Kinesys Elevation 1 Plus User manual

© 2011 Kinesys Projects Ltd
Elevation 1+
Manual Version 1.8.0
Product Manual

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indirectly by this document.
Printed: March 2011
Elevation 1+
© 2011 Kinesys Projects Ltd
Publisher
Technical Editors
Kinesys Projects Ltd
Dave Weatherhead
Martin Honeywill
Andy Hicks

3Contents
© 2011 Kinesys Projects Ltd
Table of Contents
Part 1 Introduction 4
Part 2 Safety Advice 5
Part 3 Left Side 6
Part 4 Right Side 7
Part 5 Front View 8
Part 6 Specifications 9
Part 7 Cable Specification 10
Part 8 Software 11
Part 9 Menus 12
...................................................................................................................................131Menu Operation
...................................................................................................................................14
2Fault Conditions
...................................................................................................................................16
3Menu Structure
Part 10 Position Controller 20
Part 11 Unit Configuration 22
Part 12 Limits 24
...................................................................................................................................261Setting the Software Travel limits without a computer
Part 13 Manual and Remote Running 28
Part 14 System Integration 29
...................................................................................................................................301Elevation 1+ System Diagram Simple
...................................................................................................................................31
2Elevation 1+ Full System Diagram
Part 15 Replacing an Elevation 32
Part 16 Using an Elevation with RCDs 35
Part 17 Contact Information 36

4 Elevation 1+
© 2011 Kinesys Projects Ltd
1 Introduction
The Elevation 1+ chain hoist controller allows variable speed running and full positional
control of electric chain hoists. Any electric chain hoist that has been converted to the
correct specification can be operated by the Elevation 1+.
One significant advantage of converting motors to the Elevation 1+ specification is that
they can still be operated using a traditional motor controller without further
modifications. This allows the motors to be used with basic controller for pre-show
rigging and then be put onto the Elevation control system at a later stage allowing for
savings in rental costs to be achieved.
Elevation 1+ is provided in a hard-wearing aluminium case with a multitude of fixing
points and options available and uses rugged industry standard connections
throughout. Although designed to be operated by an external controller during show
conditions the Elevation 1+ has provision for full variable speed manual control on the
unit as well as a socket to allow a remote handset to be plugged to give basic running in
rigging applications or when a remote means of operating the units is required to offer
backup to the main computer controller.

5Safety Advice
© 2011 Kinesys Projects Ltd
2 Safety Advice
If in doubt about any aspect of moving objects always seek professional advice.
SAFETY MUST ALWAYS BE THE FIRST PRIORITY!
•If you are unsure of any aspect of moving loads with the system stop and seek
professional advice on the appropriate usage of the system.
•Never run the system without all and emergency stop switches connected and in
position. “Cheater” plugs (where supplied) are for the purpose of maintenance and
fault-finding only, and should never be used to bypass the emergency stop system
during a performance.
•Ensure all operators and maintenance personnel are aware of the location of
emergency stop switches.
•Test the emergency stop system daily.
•Never operate hoists without having a clear view of the load or reliable communication
with an observer
•If an unexpected move presents a potentially hazardous situation, use the emergency
stop button to bring all axes to an immediate stop.
•Use extreme caution when using any limit bypass facilities in the system.
•Carry out a full risk assessment for your particular application.
•Only allow competent personnel to operate the system.

6 Elevation 1+
© 2011 Kinesys Projects Ltd
3 Left Side
1
2
3
1. Mains Inlet Gland - supplied with cable to a 32A 3PN+E plug.
2. Mains Outlet Connector - unprotected pass-through.
3. Air Intake Grilles - these must not be obstructed or blocked.

7Right Side
© 2011 Kinesys Projects Ltd
4 Right Side
Right Side
1234
5
6
1. Remote Controller – this can be used for connecting a fixed or variable speed
up/down pendant.
2. Load Cell – allows the connection of an external load cell for monitoring the load
applied to the motor.
3. Data/Control In – data, supply voltage, emergency stop and remote enable are
supplied through this connection.
4. Data/Control Thru – direct pass-through connection for all the data/control in
connections.
5. Fan Outlet – this must be kept clear at all times to allow the free flow of air through
the unit.
6. Hoist Connection – motor, brake and control voltage to the hoist, limit and encoder
feedback from the hoist are all provided through this connector.

8 Elevation 1+
© 2011 Kinesys Projects Ltd
5 Front View
Front View
1
2
3
45
6
7
8
9
10
1. Control MCB – switches the control transformer and electronics. If the unit is linked to
others then turning this off may not turn off the electronics as these can be phantom
powered by other units. Disconnect the data/control in and thru connectors as well to
ensure that the unit is off.
2. Drive MCB – switches power to the drive and brake supply voltage to the hoist. The
hoist is safe and cannot be moved if this circuit breaker is off.
3. Menu Display – displays all the information about the unit status and position as well
as allowing viewing and alteration of menu parameters.
4. Menu Button – accesses the menu system and navigates backwards through the
menu tree once within it. When pressed in conjunction with enter it alternates the unit
in and out of manual mode.
5. Enter Button – confirms selections within the menu system. When pressed in
conjunction with menu it alternates the unit in and out of manual mode.
6. Menu Up Button – moves up the current menu items, increments the currently
displayed parameter value or when used in conjunction with the down button allows
the ultimate limit to be bypassed.
7. Menu Down Button – moves down the current menu items, decrements the currently
displayed parameter value or when used in conjunction with the up button allows the
ultimate limit to be bypassed.
8. Manual Up Button – enables the hoist to be run upwards locally without the use of an
external controller.
9. Manual Down Button – enables the hoist to be run downwards locally without the
use of an external controller.
10.Manual Speed Control – set the speed of all local manual moves.

9Specifications
© 2011 Kinesys Projects Ltd
6 Specifications
Supply Voltage 208v or 380v 3 phase,
neutral and earth.
Unit type preset, not user
configurable.
Supply Current Dependent on motor
type
Nominally 5A (10A for 208v)
Ambient
Temperature
-10° C to 55° C
IP rating Dependant of unit
positioning.
All electrical connections and case
openings must be protected from
water ingress.
Communications RS485 specification
Control Signals 0 - 24v d.c.
Emergency Stop Single wire 12v system –
category 2 rated
Dimensions 424w x 240h x 130d Excluding fixing hardware and cable
glands
Weight 9.5 Kg Excluding fixing hardware

10 Elevation 1+
© 2011 Kinesys Projects Ltd
7 Cable Specification
Data Cable
Male Connector: XLR7M
e.g. Neutrik NC7MX or NC7MX-B
Female Connector: XLR7F
e.g. Neutrik NC7FX or NC7FX-B
Note: alternative manufacturer’s connectors may have different pin configurations –
check compatibility with Neutrik parts before use
Cable: 3-pair 22AWG with overall shield 100/120 ohm nominal impedance
e.g. TMB “ProPlex” PC226T (for portable / touring use) Alpha 6213C (for installation use)
Cable Colour Code
Pin Function Colour (PC226T) Colour (6213C) Pair
1Data Ground shield shield shield
2Data - black black (red) pair 1A
3Data + white red pair 1B
424V DC red black (white) pair 2A
50V green white pair 2B
6Emergency Stop (12V) blue black (green) pair 3A
7Enable (24V) orange green pair 3B
Power Cable (400V Units)
Male Connector: 32A 5-pin plug “Ceeform” type Red 6h earth position
e.g. Walther 230
Female Connector: 32A 5-pin coupler “Ceeform” type Red 6h earth position
e.g. Walther 330
Cable: 5-core 6mm² 400V/700V rated (H07)
e.g. Lapp Cable 1600 1313 (H07RN-F) for portable use
Cable Colour Code
Pin Function Colour
EEarth green/yellow
L1/R Live 1 brown
L2/S Live 2 black
L3/T Live 3 grey
N Neutral blue

11Software
© 2011 Kinesys Projects Ltd
8 Software
The Elevation 1+ controller is equipped with custom position controller software that
allows a high degree of positional and speed accuracy to be achieved. Several
parameters within the software can be altered via the user interface provided by the LED
display on the front of the unit. A complete list of menus and parameters is included in
this manual. The majority of parameters can also be downloaded from the controlling
computer allowing rapid initial set-up and alteration of these settings.

12 Elevation 1+
© 2011 Kinesys Projects Ltd
9 Menus
Four buttons are available to operate the menu system: menu, enter, up and down.
Power Up
The display briefly shows the firmware revision number.
Normal Stationary Operation
Elevation 1+ display showing address 1
Elevation 1+ display showing a position of 5752mm
The display oscillates between showing comms address and position. Position is shown
as a right justified number and address has a right justified number but with an A in the
left most character. The two displays alternate every two seconds.
Normal Moving Operation
While the unit is moving the display will only show the position.
Manual/Auto operation
To operate the unit manually press the menu and enter buttons together. The unit will
show MANUAL in the display while stationary. Pressing menu and enter again will revert
to automatic mode. When this is done AUTO will show in the display for 2 seconds
before reverting back to the normal operation outlined above. There is a 2 minute
timeout on the manual mode. This timer is reset to 2 minutes every time the unit is run in
manual mode. After two minutes of inactivity the unit will revert to automatic mode as if
the menu and enter buttons had been pressed.

13Menus
© 2011 Kinesys Projects Ltd
9.1 Menu Operation
Pressing and holding the menu button for two seconds in any mode other than while the
unit is moving will allow the user to access the menu structure. There are two menu
modes.
Menu Navigation
Pressing menu from the start display enters the first menu level. Menu up and menu
down will move up and down the menu items on the first level. The menu rolls over to
the first item after the last one is reached and vice versa. Pressing enter will move into
either the selected sub-menu or will show the selected parameter value.
Parameter Edit
With the parameter value displayed the menu up and menu down buttons will scroll the
value shown within the allowable range of values. Pressing menu will return to the
previous sub-menu and the value will remain unchanged. Pressing enter will save the
new value and return to the previous sub-menu. The scroll is variable speed with the
speed of value change increasing the longer the button is pressed.

14 Elevation 1+
© 2011 Kinesys Projects Ltd
9.2 Fault Conditions
If the unit detects a fault condition the display will flash the error code on the display.
When the code is not displayed then the display is blank. The following errors codes are
possible.
drvcan - Shown when the drive is powered down. The fault
indicates a CAN Bus communications failure between the drive
and control card.
drv - Shown when the drive is tripped. The letters drv are
followed by the fault code read from the drive e.g.  =
Earth Fault
If the Elevation shows the letters drv without a Fault code, then
the Elevation has been switched to Analogue mode. This mode
needs to be turned off, in the setup menu.
limit - Ultimate limit struck
upper - Upper over-travel limit struck
lower - Lower over-travel limit struck
U Soft - Upper Soft limit reached
L Soft - Lower Soft limit reached
OLoad - Overload detected
ULoad - Underload detected
OSpeed - Overspeed detected, the motor is traveling faster than
demanded
USpeed - Underspeed detected, the motor is traveling slower
than demanded
Udog - Comms watchdog trip, a status stationary message was
received while a move was in progress

15Menus
© 2011 Kinesys Projects Ltd
Comms – Communications timeout no comms received in 2
seconds (Shown on display for 15 seconds after timeout occurs,
even if comms returns - cleared after 15 seconds)
Enc 1 - No encoder count detected
Enc 2 - Encoder reversed
Emergency Stop Trip
Unit is resetting
Running ROM firmware. Firmware update required

16 Elevation 1+
© 2011 Kinesys Projects Ltd
9.3 Menu Structure
Setup
Limits Upper
Data Max Upper Travel
Lower
Data Max Lower Travel
Bypass On
Off
Default
Ultimate Bypass
On
selectable when
ultimate struck
Off
Default setting
Default Speed
Data mm/s
Accel
Data mm/s/s
Decel
Data mm/s/s
Fast Decel
Data mm/s/s

17Menus
© 2011 Kinesys Projects Ltd
Clamps Max Speed
Data
Accel
Data
Decel
Data
Min Speed
Data
Accel
Data
Decel
Data
Offset Up
Data
Down
Data
Encoder
Data Encoder Pulses per mm
Parameters 1
Data Proportional Gain
2
Data Integral Gain
3
Data Derivative Gain

18 Elevation 1+
© 2011 Kinesys Projects Ltd
4
Data Min Drive Speed
5
Data Max Drive Speed
6
Data Pos Trip Distance
7
Data
Analog Off
Default
On
Display Flip Off
Default
On
Comms
Address
Data Comms Address
Data
Position
Data Current Position

19Menus
© 2011 Kinesys Projects Ltd
Version
Data Software Version
Product ID
Data Product Identification Code
License
Data Product License Code

20 Elevation 1+
© 2011 Kinesys Projects Ltd
10 Position Controller
The advanced position controller inside the Elevation 1+ unit takes the move profiles
that are sent to it by the controller and translates them into movement commands for the
internal drive electronics. The control software use a closed loop ‘PID’ system to
regulate the speed and position of the hoist at any given moment. The Proportional,
Integral and Derivative (PID) sections of the control loop each have a unique effect on
the accuracy and smoothness of the final motion and consequently the ‘tuning’ of these
parameters can be crucial to the correct functioning of the unit.
NOTE: Only adjust these parameters if you are confident of your abilities to tune
the system. The Elevation 1+ is supplied with a default set of parameters which are
designed to work in the vast majority of situations and environments. When tuning
the drive be sure that the device and load are free and safe to move and that there
is physical room to allow for unexpected movement and behaviour.
P1 - Proportional Gain (Default value 25000)
The proportional gain in the system creates an output that is proportional to the position
following error (the difference between its current location and its ideal location). This
gain is not affected by speed and ramps and provides the majority of the feedback
require to keep the system working correctly.
P2 - Integral Gain (Default value 1500)
The integral gain creates an output that is proportional to the sum of the errors that have
occurred during the system operation. Its effect is to reduce small steady-state position
errors. Integral gain has most effect in ensuring that the desired speed is followed as
accurately as possible and therefore applies most during the cruise phase of a move
profile.
P3 - Derivative Gain (Default value 00250)
The derivative gain is a function of the measured velocity and improves the high
frequency closed loop response. Derivative gain is the most volatile of the three settings.
Its effect is most pronounced during the acceleration and deceleration phases of a move
profile. An incorrect value for this setting can lead to instability during movement and
potentially erratic behaviour.
P4 - Min Speed Output Value To Drive (Default value 50 = 1hz)
The minimum raw speed value that can be sent to the drive. This value is measured in
units of 0.02Hz. Used to set the minimum drive speed required to obtain movement. This
value is used with the max speed output parameter to limit the range of the PID loop.
The Elevation 1+ Firmware only uses the lower 16 bits as an unsigned integer.
P5 - Max Speed Output Value To Drive (Default value 5000 = 100hz)
The maximum raw speed value that can be sent to the drive. This value is measured in
units of 0.02Hz. Used to set the maximum drive speed that may be permitted. This value