Motortech Varistep Manual de usuario
VARISTEP –
STEPPER MOTOR CARD
OPERATING MANUAL
MOTORTECH Gas Re
g
ulation
P/N 01.
5
0.00
3
– EN
|
Rev. 0
7
/201
3
Copyright
© Copyright 2013 MOTORTECH GmbH. All rights reserved.
Distribution and reproduction of this publication or parts thereof, regardless of the specific
purpose and form, are not permissible without express written approval by MOTORTECH.
Information contained in this publication may be changed without prior notice.
Trademarks
All trademarks and logos displayed or used in this publication are the property of the respective
entitled person.
Rev. 07/2013 3
1 General Information .................................................................................................... 6
1.1 What Is the Purpose of this Operating Manual? .........................................................6
1.2 Who Is this Operating Manual Targeted to?...............................................................6
1.3 Which Symbols Are Used in the Operating Manual?...................................................6
1.4 Which Abbreviations/Acronyms Are Used in the Operating Manual?........................... 7
2 Safety Instructions ..................................................................................................... 8
2.1 General Safety Instructions .....................................................................................8
2.2 Electrostatic Discharge Hazards ..............................................................................9
2.3 Special Safety Instructions for the Device ................................................................9
2.4 Proper Disposal.................................................................................................... 10
3 Intended Use ............................................................................................................. 11
3.1 Functional Description ...........................................................................................11
3.2 Applications..........................................................................................................11
4 Product Description ................................................................................................... 12
4.1 Technical Data ...................................................................................................... 12
4.1.1 Certifications ..................................................................................................... 12
4.1.2 Mechanical Data ................................................................................................ 14
4.1.3 Warning Notices on the Device............................................................................ 14
4.1.4 Product Identification – Labeling on the Device.................................................... 15
4.1.5 Electrical Data.................................................................................................... 16
4.1.6 Interfaces.......................................................................................................... 17
4.1.7 Overview Drawings............................................................................................. 18
5 Installation Instructions.............................................................................................20
5.1 Installation Instructions ........................................................................................20
6 Wiring of the Control Unit .......................................................................................... 21
6.1 Wiring Power Supply ............................................................................................. 21
6.2 Wiring Stepper Motor and Encoder ........................................................................22
6.3 Wiring Digital Inputs.............................................................................................24
6.4 Wiring Digital Outputs .......................................................................................... 25
6.5 Wiring Analog Inputs and Outputs .........................................................................26
6.6 Wiring CAN Bus ....................................................................................................28
6.7 Wiring Modbus.....................................................................................................29
7 Functions ................................................................................................................... 31
7.1 Manual and Automatic Operation ........................................................................... 31
7.2 Reference Run ...................................................................................................... 31
TABLE
O
F
CO
NTENT
S
TABLE OF CONTENTS
4 Rev. 07/2013
7.3 Open/Closed Positions ......................................................................................... 32
7.4 Configurable Opening Angles (Position 1 and 2)...................................................... 32
7.5 Change of Openings via Digital and Analog Inputs .................................................. 32
7.6 Analysis of Positions via Analog Outputs................................................................ 32
7.7 Access Control...................................................................................................... 33
8 Settings via the MICT.................................................................................................35
8.1 MICT System Requirements ................................................................................... 35
8.2 MICT Installation.................................................................................................. 35
8.3 Access Levels in the MICT ..................................................................................... 36
8.4 Configuration Pages (Overview) ............................................................................ 37
8.5 Menu Bar and Toolbar........................................................................................... 38
8.6 Online Update Settings ........................................................................................ 41
8.7 Access Control of Control Unit ...............................................................................42
8.7.1 Enabling/Disabling Access Control .....................................................................42
8.7.2 Login/Logout .................................................................................................... 43
8.7.3 Changing the PIN............................................................................................... 43
8.7.4 Resetting all PINs ..............................................................................................44
8.8 Selecting the Device Type ..................................................................................... 45
8.9 Opening an Existing Configuration File .................................................................. 45
8.10 Configuration ..................................................................................................... 45
8.10.1 External Device ................................................................................................46
8.10.2 Inputs / Outputs - Control Setup .......................................................................48
8.10.3 Positions – Values ............................................................................................51
8.10.4 Miscellaneous – Communication ...................................................................... 52
8.10.5 Miscellaneous – Service Contact....................................................................... 54
8.11 Runtime Data ...................................................................................................... 55
8.11.1 Runtime Data – Overview .................................................................................. 56
8.11.2 Runtime Data – Warnings ................................................................................. 58
8.11.3 Runtime Data – Errors....................................................................................... 59
8.11.4 Runtime Data – Diagnostics .............................................................................. 61
8.11.5 Runtime Data – Information ..............................................................................63
8.12 Log ....................................................................................................................64
9 Operation ................................................................................................................. 66
9.1 Firmware Update ..................................................................................................66
10 Disturbances............................................................................................................70
10.1 Troubleshooting.................................................................................................. 70
10.2 Possible Faults ................................................................................................... 70
Rev. 07/2013 5
10.3 Acknowledging Faults ......................................................................................... 71
10.4 Customer Service Information.............................................................................. 71
10.5 Returning Equipment for Repair / Inspection......................................................... 72
10.6 Instructions for Packaging the Equipment ............................................................ 72
11 Maintenance.............................................................................................................73
11.1 Spare Parts and Accessories................................................................................. 73
12 Index .......................................................................................................................74
6 Rev. 07/2013
Read through this operating manual carefully before use and become familiar with the machine.
Installation and start-up should not be carried out before reading and understanding this
document. Keep this manual readily available so that you can reference it as needed.
1.1 What Is the Purpose of this Operating Manual?
This manual serves as an aid for the installation and operation of the product and supports the
technical staff with all operating and maintenance tasks to be performed. Furthermore, this
manual is aimed at preventing dangers to life and health of the user and third parties.
1.2 Who Is this Operating Manual Targeted to?
The operating manual provides a code of conduct for personnel tasked with the set-up,
operation, maintenance, and repair of gas engines. A certain level of technical knowledge with
respect to the operation of gas engines and basic knowledge of electronic ignition systems are
necessary. Persons who are only authorized to operate the gas engine shall be trained by the
operating company and shall be expressly instructed concerning potential hazards.
1.3 Which Symbols Are Used in the Operating Manual?
The following symbols are used in this manual and must be observed:
Example
This symbol indicates examples, which point out necessary handling steps
and techniques. In addition, you receive additional information from the
examples, which will increase your knowledge.
Notice
This symbol indicates important notices for the user. Follow these. In
addition, this symbol is used for overviews that give you a summary of the
necessary work steps.
Warning
This symbol indicates warnings for possible risks of property damage or
risks to health. Read these warning notices carefully and take the
mentioned precautionary measures.
1 GENERAL INFORMATION
Rev. 07/2013 7
Danger
This symbol indicates warnings for danger to life, especially due to high
voltage. Read these warning notices carefully and take the mentioned
precautionary measures.
1.4 Which Abbreviations/Acronyms Are Used in the Operating Manual?
In the manual or the user interface, the following abbreviations / acronyms are used.
Abb. Term Description Explanation
CAN bus Controller Area
Network Bus
Bus for control
devices / networks
Asynchronous serial
connection system for
networking control devices
CE Conformité
Européenne
Conformity with EU
directives
Mark based on EU legislation
for certain products in
conjunction with product safety
CPU Central Processing
Unit
DC Direct Current
EMC Electromagnetic
Compatibility
Compatibility of electrical or
electronic equipment items
with their surroundings
ESD Electrostatic
Discharge
LED Light Emitting Diode Light emitting electronic semi-
conductor
MICT MOTORTECH
Integrated
Configuration Tool
Configuration software for
MOTORTECH control units
USB Universal Serial Bus Serial wiring system to connect
a computer to external
equipment
8 Rev. 07/2013
2.1 General Safety Instructions
MOTORTECH equipment is manufactured as state of the art and therefore safe and reliable to
operate. Nevertheless the equipment can cause risks or damages can occur, if the following
instructions are not complied with:
–The gas engine must only be operated by trained and authorized personnel.
–Operate the equipment only within the parameters specified in the technical data.
–Use the equipment correctly and for its intended use only.
–Never apply force.
–For all work, such as installation, conversion, adaptation, maintenance, and repair, all
equipment must be disconnected from the power supply and secured against unintentional
restarting.
–Perform only such maintenance and repair work as is described in this operating manual,
and follow the instructions given while working. For maintenance of the equipment, only use
spare parts supplied by MOTORTECH. Further work must only be performed by personnel
authorized by MOTORTECH. Non-compliance with the instructions will void any warranties
for the proper function of the equipment as well as the responsibility for the validity of the
certifications.
–Safety devices must not be dismounted or disabled.
–Avoid all activities that can impair the function of the equipment.
–Operate the equipment only while it is in proper condition.
–Investigate all changes detected while operating the gas engine or ignition system.
–Ensure compliance with all laws, directives and regulations applicable to the operation of
your system, including such not expressly stated herein.
–If the system is not entirely tight and sealed, gas may escape and lead to an explosion
hazard. Upon completion of all assembly works, please always check the system's
tightness.
–Always ensure adequate ventilation of the engine compartment.
–Ensure a safe position at the gas engine.
2 SAFETY INSTRUCTIONS
Rev. 07/2013 9
2.2 Electrostatic Discharge Hazards
Electronic equipment is sensitive to static electricity. To protect these components from damage
caused by static electricity, special precautions must be taken to minimize or prevent
electrostatic discharge.
Observe these safety precautions while you work with the equipment or in its vicinity.
–Before performing maintenance or repair work, ensure that the static electricity inherent to
your body is discharged.
–Do not wear clothing made from synthetic materials to prevent static electricity from
building up. Your clothing should therefore be made of cotton or cotton mix materials.
–Keep plastics such as vinyl and Styrofoam materials as far away from the control system, the
modules, and the work environment as possible.
–Do not remove the circuit boards from the housing of the device.
2.3 Special Safety Instructions for the Device
Explosion hazard!
When the system is powered up, do not remove any connectors unless the
system is not located in a potentially explosive atmosphere.
Explosion hazard!
If the system is not entirely tight and sealed, gas may escape and lead to an
explosion hazard. Upon completion of all assembly works, always check the
system's tightness. Also ensure that the gauge port on the VariFuel2 is
closed.
All works involving gas-carrying parts must be executed by trained
personnel only.
Operational safety!
All screws of the connectors must be adequately tightened.
2 SAFETY INSTRUCTIONS
10 Rev. 07/2013
Risk of destruction due to electrostatic discharge!
The VariStep stepper motor card may only be installed by specialized
personnel who has been trained in handling ESD sensitive components and
with due regard to relevant ESD standards. It must be installed into a
control cabinet, and it is necessary to comply with the ESD standard
DIN EN 61340-5-1; VDE 0300-5-1:2008-07.
Damages caused by electrostatic discharge are not covered by the
guarantee.
Risk of burning!
The surfaces of the system may heat up to high temperatures.
Risk of damage!
The stepper motor of the VariFuel2 is not suitable for carrying or lifting a
gas mixer. There is a danger that the stepper motor could break, and if the
gas mixer were to fall, it could result in injury or property damage.
Always carry or lift the gas mixer by its exterior housing.
2.4 Proper Disposal
After the expiration of its service life, MOTORTECH equipment can be disposed of with other
commercial waste, or it may be returned to MOTORTECH. We will ensure its environmentally
friendly disposal.
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