge cycle 
is completed the battery shall be removed and the power disconnected. 

DC power cord 
Connection of the DC power is on the ROKA connector on the left side of the charger. The center 
lead is +. This is also marked on the cord. The –lead is the ribbed cord, +lead is at the smooth cord 

MAN‐07‐007‐08                                                                                                                                                    19  

 
    MC‐3 Series instruction manual 

Indicators 
The MC‐3 series charger is equipped with one LED, placed on front, close to the battery 
compartment. Charger status is indicated by the following LED colors: 

Charge status  LED  
Battery absent  Green 
Temperature charge cutoff  Yellow 
Battery inserted with no supply voltage  Yellow 
Fast charging  Red 
Charge complete  Green 

8.2.3 Charger ordering numbers from CMC

Versions 
There is only one version of the MC‐3 series charger covering virtually all different supply voltages. 
To apply to different main supply voltage standards there is different mains supply cords. All 
ordering numbers are listed below. 
M5‐1080‐3600  Charger MC‐3 series 
M5‐1140‐3600  Power cord EUR/C7 
M5‐1140‐3603  Power cord US/C7 
M5‐1140‐3601  Power cord UK/C7 
M5‐1140‐3602  Power cord AUSTR/C7 
M5‐1140‐3604  DC power cord with plug 
M5‐1080‐3699  Kit with charger and all 5 power cord. 
M5‐1051‐3600  MC‐BAT3 
M9‐1051‐3600  MC‐EX‐BAT3 

8.2.4 Charger general specifications

Input voltage AC input: 100 - 230V , max 150mA, 50 - 60 Hz


DC input: 12 – 24V
Operating -20C - +40C
Temperature Ambient Charging takes place in the temeratur interval +10C - +40C only
Storage Temperature -25C - +80C

Humidity 10-90%
Max height for usage 2000 moh
Mounting of the PSU Two key holes on the bottom of the unit support wall mounting in two
directions
Galvanic Separation Yes
Power inlet AC: IEC conn 2,5A PCB RA
DC: DC-connector 1,9mm pin Roka 520 2550
- terminal is the ribbed cord, + terminal is the smooth cord
Output connector 2x gold plated pin

MAN‐07‐007‐08                                                                                                                                                    20  

 
    MC‐3 Series instruction manual 

8.2.5 Charger mechanical outline:

76,00 mm
 

202,00 mm 37,5 mm

8.2.6 Charger cleaning/maintenance
With no battery or power connected to the charger, the charger can be carefully cleaned with a 
damp cloth. 

8.2.7 Charger marking


 

P/N 1080‐3600 

100 ‐ 230V  , max 150mA, 50 ‐ 60 Hz 

12 – 24V     

S/N XXXXXXXXXXXXXXXXXXXXXXXXXXXXXXX 

www.cavotec.com 

MAN‐07‐007‐08                                                                                                                                                    21  

 
    MC‐3 Series instruction manual 

8.3 Cable mode


Some terminal models are equipped with a cable and batteries, and some with only a cable. The 
cable is connected to the base unit, and serves as both power supply for the terminal unit and 
communication link to the base unit. For models with both radio function and cable, the radio mode 
is automatic deactivated as soon as the cable is connected. The terminal and the base unit then 
communicate via the cable.  After connecting or disconnecting the cable, press Start button to 
establish communication with base unit again. 

Plug for cable mode 

                                                   

9 Maintenance
The terminal and base unit do not need any maintenance. However, the units should be inspected 
for damage and cleaned regularly with a damp cloth, for all displays, labels and symbols to be read 
properly. 

If opening the terminal housing, ensure the gasket is fixed properly when closing the terminal. 
The terminal unit shall only be opened by qualified personnel; failure in fixing the gasket may 
degrade the IP degree. 

If the rubber boots on the terminal’s joysticks/switches are damaged, they should be replaced at 
once. Contact your local CMC distributor.  

Your local CMC distributor is found at www.cavotec.com 

9.1 Spare/Replacement
Spare parts can be ordered through your local CMC distributor. You will need the serial number (ID 
code) from the system, see section 1.1 Marking, and the part number. 

Dispose of electronic products according to local rules. 

Your local CMC distributor is found at www.cavotec.com 

9.2 Service
Service can be arranged with your local distributor. You will need the serial number from the system 
and description of the service required. 

MAN‐07‐007‐08                                                                                                                                                    22  

 
    MC‐3 Series instruction manual 

9.3 Fault reporting


CMC is continuously working to improve our systems, to be able to deliver as safe and good products 
as possible. For best possible improvement, it is crucial to get feedback from customers. 

Non‐conformities on the product, functionality or quality should be reported back to CMC. 

If a hazardous situation or a fatal error should occur on the delivered system, please report back to 
CMC for analysis. 

Reporting of non‐conformities can be done via your local distributor. You will need the serial number 
from the system and description of the service required. 
Your local CMC distributor is found at www.cavotec.com 

10 Warranty
All the deliveries are thoroughly tested and packed before they leave CMC. If the delivery is found to 
be damaged when it is opened, inform the carrier immediately. CMC does not cover any damages 
caused by transport.  

All systems are delivered warranted against material and manufacturing faults. The warranty covers 
repairs authorized by CMC at a Cavotec premises. Expenses for service outside CMC are not 
included. 

Repairs done without authority from CMC may invalidate any warranty. 

Information in this document is subject to change without notice. 

Cavotec Micro-control AS 


Gevinglia 112, 7517 Hell 
E‐mail: mc@cavotec.com 
Tel.: + 47 74 84 31 00 
 
Service office: 
E‐mail: support.cmc@cavotec.com 
Tel.: + 47 74 84 31 00 
 
Your local distributor is found at  
www.cavotec.com 

© 2011 Cavotec Micro‐control AS  
All rights reserved 

MAN‐07‐007‐08                                                                                                                                                    23  

 
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11%47>9/
Magnetic proximity sensors
Cylindrical threaded housing, MM08

Model Name > MM08-60APS-ZUK


Part No. > 1040027

%XEKPERGI
• Detection of magnets
• Long sensing distances up to 60 mm or even more based on the magnet strength
• Short-circuit, reverse polarity and power-up pulse suppression protection
• Robust nickel-plated brass housing with fine thread M8 x 1 mm
• IP 67 enclosure rating
• PNP or NPN output
• High switching frequency
• LED status indicator
=SYVFIRIJMXW
• Non-contact operation eliminates interference from dirt, dust and vibrations,
increasing sensor life and reducing maintenance costs
• Space-saving installation due to small design
• Large operating distances with reliable switching increase throughput
• Non-contact, universal detection through several substances, including plastic
containers and pipes protective PTFE walls and non-magnetic metal walls

Features

Mechanics/electronics

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à
à

Dimensional drawing

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Connection diagram

Operating distance

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Connection type

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SICK AG | Waldkirch | Germany | www.sick.com


HR - 10002 Zagreb – PP202
Hrvatska, Zagreb, Fallerovo šetalište 22
Tel : (+385 1) 3667 273
Fax : (+385 1) 3667 287
E mail : prodaja@koncar-mes.hr
www.koncar-mes.hr

UPUTE ZA UPORABU I ODRŽAVANJE


EN NISKONAPONSKIH ASINKRONIH KAVEZNIH
ELEKTROMOTORA
ZATVORENE IZVEDBE VELIČINA 56 – 315 I
ZAŠTIĆENE IZVEDBE VELIČINA 180 – 250

OPERATION & MAINTENANCE INSTRUCTIONS FOR


EN LOW VOLTAGE SQUIRREL-CAGE T.E.
INDUCTION MOTORS
FRAME SIZES 56-315 AND
DRIP-PROOF MOTORS FRAME SIZES 180 – 250

Zahvaljujemo Vam što ste kupili naš elektromotor. Molimo Vas da prije početka ugradnje
i korištenja pažljivo pročitate ove upute.

Thank you for purchasing our electric motor. Before installation and use please read
these instructions carefully.

2752514 / SRPANJ/July 2008


1. GENERAL

These basic instructions are referring to catalogue EN/IEC low voltage squirrel-cage
induction motors of totally enclosed design (index of protection IP55 or higher acc. to
IEC 60034-5), of ribbed frame outer surface cooled with own fan situated under the fan
cover (cooling method IC411 acc. to IEC 60034-6), in frame sizes 56-315 or of drip-
proof design (index of protection IP23 acc. to IEC 60034-5) of smooth surface frame
cooled internally with own fan situated under the NDE bearing shield (cooling method
IC01 acc. to IEC 60034-6) in frame sizes 180-250. Series, design and type can be
determined from the type designation of the motor.
Type designation consists of a group of letters and numbers determined by internal
manufacturer’s standard.
A B C D
5 AZ 100LB-4 A
D- Optional equipment
C- Motor size, frame & polarity
B- Design and type of machine
A- Series designation

Series designation (mark A):


5 motor series design in aluminum alloy housing (design B3 – cast feet)
6 motor series design in aluminum alloy housing (design B3 - mounted feet)
7 and 8 motor series design in cast iron housing (design B3 - mounted feet)
Motor type designation (mark B):
AZ totally enclosed induction motor
AZA motors with different mechanical construction
ABZ shipboard use motors
AZC single-phase capacitor run motors
AZCD single-phase capacitor run/start motors
AZCG single phase induction generators
AZCJ single-phase capacitor start motors
AZCS motors in Steinmetz connection
AZD motors for elevator drives
AZE motors with different electrical design than standard
AZG induction generators
AZH motors with increased power output
AZK motors with electromagnetic brake
AZN explosion-proof motors: ex. protection: “non-sparking electrical apparatus for
zone 2 without el. circuit breakage-EEx nA II”
AZP multi-speed motors with constant torque at all speeds
AZPV multi-speed motors for fans
AZS explosion-proof motors: ex. protection “increased safety – EEx e II”
AT explosion–proof motors: ex. protection: “flame proof - EEx d(e) I/II”
AZV motors for fan drives with special winding
AO drip-proof (IP23) motors
AOG drip-proof (IP23) induction generators
ABO shipboard use drip-proof (IP 23) motors

17
Mark C describes as follows:
56 – 315 frame size
S, M, L housing length
A, B, C active part length in same length of housing
2,4, 6/4.. motor polarity

Optional mark or machine construction (mark D):

A motors with winding heater


G motors with feedback device
K motors with connection cable
S motors with build-in switch
T motors with thermal protection
V force ventilated motors (separate fan)
Z motors with stator winding filled with compound
All motors from this catalogue are made in their basic design in the index of protection
IP55. This is the art of protection which protects persons against the contact with the
parts under electrical tension (“live” parts), and the moving parts inside of enclosure.
Further, it protects the electric device itself from the harmful down settling of dust and
from the water jets from all directions. Index of protection is defined on the motor’s
nameplate and should be considered when installing the motor into the working position.
On request, there are also motors made to comply with other indexes of protection,
usually IP56, IP65 and IP66.

2. TRANSPORTATION AND STORAGE


The motors must be transported by means and in such a way which prevents the
possible damage, i.e. they must be positioned exactly like they are situated in their basic
and original transport packing. The storage in dry indoor areas far away from possible
corrosion hazards is recommended. In case of longer storage time, it is necessary at
least once per year to turn the rotor manually for one full circle. If more than 3 years
have passed from the delivery time during which the motor was not put into motion, it is
necessary to change the bearings, or if those are regreasing kind, follow the procedure
described in the paragraph 6.
Motor storage handling must be performed in a regular way using the lifting rings on
motors or the pallet system.
3. SETTING INTO WORKING POSITION
Foot-mounted motors must be put on a hard ground adequately to their size and
mounting requests stated in IEC 60034-7 and fixed with screws. Flange-mounted motors
are fixed directly with screws on the counter flange of driven machine.
Before setting the motor into working position the protective cylindrical cover is to be
removed from shaft. The motors must be situated in such way which assures the
sufficient ventilation and heat transfer area. Minimum distance in mm, from fan cover or
from suction/exhaust jalousie openings, to an obstacle must be at least equal to the
rated motor frame size/shaft height figure.
The motors are intended for outdoor and indoor mounting for duty in ambient of
moderate humidity, low corrosive aggressiveness, temperature range from -20 to +40°C
and up to 1000 m height above the sea level, or for mounting indoors, dust-free areas
(group AO,ABO).

18
In case of reduced cooling condition at higher altitudes or higher environmental
temperatures, motor power should be changed according to tables below:

Cooling air temperature °C 30 35 40 45 50 55 60

% rated power 100 100 100 96 91 86 80

Altitude above the sea level [m] 2000 3000 4000

% rated power at ambient temperature of 40°C 92 % 84% 78%

Rated power at ambient temp. in °C 32°C 24°C 16°C

Motors produced with protected windings for tropical working conditions bear the
marking ”TROPICALIZED”.
Before every installation the motor must be checked for possible damages or possible
irregular mounting circumstances which can influence the proper operation. During
assembly on transmission unit or driven machine, punching and applying of excessive
force must be avoided, especially in direction of motor drive axis because this can cause
bearing damage or permanent disturbance of safety gaps in motors protected with
”explosion-proof enclosure – d”. If needed, the data about permitted radial and axial
forces acting on motor DE and depending upon the mounting arrangement can be
requested from manufacturer. All fixing screws must be tightened with adequate torque
in order to assure smooth work of motor itself, without vibrations, deformations or
overstress. The screws must be secured from unfastening.
If non-elastic couplings are used, the proper coaxial alignment with DE shaft must be
assured during assembly (acc. to the sketch) and at belt transmissions the magnitude of
belt tension force and it’s perpendicularity to the DE shaft must be considered.

COUPLING

DRIVEN ELECTRIC
MACHINE MOTOR

Rotors are dynamically balanced with half-key acc. to ISO 8821, so that all elements
which are directly mounted on DE motor shaft must be also dynamically balanced on the
same way.

19
4. CONNECTING TO THE POWER SUPPLY NETWORK AND SAFETY/PROTECTION
MEASURES
Before connecting the motor to the power supply the special care must be taken about
the following:

 that the motor data on nameplate corresponds to the power supply voltage and
frequency
 that the terminals are connected according to appropriate connection diagram
labeled inside of motor terminal box, or according to the nameplate data and the
power supply itself (in case if motor starting via the Y/D switch is requested, the
bridges from terminal plate must be removed!)
 that the protection of live parts is maintained according to local safety regulations.
The earthing lead must be connected to specially marked place inside of terminal
box and the motor must be earthed also via the bolt situated outside on the frame.
Earthing lead cross-section area must be greater than or equal to those one of
phase lead. Outer earthing clappings are foreseen for earthing lead of minimum
cross section area of 4mm2 (frame sizes up to 180) or of 16mm2 (frame sizes 200
to 315)
 all valid safety measures must be regarded acc. to actual protection system
against the electric current shock
 that terminal box interior is free from dirt, connecting material particles or the like
 that all terminals on motor terminal plate are hard tightened
 that energy supply cable (and eventually cable(s) for auxiliary devices supply) is
adequately sealed by the means of the motor terminal box cable glands
 that adequate protection against short-circuit and overload (fuses, bimetal relays,
thermal protection or the like) is assured
 that motor connecting to the power supply is performed with the cable of adequate
dimensions and heat resistance (for AT series motors there are special requests
stated for cables defined in “Manufacturer’s declaration”)
On three-phase power supply with voltages 400V can be connected the motors with
nameplate data D/Y 400/690V in winding connection delta (D) acc. to connection
diagram labeled inside of terminal box.
On same power supply network, motors with nameplate data D/Y 230/400V in
connection star (Y) can also be connected. Motors with those data can be connected
also on three-phase network voltage 230V but they must be in winding connection delta
(D). Generally, the motors are connected to the power supply network via the three-pole
switch, thee-pole motor protection circuit breaker or contactor.
In case of starting via the star-delta (Y/D) switch, the winding connection of motor for
rated voltage must be delta (D). In this case the starting current amounts 1/3 of such
current in direct connection as does the starting torque, and this must be considered, i.e.
in such way only motors with no load can be started. Two-speed motors with series-
parallel winding (tap wound –speed ratio 1:2) are started by means of special switch.
Net connecting of two and multi-speed motors is performed in accordance to the
connection diagram labeled inside of motor terminal box with adequate protection
against the short circuit and overload.
Generally, the three-phase motors manufactured by KONČAR-MES d.d. are designed
acc. to requests of standard IEC 60038 and can work without problems under rated
power and torque load with network voltage aberration of ±10%, until the single-phase
KONČAR-MES d.d motors can work under such conditions with network
voltage/frequency aberration of ±5% / ±1%. If the voltage aberration is greater, the
motor cannot be loaded with rated torque but with the torque which must be corrected in
proportion to voltage drop.
Drives where the motor is supplied via the static frequency converter (speed regulator),
the recommendations from the standard IEC 60034-17 are applied, so considering
20
these, the care must be taken when choosing the rotational speed regulator. For motor
supply it is desirable to use the frequency converter (rotational speed regulator)
equipped with output dU/dt filter in order to achieve higher motor winding longevity. For
such supply it is useful to contact the motor manufacturer regarding the motor
characteristics and regulation range.
If motor has built-in anti-condensation heaters, they are to be connected acc. to the
attached connection instruction and energized during the motor is in standstill state.

5. ROTATION DIRECTION CHANGE AND NUMBER OF STARTS PER HOUR


The motors of standard design have the clockwise direction of rotation viewed from the
shaft DE, and they are connected acc. attached instructions. Change of rotation
direction is usually performed by changing the terminal sequence of two supply net
phases. At often changing of rotation direction, the special switch for reversing is to be
used, taking care about the permissible reversions per hour for particular drive and load
(if necessary, consult the manufacturer). The same is valid for permitted number of
starts in order to not overload the motor.
Rotation direction change at single-phase motors is performed with connector exchange
of main or of auxiliary phase. Before reversing the motor must be at standstill (on
contrary, it will keep the same rotation direction).

6. MAINTENANCE
The motors are designed for the easy and simple maintenance. Properly installed and
electrically / thermally protected they can work for years.
Periodically they need to be exterior cleaned and if they work in environment where
impurities can close the ventilation openings on fan cover or fill the spaces between the
cooling ribs, such impurities must be blown out with compressed air or swept-off with
brush. Any aberration from motor ratings or irregular motor operation must be carefully
inspected for possible cause (i.e. increased motor current, temperature increase over
the permitted value for the declared insulation class, increased vibrations, peculiar
noises, specific insulation smell presence, activated motor protection devices or the
like).
If this is caused by the motor, the repair work must be performed by the authorized and
skilled personnel only.
For spare parts contact the manufacturer with exactly determined motor type mark and
code number from motor nameplate (please note the ordering instruction attached).
Standard bearing assembly is with single row deep-grove ball bearings (ZZ or 2RS),
with clearance C3 (motors of 7AT132-280 series are made with standard clearance
bearings) as listed in table below. The bearings are lubricated for life. Bearing change in
case of breakdown, noise or at regular service intervals must be performed with
adequate tools without applying of excessive force and punching.
If bearings with regressing possibility are built-in, the intervals between regreasing are
as shown in the diagram attached. During service repair such bearings are to be taken
off from shaft in the proper way, washed well in gasoline, dried, put on the shaft in the
proper way, regreased with adequate grease in such way that approx. 2/3 of bearing
nest free space is filled with grease. Alternatively, the regreasing can be performed also
during the motor is in operation, via regreasing nipples situated on bearing shields using
the hand pump for consistent grease. Depending upon the motor size (mostly 132-280),
at each regreasing approx. 20-40 grams of grease must be pressed-in. Recommended
grease brands are LIS-2 (INA), SHELL ALVANIA G3, ESSO UNIREX N3, or all others
lithium soap based with drip temperature of 180-200 0C and for use in environment
temperature range from –20 0C to +150 0C.

21
Frame size Bearing type on Bearing type on both
both sides for series sides for series 8.
5. i 7.
T.E. design 56 6201 – 2Z ili 2RS
63 6202 – 2Z ili 2RS
71 6203 – 2Z ili 2RS
80 6204 – 2Z ili 2RS
90 6205 – 2Z ili 2RS
100 6206 – 2Z ili 2RS
112 6306 – 2Z ili 2RS
132 6208 – 2Z ili 2RS
160 6309 – 2Z ili 2RS
180 6310 – 2Z ili 2RS 6311
200 6312 – 2Z ili 2RS 2 pol: 6312
4 pol: NU 312 / 6312
225 6313 – 2Z ili 2RS 2 pol: 6313
4 pol: NU 313 / 6313
250 6314 – 2Z ili 2RS 2 pol: 6315
4 pol: NU 315 / 6315
280 6316 C3 2 pol: 6317 / 6314
4 pol: NU 317 / 63142
315 6316 C3 pol: 6317 / 6317
4 pol: NU 319 / 6319
Drip-proof 180 6212 – 2Z ili 2RS
design 200 6213 – 2Z ili 2RS
225 6214 – 2Z ili 2RS
250 6216 – 2Z ili 2RS

On request, in motors of frame sizes 132-250 also the single-row roller bearings can be
built-in series NU.

Remarks :
• table is valid for all polarities of single and multi-speed motors and for all mounting
arrangements acc. to IEC 60034-7 (EN60034-7)
• nominal bearing life under rated working conditions is minimal 40000 working hours
for 4, 6 and 8-poles motors, and minimal 20000 working hours for 2-poles motors
connected to 50Hz power supply network.

22
Bearing regreasing interval determining diagram:
N[min-1]

Deep-groove Roller
ball bearings bearings

Example :
Deep-groove ball bearing with inner dia. of 40mm and rotational speed of 1500 rpm
needs to be regreased approximately after every 6000 working hours (interpolation).

d - inner bearing diameter (mm)


n - rpm (min-1)
tf - regreasing interval (working hours)

During each disassembly of motor, we recommend installation of new shaft seals and
seals securing the protection index of the motor.

23
7. BASIC DESIGNATION OF MOTORS IN THE PRODUCT RANGE

Each motor in the product range is supplied with nameplate where basic information
about the product and rated electrical data are stated.

KONCAR-MES Croatia
Code No
~ Type
Basic name plate
V A
kW cos
Hz HP min-1

To °C Cl. IP S IEC 60034-1 VDE 0530

Made in
Basic name plate for KONCAR - MES Croatia
multi voltage area or Code No kg
ones used for ~ Mot
EExd(e) controlled To °C IC Cl. Rise IP
via rotational speed Hz kW V A cos rpm
regulator (duty
regime S9)

DE/NDE IEC 34, VDE0530

There is following data stated on the nameplate:


Code: Motor number used for identification during the production process, and as a
reference for ordering spare parts for the motor in the maintenance process.
0
N: Factory motor number combined with the date of production
~: Number of motor phases( 1- single phase, 3 – three phase)
Type: Motor type designation mark according to the explanation from the introductory
part of this instructions combined with mounting arrangement (B3, B5, B14…)
V, Hz : Voltage and frequency of the power supply for which the motor is built, and where
motor generates rated characteristics when under rated loaded stated in kW
column
-1
A, min ,cos φ: rated characteristics generated by the motor when under rated loaded stated
To : Environment temperature for which the motor is built, and at which it can be
loaded with rated power.
Cl : Insulation system used in the motor (F- the highest allowed temperature 155°C, H-
180°C)
IP : Index of protection achieved by housing and bearing shields design with regard to
the harmful influence of water and dust.
S: Type of duty regime for which the motor is built (S1 – S10)

The last line of the name plate contains information on installed auxiliary equipment.
For single phase motors – information about installed run/start capacitors.
For motors with breaks – information about rated brake torque and voltage.
For pex motors - information about installed protective elements (PTC..).
For motors with winding heaters - information power and voltage of heaters.
For motors with forced ventilation (separate fan) – information about fan voltage and power…
For motors equipped with nameplate for multi voltage area or ones used for EExd(e) controlled via
rotational speed regulator (duty regime S9), information about rotational velocity and belonging rated
characteristics is entered.

On such nameplates additional information can be found:


IC: type of cooling (IC411 – own ventilation, IC 410 – without ventilation…)
Rise: information about declared heating of the motor at rated conditions (B – 80K, F – 105K
at the environment temperature of 40°C
DE/NDE: information about installed bearing type

24
This series of motors 5/6/7/8 is designed and tested in accordance with IEC 60034-1
(line 8.5 and 8.6) and can work over the static frequency converter under conditions in
accordance with IEC 60034-17 in regulation range from 5 to 60 Hz for motor polarity
2p=2 and for other polarities in regulation range from 5 to 100 Hz with loads shown in
graph 1. Motors suited for supply over static frequency converter have in their winding
built-in thermal protection. The static frequency converter itself is situated outside of
dangerous zone. On additional name plate are characteristic of motor for different
frequency.

Graph 1. Supply over static frequency converter (permitted loads are valid for
continuous work-duty S1)
M / M n (% ) = f( f(H z ) ) - su p p ly o v e r s ta tic fre q u e n c y co n v e rte r

100

90

80

70

60
M / Mn %

50

40

30

20 own
10 ventilation
0
5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100
f ( Hz ) forced
ventilation
Nameplates are generally held in place by rivets on the main motor housing, and where
that is not possible, they are placed on the fan cover or in case of single phase motors
on the plastic box, or where readability of stated information is assured.
When ordering spare parts, most important information is Code of the motor, and of
course the information about the needed spare part that needs to be replaced during
repair or regular maintenance.

Along with this instructions, exploded assembly drawing with ordering information is
supplied.

8. OPERATION & MAINTENANCE EXTRAS REGARDING EACH OF


DESIGNS/SERIES/TYPE DESIGNATIONS
MOTORS OF SERIES/TYPE DESIGNATIONS 5.xAZC/AZCD (SINGLE-PHASE
MOTORS)
 during mounting and handling care must be taken that there will be no punching on
thermoplastic terminal box (in which start and run capacitors are situated)
 mostly used winding overheat protection at single-phase motors is with bimetal
thermo-switches (automatic restarting) and klixons (manual restarting)
 motors with thermal protection for automatic restarting are to be used only there
where this is permitted by security regulations in order to avoid injuries (i.e.
never at circular saws, joiners trade and grinding machines, mills, lawn movers or
the like)
 it is not recommended to start single-phase motors with capacitors more than 20
times per hour for the reason of possible damage to the capacitors
 normally these motors are connected on power supply network voltage of 230V
±5% 50Hz by which they attain their nameplate declared ratings

25
MOTORS OF SERIES/TYPE DESIGNATIONS 5.xAZK/AZPK AND 7AZK/AZPK
(WITH MOUNTED FAIL-SAFE ELECTROMAGNETIC BRAKE)
 when connecting, the connecting instructions labeled inside of motor terminal box
must be obeyed
 depending on duty request regarding the brake activation time (supply switched-
off), the brake, can be connected in such way, that it’s disconnecting isperformed
via the alternate current circuit (normal activation) or via the direct current circuit, by
means of which the activating time can be shortened up to 30-40 times
 depending on available source supply, in motors can be built-in:
- bridge rectifier when the motor is intended for delta connection (380/400 D) with
earthing lead existent (rectifier is connected between phase and earthing), or for
star connection (380/400 Y) where the rectifier is connected between one phase
and motor star point, rectifier voltage=220/230V
- half-wave rectifier when the motor is intended for delta connection (380/400 D)
with earthing lead not existent (rectifier is connected between two phases),
rectifier voltage=380/400V. Brake coil winding is in both cases for supply voltage
of 190VDC
 brake with coil winding supply voltage of 24 VDC or 48VDC is connected via
transformer and supply rectifier situated in the adequate switching cabinet,
provided by customer, and is connected with the motor in operation via connector
switch
 brake air gap is set by the manufacturer by screws (pos.3) on it’s nominal value (I =
0.3 – 0.45 mm)
We recommend to order as a spare part the adequate brake rectifier (pos.34) from
the list of standard spares.
Sketch of fail-safe electromagnetic brake

I = 0.3-0.45 mm

1 Rubber cover 6 NDE shield


2 Air gap 7 Friction disc
3 Brake assembly screw 8 Armature plate
4 Fan 9 Spring
5 Fan cover 10. Brake solenoid

26
MOTORS OF SERIES/TYPE DESIGNATIONS 5 AND 7AT (ATP, ATPV, ABT, ABTP,
ABTPV), EXPLOSION PROTECTED WITH TYPE OF PROTECTION “EXPLOSION-
PROOF-d”
MOTORS OF SERIES/TYPE DESIGNATIONS 5.xAZS (ABZS), EXPLOSION
PROTECTED WITH TYPE OF PROTECTION “INCREASED SAFETY-e”
MOTORS OF SERIES/TYPE DESIGNATIONS 5.x AND 7AZN (ABZN EXPLOSION
PROTECTED WITH TYPE OF PROTECTION “NON SPARKING ELECTRICAL
APPARATUS FOR ZONE 2-n”

For these motor series, together with these instructions, the “manufacturer‘s declaration”
is also issued as a proof that control and testing were performed and that motors are
manufactured according to the certified documentation.

• motors must be installed and used in accordance with adequate regulations for
explosion protection regarding the dangerous zones classification, areas of use
and explosive groups of inflammable materials or in accordance with motor
nameplate and ex-protection nameplate data. Motors with Ex-protection “d” i “n”
can be power supplied via static frequency converter in conditions according to IEC
60034-17. In such case motors must have built-in thermal-protection in stator
winding. For these motors along with the “Manufacturer’s statement”, “Appendix to
the Manufacturer’s statement” is also issued, defining regulation range and
required torque/power reduction depending on the operating conditions. In case of
uncertainties, contact the manufacturer.
• motors with Ex-protection by shielding “d” intended for use in mining are not
suitable for hard operating conditions areas.
• overload protection in the control box (on installations), should be adjusted
according to the HRN IEC 60079-14 norm, and for motors with Ex-protection
increased safety additionally, in accordance with critical heating time until reaching
the allowed over-temperature of the motor for certain temperature class stated in
motor type designation marking and IA/IN rate stated on the motor name plate and
tE.
• all motors must be equipped with appropriate cable glands in accordance with
requirements of corresponding norms. For cable gland with cylindrical threading,
protection against unfastening is achieved by nut on the inside of the housing,
(counter-nut), or appropriate filling (i.e. LOCTITE 243). Motors are shipped form the
factory without the filling, and responsibility for securing the gland against
unfastening, lays on authorized personnel when installing the motor.
 On motors delivered with threaded holes for attaching cable glands and thread
protecting closed plastic plugs manufactured according to regulations, an
authorized contractor is obliged to install certified cable glands into these holes or,
if there are any extra holes, close them with certified plugs according to
regulations. In addition while performing connecting; the motors have to be
connected with isolated terminals.
 In case of assembly and disassembly of motors, existing mechanical protection has
to be provided (use of sealing agents on contact surfaces, coating of screw joints
with fillers, grease fulfilments in bearings, greasing of shaft seals...)

27
Specificities regarding the X-mark of EX-Agency certificate

With regard to the specificities concerning the use limitations, installation and
maintenance of Ex-motors form the production range and inability to list them all
here, we ask kindly the user and the personnel authorized for installing of the
equipment to study the Manufacturer’s statement where all limitations for the
motor are stated.
Repair of these motors must be conducted by manufacturer KONČAR - MES d.d.
or listed authorized repair services. In Republic of Croatia these are the ones
listed in Registry of repairman under technical supervision of Ex-Agency
DZNMRH. In foreign countries these are repairman in compliance with local
regulations.
Without special written permission from the manufacturer any action that has or
may have influence on anti-explosion protection of the motor (during warranty
period or after) is absolutely liability of the ones carrying out the procedure,
especially :

- when procedures are carried out on protective systems of Ex-


protection “d” motors. During such procedures it’s necessary to request
instructions (and dimensions) from KONČAR – MES d.d. because air
gaps are smaller than ones allowed by the table 2. of HRN EN 60079-1
norm.

- screws assuring the integrity of “d” protection have minimal tensile


strength of 800N/mm2, and screws used for fixation of shields on
housings in sizes 200-250 have minimal tensile strength of 1200N/mm2.

28
Designation of motors with Ex-protection

Every motor with Ex-protection, along with basic nameplate according to paragraph 7. of
this instructions, has on it’s housing additional plate with information about type of anti-
explosive protection.

Motors with Ex-protection “shielding – Exd”, “increased safety – Exe” and


protection “non-sparking electrical apparatus - ExnA” nameplate

Nameplate for Zagreb, Fallerovo


Exd(e) motors and
KONCAR-MES šetalište 22
Code No HR Ex - agencija
Exe motors with
Type rating
Ex – Agency
certificate Type
Protection S
IA / I N = t E=
/AA1 S

Nameplate for
Exd(e) motors and
Exe motors with
CESI certificate
(market EU)

There is following data stated on the nameplate:

Code: Motor number used for identification during the production process, and as a
reference for ordering spare parts for the motor in the maintenance process.
0
N: Factory motor number
Type: Type designation of the motor
Protection: Type of anti-explosion protection

Additionally for motors with Ex-protection “increased safety – e”


IA/IN: ratio of short circuit current and rated current of the motor
tE: time period in which a device must disconnect the motor from the mains, and
during that period no part of electrical appliance surface shall reach the
temperature of the stated temperature class.

29
9. POSSIBLE FAILURES AND INTERFERENCES AT WORK OF SQUIRREL-
CAGE INDUCTION MOTORS AND THEIR REMEDYING
FAILURE /
INTERFERENCE POSSIBLE CAUSE HOW TO CURE / REMEDY
SYMPTOMS
-Supply interrupted, one of feeder -Check fuses, motor switch or
lead broke, lines broke, for example contactor
one over the fuse or protection circuit breaker…
Motor cannot run up, -Stator winding circuit interrupted, -Separate supply leads, check the
no noise at all or the disconnection in Y/D switch, motor winding on terminal plate terminals,
humming is strong protection fallen out check the elements of electrical
-Damaged bearings protection
-Improper connecting -Change the bearings
-Main or auxiliary phase interrupted -Connect the motor acc. to
-Damaged capacitor (motor runs up appropriate instructions
if pushed per hand) -Winding repair or change
-Damaged centrifugal switch -Change capacitor
-Klixon off or damaged -Centrifugal switch repair or change
-Klixon on - or must be exchanged
-Load torque too high (overload) -Must be in accordance with motor
-Motor intended for D connection, frame size
Motor cannot
but Y connected -Apply the regular way of motor
accelerate
-Supply voltage too low connecting
under load, or
-Faulty feeder lead –Stabilize the supply voltage
accelerate
-Rotor squirrel stick or short-circuit -Check the supply rightness
hardly, sudden drop of
ring interrupted -Change the rotor
rotational speed under
load
-Feeder leads from motor switch to -Separate and insulate the leads
At start, fuse blows or motor are in short circuit
protection circuit -Two phases of stator winding are in -Separate the motor from supply
breaker switches-off short circuit or earth connected probably it is necessary to be
-Wrongly chosen/adjusted motor rewound
protection -Choose/adjust motor protection
properly
-Motor overload (at single phase -Measure the motor current. If it is far
Motor warming in motors klixon is witching-off) too high in comparison to the rated
operation is high -Too high or too low supply voltage one, cure the overload cause
scraping noises , -Too high motor switching-on -Stabilize the supply voltage
motor protection is intensity -Lower the switching-on intensity
switching-off after -Motor work on single phase -Check supply leads
some time -Rotor scraps on to stator -Rotor or motor need to be repaired
-Wrong stator winding connection -Connect motor properly acc. to
Motor warming is high -Supply voltage to high nameplate data and appropriate
even under no load, -Insufficient cooling instructions
pulls high current, -Short circuit between winding coils -Stabilize the supply voltage
humms, (1ph motors or motor mass -Assure undisturbed air flow to and
- thermal protection is around the motor
switching-off) -Change of winding
-Electrical reasons -Consult the manufacturer
-Bearing damage -Change the bearings
-Damage in gearbox mounted on -Check the gearbox
Motor in operation
-Rotor unbalanced -Rebalance dynamically the rotor of
causes increased and -Insufficient fixing on the ground or
drive
abnormal noise
flange -Tighten the appropriate screws with
-Friction disc scraps adequate torque
-Check the air gap or wear-off of
friction disc lining

30
10. WORKING LIFE OF MOTORS MANUFACTURED BY KONČAR-MES d.d.
• under normal conditions of use foreseen by these operation & maintenance
instructions and with regular maintenance the motor working life is more longer
• The manufacturer assures the availability of spare parts in the period of time
up to 7 years including also the period of time under which the warranty is valid. Service
at manufacturer is possible also for products older than 7 years with special contracting
conditions
• All production documentation is available 10 years after the production cease
date of the particular type
• For packing ecologic materials are used which have also been reprocessed
(recycled), deposited or destroyed without danger for the environment. For this purpose
packaging materials are also appropriately marked.
• After you have stopped using the motor be careful it has not become a burden
for the environment. Hand it over to authorize collectors.
11. WARRANTY CLAIMS
Breakdowns in duty or damages detected on products prior to the expiry of warranty
need to be, if they are induced with material faults or bad manufacturing quality,
reported to manufacturer " KONČAR - MES d.d. " indicating the following data :
 exact motor nameplate data (type description and code number)
 how was the motor connected while in operation
 characteristics of the drive
 how deficiency/fault appeared (the appearance art of the fault)
Breakdowns in duty or damages due to inadequate use and careless transportation /
storage / connecting, are not considered as justified warranty claims during period of
warranty. The same is valid also if the product, before it’s return to the manufacturer,
was disassembled during period of warranty.
12. DECLARATION OF WARRANTY
Quality managing system introduced in KONČAR –MES d.d. is certified in accordance
to the requests stated in ISO 9001 standard. Based on this, the regular work of our
products is assured with rigorous process control and final inspection before dispatch to
the customer, on ground of which the warranty is issued. If despite of this, irregular
operation or disturbance in duty, caused with bad manufacturing quality or material fault
appears, we oblige ourselves to cover all repair/correction costs and that guaranteed
regularity of product will be established again.
Warranty is valid 12 months from the day of product sale/takeover, what is testified with
salesman’s stamp, datum and signature on warranty leaflet and attached invoice.
The customer is obliged to follow the operation and maintenance instructions attached
to every motor which bears the KONČAR –MES d.d. manufacturer‘s logo.
We cover the transportation costs regarding the necessary warranty service repair, on
basis of properly issued invoice according to valid railway or postal charges from
outgoing railway or postal station.
If, during the period of warranty, repair work will consume more than 10 days counting
from the day of reclamation report/motor return, the date of warranty expiry will be
postponed for the same number of days the repair work actually took.
If the repair work is not executed during 45 days counting from the day of report/return,
or it is impossible to remedy the fault, we will exchange the product with a new one. The
faults that did not occur due to material faults or bad manufacturing quality are not
considered as manufacturer’s faults, and therefore induced costs of their
repair/correction are liability of the buyer of product according to valid KONČAR-MES
d.d. manufacturer‘s pricelist.
The repairs during and beyond from warranty period are performed by KONČAR-MES
d.d. HR-10001, Zagreb, Fallerovo šetalište 22, Republic of Croatia.
31
32
Uputa za naručivanje
Svi standardni dijelovi navedeni u gornjoj tabeli razlikuju se prema tipu motora, veličini,
seriji te mogućim specijalnostima .
Radi točnog određivanja istih, molimo u narudžbi navesti slijedeće :
 pozicija i naziv rezervnog dijela prema rastavnom crtežu i tabeli
 tipska oznaka motora
 kodni broj motora
Primjer:
} s natpisne pločice motora

Poz. 5 Ventilator
5.5AZS 71B-2/T3 ; B3
A500201

Ordering guideline
All above listed standard spare parts differ between each other depending upon the type
of motor, frame size, series and possible peculiarities.
To allow us to pinpoint them exactly, please assure when ordering, that the following
data are available:
 name and position number of the spare part according to the above list and
exploded view


type designation of the motor
motor code number } from the motor name plate

Example:
Pos. 5 Fan
5.5AZS 71B-2/T3 ; B3
A500201

33
EN/IEC
trofazni motori potpuno zatvorene izvedbe
tipskih oznaka
AZ, AZN, AZH, AZP, AZPV, ABZ, ABZH, ABZP i ABZPV
u veličinama
56 – 160 ( serija 5.x i 6 )
112 – 315 ( serija 7 i 8 )

EN/IEC
Three phase cage induction motors
type designation
AZ, AZN, AZH, AZP, AZPV, ABZ, ABZH, ABZP i ABZPV
sizes
56 – 160 (series 5.x and 6)
132 – 315 (series 7 and 8)

Poz./Pos. Naziv Name


1 Stator komplet Wound stator
2 Rotor ( uravnotežen polu-klinom ) Rotor (half- key balanced)
3 Ležajni štit prednji - B3, B5, B14 DE shield - B3, B5, B14
4 Ležajni štit stražnji NDE shield
5 Ventilator Fan
6 Ventilatorska kapa Fan cover
7 Priključna pločica Terminal block
8 Brtva ormarića Terminal box seal
9 Ormarić Terminal box
10 Brtva poklopca ormarića Terminal box lid seal
11 Poklopac ormarića Terminal box lid
12 Poklopac Lid
13 Brtvena uvodnica Cable gland
14 Čep Plug
15 Ležaj PS Bearing DE
15.1 Ležaj SS Bearing NDE
16 Ležajna opruga Resilient preloading ring
17 Prstenasti uskočnik Circlip
18 Klin osovine Shaft key
18.1 Klin osovine 2SKV Shaft key NDE
19 Osovinsko brtvilo PS DE shaft seal
19.1 SS V - osovinsko brtvilo (200-250) NDE shaft seal (200-250)
20 Desna noga Frame foot, right
21 Lijeva noga Frame foot, left
22 Vijčana karika Lifting ring

34
Trofazni motori EN/IEC veličine :
56 - 160 ( 5.xAZ i 6AZ. serija )
112 - 315 ( 7AZ i 8 AZ serija )

Three phase cage induction motors EN/IEC sizes:


56 - 160 ( 5.xAZ and 6AZ series )
112 - 315 ( 7AZ and 8AZ series )

35
JAMSTVENI LIST
HR - 10002 Zagreb – PP202
Hrvatska, Zagreb, Fallerovo šetalište 22 WARRANTY
Tel : (+385 1) 3667 273
Fax : (+385 1) 3667 287 LEAFLET
E mail : prodaja@koncar-mes.hr
www.koncar-mes.hr

Proizvod / NISKONAPONSKI ASINKRONI KAVEZNI ELEKTROMOTOR


Product
LOW VOLTAGE SQUIRREL-CAGE INDUCTION ELECTRIC
MOTOR

CODE No

~ TYPE

kW IM

V Hz IP

Pečat i potpis / Stamp and singnature:

Datum prodaje / Date of sale:

Pečat i potpis prodavatelja / Salesman's stamp and signature:

44
TRIMAT Ltd
Hurst Business Park
Brierley Hill
West Midlands DY5 1UF
ENGLAND
Tel.: +44 (0) 1384 473400
Fax: +44 (0) 1384 261010
Email: sales@trimat.co.uk
www.trimat.co.uk

PRODUCT DATA SHEET

TRIMAT GBC
.6

.5

.4

.3

.2

.1

50° 100° 150° 200° 250° 300° 350° 400°

Material Description:
°C
Trimat GBC is a semi-flexible asbestos-free brake lining, manufactured from a solid woven fabric of both natural and
man-made yarns with a brass wire inclusion, which helps to stabilise the friction value by conducting heat from the
operating surface.
When the woven fabric is impregnated with the specially developed synthetic resin it produces a friction material with
excellent stability and high resistance to wear.
Both surfaces can be supplied ground, making it suitable for bonding and riveting to either internal or external contracting
braking systems.
This material can be supplied for use on oil immersed applications, although the friction value will be much lower than
shown on the friction/temperature graph which is based on dry conditions.
A most efficient general purpose brake lining suitable for use on most applications, including winches, cranes, earth-
moving and agricultural equipment, forging machinery and many others. Because of its versatility it is of course an ideal
quality to stock.

Technical Details:

Property Typical Values


Coefficient of Friction (dynamic) 0.48
3 3
Wear Rate 11.0 mm /MJ (0.0018 in /hp.hr)
Specific Gravity 1.24
Rivet Holding Capacity 102.0 N/mm² (14790 psi)
Ultimate Tensile Strength 34.0 N/mm² (4930 psi)
Ultimate Shear Strength 27.7 N/mm² (4017 psi)
Ultimate Compressive Strength 137.0 N/mm² (19865 psi)

Recommended Operating Range:

Maximum Intermittent Temperature 230°C (450°F)


Maximum Continuous Temperature 150°C (300°F)
Pressure 0.07-2.0 N/mm² (10-290 psi)
Maximum Rubbing Speed 25 m/s (5000 ft/min)

Recommended Mating Surfaces:

Close grained cast iron, forged or cold rolled steel should be 180 Brinnell or over.

Available Sizes:
Supplied in roll form, cut and shaped linings

Nominal Roll Lengths: 10 metres (33ft)


Thickness: PP ´ WRPP ó´
Width: up to 530mm (21´

NOTE: There is no standard test procedure for industrial Friction Materials, therefore it could be misleading to compare different manufacturers test results. The Co-efficient of
Friction/Temperature Graph illustrated, should be used for comparison of the various Trimat qualities only.

Date of Publication: November 1995 Revised: September 2011


TM

MATERIAL HEALTH, SAFETY & ENVIRONMENTAL


DATA SHEET FOR TRIMAT GBC

1) IDENTIFICATION OF THE PRODUCT AND COMPANY


Product Identification: TRIMAT GBC
Company: TRIMAT Ltd.,
Address: Narrowboat Way
Hurst Business Park
Brierley Hill
West Midlands. DY5 1UF
ENGLAND
Telephone Number: 01384 473400
Fax Number: 01384 261010
E-mail: sales@trimat.co.uk

2) COMPOSITION/INFORMATION ON INGREDIENTS
This product is a woven fabric of natural and man-made yarns with brass reinforcing wire and impregnated with a
propriety friction resin which is fully cured.

3) HAZARDS IDENTIFICATION
During its use this product will generate an amount of dust which will contain glass fibre particles. These may cause
irritation to the skin and eyes on contact.
The maximum exposure for the dust generated either in operation or machining is 5mg/m³ or 2f/ml. If the dust enters the
eyes treatment will be required; it may also cause slight skin irritation.
There are no known effects should the dust be ingested or inhaled.

4) FIRST AID MEASURES


In the event of dust entering the eyes they must be flushed with copious amounts of cold water. Should skin irritation occur
whilst working with this product, wash the effected area with soap and water.

5) FIRE-FIGHTING MEASURES
The product itself presents no fire risk. If however a fire occurs in the vicinity, then extinguish with water. Decomposition/
Combustion Products produced are Carbon Monoxide.

6) ACCIDENTAL RELEASE MEASURES

The very nature of this product, and others within the range is such that accidental release is most unlikely if not impossible.

7) HANDLING & STORAGE

The usual precaution for manual handling i.e. the wearing of good quality fabric gloves, must be observed. The material
can be stored in any dry place.

8) EXPOSURE CONTROL/PERSONAL PROTECTION

When replacing worn brake lining, dust will be present, therefore the measures as stated in the section headed ‘Other
Information’ must be adhered to.

Page 1 of 2
PRODUCT: TRIMAT GBC

9) PHYSICAL AND CHEMICAL PROPERTIES

Appearance: This material is a solid woven fabric made up of natural and man-made yarn with
a brass wire reinforcement. It is impregnated with a propriety friction resin which
is fully cured and light brown in colour. It gives off no odour.
Boiling Point: The material does not have a boiling point, melting point or flash point.
Flammability: Trimat GBC is not a flammable material, does not have a potential for
autoflammability and will not explode.
Oxidizing Properties: GBC will not oxidize.
Relative Density: 1.24.
Solubility: Trimat GBC is insoluble in water or fat.

10) STABILITY AND REACTIVITY


Trimat GBC will remain stable when used for the purpose for which it was designed.

11) TOXICOLOGICAL INFORMATION


Oral LD50, Dermal LD50, and Inhalation LD50 levels are such that there is nothing adverse in this product.

12) ECOLOGICAL INFORMATION


The Trimat range of products are such that they cannot have known effect (behavioural or enviromental) that can be
reasonably forseen.

13) DISPOSAL CONSIDERATIONS


Trimat GBC may be disposed of with normal waste. There are no statutory notifications required. There are no known
restrictions for its disposal. It is considered safe to dispose of this material at any landfill sites. There is no category/waste
number.

14) TRANSPORT INFORMATION


Trimat GBC can be transported safely wrapped or boxed as supplied by the manufacturer. There are no labelling
requirements.

15) REGULATORY INFORMATION


As a general precaution, eye protection suitable for dust, a non-toxic particle mask should be worn if the product is to be
cut or drilled. Gloves should be worn when handling. Dust levels must be kept below 5mg/m³ (2 f.ml).

16) OTHER INFORMATION


Friction materials contain fibres and the dust formed in used brake and clutch parts will be free fibrous materials. To
prevent dust particles from becoming airborne always use the following safe practises:-
When replacing worn linings remove the accumulated dust by using an industrial vacuum cleaner fitted with a high
efficiency filter system. Alternatively, wipe down the components with a damp cloth.
Do not use compressed air or dry brushing to remove dust from brake and clutch parts.
When further processing new unused linings prior to workshop fitting, eg. cutting and drilling, always employ the use of
local exhaust equipment where available. If not available use an industrial vacuum cleaner.
Where sweeping is necessary use a dust suppressant or water.
The appropriate personal protection should of course be worn wherever required.
Personnel who are expected to work with brake lining material must be trained in its safe handling and where necessary
must be instructed in the use of personal protection equipment.

The information provided in this safety data sheet is based on present knowledge and whilst given in all good faith and
intentions does not constitute a guarantee for any of the product features or establish a legally valid contractual
relationship.
The details given are true and accurate provided that the product is used for the purpose for which it is designed.
Date of Publication: November, 1995
Revised: March, 2001

Page 2 of 2
BRAKE LINING M9020
Description
M9020 is a heavy duty composite woven from yarns
containing brass wire.

It is suitable for light to heavy duty service,


applications include:

- Winches
- Cranes
- Hoists

and other heavy duty industrial purposes.

This dense, tough material exhibits exceptional


resistence to heat and compression under high
loads. M9020 has excellent fade and recovery
stability. It is capable of running in oil immersed
Physical / Mechanical and
applications, however the coefficient of friction will
Friction properties
decrease.
Density 1,6 g/cm³
M9020 is approved by Germanischer Lloyd for
use in G/L classed marine winches Ultimate shear strength 42 N/mm²
(Cert.no: 21 138 04HH). Tensile strength 33 N/mm²
Rivet holding capacity 110 N/mm²

Coefficient of Friction - normal 0,53


Short material description
Coefficient of Friction - hot 0,53
Woven x Coefficient of Friction - @ 200°C 0,56
Moulded
Oil-Resistant x
Metallic x
Recommended operating range
Asbestos free x
Pressure 3,5 N/mm²
Maximum rubbing speed 21 m/s
Material availability
Maximum intermittent temp. 280 C
°
Sheet x Maximum continuous temp. 250 C
°
Roll x
Lining x
Disc Temperature Sensitivity

Width up to 380mm 0,7


Thickness 4 to 30mm 0,6
Length 10 meters 0,5
Friction

0,4
0,3
0,2
All the information on this data sheet are obtained by scientific and 0,1
laboratory testings. But it is suggested that this material be thorougly 0
tested and is suitability for use be determined before final 0 50 100 150 200 250 300 350
acceptance.
Temperature in C
°

Kühne Intertech GmbH - Witternstraße 20 - 21107 Hamburg - Tel: +49 (0)40 315001 - Fax: +49 (0)40 315060
Faults - Causes - Remedies

Drive does not start, no fault displayed


• If the display does not light up, check the power supply to the drive.
• The assignment of the "Fast stop" or "Freewheel" functions will prevent the drive starting if the corresponding logic inputs are not
powered up. The ATV71 then displays [Freewheel] (nSt) in freewheel stop and [Fast stop] (FSt) in fast stop. This is normal since these
functions are active at zero so that the drive will be stopped safely if there is a wire break.
• Make sure that the run command input or inputs are activated in accordance with the selected control mode ([2/3 wire control] (tCC)
and [2 wire type] (tCt) parameters, page 89).
• If an input is assigned to the limit switch function and this input is at zero, the drive can only be started up by sending a command for
the opposite direction (see pages 155 and 193).
• If the reference channel or command channel is assigned to a communication bus, when the power supply is connected, the drive
will display [Freewheel] (nSt) and remain in stop mode until the communication bus sends a command.

Faults, which cannot be reset automatically


The cause of the fault must be removed before resetting by turning off and then back on. 
AnF, brF, ECF, EnF, SOF, SPF and tnF faults can also be reset remotely by means of a logic input or control bit ([Fault reset] (rSF)
parameter, page 220).
AnF, EnF, InFA, InFb, SOF, SPF, and tnF faults can be inhibited and cleared remotely by means of a logic input or control bit ([Fault inhibit
assign.] (InH) parameter, page 231).

Fault Name Probable cause Remedy

AI2F [AI2 input] • Non-conforming signal on analog input • Check the wiring of analog input AI2 and the value of the
AI2 signal.
AnF [Load slipping] • The encoder speed feedback does not • Check the motor, gain and stability parameters.
match the reference • Add a braking resistor.
• Check the size of the motor/drive/load.
• Check the encoder’s mechanical coupling and its wiring.
• If the "torque control" function is used, see "Note" on page
184.
bOF [DBR overload] • The braking resistor is under excessive • Check the size of the resistor and wait for it to cool down
stress • Check the [DB Resistor Power] (brP) and [DB Resistor value]
(brU) parameters, page 238.
brF [Brake feedback] • The brake feedback contact does not • Check the feedback circuit and the brake logic control circuit
match the brake logic control • Check the mechanical state of the brake
• The brake does not stop the motor • Check the brake linings
quickly enough (detected by measuring
the speed on the "Pulse input" input).
bUF [DB unit sh. Circuit] • Short-circuit output from braking unit • Check the wiring of the braking unit and the resistor.
• Braking unit not connected • Check the braking resistor
• The monitoring of this fault must be disabled by the [Brake
res. fault Mgt.] (bUb) parameter, page 238 if there is no
resistor or braking unit connected to the drive, at and above
55 kW (75 HP) for ATV71pppM3X and at and above 90 kW
(120 HP) for ATV71pppN4.
CrF1 [Precharge] • Charging relay control fault or • Turn the drive off and then back on again
charging resistor damaged • Check the internal connections
• Inspect/repair the drive
CrF2 [Thyr. soft charge] • DC bus charging fault (thyristors)

[Differential curent • Current difference between power • Check thyristor with [TEST THYRISTORS]
dCF Fault] block A and B (ATV71EC71N4 ... • Check IGBT with [TRANSISTOR TEST]
M13N4 or ATV71EM12Y...M20Y only) • Check current transformer
ECF [Encoder coupling] • Break in encoder’s mechanical coupling • Check the encoder’s mechanical coupling

EEF1 [Control Eeprom] • Internal memory fault, control card • Check the environment (electromagnetic compatibility)
• Turn off, reset, return to factory settings
• Inspect/repair the drive
EEF2 [Power Eeprom] • Internal memory fault, power card

EnF [Encoder] • Encoder feedback fault • Check [Number of pulses] (PGI) and [Encoder type] (EnS)
page 77.
• Check that the encoder’s mechanical and electrical
operation, its power supply and connections are all correct
• If necessary, reverse the direction of rotation of the motor
([Output Ph rotation] (PHr) parameter, page 70) or the
encoder signals
FCF1 [Out. contact. stuck] • The output contactor remains closed • Check the contactor and its wiring
although the opening conditions have • Check the feedback circuit
been met

268 1755855 12/2009


Faults - Causes - Remedies

Faults, which cannot be reset automatically (continued)

Fault Name Probable cause Remedy

HdF [IGBT • Short-circuit or grounding at the drive • Check the cables connecting the drive to the motor, and the
desaturation] output motor insulation.
• Perform the diagnostic tests via the [1.10 DIAGNOSTICS]
menu.
ILF [internal com. link] • Communication fault between option • Check the environment (electromagnetic compatibility)
card and drive • Check the connections
• Check that no more than 2 option cards (max. permitted)
have been installed on the drive
• Replace the option card
• Inspect/repair the drive
InF1 [Rating error] • The power card is different from the • Check the reference of the power card
card stored
InF2 [Incompatible PB] • The power card is incompatible with the • Check the reference of the power card and its compatibility.
control card
InF3 [Internal serial link] • Communication fault between the • Check the internal connections
internal cards • Inspect/repair the drive
InF4 [Internal-mftg zone] • Internal data inconsistent • Recalibrate the drive (performed by Schneider Electric
Product Support).
InF6 [Internal - fault • The option installed in the drive is not • Check the reference and compatibility of the option.
option] recognized
InF7 [Internal-hard init.] • Initialization of the drive is incomplete • Turn off and reset.
InF8 [Internal-ctrl supply] • The control power supply is incorrect • Check the control section power supply

InF9 [Internal- I measure] • The current measurements are incorrect • Replace the current sensors or the power card.
• Inspect/repair the drive
InFA [Internal-mains • The input stage is not operating • Perform the diagnostic tests via the [1.10 DIAGNOSTICS]
circuit] correctly menu.
• Inspect/repair the drive
InFb [Internal- th. • The drive temperature sensor is not • Replace the drive temperature sensor
sensor] operating correctly • Inspect/repair the drive
• The braking unit's temperature sensor • Replace the braking unit's temperature sensor
is not operating correctly. • Inspect/repair the braking unit
• The monitoring of this fault must be disabled by the [Brake
res. fault Mgt.] (bUb) parameter, page 238 if there is no
braking unit connected to the drive.
InFC [Internal-time • Fault on the electronic time • Inspect/repair the drive
meas.] measurement component
InFE [internal- CPU ] • Internal microprocessor fault • Turn off and reset. Inspect/repair the drive.
OCF [Overcurrent] • Parameters in the [SETTINGS] (SEt-) • Check the parameters.
and [1.4 MOTOR CONTROL] (drC-) • Check the size of the motor/drive/load.
menus are not correct. • Check the state of the mechanism.
• Inertia or load too high
• Mechanical locking
PrF [Power removal] • Fault with the drive’s "Power removal" • Inspect/repair the drive
safety function
SCF1 [Motor short circuit] • Short-circuit or grounding at the drive
• Check the cables connecting the drive to the motor, and the
output motor insulation.
SCF2 [Impedant sh. circuit] • Perform the diagnostic tests via the [1.10 DIAGNOSTICS]
menu.
SCF3 [Ground short circuit]
• Significant earth leakage current at the • Reduce the switching frequency.
drive output if several motors are • Connect chokes in series with the motor.
connected in parallel • Check the adjustment of speed loop and brake.
• Increase the [Time to restart] (ttr), page 66.

SOF [Overspeed] • Instability or driving load too high • Check the motor, gain and stability parameters.
• Add a braking resistor.
• Check the size of the motor/drive/load.
• Check the parameters settings for the [FREQUENCY
METER] (FqF-) function, page 235, if it is configured

1755855 12/2009 269


Faults - Causes - Remedies

Faults, which cannot be reset automatically (continued)

Fault Name Probable cause Remedy

SPF [Speed fdback loss] • Encoder feedback signal missing • Check the wiring between the encoder and the drive
• Check the encoder
• Signal on "Pulse input" missing, if the • Check the wiring of the input cable and the detector used
input is used for speed measurement
tnF [Auto-tuning] • Special motor or motor whose power is • Check that the motor/drive are compatible
not suitable for the drive
• Motor not connected to the drive • Check that the motor is present during auto-tuning
• If an output contactor is being used, close it during auto-
tuning

270 1755855 12/2009


Faults - Causes - Remedies

Faults that can be reset with the automatic restart function, after the cause has disappeared
These faults can also be reset by turning on and off or by means of a logic input or control bit ([Fault reset] (rSF) parameter, page 220).
APF, CnF, COF, EPF1, EPF2, FCF2, LFF2, LFF3, LFF4, ObF, OHF, OLF, OPF1, OPF2, OSF, OtF1, OtF2, OtFL, PHF, PtF1, PtF2, PtFL,
SLF1, SLF2, SLF3, SrF, SSF and tJF faults can be inhibited and cleared remotely by means of a logic input or control bit ([Fault inhibit
assign.] (InH)parameter, page 231).

Fault Name Probable cause Remedy

APF [Application fault] • Controller Inside card fault • Please refer to the card documentation
bLF [Brake control] • Brake release current not reached • Check the drive/motor connection
• Check the motor windings
• Check the [Brake release I FW] (Ibr) and [Brake release I
Rev] (Ird) settings, page 161
• Brake engage frequency threshold • Apply the recommended settings for [Brake engage freq]
[Brake engage freq] (bEn) only (bEn).
regulated when brake logic control is
assigned
CnF [Com. network] • Communication fault on • Check the environment (electromagnetic compatibility)
communication card • Check the wiring.
• Check the time-out
• Replace the option card
• Inspect/repair the drive
COF [CANopen com.] • Interruption in communication on the • Check the communication bus.
CANopen bus • Check the time-out
• Refer to the CANopen User's Manual
EPF1 [External flt-LI/Bit] • Fault triggered by an external device, • Check the device which caused the fault, and reset
depending on user
EPF2 [External fault • Fault triggered by a communication • Check for the cause of the fault and reset
com.] network

FCF2 [Out. contact. • The output contactor remains open • Check the contactor and its wiring
open.] although the closing conditions have • Check the feedback circuit
been met
LCF [input contactor] • The drive is not turned on even though • Check the contactor and its wiring
[Mains V. time out ] (LCt) has elapsed. • Check the time-out
• Check the line/contactor/drive connection
• Loss of the 4-20 mA reference on • Check the connection on the analog inputs.

LFF2 [AI2 4-20mA loss]
analog input AI2, AI3 or AI4


LFF3 [AI3 4-20mA loss]

LFF4 [AI4 4-20mA loss]


ObF [Overbraking] • Braking too sudden or driving load • Increase the deceleration time
• Install a braking resistor if necessary
• Activate the [Dec ramp adapt.] (brA) function, page 140, if it
is compatible with the application
OHF [Drive overheat] • Power board -PCB over temperature • Check the motor load, the drive ventilation and the ambient
• Braking unit over temperature temperature. Wait for the drive to cool down before restarting
• Phase module over temperature
• Rectifier over temperature
OLF [Motor overload] • Triggered by excessive motor current • Check the setting of the motor thermal protection, check the
motor load. Wait for the drive to cool down before restarting.
OPF1 [1 output phase • Loss of one phase at drive output • Check the connections from the drive to the motor
loss]

1755855 12/2009 271


Faults - Causes - Remedies

Faults that can be reset with the automatic restart function, after the cause has disappeared
(continued)

Fault Name Probable cause Remedy

OPF2 [3 motor phase loss] • Motor not connected or motor • Check the connections from the drive to the motor
power too low • If an output contactor is being used, parameterize [Output
• Output contactor open Phase Loss] (OPL) = [Output cut] (OAC), page 224.
• Instantaneous instability in the • Test on a low power motor or without a motor:In factory
motor current settings mode, motor phase loss detection is active [Output
Phase Loss] (OPL) = [Yes] (YES). To check the drive in a test
or maintenance environment, without having to use a motor
with the same rating as the drive (in particular for high power
drives), deactivate motor phase loss detection [Output Phase
Loss] (OPL) = [No] (nO)
• Check and optimize the following parameters: [IR
compensation] (UFr), page 74, [Rated motor volt.] (UnS) and
[Rated mot. current] (nCr) page 69 and perform [Auto-tuning]
(tUn) page 70.
OSF [Mains overvoltage] • Line voltage too high • Check the line voltage
• Disturbed mains supply
OtF1 [PTC1 overheat] • Overheating of the PTC1 probes • Check the motor load and motor size.
detected • Check the motor ventilation.
• Overheating of the PTC2 probes • Wait for the motor to cool before restarting
OtF2 [PTC2 overheat]
detected • Check the type and state of the PTC probes

OtFL [LI6=PTC overheat] • Overheating of PTC probes


detected on input LI6
PtF1 [PTC1 probe] • PTC1 probes open or short- • Check the PTC probes and the wiring between them and the
circuited motor/drive
PtF2 [PTC2 probe] • PTC2 probes open or short-
circuited
PtFL [LI6=PTC probe] • PTC probes on input LI6 open or
short-circuited
SCF4 [IGBT short circuit] • Power component fault • Perform a test via the [1.10 DIAGNOSTICS] menu.
• Inspect/repair the drive
SCF5 [Motor short circuit] • Short-circuit at drive output • Check the cables connecting the drive to the motor, and the
motor’s insulation
• Perform tests via the [1.10 DIAGNOSTICS] menu.
• Inspect/repair the drive
SLF1 [Modbus com.] • Interruption in communication on • Check the communication bus.
the Modbus bus • Check the time-out
• Refer to the Modbus User's Manual
SLF2 [PowerSuite com.] • Fault communicating with • Check the PowerSuite connecting cable.
PowerSuite • Check the time-out
SLF3 [HMI com.] • Fault communicating with the • Check the terminal connection
graphic display terminal • Check the time-out
SrF [TORQUE TIME • The time-out of the torque control • Check the function’s settings
OUT FLT] function is attained • Check the state of the mechanism

• Check the parameters of [TORQUE LIMITATION] 


SSF [Torque/current lim] • Switch to torque limitation • Check if there are any mechanical problems

(tLA-) page 186 and the parameters of the 


[TORQUE OR I LIM. DETECT.] (tId-) fault, page 233).
tJF [IGBT overheat] • Drive overheated • Check the size of the load/motor/drive.
• Reduce the switching frequency.
• Wait for the motor to cool before restarting

272 1755855 12/2009


Faults - Causes - Remedies

Faults that can be reset as soon as their causes disappear

The USF fault can be inhibited and cleared remotely by means of a logic input or control bit ([Fault inhibit assign.] (InH) parameter, page
231).

Fault Name Probable cause Remedy

CFF [Incorrect config.] • Option card changed or removed • Check that there are no card errors.
• In the event of the option card being changed/removed
deliberately, see the remarks below

• Control card replaced by a control • Check that there are no card errors.
card configured on a drive with a • In the event of the control card being changed deliberately,
different rating see the remarks below

• The current configuration is • Return to factory settings or retrieve the backup


inconsistent configuration, if it is valid (see page 250)

CFI [Invalid config.] • Invalid configuration • Check the configuration loaded previously.
The configuration loaded in the drive • Load a compatible configuration
via the bus or communication network
is inconsistent.
dLF [Dynamic load • Abnormal load variation • Check that the load is not blocked by an obstacle
fault] • Removal of a run command causes a reset

HCF [Cards pairing] • The [CARDS PAIRING] (PPI-) • In the event of a card error, reinsert the original card
function, page 239, has been • Confirm the configuration by entering the [Pairing password]
configured and a drive card has been (PPI) if the card was changed deliberately
changed
PHF [Input phase loss] • Drive incorrectly supplied or a fuse • Check the power connection and the fuses.
blown
• Failure of one phase
• 3-phase ATV71 used on a single- • Use a 3-phase line supply.
phase line supply
• Unbalanced load • Disable the fault by[Input phase loss] (IPL) = [No] (nO). (page
This protection only operates with the 225)
drive on load
USF [Undervoltage] • Line supply too low • Check the voltage and the parameters of [UNDERVOLTAGE
• Transient voltage dip MGT] (USb-), page 228

Option card changed or removed


When an option card is removed or replaced by another, the drive locks in [Incorrect config.] (CFF) fault mode on power-up. If the card has
been deliberately changed or removed, the fault can be cleared by pressing the ENT key twice, which causes the factory settings to be
restored (see page 250) for the parameter groups affected by the card. These are as follows:

Card replaced by a card of the same type


• I/O cards: [Drive menu] (drM)
• Encoder cards: [Drive menu] (drM)
• Communication cards: only the parameters that are specific to communication cards
• Controller Inside cards: [Prog. card menu] (PLC)

Card removed (or replaced by a different type of card)


• I/O card: [Drive menu] (drM)
• Encoder card: [Drive menu] (drM)
• Communication card: [Drive menu] (drM) and parameters specific to communication cards
• Controller Inside card: [Drive menu] (drM) and [Prog. card menu] (PLC)

Control card changed


When a control card is replaced by a control card configured on a drive with a different rating, the drive locks in [Incorrect config.] (CFF)
fault mode on power-up. If the card has been deliberately changed, the fault can be cleared by pressing the ENT key twice, which causes
all the factory settings to be restored.

1755855 12/2009 273


Product data sheet ATV71HD55Y
Characteristics variable speed drive ATV71 - 55kW - 690V

Main
Range of product Altivar 71
Product or component Variable speed drive
type
Product specific appli- Complex, high-power machines
cation
Component name ATV71
Motor power kW 45 kW at 500 V 3 phases
55 kW at 690 V 3 phases
Motor power hp 60 hp at 575 V 3 phases
Motor cable length <= 10 m shielded cable
<= 10 m unshielded cable
Power supply voltage 500...690 V (- 15...10 %)

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.
Network number of 3 phases
phases
Line current 57 A for 600 V 3 phases / 60 hp
63 A for 690 V 3 phases 55 kW
68 A for 500 V 3 phases 45 kW
EMC filter Integrated
Assembly style With heat sink
Variant Reinforced version

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.
Prospective line Isc <= 22 kA, 3 phases

Neither Schneider Electric Industries SAS nor any of its affiliates or subsidiaries shall be responsible or liable for misuse of the information contained herein.
Nominal output current 62 A at 2.5 kHz 575 V 3 phases / 60 hp
62 A at 2.5 kHz 690 V 3 phases 55 kW
68 A at 2.5 kHz 500 V 3 phases 45 kW
Maximum transient cur- 102 A for 60 s 3 phases 45 kW
rent 112.2 A for 2 s 3 phases / 60 hp
112.2 A for 2 s 3 phases 55 kW
Speed drive output fre- 0.1...500 Hz
quency
Nominal switching fre- 2.5 kHz
quency
Switching frequency 2.5...4.9 kHz adjustable
2.5...4.9 kHz with derating factor
Asynchronous motor ENA (Energy adaptation) system for unbalanced
control profile loads
Flux vector control (FVC) with sensor (current vec-
tor)
Sensorless flux vector control (SFVC) (voltage or
current vector)
Voltage/Frequency ratio (2 or 5 points)
Type of polarization No impedance for Modbus

Complementary
Product destination Asynchronous motors
Synchronous motors
Power supply voltage limits 425...759 V
Power supply frequency 50...60 Hz (- 5...5 %)
Power supply frequency limits 47.5...63 Hz
Speed range 1...100 for asynchronous motor in open-loop mode, without speed feedback
1...1000 for asynchronous motor in closed-loop mode with encoder feedback
1...50 for synchronous motor in open-loop mode, without speed feedback
Speed accuracy +/- 0.01 % of nominal speed for 0.2 Tn to Tn torque variation in closed-loop mode
with encoder feedback
+/- 10 % of nominal slip for 0.2 Tn to Tn torque variation without speed feedback

Feb 7, 2013
1
Torque accuracy +/- 15 % in open-loop mode, without speed feedback
+/- 5 % in closed-loop mode with encoder feedback
Transient overtorque 170 % of nominal motor torque +/- 10 % for 60 s every 10 minutes
220 % of nominal motor torque +/- 10 % for 2 s
Braking torque < 150 % with braking or hoist resistor
30 % without braking resistor
Synchronous motor control profile Vector control without speed feedback
Regulation loop Adjustable PI regulator
Motor slip compensation Adjustable
Automatic whatever the load
Not available in voltage/frequency ratio (2 or 5 points)
Suppressable
Diagnostic 1 LED red presence of drive voltage
Output voltage <= power supply voltage
Insulation Electrical between power and control
Type of cable for mounting in an enclosure With a NEMA Type1 kit: 3-strand UL 508 cable at 40 °C, copper 75 °C PVC
With an IP21 or an IP31 kit: 3-strand IEC cable at 40 °C, copper 70 °C PVC
Without mounting kit: 1-strand IEC cable at 45 °C, copper 70 °C PVC
Without mounting kit: 1-strand IEC cable at 45 °C, copper 90 °C XLPE/EPR
Electrical connection AI1-/AI1+, AI2, AO1, R1A, R1B, R1C, R2A, R2B, LI1...LI6, PWR terminal 2.5
mm² / AWG 14
L1/R, L2/S, L3/T, U/T1, V/T2, W/T3, PC/-, PO, PA/+, PA, PB terminal 150 mm²
Tightening torque AI1-/AI1+, AI2, AO1, R1A, R1B, R1C, R2A, R2B, LI1...LI6, PWR 0.6 N.m
L1/R, L2/S, L3/T, U/T1, V/T2, W/T3, PC/-, PO, PA/+, PA, PB 41 N.m / 360 lb.in
Supply Internal supply for reference potentiometer (1 to 10 kOhm), 10.5 V DC +/- 5 % ,
<= 10 mA for overload and short-circuit protection
Internal supply, 24 V DC , voltage limits 21...27 V, <= 200 mA for overload and
short-circuit protection
Analogue input number 2
Analogue input type AI1-/Al1+ bipolar differential voltage +/- 10 V DC, input voltage 24 V max , resolu-
tion 11 bits + sign
AI2 software-configurable current 0...20 mA , impedance 242 Ohm, resolution 11
bits
AI2 software-configurable voltage 0...10 V DC, input voltage 24 V max,
impedance 30000 Ohm, resolution 11 bits
Input sampling time AI1-/Al1+ 2 ms, +/- 0.5 ms for analog input(s)
Al2 2 ms, +/- 0.5 ms for analog input(s)
LI1...LI5 2 ms, +/- 0.5 ms for discrete input(s)
LI6 (if configured as logic input) 2 ms, +/- 0.5 ms for discrete input(s)
Response time <= 100 ms in STO (Safe Torque Off)
AO1 2 ms, tolerance +/- 0.5 ms for analog output(s)
R1A, R1B, R1C 7 ms, tolerance +/- 0.5 ms for discrete output(s)
R2A, R2B 7 ms, tolerance +/- 0.5 ms for discrete output(s)
Absolute accuracy precision AI1-/Al1+ +/- 0.6 % for a temperature variation 60 °C
AI2 +/- 0.6 % for a temperature variation 60 °C
AO1 +/- 1 % for a temperature variation 60 °C
Linearity error AI1-/Al1+, AI2 +/- 0.15 % of maximum value
AO1 +/- 0.2 %
Analogue output number 1
Analogue output type AO1 software-configurable logic output 10 V <= 20 mA
AO1 software-configurable current 0...20 mA, impedance 500 Ohm, resolution 10
bits
AO1 software-configurable voltage 0...10 V DC, impedance 470 Ohm, resolution
10 bits
Discrete output number 2
Discrete output type R1A, R1B, R1C configurable relay logic NO/NC, electrical durability 100000 cy-
cles
R2A, R2B configurable relay logic NO, electrical durability 100000 cycles
Minimum switching current Configurable relay logic 3 mA at 24 V DC
Maximum switching current R1, R2 on inductive load, 2 A at 250 V AC, cos phi = 0.4,
R1, R2 on inductive load, 2 A at 30 V DC, cos phi = 0.4,
R1, R2 on resistive load, 5 A at 250 V AC, cos phi = 1,
R1, R2 on resistive load, 5 A at 30 V DC, cos phi = 1,
Discrete input number 7
Discrete input type LI1...LI5: programmable 24 V DC with level 1 PLC, impedance: 3500 Ohm
LI6: switch-configurable 24 V DC with level 1 PLC, impedance: 3500 Ohm
LI6: switch-configurable PTC probe 0...6 , impedance: 1500 Ohm
PWR: safety input 24 V DC, impedance: 1500 Ohm conforming to[pace]ISO
13849-1 level d

2
Discrete input logic LI1...LI5 negative logic (sink), > 16 V (state 0), < 10 V (state 0)
LI1...LI5 positive logic (source), < 5 V (state 0), > 11 V (state 0)
LI6 (if configured as logic input) negative logic (sink), > 16 V (state 0), < 10 V
(state 0)
LI6 (if configured as logic input) positive logic (source), < 5 V (state 0), > 11 V
(state 0)
Acceleration and deceleration ramps Automatic adaptation of ramp if braking capacity exceeded, by using resistor
Linear adjustable separately from 0.01 to 9000 s
S, U or customized
Braking to standstill By DC injection
Protection type Drive against exceeding limit speed
Drive against input phase loss
Drive break on the control circuit
Drive input phase breaks
Drive line supply overvoltage
Drive line supply undervoltage
Drive overcurrent between output phases and earth
Drive overheating protection
Drive overvoltages on the DC bus
Drive short-circuit between motor phases
Drive thermal protection
Motor motor phase break
Motor power removal
Motor thermal protection
Insulation resistance > 1 MOhm at 500 V DC for 1 minute to earth
Frequency resolution Analog input 0.024/50 Hz
Display unit 0.1 Hz
Communication port protocol CANopen
Modbus
Type of connector 1 RJ45 for Modbus on front face
1 RJ45 for Modbus on terminal
Male SUB-D 9 on RJ45 for CANopen
Physical interface 2-wire RS 485 for Modbus
Transmission frame RTU for Modbus
Transmission rate 20 kbps, 50 kbps, 125 kbps, 250 kbps, 500 kbps, 1 Mbps for CANopen
4800 bps, 9600 bps, 19200 bps, 38.4 Kbps for Modbus on terminal
9600 bps, 19200 bps for Modbus on front face
Data format 8 bits, 1 stop, even parity for Modbus on front face
8 bits, odd even or no configurable parity for Modbus on terminal
Number of addresses 1...127 for CANopen
1...247 for Modbus
Method of access Slave for CANopen
Marking CE
Operating position Vertical +/- 10 degree
Depth 290 mm
Height 630 mm
Width 320 mm
Product weight 68 kg
Option card CC-Link communication card
Controller inside programmable card
DeviceNet communication card
Ethernet/IP communication card
Fipio communication card
I/O extension card
Interbus-S communication card
Interface card for encoder
Modbus Plus communication card
Modbus TCP communication card
Modbus/Uni-Telway communication card
Overhead crane card
Profibus DP communication card
Profibus DP V1 communication card

3
Environment
Noise level 63.7 dB conforming to 86/188/EEC
Dielectric strength 3110 V DC between earth and power terminals
5345 V DC between control and power terminals
Electromagnetic compatibility 1.2/50 µs - 8/20 µs surge immunity test conforming to IEC 61000-4-5 level 3
Conducted radio-frequency immunity test conforming to IEC 61000-4-6 level 3
Electrical fast transient/burst immunity test conforming to IEC 61000-4-4 level 4
Electrostatic discharge immunity test conforming to IEC 61000-4-2 level 3
Radiated radio-frequency electromagnetic field immunity test conforming to IEC
61000-4-3 level 3
Voltage dips and interruptions immunity test conforming to IEC 61000-4-11
Standards EN 55011 class A group 2
EN 61800-3 environments 1 category C3
EN 61800-3 environments 2 category C3
EN/IEC 61800-3
EN/IEC 61800-5-1
IEC 60721-3-3 class 3C2
UL Type 1
Product certifications CSA
C-Tick
GOST
NOM 117
UL
Pollution degree 2 conforming to EN/IEC 61800-5-1
3 conforming to UL 840
IP degree of protection IP20 on upper part without blanking plate on cover conforming to EN/IEC 60529
IP20 on upper part without blanking plate on cover conforming to EN/IEC
61800-5-1
IP21 conforming to EN/IEC 60529
IP21 conforming to EN/IEC 61800-5-1
IP41 on upper part conforming to EN/IEC 60529
IP41 on upper part conforming to EN/IEC 61800-5-1
IP54 on lower part conforming to EN/IEC 60529
IP54 on lower part conforming to EN/IEC 61800-5-1
Vibration resistance 1 gn (f = 13...200 Hz) conforming to EN/IEC 60068-2-6
1.5 mm peak to peak (f = 3...13 Hz) conforming to EN/IEC 60068-2-6
Shock resistance 15 gn for 11 ms conforming to EN/IEC 60068-2-27
Relative humidity 5...95 % without condensation conforming to IEC 60068-2-3
5...95 % without dripping water conforming to IEC 60068-2-3
Ambient air temperature for operation -10...50 °C without derating
Ambient air temperature for storage -25...70 °C
Operating altitude <= 1000 m without derating
1000...2260 m with current derating 1 % per 100 m
RoHS EUR status Compliant
RoHS EUR conformity date 1101

4
Product data sheet ATV71HD55Y
Dimensions Drawings

UL Type 1/IP 20 Drives

Dimensions without Option Card

Dimensions with 1 Option Card (1)

(1) Option cards: I/O extension cards, communication cards or "Controller Inside” programmable card.

Dimensions with 2 Option Cards (1)

(1) Option cards: I/O extension cards, communication cards or "Controller Inside” programmable card.

5
Product data sheet ATV71HD55Y
Mounting and Clearance

Mounting Recommendations

Depending on the conditions in which the drive is to be used, its installation will require certain precautions and the use of appropriate
accessories.
Install the unit vertically:
● Avoid placing it close to heating elements
● Leave sufficient free space to ensure that the air required for cooling purposes can circulate from the bottom to the top of the unit.

Clearance

Mounting Types
Type A Mounting

Type B Mounting

Type C Mounting

By removing the protective blanking cover from the top of the drive, the degree of protection for the drive becomes IP 20.
The protective blanking cover may vary according to the drive model (refer to the user guide).
The protective blanking cover must be removed from ATV 71P•••N4Z drives when they are mounted in a dust and damp proof enclosure.

Specific Recommendations for Mounting the Drive in an Enclosure

Ventilation
To ensure proper air circulation in the drive:

6
● Fit ventilation grilles.
● Ensure that there is sufficient ventilation. If there is not, install a forced ventilation unit with a filter. The openings and/or fans must
provide a flow rate at least equal to that of the drive fans (refer to the product characteristics).

● Use special filters with IP 54 protection.


● Remove the blanking cover from the top of the drive.

Dust and Damp Proof Metal Enclosure (IP 54)


The drive must be mounted in a dust and damp proof enclosure in certain environmental conditions: dust, corrosive gases, high humidity with
risk of condensation and dripping water, splashing liquid, etc.
This enables the drive to be used in an enclosure where the maximum internal temperature reaches 50°C.

7
Product data sheet ATV71HD55Y
Connections and Schema

Wiring Diagram Conforming to Standards EN 954-1 Category 1, IEC/EN 61508 Capacity SIL1, in Stopping
Category 0 According to IEC/EN 60204-1

Three-Phase Power Supply with Upstream Breaking via Contactor

A1 ATV71 drive
KM1 Contactor
L1 DC choke
Q1 Circuit-breaker
Q2 GV2 L rated at twice the nominal primary current of T1
Q3 GB2CB05
S1, XB4 B or XB5 A pushbuttons
S2
T1 100 VA transformer 220 V secondary
(1) Line choke (three-phase); mandatory for ATV71HC11Y…HC63Y drives (except when a special transformer is used (12-pulse)).
(2) For ATV71HC40N4 drives combined with a 400 kW motor, ATV71HC50N4 and ATV71HC40Y…HC63Y, refer to the power terminal
connections diagram.
(3) Fault relay contacts. Used for remote signalling of the drive status.
(4) Connection of the common for the logic inputs depends on the positioning of the SW1 switch. The above diagram shows the internal
power supply switched to the “source” position (for other connection types, refer to the user guide).
(5) There is no PO terminal on ATV71HC11Y…HC63Y drives.
(6) Optional DC choke for ATV71H•••M3, ATV71HD11M3X…HD45M3X, ATV71•075N4…•D75N4 and ATV71P•••N4Z drives. Connected in
place of the strap between the PO and PA/+ terminals. For ATV71HD55M3X, HD75M3X, ATV71HD90N4…HC50N4 drives, the choke
is supplied with the drive; the customer is responsible for connecting it.
(7) Software-configurable current (0…20 mA) or voltage (0…10 V) analog input.
(8) Reference potentiometer.
All terminals are located at the bottom of the drive. Fit interference suppressors on all inductive circuits near the drive or connected on the
same circuit, such as relays, contactors, solenoid valves, fluorescent lighting, etc.

Wiring Diagram Conforming to Standards EN 954-1 Category 1, IEC/EN 61508 Capacity SIL1, in Stopping
Category 0 According to IEC/EN 60204-1

8
Three-Phase Power Supply with Downstream Breaking via Switch Disconnector

A1 ATV71 drive
L1 DC choke
Q1 Circuit-breaker
Q2 Switch disconnector (Vario)
(1) Line choke (three-phase), mandatory for ATV71HC11Y…HC63Y drives (except when a special transformer is used (12-pulse)).
(2) For ATV71HC40N4 drives combined with a 400 kW motor, ATV71HC50N4 and ATV71HC40Y…HC63Y, refer to the power terminal
connections diagram.
(3) Fault relay contacts. Used for remote signalling of the drive status.
(4) Connection of the common for the logic inputs depends on the positioning of the SW1 switch. The above diagram shows the internal
power supply switched to the “source” position (for other connection types, refer to the user guide).
(5) There is no PO terminal on ATV71HC11Y…HC63Y drives.
(6) Optional DC choke for ATV71H•••M3, ATV71HD11M3X…HD45M3X, ATV71•075N4…•D75N4 and ATV71P•••N4Z drives. Connected in
place of the strap between the PO and PA/+ terminals. For ATV71HD55M3X, HD75M3X, ATV71HD90N4…HC50N4 drives, the choke
is supplied with the drive; the customer is responsible for connecting it.
(7) Software-configurable current (0…20 mA) or voltage (0…10 V) analog input.
(8) Reference potentiometer.
All terminals are located at the bottom of the drive. Fit interference suppressors on all inductive circuits near the drive or connected on the
same circuit, such as relays, contactors, solenoid valves, fluorescent lighting, etc.

Wiring Diagram Conforming to Standards EN 954-1 Category 3, IEC/EN 61508 Capacity SIL2, in Stopping
Category 0 According to IEC/EN 60204-1

9
Three-Phase Power Supply, Low Inertia Machine, Vertical Movement

A1 ATV71 drive
A2 Preventa XPS AC safety module for monitoring emergency stops and switches. One safety module can manage the “Power Removal”
function for several drives on the same machine. In this case, each drive must connect its PWR terminal to its + 24 V via the safety
contacts on the XPS AC module. These contacts are independent for each drive.
F1 Fuse
L1 DC choke
Q1 Circuit-breaker
S1 Emergency stop button with 2 contacts
S2 XB4 B or XB5 A pushbutton
(1) Power supply: 24 Vdc or Vac, 48 Vac, 115 Vac, 230 Vac.
(2) S2: resets XPS AC module on power-up or after an emergency stop. ESC can be used to set external starting conditions.
(3) Requests freewheel stopping of the movement and activates the “Power Removal” safety function.
(4) Line choke (three-phase), mandatory for and ATV71HC11Y…HC63Y drives (except when a special transformer is used (12-pulse)).
(5) The logic output can be used to signal that the machine is in a safe stop state.
(6) For ATV71HC40N4 drives combined with a 400 kW motor, ATV71HC50N4 and ATV71HC40Y…HC63Y, refer to the power terminal
connections diagram.
(7) Fault relay contacts. Used for remote signalling of the drive status.
(8) Connection of the common for the logic inputs depends on the positioning of the SW1 switch. The above diagram shows the internal
power supply switched to the “source” position (for other connection types, refer to the user guide).
(9) Standardized coaxial cable, type RG174/U according to MIL-C17 or KX3B according to NF C 93-550, external diameter
2.54 mm /0.09 in., maximum length 15 m / 49.21 ft. The cable shielding must be earthed.
(10) There is no PO terminal on ATV71HC11Y…HC63Y drives.
(11) Optional DC choke for ATV71H•••M3, ATV71HD11M3X…HD45M3X, ATV71•075N4…•D75N4 and ATV71P•••N4Z drives. Connected in
place of the strap between the PO and PA/+ terminals. For ATV71HD55M3X, HD75M3X, ATV71HD90N4…HC50N4 drives, the choke
is supplied with the drive; the customer is responsible for connecting it.
(12) Software-configurable current (0…20 mA) or voltage (0…10 V) analog input.
(13) Reference potentiometer.
All terminals are located at the bottom of the drive. Fit interference suppressors on all inductive circuits near the drive or connected on the
same circuit, such as relays, contactors, solenoid valves, fluorescent lighting, etc.

Wiring Diagram Conforming to Standards EN 954-1 Category 3, IEC/EN 61508 Capacity SIL2, in Stopping
Category 1 According to IEC/EN 60204-1

10
Three-Phase Power Supply, High Inertia Machine

A1 ATV71 drive
A2 Preventa XPS ATE safety module for monitoring emergency stops and switches. One safety module can manage the "Power Removal”
(5) safety function for several drives on the same machine. In this case the time delay must be adjusted on the drive controlling the motor
that requires the longest stopping time. In addition, each drive must connect its PWR terminal to its + 24 V via the safety contacts on
the XPS ATE module. These contacts are independent for each drive.
F1 Fuse
L1 DC choke
Q1 Circuit-breaker
S1 Emergency stop button with 2 N/C contacts
S2 Run button
(1) Power supply: 24 Vdc or Vac, 115 Vac, 230 Vac.
(2) Requests controlled stopping of the movement and activates the “Power Removal” safety function.
(3) Line choke (three-phase), mandatory for ATV71HC11Y…HC63Y drives (except when a special transformer is used (12-pulse)).
(4) S2: resets XPS ATE module on power-up or after an emergency stop. ESC can be used to set external starting conditions.
(5) For stopping times requiring more than 30 seconds in category 1, use a Preventa XPS AV safety module which can provide a
maximum time delay of 300 seconds.
(6) The logic output can be used to signal that the machine is in a safe state.
(7) For ATV71HC40N4 drives combined with a 400 kW motor, ATV71HC50N4 and ATV71HC40Y…HC63Y, refer to the power terminal
connections diagram.
(8) Fault relay contacts. Used for remote signalling of the drive status.
(9) Connection of the common for the logic inputs depends on the positioning of the SW1 switch. The above diagram shows the internal
power supply switched to the “source” position (for other connection types, refer to the user guide).
(10) Standardized coaxial cable, type RG174/U according to MIL-C17 or KX3B according to NF C 93-550, external diameter
2.54 mm/0.09 in., maximum length 15 m/49.21 ft. The cable shielding must be earthed.
(11) Logic inputs LI1 and LI2 must be assigned to the direction of rotation: LI1 in the forward direction and LI2 in the reverse direction.
(12) There is no PO terminal on ATV71HC11Y…HC63Y drives.
(13) Optional DC choke for ATV71H•••M3, ATV71HD11M3X…HD45M3X, ATV71•075N4…•D75N4 and ATV71P•••N4Z drives. Connected in
place of the strap between the PO and PA/+ terminals. For ATV71HD55M3X, HD75M3X, ATV71HD90N4…HC50N4 drives, the choke
is supplied with the drive; the customer is responsible for connecting it.
(14) Software-configurable current (0…20 mA) or voltage (0…10 V) analog input.
(15) Reference potentiometer.
All terminals are located at the bottom of the drive. Fit interference suppressors on all inductive circuits near the drive or connected on the
same circuit, such as relays, contactors, solenoid valves, fluorescent lighting, etc.

11
Product data sheet ATV71HD55Y
Performance Curves

Derating Curves

The derating curves for the drive nominal current (In) depend on the temperature, the switching frequency and the mounting type. For
intermediate temperatures (e.g. 55°C), interpolate between 2 curves.

X Switching frequency
(1) Mounting type
Above 50ºC, the drive should be fitted with a control card fan kit.

12
JY997D18801F(ENGLISH)

.
from February 1st, 2006 FX 3U-128MR/ES(-A) FX3U-128MT/ES(-A)
STARTUP AND Certification of UL, cUL standards FX3U-128MT/ESS
MAINTENANCE
FX3U- MR/DS FX3U- MT/DS
PRECAUTIONS
FX 3U main units and input/output extension units/blocks supporting FX3U- MT/DSS
Do not touch any terminal while the PLC's power is on. UL, cUL standards are as follows: Where indicates:16,32,48,64,80
Doing so may cause electric shock or malfunctions.
Before cleaning or retightening terminals externally cut off all UL, cUL file number :E95239 Standard Remark
FX3U SERIES PROGRAMMABLE phases of the power supply. Models : MELSEC FX3U series manufactured
EN61131-2:2003 Compliance with all relevant aspects
CONTROLLERS Failure to do so may cause electric shock. FX3U- MR/ES(-A) FX 3U- MT/ES(-A)
Programmable controllers of the standard.
FX3U- MT/ESS
Make sure to connect the battery for memory backup correctly. - Equipment Radiated Emissions
Where indicates:16,32,48,64,80,128
HARDWARE MANUAL Do not charge, disassemble, heat, short-circuit, or expose the requirements and tests Mains Terminal Voltage Emissions
FX3U- MR/DS FX3U- MT/DS
battery to fire. RF immunity
FX3U- MT/DSS
Doing so may rupture or ignite it. Fast Transients
Manual Number JY997D18801 Where indicates:16,32,48,64,80
Before modifying or disrupting the program in operation or ESD Surge
FX3U-232ADP FX3U-485ADP
Revision F running the PLC, carefully read through this manual and the FX3U-4AD-ADP FX 3U-4DA-ADP Voltage drops and interruptions
associated manuals and ensure the safety of the operation. FX3U-4AD-PT-ADP FX 3U-4AD-TC-ADP Conducted
Date March 2007
FX3U-4HSX-ADP FX3U-2HSY-ADP Power magnetic fields

This manual describes the part names, dimensions, mounting, STARTUP AND Models : MELSEC FX2N series manufactured Models : MELSEC FX2N series manufactured
cabling and specifications for the product. This manual is extracted MAINTENANCE FX2N- ER-ES/UL FX2N- ET-ESS/UL from July 1st, 1997 FX 2N- ER-ES/UL FX2N- ET-ESS/UL
from FX 3U Series User's Manual - Hardware Edition. Refer to FX 3U PRECAUTIONS Where indicates:32,48 Where indicates:32,48
Series User's Manual - Hardware Edition for more details. Before FX2N-16EX-ES/UL FX2N-16EYR-ES/UL
FX2N-48ER-DS FX 2N-48ET-DSS
use, read this manual and manuals of relevant products fully to Turn off the power to the PLC before attaching or detaching the
memory cassette. If the memory cassette is attached or FX2N-48ER-UA1/UL FX2N-16EYT-ESS/UL
acquire proficiency in the handling and operating the product. Make
sure to learn all the product information, safety information, and detached while the PLC's power is on, the data in the memory FX2N-8ER-ES/UL FX 2N-8EX-ES/UL from April 1st, 1998 FX 2N-48ER-DS FX2N-48ET-DSS
precautions. may be destroyed, or the memory cassette may be damaged. FX2N-8EYR-ES/UL FX2N-8EYT-ESS/UL from August 1st, 1998 FX 2N-48ER-UA1/UL
And, store this manual in a safe place so that you can take it out and Do not disassemble or modify the PLC. FX2N-8EX-UA1/UL from August 1st, 2005 FX 2N-8ER-ES/UL FX2N-8EX-ES/UL
read it whenever necessary. Always forward it to the end user. Doing so may cause fire, equipment failures, or malfunctions. FX2N-16EX-ES/UL FX 2N-16EYR-ES/UL FX2N-8EYR-ES/UL FX2N-8EYT-ESS/UL
Registration For repair, contact your local Mitsubishi Electric distributor. FX2N-16EYT-ESS/UL
The company name and the product name to be described in this Turn off the power to the PLC before connecting or disconnecting For the products above, PLCs manufactured
manual are the registered trademarks or trademarks of each any extension cable. before March 31st, 2002 are compliant with EN50081-2 (EN61000-
company. Failure to do so may cause equipment failures or malfunctions. 6-4) and EN50082-2
Turn off the power to the PLC before attaching or detaching the
Compliance with EC directive(CE Marking ) from April 1st, 2002 to April 30th, 2006 are compliant with EN50081-
Effective Mar. 2007
following devices. 2 (EN61000-6-4) and EN61131-2:1994+A11:1996+A12:2000
Specifications are subject to change without notice. after May 1st, 2006 are compliant with EN61131-2:2003
Failure to do so may cause equipment failures or malfunctions. This document does not guarantee that a mechanical system
2005 Mitsubishi Electric Corporation - Display module, peripheral devices, expansion boards, and including this product will comply with the following standards.
special adapters Compliance to EMC directive and LVD directive of the entire Standard Remark
Safety Precaution (Read these precautions before use.) - Connector conversion adapter, extension blocks, and FX mechanical system should be checked by the user / manufacturer. EN61000-6-4:2001 Compliance with all relevant aspects
Series terminal blocks For more details please contact the local Mitsubishi Electric sales - Generic emission of the standard.
This manual classifies the safety precautions into two categories: - Battery and memory cassette site. standard Radiated Emissions
and . Industrial environment Mains Terminal Voltage Emissions
Requirement for Compliance with EMC directive EN50081-2:1993
DISPOSAL
PRECAUTIONS Electromagnetic
Indicates that incorrect handling may cause The following products have shown compliance through direct
compatibility
hazardous conditions, resulting in death or testing (of the identified standards below) and design analysis
Please contact a certified electronic waste disposal company EN50082-2:1995 Compliance with all relevant aspects
severe injury. (through the creation of a technical construction file) to the European
for the environmentally safe recycling and disposal of your
Directive for Electromagnetic Compatibility (89/336/EEC) when used Electromagnetic of the standard.
device.
as directed by the appropriate documentation. compatibility RF immunity
Indicates that incorrect handling may cause - Generic immunity Fast Transients
hazardous conditions, resulting in medium or TRANSPORT AND Type : Programmable Controller (Open Type Equipment) standard ESD
slight personal injury or physical damage. STORAGE Models : MELSEC FX3U series manufactured Industrial environment Conducted
PRECAUTIONS from May 1st, 2005 FX 3U- MR/ES(-A) Power magnetic fields
Where indicates:16,32,48,64,80 EN61131-2:1994 Compliance with all relevant aspects
Before transporting the PLC, turn on the power to the PLC to
FX3U-4HSX-ADP FX3U-2HSY-ADP /A11:1996 of the standard.
check that the BATT LED is off.
If the PLC is transported with the BATT LED on or the battery FX3U-FLROM-16 FX3U-FLROM-64L /A12:2000 RF Immunity
It is important to follow all precautions for personal safety. FX3U-7DM Programmable controllers Fast Transients
exhausted, the battery-backed data may be unstable during
transportation. from June 1st, 2005 FX 3U-232ADP FX 3U-485ADP - Equipment ESD
FX3U-4AD-ADP FX3U-4DA-ADP requirements and tests Damped oscillatory wave
The PLC is a precision instrument. During transportation, avoid
impacts larger than those specified in Section 2.1. Failure to do FX3U-4AD-PT-ADP FX3U-4AD-TC-ADP EN61131-2:2003 Compliance with all relevant aspects
so may cause failures in the PLC. FX3U-232-BD FX3U-422-BD Programmable controllers of the standard.
After transportation, verify the operations of the PLC. - Equipment Radiated Emissions
FX3U-485-BD FX3U-USB-BD
requirements and tests Mains Terminal Voltage Emissions
FX3U-FLROM-64 FX3U-CNV-BD RF immunity
from November 1st, 2005 FX3U- MT/ES(-A) Fast Transients
Marine standard
FX3U- MT/ESS ESD Surge
Where indicates:16,32,48,64,80 Voltage drops and interruptions
Please consult with Mitsubishi Electric for the information on marine
standard practices and the corresponding types of equipment. Conducted
Power magnetic fields
Requirement for Compliance with LVD directive Caution for Analog Products in use With terminal cover open
The analog special adapters have been found to be compliant to the Incorporated Items [2]
The following products have shown compliance through direct European standards in the aforesaid manual and directive. However, [3]
testing (of the identified standards below) and design analysis for the very best performance from what are in fact delicate
(through the creation of a technical construction file) to the European Check if the following product and items are included in the package:
measuring and controlled output device Mitsubishi Electric would like
Directive for Low Voltage (73/23/EEC) when used as directed by the to make the following points; Product Manual Dust proof sheet [4]
appropriate documentation. As analog devices are sensitive by nature, their use should be (1 sheet)
considered carefully. For users of proprietary cables (integral with
Type : Programmable Controller (Open Type Equipment) 3U

sensors or actuators), these users should follow those S/S 0V X0 X2 X4 X6 X10 X12 X14 X16 X20 X22 X24 X26
L N 24V X1 X3 X5 X7 X11 X13 X15 X17 X21 X23 X25 X27
X27 This
Models : MELSEC FX3U series manufactured
0 1 2 3 4 5 6 7
manufacturers installation requirements. IN
POWE
POWE
RR
RUN
RUN
manual
BAT
BAT
TT
from May 1st, 2005 FX 3U- MR/ES(-A) ERROR
ERROR
Mitsubishi Electric recommend that shielded cables should be used. FX3U-48MR/ES 0 1 2 3 4 5 6 7
OUT
0 1 2 3 4 5 6 7
FX -48M
Y0 Y2 Y4 Y6 Y10 Y12 Y14 Y16 Y20 Y22 Y24 Y26 COM5
COM1 Y1 Y3 COM2 Y5 Y7 COM3 Y11 Y13 COM4 Y15 Y17 Y21 Y23 Y25 Y27
Where indicates:16,32,48,64,80 If NO other EMC protection is provided, then users may experience R

from November 1st, 2005 FX3U- MT/ES(-A) temporary induced errors not exceeding +10%/-10% in very heavy [3]
[1] [5]
FX3U- MT/ESS industrial areas.
Where indicates:16,32,48,64,80 However, Mitsubishi Electric suggest that if adequate EMC
No. Name
from February 1st, 2006 FX3U-128MR/ES(-A) precautions are followed with general good EMC practice for the
users complete control system, users should expect normal errors 1. Outline [1] Protective terminal covers (FX3U- M / -A is excluded)
FX3U-128MT/ES(-A)
as specified in this manual.
FX3U-128MT/ESS [2] Power supply, Input (X) terminals
FX3U- MR/DS Terminal block mounting screws
- Sensitive analog cable should not be laid in the same trunking 1.1 Part names [3]
Where indicates:16,32,48,64,80 or cable conduit as high voltage cabling. Where possible users (FX 3U-16M terminal block cannot be installed/removed)
should run analog cables separately. [1] [4] Terminal names
Standard Remark [2] [9]
- Good cable shielding should be used. When terminating the
[3] [10] [5] Output (Y) terminals
EN61131-2:2003 The equipment has been assessed shield at Earth - ensure that no earth loops are accidentally
Programmable controllers as a component for fitting in a created.
- Equipment suitable enclosure which meets the - When reading analog values, EMC induced errors can be 1.2 External dimensions and weight
requirements and tests requirements of EN61131-2:2003 smoothed out by averaging the readings. This can be achieved [11]
either through functions on the analog special adapter/block or [4] [12]
3U
Models :MELSEC FX2N series manufactured through a users program in the FX3U Series PLC main unit. FX3U-16M and FX3U-32M do not have the (*)-marked mounting holes.
from July 1st, 1997 FX 2N- ER-ES/UL FX 2N- ET-ESS/UL Unit:mm(inches)
Associated manuals [5]
Where indicates:32,48 *
FX 3U Series PLC (main unit) comes with this document (hardware
FX 2N-16EYR-ES/UL [13] S/S 0V X0 X2 X4 X6 X10 X12 X14 X16 X20 X22 X24 X26
[6] L N 24V X1 X3 X5 X7 X11 X13 X15 X17 X21 X23 X25 X27
manual). [8]
from April 1st, 1998 FX 2N-48ER-DS [7]
For a detailed explanation of the FX 3U Series hardware and
from August 1st, 1998 FX 2N-48ER-UA1/UL information on instructions for PLC programming and special No. Name 3U

from August 1st, 2005 FX 2N-8ER-ES/UL FX 2N-8EYR-ES/UL extension unit/block, refer to the relevant documents. Y0 Y2 Y4 Y6 Y10 Y12 Y14 Y16 Y20 Y22 Y24 Y26 COM5
COM1 Y1 Y3 COM2 Y5 Y7 COM3 Y11 Y13 COM4 Y15 Y17 Y21 Y23 Y25 Y27
[1] Top cover
For the products above, PLCs manufactured Manual name Manual No. Description [2] Battery cover *
before March 31st, 2002 are compliant with IEC1010-1 W1 9(0.36")
FX 3U Series Explains FX3U Series PLC [3] Special adapter connecting hooks (2 places) 86(3.39")
from April 1st, 2002 to April 30th, 2006 are compliant with EN61131- JY997D16501 W
User's Manual specification details for I/O,
2:1994+A11:1996+A12:2000 MODEL CODE: [4] Expansion board dummy cover Mounting hole pitches
- Hardware wiring, installation, and
after May 1st, 2006 are compliant with EN61131-2:2003 09R516
Edition maintenance. [5] RUN/STOP switch
W1:
Standard Remark FX 3U/FX 3UC [6] Peripheral device connecting connector
Describes PLC W: mm (inches)
Series Model name :
IEC1010-1:1990 The equipment has been assessed JY997D16601 programming for basic/ [7] DIN rail mounting hooks mm (inches)
Programming kg (lbs)
/A1:1992 as a component for fitting in a MODEL CODE: applied instructions STL/ [8] Model name (abbreviation)
Manual
Safety requirements for suitable enclosure which meets the 09R517 SFC programming and FX3U-16M 130 (5.12”) 103 (4.06”) 0.6 (1.32lbs)
- Basic & Applied [9] Input display LEDs (Red)
electrical equipment for requirements of IEC 1010-1: devices.
Instruction Edition
measurement, control, and 1990+A1:1992 [10] Terminal block covers FX3U-32M 150 (5.91”) 123 (4.85”) 0.65 (1.43lbs)
laboratory use FX Series User’s Explains N:N link, parallel
JY997D16901 [11] Extension device connecting connector cover FX3U-48M 182 (7.17”) 155 (6.11”) 0.85 (1.87lbs)
- General requirements Manual - Data link, computer link, no
MODEL CODE: protocol communication by Operation status display LEDs FX3U-64M 220 (8.67”) 193 (7.6”) 1.00 (2.2lbs)
Communication RS instructions/FX 2N-
EN61131-2:1994 :2003 The equipment has been assessed 09R715
Edition 232IF. POWER Green On while power is on the PLC. FX3U-80M 285 (11.23”) 258 (10.16”) 1.20 (2.64lbs)
/A12:2000 as a component for fitting in a
/A11:1996 suitable enclosure which meets the FX 3U / FX 3UC RUN Green On while the PLC is running. FX3U-128M *1 350 (13.78”) 323 (12.72”) 1.80 (3.96lbs)
Programmable controllers requirements of EN61131-2: Describes specifications for [12]
Series JY997D16701 BATT Red Lights when the battery voltage drops.
- Equipment 1994+A11:1996+A12:2000, :2003 analog control and
User's Manual MODEL CODE: *1 FX 3U -128M does not have DC power supply.
requirements and tests programming methods for Red Flashing when a program error occurs.
- Analog Control 09R619
FX 3U / FX 3UC Series PLC. ERROR Installation
Edition Red Lights when a CPU error occurs.
35-mm-wide DIN rail or Direct (screw) mounting (M4)
FX 3U / FX 3UC [13] Output display LEDs (Red)
Caution for compliance with EC Directive Explains the specifications
Series JY997D16801
for positioning control of
User's Manual MODEL CODE:
Installation in Enclosure FX 3U / FX 3UC Series and
- Positioning 09R620
programming procedures
Programmable logic controllers are open-type devices that must be Control Edition
installed and used within conductive control boxes. Please use the
FX3U Series programmable logic controllers while installed in How to obtain manuals
conductive shielded control boxes. Please secure the control box lid For the necessary product manuals or documents, consult with the
to the control box (for conduction). Installation within a control box Mitsubishi Electric dealer from where you purchase your product.
greatly affects the safety of the system and aids in shielding noise
from the programmable logic controller.
Item Specification 2.2 Installation location 2.3 Procedures for installing to and detaching from
2. Installation (general specifications) Ambient
DIN rail
5 to 95%RH (no condensation) when operating Install the PLC in an environment conforming to the generic
humidity specifications (section 2.1), installation precautions and notes. The main unit can be installed on a DIN46277 rail [35 mm (1.38”)
As for installation of the input/output extension blocks, special
Conforms to EN 68-2-6 For more details, refer to FX 3U Series User's Manual - Hardware wide].
adapters and expansion boards, refer to FX3U Series User's Manual
Edition.
- Hardware Edition. Fre- Accele- 2.3.1 Installation
quency ration Installation location in enclosure
INSTALLATION (Hz) (m/s2) 1) Connect the expansion boards and special adapters to the main
PRECAUTIONS unit.
Vibration 10 to 57 - 0.035
Use the product within the generic environment specifications resistance
described in section 2.1 of this manual. 4.9 - 2) Push out all DIN rail mounting hooks (below fig.A)
Never use the product in areas with excessive dust, oily smoke,
-8M
FX3U 4
C
conductive dusts, corrosive gas (salt air, Cl2, H2S, SO2 or NO2),
10 to 57 - 0.075
flammable gas, vibration or impacts, or exposed to high
temperature, condensation, or rain and wind. 9.8 -
If the product is used in such conditions, electric shock, fire, 2) 2)
malfunctions, deterioration or damage may occur. Compliant with EN 68-2-27
Shock
Do not touch the conductive parts of the product directly to avoid (147 m/s2 Acceleration, Action time: 11ms, 3 times by
resistance
failure or malfunctions. half-sine pulse in each direction X, Y, and Z) A
2) A 2)
Install the product securely using a DIN rail or mounting screws. By noise simulator at noise voltage of 1,000 Vp-p, Space in enclosure
Noise
Install the product on a flat surface. noise width of 1 s, rise time of 1 ns and period of 30 Extension devices can be connected on the left and right sides of the
resistance
If the mounting surface is rough, undue force will be applied to to 100 Hz main unit of the PLC.
the PC board, thereby causing nonconformities. If you intend to add extension devices in the future, keep necessary 3) Fit the upper edge of the DIN rail
1.5kV AC for one mounting groove (right fig.C)
When drilling screw holes or wiring, make sure cutting or wire Dielectric spaces on the left and right sides.
minute onto the DIN rail.
debris does not enter the ventilation slits. withstand Compliant with JEM-1021 C
500V AC for one Configuration without extension cable
Failure to do so may cause fire, equipment failures or voltage*1 Between each terminals*1 and
malfunctions. minute
ground terminal A
Be sure to remove the dust proof sheet from the PLC's Insulation 5M or more by
ventilation port when installation work is completed. Failure to resistance*1 500V DC megger FX3U
do so may cause fire, equipment failures or malfunctions. A Series A 4) Lock the DIN rail mounting hooks (below fig.D) while pressing the
Class D grounding (grounding resistance: 100 or
Connect the extension cables, peripheral device cables, input/ main PLC against the DIN rail.
Grounding less) <Common grounding with a heavy electrical
output cables and battery connecting cable securely to their *2 unit
system is not allowed.> S/S
S/S 0V X0 X2
X2 X4 X6 X10
X10 X12
X12 X14 X16
X16 X2 0 X22 X24 X26
X26 S/S 0V X0 X2 X4 X6 X10 X12 X14 X16 X2 0 X22 X24 X26
designated connectors. L N 224V
4V X1 X3 X5 X7 X11 X1
X133 X15 X17 X21
X21 X23 X25
X25 X27
X27 L N 2 4V X1 X3 X5 X7 X11 X13 X15 X17 X21 X23 X25 X27
X 27

0 1 2 3 4 5 6 7 0 1 2 3 4 5 6 7
IN
IN IN

PO WER PO WER

RU N
RUN RU N
Unsecured connection may cause malfunctions. Working Free from corrosive or flammable gas and excessive BATT BATT

ERROR
ER RO R ER RO R
A A 50mm (1.97") OUT
0 1 2 3 4 5 6 7
OUT
0 1 2 3 4 5 6 7
atmosphere conductive dusts 0 1 2 3 4 5 6 7 0 1 2 3 4 5 6 7

Y0
Y0 Y2 Y4 Y6 Y10 Y12 Y14 Y16
Y16 Y20 Y22
Y22 Y24 Y26
Y26 COM5
COM5 Y0 Y2 Y4 Y6 Y10 Y12 Y14 Y16 Y20 Y22 Y24 Y26 COM5
Turn off the power before attaching or detaching the following COM1 Y1 Y3 COM2 Y5 Y7 COM3 Y11
Y11 Y13
Y1 3 COM4 Y15
Y15 Y17 Y2
Y211 Y23
Y23 Y25 Y2
Y2 7 COM1 Y1 Y3 COM2 Y5 Y7 C OM3 Y11 Y13 COM4 Y15 Y17 Y21 Y23 Y25 Y2 7

R R

devices. Working
Failure to do so may cause device failures or malfunctions. Compliant with IEC61131-2 (<2000m)*3 D D
altitude Configuration in 2 stages with extension cable
- Peripheral devices, display modules, expansion boards and 4) 4)
special adapters *1 A
- Extension units/blocks and the FX Series terminal block
Dielectric Insulation
- Battery and memory cassette Terminal 2.4 Procedures for installing directly (with M4
strength resistance
screws)
Notes Between power supply FX3U Series A
1.5 kV AC for A
terminal (AC power) and main unit The product can be installed directly on the panel (with screws).
When a dust proof sheet is supplied with an extension unit/ one minute
ground terminal
block, keep the sheet applied to the ventilation slits during 2.4.1 Mounting hole pitches
installation and wiring work. Between power supply
500V AC for Refer to the External Dimensions (section 1.2) for the product's
terminal (DC power) and
To prevent temperature rise, do not install the PLC on a floor, a one minute
ground terminal A Extension mounting hole pitch information.
ceiling or a vertical surface.
Install it horizontally on a wall as shown in section 2.2. cable As for the details of the mounting hole pitches for extension unit/
Between input terminal Input/output ·FX 0N-65EC block and special adapters, refer to the following manual.
500V AC for 5M or more by
Keep a space of 50 mm (1.97”) or more between the unit main (24V DC) and ground powered ·FX 0N-30EC
one minute 500V DC megger A Refer to FX3U Series User's Manual - Hardware Edition.
body and another device or structure (part A). Install the unit as terminal extension
far away as possible from high-voltage lines, high-voltage A Another 2.4.2 Installation
Between output terminal unit
devices and power equipment. 1.5 kV AC for equipment
(relay) and ground
one minute A 1) Make mounting holes in the
terminal
WIRING Another equipment mounting surface referring to
Between output terminal A 50mm (1.97")
PRECAUTIONS 500V AC for the external dimensions
(transistor) and ground diagram. B
Cut off all phases of the power supply externally before one minute
terminal
installation or wiring work in order to avoid damage to the 2.2.1 Affixing The Dust Proof Sheet 2) Fit the main unit (A in the right
product or electric shock. figure) based on the holes, and
For dielect ric with sta nd volt age test an d in sul at io n The dust proof sheet should be affixed to the ventilation port before secure it with M4 screws (B in
resistance test of each product, refer to the following manual. beginning the installation and wiring work. the right figure).
2.1 Generic specifications [Main unit] Refer to FX 3U Series User's Manual - Hardware Edition. For the affixing procedure, refer to the instructions on the The mounting hole pitches and
*2 For common grounding, refer to section 3.3. dust proof sheet. number of screws depend on
t h e p r o d u c t . R e f e r t o th e A
Item Specification Be sure to remove the dust proof sheet when the installation and
*3 The PLC cannot be used at a pressure higher than the external dimensions diagram.
Ambient 0 to 55 C (32 to 131 F) when operating and -25 to atmospheric pressure to avoid damage. wiring work is completed. B
temperature 75 C (-13 to 167 F) when stored
WIRING 3.2 Power supply specifications and example of *7 When attaching high-speed input/output special adapter
3. Power supply/input/output specifications external wiring (FX 3U -4HSX-ADP, FX 3U -2HSY-ADP) and special function
PRECAUTIONS
block (FX 0N -3A, FX 2N -2AD, FX 2N -2DA), the number of
and examples of external wiring Connect the AC power supply to the dedicated terminals Refer to FX3U Series User's Manual - Hardware Edition. connectable modules to the main unit is limited, due to the
specified in this manual. current consumption (internal 24V DC) at startup. The following
As for the details of the power supply wiring and input/output wiring, If an AC power supply is connected to a DC input/output 3.2.1 Power supply specifications manual shows further information.
refer to FX3U Series User's Manual - Hardware Edition. terminal or DC power supply terminal, the PLC will burn out. Refer to FX3U Series User’s Manual - Hardware Edition.
The specifications for the power supply of the main unit are
Do not wire vacant terminals externally.
DESIGN shown in the following table. 3.2.2 Example of external wiring (AC power type)
Doing so may damage the product.
PRECAUTIONS Specification
Use class D grounding (grounding resistance of 100 or less) 100 to 240V AC power is supplied to the main unit. For the details of
Item
Make sure to have the following safety circuits outside of the with a wire of 2mm2 or thicker on the grounding terminal of the AC power type DC power type*7 wiring work, refer to section 3.1.
PLC to ensure safe system operation even during external FX3U Series main unit.
Supply voltage 100 - 240V AC 24 V DC 100 to 240V AC
power supply problems or PLC failure. However, do not connect the ground terminal at the same point
Otherwise, malfunctions may cause serious accidents. as a heavy electrical system. Allowable supply voltage
85 - 264V AC 16.8-28.8V DC *6
1) Most importantly, have the following: an emergency stop When drilling screw holes or wiring, make sure cutting or wire range
circuit, a protection circuit, an interlock circuit for opposite Breaker
debris does not enter the ventilation slits. Rated frequency 50/60Hz
movements (such as normal vs. reverse rotation), and an Failure to do so may cause fire, equipment failures or Power on
interlock circuit (to prevent damage to the equipment at the malfunctions. Operation can be Operation can be Emer-
continued upon continued upon gency
upper and lower positioning limits). stop
Allowable instantaneous occurrence of occurrence of PL MC
2) Note that when the PLC CPU detects an error, such as a Notes PLC
power failure time instantaneous instantaneous
watchdog timer error, during self-diagnosis, all outputs are
Input/output wiring 50 to 100 m (164’1” to 328’1”) long will power failure for power failure for 5 MC
turned off. Also, when an error that cannot be detected by
cause almost no problems of noise, but, generally, the wiring 10 ms or less. *4 ms or less.
the PLC CPU occurs in an input/output control block, Fuse
output control may be disabled. length should be less than 20 m (65’7”) to ensure the safety. FX 3U-16M to L
250V AC 3.15A
External circuits and mechanisms should be designed to Extension cables are easily affected by noise. Lay the cables Power 32M *
ensure safe machinery operation in such a case. at a distance of at least 30 to 50 mm (1.19” to 1.97”) away from fuse FX 3U-48M to N
3) Note that when an error occurs in a relay, triac or transistor the PLC output and other power lines. 250V AC 5A MC MC
128M *5
output device, the output could be held either on or off.
For output signals that may lead to serious accidents, 30 A max. 5 ms or
external circuits and mechanisms should be designed to less/100 V AC 35 A max. 0.5 ms
3.1 Wiring Rush current *Class D grounding
ensure safe machinery operation in such a case. 65 A max. 5 ms or or less/24 V DC
less/200 V AC Refer to section 3.3
3.1.1 Cable end treatment and tightening torque for details. DC
DESIGN FX 3U-16M 30W 25W power
For the terminals of FX3U series PLC, M3 screws are used. supply
PRECAUTIONS FX 3U-32M 35W 30W
The electric wire ends should be treated as shown below.
Do not bundle the control line together with or lay it close to the Power FX 3U-48M 40W 35W
Tighten the screws to a torque of 0.5 N m to 0.8 N m.
main circuit or power line. As a guideline, lay the control line at FX 3U-64M 45W 40W DC AC
*1
least 100mm (3.94") or more away from the main circuit or When one wire is connected to one terminal
power line. FX 3U-80M 50W 45W Power supply for loads connected
3.2 (0.13") Terminal Solderless to PLC output terminals
Noise may cause malfunctions. screw terminal FX 3U-128M *5 65W
6.2 mm (0.24")
Install module so that excessive force will not be applied to the or less
24V DC FX 3U-16M to 3.2.3 Example of external wiring (DC power type)
built-in programming connectors, power connectors or I/O 400 mA or less
3.2 (0.13") service 32M
connectors. 24V DC power is supplied to the main unit. For the details of wiring
Failure to do so may result in wire damage/breakage or PLC 6.2 mm (0.24") ’[Žq
Terminal
power FX 3U-48M to
600 mA or less work, refer to section 3.1.
failure. or less supply *2 128M *5
24V DC
5V DC built-in power
Notes When two wires are connected to one terminal 500 mA or less
supply *3
3.2 (0.13")
Simultaneously turn on and off the power supplies of the main 6.2 mm (0.24") Terminal Solderless *1 Does not include the power consumption of extension units / Circuit protector
unit and extension devices. or less screw terminal
special extension units, and of the extension blocks / special
Even if the power supply causes an instantaneous power failure 6.3 mm(0.25") extension blocks connected to those units. Power on Emer-
for less than 10 ms, the PLC can continue to operate. or more For the power (current) consumed by the extension units/ gency
If a long-time power failure or an abnormal voltage drop occurs, 3.2 (0.13") blocks for input/output, refer to FX 3U Series User's Manual - stop
the PLC stops, and output is turned off. When the power 6.2 mm (0.24") Terminal Hardware Edition. PL MC
PLC
supply is restored, it will automatically restart (when the RUN or less For the power consumed by the special extension units/blocks,
input is on). 6.3 mm(0.25") refer to the appropriate manual. MC
or more
*2 When input/output extension blocks are connected, the 24V Fuse
WIRING 3.1.2 Removal and installation of quick-release terminal DC service power supply is consumed by the blocks, and the
PRECAUTIONS block current value to be used by the main unit is reduced. *
Cut off all phases of the power supply externally before *3 Cannot be used to supply power to an external destination.
Removal Unscrew the terminal block mounting screw [both right The power is supplied to input/output extension blocks, special MC MC
installation or wiring work in order to avoid damage to the and left screws] evenly, and remove the terminal block.
product or electric shock. extension blocks, special adapters and expansion boards.
Installation Place the terminal block in the specified position, and
tighten the terminal block mounting screw evenly [both *4 When the supply voltage is 200 V AC, the time can be changed
to 10 to 100 ms by editing the user program. *Class D grounding
right and left secrews]. Refer to section 3.3
Tightening torque 0.4 to 0.5 N m *5 FX3U -128M does not have DC power supply. for details. Power supply for loads connected
* Pay attention so that the center of the terminal block *6 When supply voltage is DC 16.8-19.2V, the connectable to PLC output terminals
is not lifted. extension equipment decreases. The following manual shows
further information.
Refer to FX3U Series User’s Manual - Hardware Edition.
3.3 Grounding Item Specification 3.4.4 Instructions for connecting input devices 4) In the case of 2-wire proximity switch:
Use a two-wire proximity switch whose leakage current, , is
Ground the PLC as stated below. Sink input: 1) In the case of no-voltage contact: 1.5 mA or less when the switch is off.
No-voltage contact input The input current of this PLC is 5 to 7 mA/24V DC. When the current i s 1.5 mA o r more, con nect a bleed er
NPN open collector transistor Use input devices applicable to this minute current. resistance, Rb, obtained from formula as shown in the following
Input signal form
Source input: If no-voltage contacts (switches) for large current are used, figure.
No-voltage contact input contact failure may occur.
PNP open collector transistor 6
Another Another Another <Example> Products of OMRON Rb (k )
PLC equipment PLC equipment PLC equipment Input circuit insulation Photocoupler insulation I -1.5
Model Sink input Source input
LED on panel lights when photocoupler Type Type Model name
Input operation display name
Independent grounding Shared grounding Common grounding is driven.
(Best condition) (Good condition) (Not allowed) Models Z, V Operation
Microswitch Model A3P 24V 0V
*1 FX 3U-128M does not have DC power supply. and D2RV switch Rb Rb
Use ground wires thicker than AWG14 (2 mm2). 2-wire 2-wire
*2 FX 3U-16M terminal block cannot be installed/removed Proximity Photoelectric S/S proximity S/S proximity
Position the grounding point as close to the PLC as possible to Model TL Model E3S sensor sensor
*3 For DC power type, the power range applies to "3.2.1 term switch switch
decrease the length of the ground wire.
Power supply specifications." X X
2) In the case of input device with built-in series diode:
3.4.2 Examples of input wiring[AC power type] The voltage drop of the series diode should be approx. 4 V or
I I
3.4 Input specifications and external wiring
less.
Refer to FX 3U Series User's Manual - Hardware Edition. 1. Sink input 2. Source input When lead switches with a series LED are used, up to two
switches can be connected in series. 0V 24V
3.4.1 Input specifications Fuse Fuse Also make sure that the input current is over the input-sensing
L L
level while the switches are ON.
* *
Item Specification Sink input Source input
N N 3.5 Relay output specifications and example of
3U 8 points external wiring
100 to 240V AC 100 to 240V AC
3U 16 points S/S S/S 24V 0V Refer to FX3U Series User's Manual - Hardware Edition.
3U 24 points 0V 0V
Number of S/S S/S 3.5.1 Relay output specifications
24V 24V
input 3U 32 points LED LED
points Item Specification
3U 40 points X000 X000 X X
FX 3U-16MR/ 8 points
3U X001 X001
64 points 3-wire type 3-wire type 0V 24V FX 3U-32MR/ 16 points
*1 X002 X002
sencer sencer Number of FX 3U-48MR/
X003 X003 24 points
Input connecting type Removable terminal block (M3 screw)*2 output
points FX 3U-64MR/ 32 points
3) In the case of input device with built-in parallel resistance:
Input form Sink/source *Class D grounding Use a device having a parallel resistance, Rp, of 15 k or more. FX 3U-80MR/ 40 points
Refer to section 3.3 for details. When the resistance is less than 15 k , connect a bleeder
Input signal voltage 3 64 points
24V DC 10%, -10%* resistance, Rb, obtained from the formula as shown in the
X000 to 3.4.3 Examples of input wiring[DC power type] following figure. Removable terminal block
3.9k Output connecting type
X005 (M3 screw)*2
1. Sink input 2. Source input 4Rp
X006, X007 3.3k Rb (k ) Output form Relay
Fuse Fuse 15-Rp 30V DC or less
X010 or 4.3k
Sink input Source input External power supply 240V AC or less ("250V AC or less" if
more (Does not apply to FX 3U-16M *1 *1 not a CE, UL, cUL compliant item)
X000 to The total load current of
6mA/24V DC 24V 0V
X005 24V DC 24V DC resistance loads per
Input common terminal should be
signal X006, X007 7mA/24V DC S/S S/S S/S Rb S/S Rb the following value or less.
current (0V) (0V) 2A 1 output point/common
X010 or 5mA/24V DC *2 *2 Resistance load
(24V) (24V) Max. load /point terminal: 2 A
more (Does not apply to FX3U -16M .) X X 4 output point/common
X000 to terminal: 8 A
3.5 mA or more X000 X000 15 k 15 k 8 output point/common
X005
X001 X001 or more Rp or more Rp terminal: 8 A
X006, X007 4.5 mA or more X002 3-wire type X002 3-wire type Inductive load 80VA
sencer 0V 24V
sencer
X010 or 3.5 mA or more X003 X003 Min. load 5V DC, 2 mA (reference value)
more (Does not apply to FX 3U-16M
Open circuit leakage current -
OFF input sensitivity *1 Class D grounding
1.5 mA or less Refer to section 3.3 for details. OFF ON Approx. 10 ms
current
*2 Do not connect the (0V) and (24V) terminal with others, ON OFF Approx. 10 ms
Input response time Approx. 10 ms since they are not available.
Circuit insulation Mechanical insulation
LED lights when power is applied to
Display of output operation
relay coil.
*1 FX 3U-128M does not have DC power supply.
*2 FX 3U-16M terminal block cannot be installed/removed
Number of output points per common terminal 3.5.4 Cautions in external wiring Interlock Item Specification
On FX 3U -16M , one common terminal is used for 1 output point. Loads, such as contactors for normal and reverse rotations, that
Protection circuit for load short-circuiting must not be turned on simultaneously should have an interlock in the 5 s or less/10 mA or more
On models other than FX 3U-16M , 1 common terminal is used Y000 to Y002
When a load connected to the output terminal short-circuits, the PLC program and an external interlock as shown (5 to 24V DC)
for 4 or 8 output points. OFF ON
printed circuit board may be burnt out. Fit a protective fuse on the below. 0.2 ms or less/200 mA or
3.5.2 Life of relay output contact output circuit. Y003 or more
Limit of Response more (at 24V DC)
PLC output normal time 5 s or less/10 mA or more
The product life of relay contacts considerably varies depending on Load Interlock rotation Y000 to Y002
contact (5 to 24V DC)
the load type used. Take care that loads generating reverse Y
electromotive force or rush current may cause poor contact or ON OFF
Fuse 0.2 ms or less/200 mA or
deposition of contacts which may lead to considerable reduction of Y003 or more
more (at 24V DC)
the contact product life. 100V AC
1) Inductive load COM
Circuit insulation Photocoupler insulation
Limit of
Inductive loads generate large reverse electromotive force PLC PLC output reverse LED on panel lights when
between contacts at shutdown may cause arcing. At a fixed contact Display of output operation
rotation photocoupler is driven.
current consumption, as the power factor (phase between current
Protection circuit of contact when inductive load is used
and voltage) gets smaller, the arc energy gets larger. Common mode *1 FX 3U-128M does not have DC power supply.
The standard life of the contact used for Inductive loads, such as An internal protection circuit for the relays is not provided for the *2 FX 3U-16M terminal block cannot be installed/removed
contactors and solenoid valves, is 500 thousand operations at relay output circuit in this product. It is recommended to use Use output contacts (*) of the PLC in the common mode.
20VA. inductive loads with built-in protection circuits. When using loads Number of output points per common terminal
The following table shows the approximate life of the relay based without built-in protection circuits, insert an external contact
On FX3U-16M , one common terminal is used for 1 output point.
on the results of our operation life test. protection circuit, etc. to reduce noise and extend the product life. *
On models other than FX 3U-16M , 1 common terminal is used
Test condition: 1 sec. ON / 1 sec.OFF. 1) DC circuit Bad for 4 or 8 output points.
Load capacity Contact life Connect a diode in parallel with the load. *
U s e a d i o d e ( f o r c o mm u t a t io n ) h a vi n g t h e f o l l o w i n g
0.2A/100V AC specifications.
20VA 3 million times 3.6.1 External Wiring of Transistor Output
0.1A/200V AC Item Standard *
Good 1. External Wiring of Sink Output Type
0.35A/100V AC Reverse voltage 5 to 10 times the load voltage
35VA 1 million times *
0.17A/200V AC Forward current Load current or more Load
Y000
0.8A/100V AC
80VA 2 hundred thousand times Y001
0.4A/200V AC PLC output Inductive
load 3.6 Transistor output specifications and example of Fuse 24V DC
contact external wiring
The product life of relay contacts becomes considerably shorter
than the above conditions when the rush overcurrent is shut COM1
down. Refer to FX3U Series User's Manual - Hardware Load
For countermeasures while using inductive loads, Diode Edition.Transistor output specifications
Y004
refer to Subsection 3.5.4. (for commutation)
Some types of inductive loads generate rush current 5 to 15 times Item Specification Y005
2) AC circuit
the stationary current at activation. Make sure that the rush Fuse 24V DC
Connect the surge absorber (combined CR components such as FX3U-16MT/ 8 points
current does not exceed the current corresponding to the a surge killer and spark killer, etc.) parallel to the load.
maximum specified resistance load. FX3U-32MT/ 16 points COM2
Select the rated voltage of the surge absorber suitable to the PLC
2) Lamp load output used. Refer to the table below for other specifications. Number FX3U-48MT/ 24 points
Lamp loads generally generate rush current 10 to 15 times the of output
Item Standard points FX3U-64MT/ 32 points 2. External Wiring of Source Output Type
stationary current. Make sure that the rush current does not
exceed the current corresponding to the maximum specified Electrostatic capacity Approx. 0.1 F FX3U-80MT/ 40 points
resistance load. Load
Resistance value Approx. 100 to 200 FX3U-128MT/ES(S) *1 64 points Y000
3) Capacitive load
Capacitive loads can generate rush current 20 to 40 times the Removable terminal block Y001
Output connecting type
stationary current. Make sure that the rush current does not Inductive (M3 screw) *2 Fuse
PLC output 24V DC
exceed the current corresponding to the maximum specified load
contact Output FX3U- MT/ S(-A) Transistor(Sink)
resistance load. Capacitive loads such as capacitors may be +V0
present in electronic circuit loads including inverters. form FX3U- MT/ SS Transistor(Source)
For the maximum specified resistance load, Load
External power supply 5 to 30V DC Y004
refer to Subsection 3.5.1.
Surge absorber The total load current of
3.5.3 Example of relay output wiring Y005
resistance loads per Fuse
Reference 24V DC
common terminal should be
Manufacturer Model name the following value or less. +V1
Load - 1 output point/common
Y000 Okaya Electric Industries Co., Ltd. CR-10201 Resistance load PLC
Max. load terminal: 0.5 A
Y001 Rubycon Corporation 250MCRA104100M B0325 - 4 output point/common
Fuse terminal: 0.8A
- 8 output point/common
COM1
24V DC terminal: 1.6A
Load Inductive load 12 W/24V DC
Y010
Min. load
Y011
Fuse Open circuit leakage current 0.1 mA or less/30V DC
COM2 ON voltage 1.5 V or less
100V AC PLC
3.6.2 Cautions in external wiring Interlock
Loads, such as contactors for normal and reverse rotations, that 4. Terminal block layouts
Protection circuit for load short-circuits must not be turned on simultaneously should have an interlock in the
A short-circuit at a load connected to an output terminal could cause PLC program and an external interlock as shown below.
burnout at the output element or the PCB. To prevent this, a FX3U-16MR/ S(-A) FX3U-16MT/ S(-A)
protection fuse should be inserted at the output. 1. External Wiring of Sink Output Type S/S 0V X0 X2 X4 X6 S/S 0V X0 X2 X4 X6
Use a load power supply capacity that is at least 2 times larger than L N 24V X1 X3 X5 X7 L N 24V X1 X3 X5 X7
the total rated fuse capacity. + Limit of normal
-
1. External Wiring of Sink Output Type rotation Interlock
Y0 Y1 Y2 Y3 Y4 Y5 Y6 Y7 Y0 Y1 Y2 Y3 Y4 Y5 Y6 Y7
Y0 Y1 Y2 Y3 Y4 Y5 Y6 Y7 COM0 COM1 COM2 COM3 COM4 COM5 COM6 COM7
Load
Y FX3U-32M / S(-A) -DC power type
Fuse Limit of reverse PLC output S/S 0V X0 X2 X4 X6 X10 X12 X14 X16 DC power terminal block differs from AC
rotation element
L N 24V X1 X3 X5 X7 X11 X13 X15 X17 power terminal block as follows.
2.External Wiring of Source Output Type AC Power Type DC Power Type
COM Y0 Y2 Y4 Y6 Y10 Y12 Y14 Y16
PLC
- Limit of normal
+ COM1 Y1 Y3 COM2Y5 Y7 COM3 Y11Y13 COM4 Y15 Y17 S/S 0V S/S (0V)
rotation Interlock 24V (24V)

2. External Wiring of Source Output Type


FX3U-48M / S(-A)
S/S 0V X0 X2 X4 X6 X10 X12 X14 X16 X20 X22 X24 X26
L N 24V X1 X3 X5 X7 X11 X13 X15 X17 X21 X23 X25 X27
Load
Y Limit of reverse PLC output
rotation element Y0 Y2 Y4 Y6 Y10 Y12 Y14 Y16 Y20 Y22 Y24 Y26 COM5
Fuse COM1 Y1 Y3 COM2Y5 Y7 COM3 Y11Y13 COM4 Y15 Y17 Y21 Y23 Y25 Y27

FX3U-64M / S(-A)
+V S/S 0V 0V X0 X2 X4 X6 X10 X12 X14 X16 X20 X22 X24 X26 X30 X32 X34 X36
PLC L N 24V 24V X1 X3 X5 X7 X11 X13 X15 X17 X21 X23 X25 X27 X31 X33 X35 X37

Y0 Y2 Y4 Y6 Y10 Y12 Y14 Y16 Y20 Y22 Y24 Y26 Y30 Y32 Y34 Y36 COM6
Contact protection circuit for inductive loads COM1 Y1 Y3 COM2Y5 Y7 COM3 Y11Y13 COM4 Y15 Y17 COM5 Y21 Y23 Y25 Y27 Y31 Y33 Y35 Y37
When an inductive load is connected, connect a diode (for
commutation) in parallel with the load as necessary.
The diode (for commutation) must comply with the following FX3U-80M / S(-A)
specifications. S/S 0V 0V X0 X2 X4 X6 X10 X12 X14 X16
Item Guide L N 24V 24V X1 X3 X5 X7 X11 X13 X15
Reverse voltage 5 to 10 times of the load voltage
X20 X22 X24 X26 X30 X32 X34 X36 X40 X42 X44 X46
Forward current Load current or more
X17 X21 X23 X25 X27 X31 X33 X35 X37 X41 X43 X45 X47
1. External Wiring of Sink Output Type
Y30 Y32 Y34 Y36 Y40 Y42 Y44 Y46
Y27 COM6Y31 Y33 Y35 Y37 COM7 Y41 Y43 Y45 Y47
Inductive load
Y
Y0 Y2 Y4 Y6 Y10 Y12 Y14 Y16 Y20 Y22 Y24 Y26
Fuse COM1 Y1 Y3 COM2Y5 Y7 COM3 Y11Y13 COM4 Y15 Y17 COM5 Y21 Y23 Y25
Diode (for
commutation)
FX3U-128M /ES(-A)*1
COM S/S 0V 0V X0 X2 X4 X6 X10 X12 X14 X16 X20 X22 X24 X26
PLC L N 24V 24V X1 X3 X5 X7 X11 X13 X15 X17 X21 X23 X25

2. External Wiring of Source Output Type X30 X32 X34 X36 X40 X42 X44 X46 X50 X52 X54 X56 X60 X62 X64 X66 X70 X72 X74 X76
X27 X31 X33 X35 X37 X41 X43 X45 X47 X51 X53 X55 X57 X61 X63 X65 X67 X71 X73 X75 X77
Inductive load
Y Y44 Y46 COM8 Y51 Y53 Y55 Y57 Y60 Y62 Y64 Y66 COM10 Y71 Y73 Y75 Y77
Fuse
Y43 Y45 Y47 Y50 Y52 Y54 Y56 COM9 Y61 Y63 Y65 Y67 Y70 Y72 Y74 Y76
Diode (for
commutation) Y0 Y2 COM2 Y5 Y7 Y10 Y12 COM4 Y15 Y17 Y20 Y22 Y24 Y26 COM6 Y31 Y33 Y35 Y37 Y40 Y42
+V COM1 Y1 Y3 Y4 Y6 COM3 Y11 Y13 Y14 Y16 COM5 Y21 Y23 Y25 Y27 Y30 Y32 Y34 Y36 COM7 Y41

PLC *1 FX3U-128 M /ES(-A) does not have DC power supply.


FX3U-16MT/ SS
S/S 0V X0 X2 X4 X6
L N 24V X1 X3 X5 X7

Y0 Y1 Y2 Y3 Y4 Y5 Y6 Y7
+V0 +V1 +V2 +V3 +V4 +V5 +V6 +V7

FX3U-32MT/ SS
S/S 0V X0 X2 X4 X6 X10 X12 X14 X16
L N 24V X1 X3 X5 X7 X11 X13 X15 X17

Y0 Y2 Y4 Y6 Y10 Y12 Y14 Y16


+V0 Y1 Y3 +V1 Y5 Y7 +V2 Y11 Y13 +V3 Y15 Y17

FX3U-48MT/ SS
S/S 0V X0 X2 X4 X6 X10 X12 X14 X16 X20 X22 X24 X26
L N 24V X1 X3 X5 X7 X11 X13 X15 X17 X21 X23 X25 X27

Y0 Y2 Y4 Y6 Y10 Y12 Y14 Y16 Y20 Y22 Y24 Y26 +V4


+V0 Y1 Y3 +V1 Y5 Y7 +V2 Y11 Y13 +V3 Y15 Y17 Y21 Y23 Y25 Y27

FX3U-64MT/ SS
S/S 0V 0V X0 X2 X4 X6 X10 X12 X14 X16 X20 X22 X24 X26 X30 X32 X34 X36
L N 24V 24V X1 X3 X5 X7 X11 X13 X15 X17 X21 X23 X25 X27 X31 X33 X35 X37

Y0 Y2 Y4 Y6 Y10 Y12 Y14 Y16 Y20 Y22 Y24 Y26 Y30 Y32 Y34 Y36 +V5
+V0 Y1 Y3 +V1 Y5 Y7 +V2 Y11 Y13 +V3 Y15 Y17 +V4 Y21 Y23 Y25 Y27 Y31 Y33 Y35 Y37

FX3U-80MT/ SS
S/S 0V 0V X0 X2 X4 X6 X10 X12 X14 X16
L N 24V 24V X1 X3 X5 X7 X11 X13 X15

X20 X22 X24 X26 X30 X32 X34 X36 X40 X42 X44 X46
X17 X21 X23 X25 X27 X31 X33 X35 X37 X41 X43 X45 X47

Y30 Y32 Y34 Y36 Y40 Y42 Y44 Y46 This manual confers no industrial property rights or any rights of any other kind,
Y27 +V5 Y31 Y33 Y35 Y37 +V6 Y41 Y43 Y45 Y47 nor does it confer any patent licenses. Mitsubishi Electric Corporation cannot be
held responsible for any problems involving industrial property rights which may
occur as a result of using the contents noted in this manual.
Y0 Y2 Y4 Y6 Y10 Y12 Y14 Y16 Y20 Y22 Y24 Y26
Warranty
+V0 Y1 Y3 +V1 Y5 Y7 +V2 Y11 Y13 +V3 Y15 Y17 +V4 Y21 Y23 Y25 Mitsubishi will not be held liable for damage caused by factors found not to be
the cause of Mitsubishi; opportunity loss or lost profits caused by faults in the
FX3U-128MT/ESS*2 Mitsubishi products; damage, secondary damage, accident compensation
caused by special factors unpredictable by Mitsubishi; damages to products
S/S 0V 0V X0 X2 X4 X6 X10 X12 X14 X16 X20 X22 X24 X26 other than Mitsubishi products; and to other duties.
L N 24V 24V X1 X3 X5 X7 X11 X13 X15 X17 X21 X23 X25
For safe use
X30 X32 X34 X36 X40 X42 X44 X46 X50 X52 X54 X56 X60 X62 X64 X66 X70 X72 X74 X76 d This product has been manufactured as a general-purpose part for general
X27 X31 X33 X35 X37 X41 X43 X45 X47 X51 X53 X55 X57 X61 X63 X65 X67 X71 X73 X75 X77 industries, and has not been designed or manufactured to be incorporated in
a device or system used in purposes related to human life.
d Before using the product for special purposes such as nuclear power, electric
Y44 Y46 +V7 Y51 Y53 Y55 Y57 Y60 Y62 Y64 Y66 +V9 Y71 Y73 Y75 Y77 power, aerospace, medicine or passenger movement vehicles, consult with
Y43 Y45 Y47 Y50 Y52 Y54 Y56 +V8 Y61 Y63 Y65 Y67 Y70 Y72 Y74 Y76 Mitsubishi Electric.
d This product has been manufactured under strict quality control. However
when installing the product where major accidents or losses could occur if the
Y0 Y2 +V1 Y5 Y7 Y10 Y12 +V3 Y15 Y17 Y20 Y22 Y24 Y26 +V5 Y31 Y33 Y35 Y37 Y40 Y42 product fails, install appropriate backup or failsafe functions in the system.
+V0 Y1 Y3 Y4 Y6 +V2 Y11 Y13 Y14 Y16 +V4 Y21 Y23 Y25 Y27 Y30 Y32 Y34 Y36 +V6 Y41

HEAD OFFICE : TOKYO BUILDING, 2-7-3 MARUNOUCHI, CHIYODA-KU, TOKYO 100-8310,


*2 FX3U-128MT/ESS does not have DC power supply. JAPAN
HIMEJI WORKS : 840, CHIYODA CHO, HIMEJI, JAPAN
FACTORY TESTING
APPLICATIONS