Columbus mckinnon Pulse Manual

P/N: 11817503 REV. AA June 2014

MONITOR

INSTALLATION, OPERATION

& SERVICE MANUAL

MONITOR

Pulse™Monitor Software Version 1.0.1

Pulse™Monitor Card Software Revision 1.4.0

Pulse™Monitor Card Product Revision 0.1.0.0

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MONITOR

TABLE OF CONTENTS

Introduction �� 3

INSTALLATION

Pulse Monitor Kits �� 4–5

Software Installation �� 6

Initial Programming �� 6

Tools Required For Installation �� 7

Mounting Pulse Monitor Card �� 7

Wiring �� 8

OPERATION

Speciﬁcations �� 9

Downloading Motor Data �� 10–11

Software Functions �� 11

Cumulative Data �� 11

Monitor Version �� 12

Assigning Serial Number �� 12

Setting Time and Date �� 12

Setting Voltage �� 13

Reading Data �� 13

Voltage Graph �� 13

Data Filters �� 14

Viewing Data Type (Current vs� History) �� 14

Changing Order of Data Grid �� 15

Saving and Printing Motor Data �� 15

SERVICE

Troubleshooting Chart �� 16

Appendix 1 – Wiring Diagrams �� 17–23

Appendix 2 – Voltage Measurement Accuracy �� 24

Replacement Parts�� 24

Customer Service�� 24

NOTE: Pulse is not a trademark of Columbus McKinnon Corporation.

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MONITOR

INTRODUCTION

Congratulations on the purchase of a Pulse monitor� The Pulse monitor is an electronic device that records

key information with a time/date stamp every time an AC motor is turned on� The program data can be used

as a tool to help assist you in trouble shooting hard to ﬁgure out ﬁeld problems for machinery-using AC motors

and help determine preventative maintenance intervals�

IMPORTANT! PLEASE READ!

Before proceeding any further, please read the following important information regarding the Pulse monitor

and its proper handling and use:

The pulse monitor is powered by AC control voltage, which can cause electric shock resulting in personal injury or

loss of life. Handle monitor card with the same care and caution as all other high voltage electrical components.

Be certain the electrical power supply is OFF and locked in the open position before attempting any electrical

connections to the hoist.

Be sure to disconnect all AC input power before downloading information from or handling the Pulse monitor

circuit board.

Please read this manual completely before installing the Pulse monitor.

The Pulse monitor card must be rigidly secured in the control panel as illustrated in this manual.

Failure to do so may result in damage to the pulse monitor card and to the equipment being monitored

Only qualiﬁed personnel should perform service.

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PULSE MONITOR KITS

The Pulse monitor is available in several different kit varieties to accommodate individual needs�

Note: Shaw-Box World Series and Yale Global King hoists, which include the Pulse monitor card as standard, require a computer

interface kit (sold separately) to read the data� Kit variations are as follows:

PULSE MONITOR COMPUTER INTERFACE KIT WITH USB ADAPTOR

CATALOG NO� PINTERFACEUSB

Description Quantity

Pulse Monitor Computer Interface (9V battery not included) 1

Serial Extension Cable (6 ft.) 1

Pulse Monitor Software Disk 1

StarTech.com USB Adaptor Software Disk 1

Serial Port to USB Adaptor Cable (3 ft.) 1

Note: Kit also includes a DB9 to DB25 pin adapter for 25-pin RS232 serial communication which will not be needed in most cases�

PULSE MONITOR COMPUTER INTERFACE KIT WITHOUT USB ADAPTOR

CATALOG NO� PINTERFACEKIT

Description Quantity

Pulse Monitor Computer Interface (9V battery not included) 1

Serial Extension Cable (6 ft.) 2

Pulse Monitor Software Disk 1

PULSE MONITOR COMPLETE KIT

CATALOG NUMBERS

PCOMPLETEKIT1 = 115 VAC CONTROL

PCOMPLETEKIT2 = 24 VAC CONTROL

Description Quantity

Pulse Monitor Card 1

Card Mounting Bracket 1

Pulse Monitor Computer Interface (9V battery not included) 1

Serial Extension Cable (6 ft.) 2

Pulse Monitor Software Disk 1

StarTech.com USB Adaptor Software Disk 1

Serial Port to USB Adaptor Cable (3 ft.) 1

Pan Head Phillips Screw Self Tap #6-32 X 5/8" 6 (2 extra)

Pan Head Phillips Screw Self Tap #10-24 X 1/4" 3 (1 extra)

Terminal Wire Insulated Female Quick Connector Panduit Part no. DNR14-188F1B-C (tab size 0.187 X 0.020) 10 (3 extra)

16# Insulated Wire 15 ft.

Note: Kit also includes a DB9 to DB25 pin adapter for 25-pin RS232 serial communication which will not be needed in most cases�

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PULSE MONITOR KITS (CONTINUED)

PULSE MONITOR COMPLETE KIT

Note: Kit also includes a DB9 to DB25 pin adapter for 25-pin RS232 serial communication which will not be needed in most cases�

PULSE MONITOR INDIVIDUAL CARD KIT

CATALOG NUMBERS

PCARDKIT1 = 115 VAC CONTROL

PCARDKIT2 = 24 VAC CONTROL

Description Quantity

Pulse Monitor Card 1

Card Mounting Bracket 1

Pulse Monitor Software Disk 1

Pan Head Phillips Screw Self Tap #6-32 X 5/8" 6 (2 extra)

Pan Head Phillips Screw Self Tap #10-24 X 1/4" 3 (1 extra)

Terminal Wire Insulated Female Quick Connector Panduit Part no. DNR14-188F1B-C (tab size 0.187 X 0.020) 10 (3 extra)

16# Insulated Wire 15 ft.

SERIAL EXTENSION CABLE

USB ADAPTOR SOFTWARE DISK

SERIAL PORT TO USB

ADAPTOR CABLE

PULSE MONITOR CARD

COMPUTER INTERFACE

PULSE MONITOR

SOFTWARE DISK

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SOFTWARE INSTALLATION

Insert the Pulse software disk into your CDROM drive� Using the

RUN command in your start menu button, browse to your CDROM

drive� Open folder 1�0�1� Double click on the Install Pulse ﬁle�

Select OK and follow instructions� During the install, say yes to

installing the Microsoft�net framework program if prompted�

This is necessary for the Pulse software to operate�

OBSERVE MINIMUM SYSTEM REQUIREMENTS:

Operating System* – Windows XP Pro SP2, or Windows 2000 SP4.

CPU – Pentium III, 450 MHz, RAM - 256 MB.

Hard Drive Space – 50MB.

One USB Serial Port, CDROM Drive.

*Please Note: Windows 8 & 8�1 not supported�

USB ADAPTER INSTALLATION

DRIVER

1� Turn on computer on and boot into Windows� Do not have

USB adapter plugged into the computer

2� Insert the driver CD into your CD/DVD drive� If AutoPlay runs,

then choose to “Browse the CD”, otherwise access the contents

of the CD via “my Computer”

3� In the “Proliﬁc/PL2302X” location, open the appropriate folder

for your operation system and run the setup�exe ﬁle� This will

launch the driver installation wizard

4� Once the installation wizard completes, the drivers will be

installed and ready for use�

HARDWARE INSTALLATION

1� Make sure the driver installation has been completed ﬁrst�

2� Plug the USB adapter into an available USB port on the

computer system�

3� Windows will automatically detect the USB adapter and

install the drivers

4� Once installation is complete, the serial port will be ready for use�

5� If connecting the serial port to a DB25 interface, use the included

DB9 to DB25 (male) adapter

VERIFYING INSTALLATION

Windows XP/Vista/7

1� From the main desktop, right click on “my computer”

(“Computer” in Vista/7) then select Manage� In the new

Computer Management window, select Device Manager

from the left window panel�

2� Double click on the “Ports (COM & LPT)” option�

The additional ports should be visible�

3� Double click on the adapter

4� Select “Port Settings” tab

5� Click on “Advanced” and at the bottom of the pop-up screen

under “COM Port Number” make sure COM1, COM2, COM3

or COM4 is selected� The Pulse software will only detect COMs

1 thru 4�

INITIAL PROGRAMMING

Initial programming can be done before or after the Pulse

monitor card is installed� Open the Pulse software on your

computer and connect the Pulse monitor card as shown in

Figure 3� It is recommended that the following parameters

be set before collecting any data�

SERIAL NUMBER

In the Serial Number Box, enter the serial number for

the system you wish to monitor� Click on the Set button

to program the serial number�

MONITOR DATE

In the Monitor Date Box, click on the Set button to set the monitor

card clock to your computers clock�

Note: If this is not done, the default time for the monitor card

is midnight, January 1, 1970�

VOLTAGE

In the Voltage Box, enter the source voltage the motor is being

powered by� Click on the Set button to program the source voltage�

For further information concerning these parameters,

see the Software Functions section of this manual.

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MONITOR

TOOLS REQUIRED FOR INSTALLATION

• Drill & #19 Drill Bit (ø .166")

• #1 Phillips Screw Driver

• Wire Strippers

• Connector Crimping Tool (Sized for 16# wire)

MOUNTING PULSE MONITOR CARD

1� Locate available space in control enclosure to t the required 3" X 5-1/4" X 2-1/2" envelope. Use a #19 drill bit (ø .166") and drill two

holes 4.75" +/- .02" apart. Attach the mounting bracket using (2) #10-24 X ¼" self-tapping screws at reference points A� See Figure 1�

2� Attach Pulse monitor card to mounting bracket using (4) #6-32 X 5/8" self-tapping screws at reference points B� See Figure 1�

PULSE MONITOR CARD

MOUNTING BRACKET

FIGURE 1

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WIRING

1� 1) Review electrical schematic� See Figure 2�

2� 2) See Appendix 1 for detailed wiring diagrams speciﬁc to selected Yale·Lift-Tech arrangements�

The Pulse monitor card is electronic equipment that requires earth ground to reduce potential for false data�

If a dedicated ground is not available, make sure reference ground to all control transformers have one common point�

FIGURE 2

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SPECIFICATIONS

The Pulse monitor records the following information:

MOTOR EVENT PARAMETERS

Motor direction is referenced as Up or Down� The Pulse monitor

can record up to two speed points� The speed points are referenced

as Slow and Fast�

The following are all the designated motor events that can be

recorded:

Motor Event Data Filters

Motor Up Slow (Normal Start), (Slow), (Up)

Motor Up Fast (Normal Start), (Fast), (Up)

Motor Down Slow (Normal Start), (Slow), (Down)

Motor Down Fast (Normal Start), (Fast), (Down)

Plug Event Excessive Plugging (Plug Event)

Motor Trip Up Thermal Shutdown (Motor Trip), (Up)

Motor Trip Up Fast Thermal Shutdown (Motor Trip), (Up)

Over Capacity Up (Over Capacity), (Up)

Over Capacity Up Fast (Over Capacity), (Up)

CURRENT MOTOR EVENTS

The Pulse monitor records all current motor events up to a maximum

of 5119 events� After 5119, each new motor event will record over

the oldest motor data beginning at memory count one�

HISTORY EVENTS

The Pulse monitor records the following motor events simultaneously

into the current and history motor event memory registers�

The motor events are plug event, motor trip and over capacity�

The history event register can store up to 64 occurrences before

recording over the oldest data located in memory count one�

CUMULATIVE RUN TIME

Every time the motor is energized, the Pulse monitor records how

long it runs and adds to the cumulative total run time� Maximum

time count is 1�9 million hours� Cumulative run time is updated

every 16 motor starts� Overall operating time cannot be reset

to zero� Cumulative Motor Starts - Pulse monitor keeps track

of overall starts of a motor� Maximum start count is 4�29 billion�

The cumulative memory location is updated every 16 motor

starts� Overall starts cannot be reset to zero�

MOTOR STARTS

A motor start is recognized by energization of either the slow or fast

motor winding for 300ms or more�

* Pulse monitor card revision 1�4�0 - counts a motor start

when either the slow or fast winding of the motor is energized�

No time constraints are in place for determining a motor start�

PLUG EVENT (EXCESSIVE PLUGGING)

A plug event is recorded when the directional contactor (node 0A

or 1A) is energized four times within any two second period of

operation� The plug event is recorded simultaneously into current

motor data and history data�

MOTOR TRIP EVENT

A motor trip event will be recorded when the monitor card terminal

K1 measures 115 volts* and terminal K2 is at 0 volts� If the event

occurs with all three terminals K1, K2 and 0A being at 0 volts

followed by numerous occurrences of terminal K1 sensing 115 volts*

and K2 remaining at 0 volts, only one event will be recorded�

OVER CAPACITY EVENT

An overcapacity trip will be recorded when the monitor card

terminals K1 and K2 measure 115 volts* and terminal 0A being at

0 volts� If the event occurs with all three terminals K1, K2 and 0A

being at 0 volts followed by numerous occurrences of terminal K1

and K2 sensing 115 volts* and 0A remaining at 0 Volts, only one

event will be recorded�

VOLTAGE

For every motor event, the voltage will be measured�**

TIME / DATE STAMP

All motor events are recorded along with the time and date the motor

event occurred� The real time clock in the Pulse monitor card has a

default starting time of midnight, January 1, 1970� Once the Pulse

monitor software connects to the card, you can change the default

time to your computer's time by pressing the Set button�

* All cited voltages are nominal referenced to ground using the

115-volt monitor card� If using the 24-volt card, all non-zero

voltage references will be 24 volts�

** See Appendix 2 for discussion of accuracy�

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DOWNLOADING MOTOR DATA

Motor event data stored in the Pulse monitor card can only be read using a personal computer (PC).

CONNECTIONS

1� Connect the Pulse monitor card, computer interface, PC and serial extension cables as shown in Figure 3�

2� Select com port

3� Open Pulse monitor software on computer and press the Connect button� See Figure 4�

FIGURE 4

PULSE

MONITOR

CARD

FIGURE 3

COMPUTER

INTERFACE

PC

Serial Extension Cable

*Serial Port to USB

Adaptor Cable

Connect to

Monitor Card

Connect to

Computer

Serial Port USB Port

*Note: For optional use of USB port or devices without a serial port.

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DOWNLOADING MOTOR DATA (CONTINUED)

4� If your connection was successful, the following message Data loaded successfully will be displayed in the lower left corner�

The monitor date, monitor version and cumulative run time / start data will also appear� See Figure 5�

SOFTWARE FUNCTIONS

CUMULATIVE DATA

The Pulse monitor card keeps track of total motor run time and total motor starts for the motor being monitored�

The displayed cumulative data is automatically updated every 16 motor starts� Note this data cannot be reset� See Figure 6�

FIGURE 5

FIGURE 6

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SOFTWARE FUNCTIONS (CONTINUED)

MONITOR VERSION

The Pulse monitor software and card revision number will automatically display once you connect to the card� See Figure 7�

ASSIGNING SERIAL NUMBER

You can assign a speciﬁc serial number to the Pulse monitor card up to 20 characters for the system you wish to retrieve data from� Click on

the serial number box and enter the respective serial number� Then press the Set button� See Figure 8�

SETTING TIME AND DATE

The time / date of all Pulse monitor cards default to midnight, January 1, 1970� By pressing the Set button in the Monitor Date box,

the software will automatically update the time in the Pulse monitor card to match the computer being used� See Figure 9�

FIGURE 7

FIGURE 8

FIGURE 9

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SOFTWARE FUNCTIONS (CONTINUED)

SETTING MOTOR VOLTAGE

The Pulse monitor card monitors the motor voltage of your system�* Enter the correct power supply voltage required for your system,

and press the Set button in the Voltage box� See Figure 10�

* See Appendix 2 for discussion of accuracy�

READING DATA

Pressing the Read Events button as shown in Figure 11 will read all data accumulated in the Pulse monitor card�

VOLTAGE GRAPH

Press the Graph button to read a graph showing a broad snapshot of what the voltage was for all motor events�*

See Figure 12� Note: To view graph at a speciﬁc date or time, select pertinent date/ time in ﬁlter box�

FIGURE 10

FIGURE 11

FIGURE 12

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SOFTWARE FUNCTIONS (CONTINUED)

DATA FILTERS

Data ﬁlters allow you to narrow down the speciﬁc type of data you wish to view� The default selects all motor events for review�

If there is speciﬁc data you do not wish to see, simply uncheck the respective box and that data will be removed from your data grid�

The ﬁlters include the different motor event types, voltage deviation, speciﬁc date and speciﬁc time� See Figure 13�

VIEW DATA TYPE (CURRENT VS. HISTORY)

The View Data Type box allows you to choose between Current data, which is the most recent motor events up to a maximum of 5119,

or History data� History data is reserved speciﬁcally for Plug Event, Motor Trip and Over Capacity events� The maximum memory count

is 64 for each event type� See Figure 14�

FIGURE 13

FIGURE 14

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SOFTWARE FUNCTIONS (CONTINUED)

CHANGING ORDER OF DATA GRID

You can also change the order in which you view the motor data by clicking on any of the column headers in the data grid� For example, the

default order for date and time begins with the oldest date and time stored� If you wish to begin viewing from the most recent data to the

oldest data, select the Date and/or Time headers and this will reverse the order� See Figure 15�

SAVING AND PRINTING MOTOR DATA

Once you have successfully downloaded the motor data to the Pulse monitor, you can save or print the data using either the File Menu

or Save and Print Hot Buttons� The ﬁle will be automatically saved as an .xml ﬁle� Use the Pulse monitor software any time you wish

to review or print the ﬁle�

FIGURE 15

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TROUBLESHOOTING CHART

Symptom Corrective Action

Prompted Message: Pulse monitor could not

be read. Check cable connections and/or 9V battery

located in the computer interface before attempting

to reconnect.

1. Check to make sure the USB connections and/or serial connections are secure.

2. Make sure the computer interface has a 9V battery installed and that the battery is good.

3. Make sure printed circuit board in the computer interface was not inadvertently switched around when

the 9V battery was installed. Labeled connectors on printed circuit board must match interface labeling.

Ie: Connect to Computer or Connect to monitor card

4. Replace 9-wire serial cables. If the problem still exists, replace the computer interface.

Prompted Message: This card is blank, no

records have been written to it yet; data displayed

is not accurate.

If the card is new, upon connection you will get this message. Once the Pulse monitor card begins

accumulating data, the message will disappear.

False motor trips. Example: Thermal trip in down

direction for hoist motion.

Check K1 or K2 input of Pulse card for ﬂoating voltage. Example: If motor is moving in down direction,

K1 and K2 should read 0 V. If K1 or K2 reads other than 0 V, check all control transformers to verify they

have a common ground. Provide common ground as necessary.

Event column of the data grid is blank. When the storage of events has reached memory capacity, a blank event is produced to signify the overwriting

of older events. A blank event will occur in both the current and history data. Disregard as an actual event.

Event has been recorded with a 1971 date stamp

after the date/time has been set on the card.

The date indicates that as power was applied to terminal 91 on the monitor card, voltage was already present

on either terminal K1,K2,0A or 1A, then removed within 1 second of power being applied to terminal 91.

In the ﬁrst second of turning on power, avoid applying a run command.

Motor Starts ﬁeld equals 4294967295 and the Run

Time (Hours) ﬁeld equals 1193046.5

The card has not accumulated a total of 16 motor starts which is required for the Motor Starts and Run Time

ﬁelds to update. Accumulate a minimum of 16 motor starts before attempting to read card data.

Data not downloading Check com port on adaptor and pulse monitor software.

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MONITOR

Columbus McKinnon Corporation

Hoist & Rigging - Americas

Amherst, NY USA

APPENDIX 1

WIRING DIAGRAMS

2-Speed Global Series 3, with geared limit switch, motor thermal switch, thermal overload relays and overcapacity limit switch�

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APPENDIX 1 (CONTINUED)

WIRING DIAGRAMS

Global Series 3 with MAGNETEK G+ Mini variable frequency drive, geared limit switch, motor thermal switch and overcapacity limit switch.

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APPENDIX 1 (CONTINUED)

WIRING DIAGRAMS

2-Speed 700 Series hoist with geared limit switch, block limit switch and motor thermal switch�

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APPENDIX 1 (CONTINUED)

WIRING DIAGRAMS

2-Speed 800 Series hoist with geared limit switch, block limit switch and motor thermal switch�

Columbus McKinnon pulse Manual

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