Ridder MotorControl RMC400 User manual

265047EN - 2019.12 - V04
Original product-manual
Ridder MotorControl RMC400
Product Manual
Lorentzstraat 32
3846 AX Harderwijk
PO Box 360
3840 AJ Harderwijk
the Netherlands
T+31 (0)341 416 854
F+31 (0)341 416 611
Iridder.com
[e-mail]
Ridder Drive Systems B.V.

TABLE OF CONTENTS
1. GUIDELINES, STANDARDS AND CONDITIONS
1.1 Applicable guidelines and standards 3
1.2 Approved personnel 3
1.3 Warning about discouraged use 3
1.4 Warranty provisions 3
2. SAFETY, PRECAUTIONS AND SYMBOLS
2.1 Signal words, instrucons and warnings 4
2.2 Precauons and safety instrucons 4
2.3 Residual risks 6
2.4 Symbols and abbreviaons 6
3. PRODUCT DETAILS
3.1 Idencaon 7
3.2 Descripon 8
3.3 Applicaon 9
3.4 Dimensions 9
3.5 Technical specicaons 9
4. INSTALL INSTRUCTIONS
4.1 Special tools and equipment 13
4.2 Installaon 13
5. CONNECT INSTRUCTIONS
5.1 Electrical material 14
5.2 Protecon - Condions and starng points 15
5.3 Overview and funcon diagram 16
5.4 Wiring diagram: Control board (RCB) 16
5.5 3-phase electric motor (208-600 VAC) 18
5.6 1-phase 3-wire electric motor (115-230 VAC) 19
5.7 1-phase 5-wire electric motor (115-230 VAC) 20
5.8 Limit switch (RSU/RLS) 20
5.9 Automac Control (ACS) (24 V AC/DC) 21
5.10 OPTIONAL - Manual Control (MC) 21
5.11 OPTIONAL - Posion Feedback (RPU) 22
5.12 OPTIONAL - Alarm (AL) 23
6. USER INSTRUCTIONS
6.1 Usage - Condions and starng points 24
6.2 Status LEDs 24
6.3 Operaon 25
6.4 Alarm 26
6.5 Safety funcons and stop funcons 26
7. COMMISSIONING INSTRUCTIONS
7.1 Commissioning - Condions and starng points 27
7.2 Check: Switching sense of the Limit Switch (RSU/RLS) 28
7.3 Check: Control direcon of the Automac Control (ACS) 29
7.4 Check: Control direcon of the Manual Control (MC) 30
8. MAINTENANCE INSTRUCTIONS
8.1 Maintenance 31
9. SERVICE
9.1 Troubleshoong 32
9.2 Blink codes 33
9.3 Technical support 34
10. ENVIRONMENT
10.1 Decommissioning and removal 34
10.2 Waste disposal 35
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1. GUIDELINES, STANDARDS AND CONDITIONS
1.1 Applicable guidelines and standards
This product complies with the provisions of the European guidelines that follow:
Machinery Direcve 2006/42/EC | Low Voltage Direcve 2006/95/EC | EMC Direcve 2004/108/EC
The harmonized standards (or parts of these standards) that follow are applicable:
NEN-EN-ISO 12100:2010 | NEN-EN-IEC 60204-1 |
NEN 82079-1 (62079: 2001) | NEN5509 | ISO 3864-2
Make sure that this product is only put into operaon if the system (in which it will be installed)
complies with the provisions of the applicable standards and guidelines.
1.2 Approved personnel
This product manual contains important informaon for installers about the installaon and
commissioning of a Ridder MotorControl RMC400 control-unit. Read this product manual and
instrucons rst before the work starts. Approved mechanical and/or electrical installers, with
professional competence, must do all work safe and responsible.
TARGET GROUP FOR EACH CHAPTER CHAPTER (refer to Table of Contents)
TARGET GROUP 1 2 3 4 5 6 7 8 9 10
User (operator) • • • • (•)
Installer / Approved personnel • • • • • • • • • •
(•) = Not fully applicable
Keep this product manual with the product during the lifespan. Make sure it is available for users
(operators), installers and approved personnel.
1.3 Warning about discouraged use
The condions that follow are applicable:
• Do not change (the construcon of) the MotorControl RMC400 control-unit.
• It is not permied to use the RMC400 control-unit to li or move people.
Refer to §3.3 for a descripon of the intended use.
1.4 Warranty provisions
For the warranty period and condions refer to the ‘Condions’ secon on our website at ridder.
com, or in the Ridder catalogue.
Regulatory Conformity
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2. SAFETY, PRECAUTIONS AND SYMBOLS
2.1 Signal words, instrucons and warnings
Signal words (ISO 3864-2)
This product manual contains safety instrucons with dierent signal words. The list that follows
gives the risk levels and possible eects of each signal word.
Instrucons and warnings on the product
Read the product manual to fully know all product properes,
before it is used or work starts!
Ê
It is not permied to use high-pressure cleaners (and related
cleaning agents)! Use a so brush with a small quanty of water
without cleaning agents.
Warning - Electrical voltage
2.2 Precauons and safety instrucons
Precauons
GENERAL
A system can be dangerous. Safety precauons and instrucons are important.
• If these precauons cannot be obeyed, then use warnings.
• The responsibility for precauons and warnings lies with the installer of the system. Refer to the,
local or naonal, laws and regulaons of the country if a cercaon (mark) is necessary.
• Parts of the electrical or electronic installaons are connected to dangerous electrical voltages.
Work without professional competence or not obeyed warning instrucons could cause injury
and/or material damage.
Suggeson to perform an operaon more eecve.
May result in damage or problems if an acon is performed
incorrectly.
May result in minor injury if the hazard is not avoided.
Signicant injury, possible death, if the hazard is not avoided.
Severe injury and possible death if the hazard is not avoided.
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• Ridder is not responsible for injury, material damage or consequenal damage if accessories are
used that Ridder did not make.
TRANSPORT, STORAGE AND PACKAGING
The condions and instrucons that follow are applicable.
• Ambient temperature: -15 to +60 °C (+5 to +140 °F).
• Ambient: A not-condensed relave humidity is necessary.
• Do a check for transport damage and missing parts immediately on incoming goods.
• Tell damages and missing parts immediately to the transport company and to your local Aer
Sales contact person.
• Do not use damaged products and if necessary do not start the work.
• Send the product to the installaon site before it is removed from the (sealed) packaging. This
prevents damage (from mechanical shocks) to the product.
• Use applicable means-of-transport with dimensions which are sucient. Use (if necessary) the
correct work equipment and accessories. Refer to “Dimensions” and “Technical specicaons”.
Make sure that the working condions comply with the, local or naonal, laws and regulaons.
• Make sure that storage areas and the areas in the means-of-transport are dry and the airow is
sucient.
• Make sure that the products do not touch the (moist) boom surface of storage areas and of the
means-of-transport (use pallets or such). The boom surfaces must be smooth.
• Make sure that the products are protected from dust, dirt and direct sunlight.
• Apply an applicable corrosion-prevenve agent to surfaces that are not painted.
• Aer installaon discard the packaging and obey the applicable naonal and/or local regulaons.
Safety instrucons
• Use (if applicable) personal protecve-equipment for protecon which agrees with the dierent
types of work.
• Do not let persons and not approved personnel be near controls and systems in operaon.
• Damaged systems must be stopped immediately unl they are repaired.
• Use safety barriers, for system parts that move, to a height of 2.5 m from the ground.
• The safety distance to the danger zone (if applicable) must agree with ISO 13857:2008.
• Do not operate systems when persons are in the danger zone and can touch the system.
• Monitor the danger zone when you work with or near the system.
• Stop and de-energize systems during maintenance and cleaning work on or near the system.
• Make sure that there is sucient space between parts that move and adjacent objects.
• Stay away from or safety areas where there is a risk to become caught in a system that moves.
• The torque and the duty cycle of the system must be in the range of the motor gearbox
parameters. Refer to the product manual of the used Ridder motor-gearbox at ridder.com.
If you do not obey the safety instrucons that follow it can be
dangerous and cause injury.
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2.3 Residual risks
Automac Controls
The Ridder control-units are usually used in automac controlled systems. Persons who do work
or stay near the system must know about that. If persons or their clothes touch the system during
operaon, it can be dangerous.
Forces
Because of the forces in the systems (in which the control unit is installed), Ridder cannot be sure
that there will be no injury to persons or damage to the system.
2.4 Symbols and abbreviaons
This secon tells about used symbols and abbreviaons in this manual. The table that follows gives
the descripons.
Symbol Description Symbol Description
1L1 Power IN (A2) PE Protecve earth
3L2 Power IN (A2) PTC PTC thermistor
5L3 Power IN (A2) RCB Ridder control-board
2T1 Power OUT (EM) RLS Limit-switch system
4T2 Power OUT (EM) RMC Ridder MotorControl
6T3 Power OUT (EM) RPD Ridder PolyDrive
ACS Automac control-system RPR Ridder PowerRoller
AL Alarm (circuit) RPU Digital posioning-meter
A1 RMC400 housing RSU Limit-switch system
A2 Control board RW Motor gearbox
D1 Status LED - Green SW Width-across-ats
D2 Status LED - Red T1, T2, T3 Load connecon
D3 Status LED - Red U1,V1,W1
U2, W2 Motor connecon
D4 Status LED - Red
EM, M Electric motor, Motor X1 Power input (RCB)
ES11,ES12 Duty switch RSU/RLS X2 Power output (EM)
ES21,ES22 Safety switch RSU/RLS X3 Transformer
GND Return wire of control signal (ACS) X4 PTC input
ICurrent in Amperes (A) X5 Fault-contact output
L1, L2, L3 Voltage source X6 Automac-control input
MC Manual Control X7 RPU reference-input
MPCB Motor-Protecon Circuit-Breaker X8 Manual-control input
N Neutral wire X9 Limit-switch input
Persons can be in danger of life if they touch a system that is in
operaon.
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3. PRODUCT DETAILS
3.1 Idencaon
EXAMPLE
Ê
This product manual is only applicable to:
• Ridder MotorControl RMC400 control-unit
• Serial numbers from 200.900.000
• Item numbers from 500000.
Idencaon is possible from the scker on the locaon shown.
Refer to the explanaon that follows on how to read the informaon.
For more informaon on item numbers and models refer to the
Ridder catalogue or website at ridder.com.
0.4-0.6: Current (I) in Ampère (A).
3: 3~ mains voltage.
Alternatives
1-3: 1~ -3~ mains voltage.
Alternatives
115-400: Mains voltage 115 V/230 V (1~) or 208 V/400 V (3~).
RMC400: General designaon Ridder RMC400 control units.
1~ - 3~ = 1-phase and 3-phase
0.6-1.0 A, 1.0-1.6 A, 1.6-2.5 A, 2.5-4.0 A, 4.0-6.3 A or 6.3-10 A.
3~ = 3-phase
400: Mains voltage 400 V (3~).
440-600: Mains voltage 440 V, 480 V or 600 V (3~).
Alternatives
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3.2 Descripon
The RMC400 is a control unit to control Ridder motor-gearboxes. All
the electrical components of the RMC400 control-unit are built-in to
a plasc housing. Supply is with or without a motor-protecon circuit-
breaker (MPCB) and manual control (MC).
The control unit is applicable to:
• Dierent supply voltages
• Dierent mains frequencies
• 3-phase and 1-phase voltages.
The control unit has a control board with a microprocessor and a
semiconductor relay.
The control board has connecons for:
• The supply voltage
• The power supply for the electric motor (EM)
• An automac control signal (24 V AC/DC) from an automac control-system (ACS)
• A manual control (MC) (units without a built-in MC)
• A fault contact (NC) that can be part of an alarm circuit
• A PTC thermistor in the electric motor (EM) for thermal protecon
• A digital posioning-meter (RPU).
The limit-switch system is also connected to the control board of the control unit.
The RMC400 control-unit transmits control signals from the automac control-system (ACS) or
manual control (MC) and monitors if these are processed without malfuncons. The control unit has
rotaonal-eld detecon and phase detecon of the supply voltage.
The 24 V AC/DC control input is protected from:
• Control in two direcons at the same me
• Sudden changes of direcon.
The control unit has status LEDs to show error messages of the system.
The RMC400 control-unit has plug connectors and terminal strips to connect the cables. To pull the
cables through, out of the housing, the control unit also has cable glands. The protecon rang of
the RMC400 housing is IP54.
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3.3 Applicaon
The control unit is used to control Ridder motor gearboxes in two direcons-of-rotaon.
The RMC400 control-unit is applicable to:
• RW motor gearboxes
• RPR PowerRollers
• RPD PolyDrives.
For other (dierent) applicaons, approval from Ridder Drive Systems is necessary.
3.4 Dimensions
Note: The dimensions and illustraons are approximate. In this product manual shown illustraons
can be dierent than the components and/or systems.
3.5 Technical specicaons
Mechanical
Dimensions (WxHxD) 254 mm x 313 mm x 147 mm (with MC)
254 mm x 313 mm x 117 mm (without MC)
Weight 2.4 - 3.2 kg
Ambient
Protecon rang IP54
Ambient temperature 0 to +60 °C (+32 to +140 °F)
Maximum relave humidity 95%
254
6.5
313
147 231
291
117
3
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The three types of control boards (RCB) that follow
are available for the RMC400 control-unit.
RCB-A (Type A):
50/60 Hz AC
1~ 115V-230 V, 12FLA, 72 LRA
3~ 208-400 V, 12 FLA, 72 LRA
RCB-B (Type B):
50/60 Hz AC
3~ 400 V, 10 FLA, 60 LRA
RCB-C (Type C):
50/60 Hz AC
3~ 440-600 V, 10 FLA, 60 LRA
Refer to the table that follows for abbreviaons,
technical specicaons and descripons of all
connecons.
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Electrical
Supply voltage
X1 Power supply Type 1-phase (1~) 3-phase (3~) Current
1L1
3L2
5L3
N*
RCB (A2)
RCB (A2)
RCB (A2)
RCB (A2)
Input
Input
Input
Input
RCB-A
1x 115 VAC
1x 230 VAC
RCB-A
-
-
3x 208 VAC
3x 400 VAC
RCB-B
3x 400 VAC
RCB-C
3x 440-480 VAC
3x 600 VAC
Max 12 A
X2 Power supply Type
2T1
4T2
6T3
N*
Electric motor (EM)
Electric motor (EM)
Electric motor (EM)
Electric motor (EM)
Output
Output
Output
Output
*N is only there on RCB-A.
X3
RCB-A
Transformer Supply voltage
1 2 3 4 5 Type 1-phase (1~) 3-phase (3~) Current
1~ Loop connecon 1x 115 VAC N.A. ~16 mA
1~ Loop connecon 1x 230 VAC N.A. ~10 mA
3~ Loop connecon N.A. 3x 208 VAC ~10 mA
3~ Loop connecon N.A. 3x 400 VAC ~ 4 mA
(X3)
RCB-B
Transformer Supply voltage
1 2 3 4 5 Type 3-phase (3~) Current
3~ N.A. N.A. N.A. 3x 400 VAC
X3
RCB-C
Transformer Supply voltage
1 2 3 Type 3-phase (3~) Current
3~ Loop connecon N.A. 3x 440-480 VAC
3~ Loop connecon N.A. 3x 600 VAC
X4 PTC IN Type Supply voltage Current
1PTC Input 0.25 V DC 1 mA
2PTC’ Power supply 0.25 V DC 1 mA
X5 Fault-contact OUT Type Supply voltage Current
1Not connected Loop-connecon pin Max 350 V Max 50 mA
2Fault OUT Switching contact Max 350 V Max 50 mA
3Fault OUT’ Switching contact Max 350 V Max 50 mA
X6 ACS Type Supply voltage Current
1Direcon B Input 24 V AC/DC 10.5/10 mA
2Common Ground Ground 10.5/10 mA
3Direcon A Input 24 V AC/DC 10.5/10 mA
X7 RPU Type Supply voltage Current
1+24V Power supply 24 V DC 50 mA
2RPU CALIBRATION A Output 24 V DC 0.5/1 mA
3RPU CALIBRATION B Output 24 V DC 0.5/1 mA
4Neutral wire Power supply
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Electrical
X8 MC Type Supply voltage Current
1+24V Power supply 24 V DC Max 15.7 mA
2Direcon A Input 24 V DC 2.1 mA
3 Auto Input 24 V DC 2.1 mA
4Direcon B Input 24 V DC 2.1 mA
5LED Output 24 V DC 4.7 mA
6LED Output 24 V DC 4.7 mA
X9 Limit-switch IN Type Supply voltage Current
1Common Power supply 7 V DC 3.3 mA
2Direcon B Input 7 V DC 1.1 mA
3Direcon A Input 7 V DC 1.1 mA
4Safety Input 7 V DC 1.1 mA
D1-D4 LED
D1 Green
D2 Red
D3 Red (RPU)
D4 Red (RPU)
4. INSTALL INSTRUCTIONS
Installaon is only permied to approved personnel.
The RMC400 control-unit is available:
• With a built-in motor-protecon circuit-breaker (MPCB) and manual control (MC)
• Without a built-in motor-protecon circuit-breaker (MPCB) and manual control (MC).
Do a check of the supplied parts in the table that follows.
Parts list
580000 RMC400 control-unit 1x 272031 Cable gland M20\IP68\PA\LC 5x
272033 Nut M20 PA 5x
NOTE: The installer must install the supplied cable glands and nuts as necessary.
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4.1 Special tools and equipment
No special tools or equipment are necessary to install, to connect or for commissioning.
4.2 Installaon
The condions and starng points that follow are applicable for installaon. Make sure that the
working condions comply with the, local or naonal, laws and regulaons.
• Do not remove the product from the packaging unl a short me before the installaon.
• Use the correct work equipment and accessories (belts, chains, pallets or such) if it is not
permied or possible to put the product manually in posion.
• The RMC400 is applicable for wall mounng.
• Make sure that you can see the operated system from all control units and control systems. Put
control units and control systems at a height of more than 1.5 m.
• The RMC400 gives informaon about the system with LEDs on the control board. Thus, easy
access and a sasfactory view is recommended for the locaon of the RMC400.
Removal cover
• Loosen the cover screws (4x, slot ± 9x2 mm) and the cover temporarily to do all necessary work.
The gasket usually stays in its posion.
• Make sure that no damage is caused to the gasket and that it does not become dirty.
• Install the cover again aer the work! Refer to the end of chapter 7.
Make sure that the correct equipment and tools are used.
Make sure that easy access to the cover of the RMC400 control-unit
is possible for all work.
(4x)
Slot
± 9x2 mm
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Cable glands
• Select the necessary number, and locaon in the boom of the housing, for the cable glands
M20. Refer to the applicable connecons in chapter 5.
• Drill the holes of ø20 mm and install the cable glands (SW24) with the nuts (SW26).
Note: Make sure that no damage is caused to the cables and the control board!
Installaon
• Install the RMC400 unit with four screws or such (maximum ø6 mm/ø11.5 mm) in the mounng
holes. The locaons of the mounng holes (recommended for the IP protecon-rang) are in the
corners of the housing!
5. CONNECT INSTRUCTIONS
Only to approved personnel it is permied to do the connect instrucons.
5.1 Electrical material
A minimum conductor diameter of 1.5 mm² is applicable to the cables in the wiring diagrams. For
the used components, electrical material and cable lengths the necessary conductor diameter can
be dierent.
272033 (5x)
ø20 mm (5x)
28 mm < Y < 40.5 mm SW=24 mm (5x)272031 (5x)
SW=26 mm (5x)
Cables!
Control Board !
Y
Y
< ø11.5 mm (4x)
< ø6 mm (4x)
Use only applicable components and electrical material. Always refer
to the related informaon and manuals.
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5.2 Protecon - Condions and starng points
The condions that follow are applicable to the wiring diagrams.
• The installer makes sure that necessary and not shown protecons are used and included in the
wiring diagrams.
• If applicable, it is possible to connect a PTC thermistor. Refer to diagrams §5.5, §5.6 and §5.7.
• Protect the electric connecons from moist condions.
Inducon
Problems with inducon must be prevented. Inducon can cause an interference with the
electronics.
Inducon can have many causes such as:
• Cable lengths
• External sources
• Too many cables together.
Electrical connecons are only permied to an electrotechnical
installer or an electrician.
For installaon and maintenance work the system must be de-
energized.
Always make sure that the protecons comply with the, local or
naonal, laws and regulaons of the country.
The installer sets the Motor-Protecon Circuit-Breaker (MPCB) to the
value of the nominal current of the electric motor.
The RMC400 does not have a short-circuit protecon and overload
protecon. To get the necessary safety, refer to the local or naonal
laws and regulaons of the country.
Separaon of cables is necessary. This prevents problems with
inducon.
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5.3 Overview and funcon diagram
The diagram that follows shows the RMC400 control-unit in a system. Ridder Drive Systems
connects the components (if applicable) in the framework A1.
5.4 Wiring diagram: Control board (RCB)
The diagrams that follow show:
• The RMC400 housing (A1) and the RCB control-board (A2)
• The standard connecons and oponal connecons with related connectors
• The related secons with the wiring diagrams and informaon.
If units have a built-in MPCB and MC, then Ridder connected:
• X1 to the motor-protecon circuit-breaker (MPCB) with standard 3-phase connecons. If
applicable, refer to the related secons (§5.6/§5.7) to change to 1-phase connecons!
• X8 to the manual control (MC).
Alarm
Automac Control Manual Control
Control Board
Supply Voltage
Temperature
Limit Switch
Power Supply 24 V DC
Supply Voltage
24 V AC/DC Control
Fault Contact
OPTIONAL
OPTIONAL
Reference Monitoring
Posion Feedback
OPTIONAL
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RMC400 housing:
RMC400 control-board (RCB):
OPTIONAL
Alarm
§5.12 OPTIONAL
§5.10 OPTIONAL
§5.11 OPTIONAL §5.5/ §5.6/ §5.7
CONTROL BOARD A2 (RCB)
Manual Control
Posion Feedback
Power In
* X3 is not there on RCB-B
Automac Control Transformer Conguraon Power Out
§5.9
Limit Switch Thermal Protecon
§5.5/ §5.6/ §5.7
§5.8
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5.5 3-phase electric motor (208-600 VAC)
• Make sure that the conguraon (RCB-A or C) on X3 (TRANSFORMER) agrees with the supply
voltage!
• Connect the electric motor (EM) to X2 (MOTOR).
• If applicable, remove the jumper from X4 and connect EM to X4 (PTC)
• Connect the supply voltage to the MPCB (if applicable) or X1 (MAINS), and PE (protecve earth).
Control board A2
(Out) (In)(In)
6 x 1,5 mm²
4 x 1,5 mm²
YES NO
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5.6 1-phase 3-wire electric motor (115-230 VAC)
• Make sure that the conguraon (RCB-A) on X3 (TRANSFORMER) agrees with the supply voltage!
• Connect the electric motor (EM) to X2 (MOTOR).
• If applicable, remove the jumper from X4 and connect EM to X4 (PTC)
• If the unit has a built-in MPCB, make sure to change the standard 3-phase connecons to 1-phase
connecons! The diagram of §5.5 (X1) must change to the diagram of §5.6 (X1, X2, MPCB).
• Connect the supply voltage to the MPCB (if applicable) or X1 (MAINS), and PE (protecve earth).
Control board A2
(Out) (In)(In)
6 x 1,5 mm²
3 x 1,5 mm²
YES NO
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5.7 1-phase 5-wire electric motor (115-230 VAC)
• Make sure that the conguraon (RCB-A) on X3 (TRANSFORMER) agrees with the supply voltage!
• Connect the electric motor (EM) to X2 (MOTOR).
• If applicable, remove the jumper from X4 and connect EM to X4 (PTC)
• If the unit has a built-in MPCB, make sure to change the standard 3-phase connecons to 1-phase
connecons! The diagram of §5.5 (X1) must change to the diagram of §5.7 (X1, X2, MPCB).
• Connect the supply voltage to the MPCB (if applicable) or X1 (MAINS), and PE (protecve earth).
5.8 Limit switch (RSU/RLS)
Connect a limit switch (RSU/RLS) to X9 of the control board (A2). Refer to the diagram that follows.
Also refer to the product manual of the used Ridder motor-gearbox at ridder.com.
Control board A2
(Out) (In)(In)
8 x 1,5 mm²
3 x 1,5 mm²
YES NO
Control board A2
Common
Safety
Safety switches Duty switch Duty switch
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