Kinesys apexDRIVE Series User manual

USER GUIDE
apexDRIVE User Guide 9200162 0v10
1
apexDRIVE
Variable Speed Chain Hoist Controller
November 2017
Version 0v10
Kinesys Projects Ltd
Unit 2 Kempton Gate Business Centre
Oldfield Road
HAMPTON
Middlesex TW12 2AF
United Kingdom

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LIMITATION OF LIABILITY
Kinesys Projects Limited accepts no liability for any consequences resulting from inappropriate,
negligent or incorrect installation or use of the equipment.
The contents of this manual are believed to be correct at the time of printing. In a commitment to
a policy of continuous development and improvement, Kinesys reserves the right to change the
specification of the product, its performance, or the contents of this manual, without notice.
All rights reserved. No parts of this manual may be reproduced or transmitted in any form or by
any means, electrical or mechanical including photocopying, recording or by an information
storage or retrieval system, without permission in writing from Kinesys Projects Limited.
© Kinesys Projects Limited
MANUFACTURER CONTACT DETAILS
Kinesys Projects Ltd
Unit 2 Kempton Gate Business Centre
Oldfield Road
HAMPTON
Middlesex
TW12 2AF
United Kingdom
Contact Information:
For general enquiries Monday to Friday, 9am to 6pm
Tel [phone]
Fax [phone]
[email protected]
www.kinesys.co.uk
For technical support Monday to Friday, 9am to 6pm
Tel: [phone]
Fax [phone]
[email protected].uk

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Document Revisions
Date
Version
Number
Redmine
Edited
by
Document Changes
24/11/17
0v10
#1579
DD /
BB
First customer release

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GLOSSARY OF TERMS USED
3 Phase
Refers to a system of power distribution of 3 electric power conductors
carrying alternating current voltages that are offset by 120ofrom each
other.
CEE Form
A type of power connector which meets IEC EN 60309. Also known as
“Commando” or “Pin and Sleeve”.
Encoder
A device used to measure the movement of a hoist.
E-Stop
Emergency Stop used to stop all movement in the system.
Ethernet
A family of computer networking technologies.
Group Halt
A group of hoists moving together that have been stopped.
Hard Limit
Refers to a physical limit with a connected chain hoist.
Harting
Hubbell
A brand name for a type of multipin connector. Also known as “Wieland”,
“EPIC” or “Lectriflex” or ILME.
A brand name for a type of power connector (US market)
OLED
Organic Light-Emitting Diode, used for the touch screen display
LED
Light-Emitting Diode.
Limit
A set point beyond which a hoist cannot move.
Loadcell
A device used to measure weight.
Multicore
A cable consisting of multiple smaller cables.
Overload
A measurement of weight higher than that required.
Pin Out
The designated use for each of the pins in a socket or connector.
Positioning
Identifying and monitoring the current position of the chain or load.
RCD
Residual Current Device used to monitor and cut power supplies in the
event of a current leakage to earth, to avoid accidental electrocution.
Also referred to as “ELCB” (Earth Leakage Circuit Breaker) or “GFCI”
(Ground Fault Circuit Interrupter).
Shackle
A U-shaped piece of metal secured with a clevis pin or bolt across the
opening.
Soft Limit
Refers to a limit set by software.
Tare
Makes allowance for the chain, hoist or container when measuring a
loads weight.
Underload
A measurement of weight lower than that required.
Vector
Kinesys Motion Control Software.
MCB
Miniature Circuit Breaker, resettable thermal overcurrent protection device

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Table of Contents
1SCOPE AND PURPOSE..............................................................................10
2INTRODUCTION..........................................................................................10
2.1 General Description & Safety Warnings........................................................................ 10
2.1.1 Do’s and Don’ts .................................................................................................................... 10
2.2 Transportation and storage............................................................................................ 11
2.2.1 Condensation........................................................................................................................ 11
2.2.2 Shocks.................................................................................................................................. 11
2.2.3 Handling................................................................................................................................ 11
2.2.4 Packaging............................................................................................................................. 11
3OVERVIEW..................................................................................................12
3.1.1 Layout................................................................................................................................... 12
3.1.2 Front Panel ........................................................................................................................... 12
3.1.3 Rear Panel............................................................................................................................ 13
4INSTALLATION...........................................................................................14
4.1 Installation precautions .................................................................................................. 14
4.1.1 Truss Mount Bracket (Primary Support)............................................................................... 14
4.1.2 Safety Bond (Secondary support) ........................................................................................ 15
4.1.3 Rack Mount Kit ..................................................................................................................... 16
5CONNECTIONS...........................................................................................18
5.1 Ethernet ............................................................................................................................ 18
5.2 Mains power connection................................................................................................. 19
5.2.1 400V apexDRIVE Power IN.................................................................................................. 19
5.2.2 208V apexDRIVE Power IN.................................................................................................. 19
5.3 Power cable pinout information..................................................................................... 20
5.3.1 400V mains input & output ................................................................................................... 20
5.3.2 208V mains input & output ................................................................................................... 20
5.4 Hoist connection.............................................................................................................. 21
6CIRCUIT PROTECTION ..............................................................................22
6.1 Control ‘POWER SUPPLY’ MCB..................................................................................... 22
6.2 ‘Drive’ MCB....................................................................................................................... 23
6.3 Brake Fuses ..................................................................................................................... 23

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7FRONT PANEL CONTROLS.......................................................................24
7.1 Emergency Stop .............................................................................................................. 24
7.2 Mode Key switch.............................................................................................................. 25
7.3 Touch screen display and menu system ...................................................................... 25
7.3.1 Menu system overview......................................................................................................... 26
7.3.2 Home screen ........................................................................................................................ 27
7.3.3 Alarms screen....................................................................................................................... 28
7.3.4 Settings screen..................................................................................................................... 29
7.3.5 Hoist information....................................................................................................... 31
7.4 Operation.......................................................................................................................... 32
7.4.1 Manual [LOCAL] operation................................................................................................... 32
7.4.1 Manual [OVERRIDE] operation............................................................................................ 33
7.4.2 Remote [REMOTE] operation............................................................................................... 34
8TROUBLESHOOTING GUIDE.....................................................................35
8.1 Safety system status....................................................................................................... 35
8.1.1 E-stop configuration.............................................................................................................. 36
8.1.2 Safety system status............................................................................................................. 36
8.1.3 Safety system reset.............................................................................................................. 36
8.1.4 Resolving safety system faults ............................................................................................. 36
8.2 Alarm conditions ............................................................................................................. 37
...............................................................................................Alarm Conditions continued
....................................................................................................................................................... 38
8.3.................................................................................................................................................. 38
8.4 Status conditions............................................................................................................. 38
..............................................................................................Status Conditions continued
....................................................................................................................................................... 39
8.5.................................................................................................................................................. 39
8.6 System menu ................................................................................................................... 40
9MAINTENANCE & REPAIR.........................................................................42
9.1 Cleaning & Inspection..................................................................................................... 42
9.2 Checking & replacing brake fuses................................................................................. 42
9.3 Checking and replacing air intake filters ...................................................................... 43

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9.4 Periodic testing................................................................................................................ 43
9.5 Spare parts....................................................................................................................... 43
10 RECALIBRATION OF TOUCHSCREEN..................................................44
11 PRODUCT SPECIFICATION....................................................................45
12 DECLARATION OF CONFORMITY.........................................................48
13 PACKAGING............................................................................................49
14 SERVICE & END OF LIFE .......................................................................49
15 SPARE PARTS.........................................................................................49

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Table of figures
Figure 1 Front panel layout............................................................................................12
Figure 2 Rear panel layout (400V).................................................................................13
Figure 3 Rear panel layout (208V).................................................................................13
Figure 4 Truss Mount for apexDRIVE & (typical) half-coupler........................................14
Figure 5 Locking DZUS fasteners..................................................................................15
Figure 6 Safety bond.....................................................................................................15
Figure 7 Rack mount - attaching rack guides ................................................................16
Figure 8 Rack mount –attaching rack ears...................................................................16
Figure 9 Rack mount - attaching rack slides to the rack frame ......................................17
Figure 10 Rack mount –sliding the drive onto the rack guides......................................17
Figure 11 Ethercon connector.......................................................................................18
Figure 12 Network connection of multiple apexDRIVE ..................................................18
Figure 13 Mains connection on 400V apexDRIVE.........................................................19
Figure 14 Mains connection on 208V apexDRIVE.........................................................19
Figure 15 Mains connection pinout on 400V apexDRIVE..............................................20
Figure 16 Mains connection pinout on 208V apexDRIVE..............................................20
Figure 17 apexDRIVE and apexHOIST Harting connectors...........................................21
Figure 18 apexHOIST (Harting) connection on apexDRIVE ..........................................21
Figure 19 Power MCB...................................................................................................22
Figure 20 Drive MCB.....................................................................................................23
Figure 21 Brake fuses...................................................................................................23
Figure 22 Emergency Stop button.................................................................................24
Figure 23 Mode Key Switch...........................................................................................25
Figure 24 ApexDRIVE menu system overview..............................................................26
Figure 25 Home screen.................................................................................................27
Figure 26 Alarm screen.................................................................................................28
Figure 27 Settings screen............................................................................................29
Figure 28 Brightness screen.........................................................................................29
Figure 29 Display timeout screen..................................................................................29
Figure 30 Version screen .............................................................................................30
Figure 31 Units screen..................................................................................................30
Figure 32 Hoist Information screen................................................................................31
Figure 33 Display screen...............................................................................................32
Figure 34 Manual control screen...................................................................................32
Figure 35 Mentor 401 connection layout........................................................................34
Figure 36 Accessing safety controller status screen......................................................35
Figure 37 Safety controller status screen ......................................................................35
Figure 38 Main settings screen .....................................................................................40
Figure 39 System menu................................................................................................40
Figure 40 Numeric keypad for password entry ..............................................................41
Figure 41 Correct orientation of apexDRIVE for screen calibration................................44
Figure 42 Touchscreen calibration screen.....................................................................44
Figure 43 Packaged Dimensions...................................................................................49

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1 Scope and Purpose
The purpose of this manual is to describe the features, functions and means of
operating the Kinesys apexDRIVE chain hoist controller.
2 Introduction
The apexDRIVE is a variable speed electric chain hoist controller designed for use
in the entertainment and events industry. It is designed exclusively for use with the
Kinesys apexHOIST range and ancillary equipment to form a complete motion
control system.
2.1 General Description & Safety Warnings
The equipment described in this manual may only be operated by personnel
qualified to do so for the specific task as detailed above.
Qualified personnel are those who, based on their training and experience, are
capable of identifying risks and avoiding potential hazards when working with this
and associated equipment.
The apexDRIVE is designed for indoor use only and to work in ambient
temperatures between 5C and 40C. The apexDRIVE has an Ingress Protection
(IP) rating of IP30.
2.1.1 Do’s and Don’ts
Do not start initial operations before a competent person or a trained
specialist has inspected the equipment.
Do not run the system without all Emergency Stop switches/buttons
connected and in position.
Do not use apexHOIST for moving loads other than in a vertical direction
Do not connect an apexDRIVE to any lifting equipment other than
apexHOIST without prior written approval by the manufacturer
Do not use any hoist without having carried out the regular inspection as
specified by the manufacturer
Do not connect an apexDRIVE to a power source other than specified on
the unit and in this manual.
Do not apply power if there is risk of condensation within the apexDRIVE
Do not obstruct the air intakes or exhaust ports, or operate the unit with
contaminated filter media (Replace media following procedure on page 43)
Do not modify an apexDRIVE in anyway unless expressly advised by the
manufacturer.
Do not attempt to connect more than one hoist per controller.

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Do not open the apexDRIVE or remove the outer casing if the system is
connected to a power source even if the apexDRIVE itself is not powered on.
Do not use an apexDRIVE if it is damaged or does not appear to be in
perfect working order.
Do not use any spare parts other than those supplied by Kinesys.
Do not subject an apexDRIVE to shocks or drops.
Do not install apexDRIVE on truss without using the dedicated truss
mounting kit and safety bond.
Do not distract the operator’s attention while they are operating the system.
Do not operate hoists without having a clear view of the load or reliable
communication with someone who does.
Do stop and investigate immediately if a hoist connected to the apexDRIVE
should move in a direction opposite to that which was expected.
2.2 Transportation and storage
2.2.1 Condensation
The apexDRIVE is designed for indoor use only. If the product has been exposed
to temperature fluctuations, for example during transport, there may be risk of
condensation which may result in damage. Do not connect the apexDRIVE to a
power source immediately. Leave the apexDRIVE disconnected until the unit has
reached the temperature of the location where it is to be installed.
2.2.2 Shocks
Do not shake, knock or drop the apexDRIVE. Avoid excessive force when
installing and operating the product.
2.2.3 Handling
Never lift the apexDRIVE by any of its cables or connectors as this may cause
damage to the unit and/or the cable.
2.2.4 Packaging
The use of a purpose made flight case (available from Kinesys as an accessory) is
recommended for regular transportation such as in touring applications. Otherwise,
where possible, please use the original packaging to transport the apexDRIVE.

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3 Overview
3.1.1 Layout
This section describes the layout of the front panel controls and the rear panel
connection option on an apexDRIVE
3.1.2 Front Panel
Figure 1 Front panel layout
1. ‘Power Supply’MCB –Used to isolate power to the control systems within the
apexDRIVE, refer to page 22 for more details.
2. ‘Drive’MCB –Used to isolate the three phase power from the internal power
electronics and the apexHOIST, refer to page 23 for more details.
3. Brake Fuses –replaceable fuses for the hoist brakes, refer to page 23 for more
details.
4. Mode Key Switch –Used to select ‘Override’, ‘Remote Control’or ‘Local’
operational modes, refer to page 25 for more details.
5. Emergency Stop button –Used to stop all movement in the system in the event
of an emergency, refer to page 24 for more details.
6. Touch Screen Display –Used to show details of the apexHOIST position,
movement, system status, faults and for navigating the system menu, refer to
page 25 for more details.
7. Manual direction controls –Used with the touch screen to allow local control of
the connected chain hoist, refer to page 32 for more details.
8. Drive ventilation –Hot air exhaust outlet
1
from the variable speed drive and
braking resistor. DO NOT OBSTRUCT AIRFLOW.
9. Carry handles –To be used for carrying and handling the drive.
1
Check condition periodically, refer to page 44
1
2
3
4
5
6
4
7
6
8
7
9
8
9
8

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3.1.3 Rear Panel
Figure 2 Rear panel layout (400V)
Figure 3 Rear panel layout (208V)
1. Air Intake Filters –Cooling air intakes for internal cooling fans. DO NOT
OBSTRUCT. These feature replaceable filter media, refer to page 43 for more
details.
2. Hoist Connector –Used to connect motor, brakes and control to apexHOIST,
refer to page 21 for more details.
3. Ethernet/ Safety Connections –Ethernet IN and OUT connections used to
link apexDRIVE units to form a networked motion control system, refer to page
18 for more details.
4. Mains Link Output –Used to daisy chain power to another apexDRIVE, refer
to page 20 for more details.
5. Mains Input –Used to connect the mains power supply for the apexDRIVE,
refer to page 19 for more details.
6. Carry handles –Used for carrying and handling the drive.
1
2
3
4
5
1
6
6
400V Version
208V Version
1
2
3
4
5
1
6
6

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4 Installation
Although it can be used freestanding, the apexDRIVE is designed to be either
truss mounted or installed in a conventional rack.
4.1 Installation precautions
When considering the location to install the apexDRIVE, make sure the device will
not be exposed to extremes of heat/cold, moisture/ humidity or dust. Refer to the
environmental requirements in the summary product specification on page 45.
When rack mounting, ensure there is enough space within the rack to allow for
cables and connections at the rear and the switches and controls at the front.
Ensure there is adequate ventilation when using the apexDRIVE installed in a
rack.
The apexDRIVE shall only be truss mounted using the optional Truss Mount
Bracket kit (Kinesys APM-01-0010) including the supplied Safety Bond.
4.1.1 Truss Mount Bracket (Primary Support)
The truss mount bracket enables the apexDRIVE to be mounted on truss using
(2/4) standard half couplers (not supplied). The truss mount bracket is attached to
the apexDRIVE using four quarter turn DZUS fasteners.
Figure 4 Truss Mount for apexDRIVE & (typical) half-coupler

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4.1.1.1 Installing the Trust mount Bracket
-Bolt the half couplers to the truss mount bracket to suit the truss layout; refer to
Kinesys drawing 9200166 for layout of common truss types.
-Position the truss mount bracket on top of the apexDRIVE and locate the four
DZUS fasteners onto the corresponding holes in the drive.
-Turn each DZUS fastener one quarter turn clockwise until a definite “Click” is
heard and felt. Verify that the bracket is secured with all four DZUS before
attempting to attach to the truss.
Figure 5 Locking DZUS fasteners
4.1.2 Safety Bond (Secondary support)
The truss mounting kit is supplied with a support. This shall be used to provide
secondary support for the drive when truss mounted. The safety bond shall be
passed around the supporting truss and clipped with the carabiner to the SAFETY
BOND tab at the rear of the product.
Figure 6 Safety bond
In the unlikely event of failure of the truss mounting or an operator omitting to
securely fix the truss mount or half couplers the safety bond will restrain the
apexDRIVE if it is dislodged.
Click!

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4.1.3 Rack Mount Kit
A Rack Mount Kit is available to enable installation of the apexDRIVE in an
industry standard 19” rack (3U height required). The rack mount kit includes:
1x pair of front ‘rack ear’ brackets
2x side mounted ‘rack guides’ and mounting screws
1x pair ‘rack slide’ brackets
1) Attach the rack guides to each side fixing on the apexDRIVE using the
supplied mounting screws.
Figure 7 Rack mount - attaching rack guides
2) Secure the front mounted rack ears using the four existing (12mm Torx) fixings
at the front edges of the enclosure.
Figure 8 Rack mount –attaching rack ears

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3) Checking the correct position, attach the rack slides to the rear of the rack
using cage nuts and bolts.
Figure 9 Rack mount - attaching rack slides to the rack frame
4) Use the rack guides on the side of apexDRIVE to slide the unit in to the fixed
rack slide and line up the rack mount holes in the desired position.
Figure 10 Rack mount –sliding the drive onto the rack guides
5) Using cage nuts and bolts, secure the apexDRIVE to the frame of the rack at
the front. Verify that all fixings are secure.

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5 Connections
5.1 Ethernet
The apexDRIVE IN and OUT Ethercon Ethernet connections enable networking of
a number of apexDRIVE units and a Mentor safety controller. The OUT connection
is used when linking more than one drive together to form a system.
Alternatively, depending on application, a DC8 v2 E-stop hub may be used. When
used with an EVO v2 system the OUT connection is not used. EVO mode must be
enabled using the option on the Safety Status screen, refer to page 36.
Ethernet cables must be shielded CAT5e type. Kinesys recommends the use of
Neutrik Ethercon connectors with ProPlex PCCAT5EP cable.
Figure 11 Ethercon connector
Figure 12 Network connection of multiple apexDRIVE
The maximum recommended length of an Ethernet link between units is 90m.
Where possible use single cables and avoid the use of joiners or couplers. Where
couplers are used reduce the maximum length of the link by 5m for each coupler
inserted.
The Ethernet standard states a 100m maximum link length between devices. In
order to extend further than 100m the use of a fibre connection will be required.
Please consult with Kinesys for further details on using a fibre connection with an
apexDRIVE.

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5.2 Mains power connection
The mains power connection to the apexDRIVE should always be the last
connection made.
The apexDRIVE is available configured for 400V mains supply or 208V mains
supply.
5.2.1 400V apexDRIVE Power IN
The 400V apexDRIVE is fitted with a 5-pole 32A type IEC 60309 CEE power
connector and requires a 3 phase mains power supply with neutral (230V Ø-N,
400V Ø-Ø, 3Ø+N+E). A earth (ground) connection is essential.
Figure 13 Mains connection on 400V apexDRIVE
5.2.2 208V apexDRIVE Power IN
The 208V apexDRIVE is fitted with a 4P+G 30A NEMA L21-30 type connector and
requires a 3 phase mains power supply with neutral (120V Ø-N, 208V Ø-Ø,
3Ø+N+E). An earth (ground) connection is essential.
Figure 14 Mains connection on 208V apexDRIVE

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5.3 Power cable pinout information
WARNING!
Serious damage may be caused by misconnection of apexDRIVE.
It is recommended that Kinesys supplied cables are used with apexDRIVE.
The following sections detail the pinout of the power connections for the
apexDRIVE
2
. Wiring standards vary and there is always the possibility that pinouts
on cables may not be compatible. If in doubt always check cables before use.
5.3.1 400V mains input & output
Figure 15 Mains connection pinout on 400V apexDRIVE
5.3.2 208V mains input & output
Figure 16 Mains connection pinout on 208V apexDRIVE
2
Connectors as seen from the rear of the apexDRIVE
L1
Phase 1
L2
Phase 2
L3
Phase 3
N
Neutral
E
Earth (Ground)
X
Phase 1
Y
Phase 2
Z
Phase 3
W
Neutral
E
Ground (Earth)
OUTPUT
INPUT
E
N
L3
L2
L1
L1
L2
L3
N
OUTPUT
INPUT
Y
N
-
X
E
E
X
-
N
Y