MagForce motor system installation: Difference between revisions
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<div style="font-size:84%">'''[http://www.ChimeMaster.com Home] > [[Chime_Master_Help|Help]] > [[Installation_documentation|Installation]] '''</div><br /> | <span class="crumbs"><div style="font-size:84%">'''[http://www.ChimeMaster.com Home] > [[Chime_Master_Help|Help]] > [[Installation_documentation|Installation]] '''</div><br /></span> | ||
[http://www.chimemaster.com/swinging-motors Chime Master MagForce™] swinging bell systems feature a unique touch-less, friction-less and nearly silent motor technology. A stationary drive module induces electro-motive eddy-current forces into a reactor plate mounted to the free swinging bell assembly. A wall mounted motion control panel intelligently experiments and quickly learns the unique physical properties of your bell then carefully manages the energy required for accurate ringing. | [http://www.chimemaster.com/swinging-motors Chime Master intelliSwing MagForce™] swinging bell systems feature a unique touch-less, friction-less and nearly silent motor technology. A stationary drive module induces electro-motive eddy-current forces into a reactor plate mounted to the free swinging bell assembly. A wall mounted motion control panel intelligently experiments and quickly learns the unique physical properties of your bell then carefully manages the energy required for accurate ringing. | ||
== Mechanical considerations == | == Mechanical considerations == | ||
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=== Straight head stocks === | === Straight head stocks === | ||
A straight head stock, especially when not incorporated with counterweight above the bell (with either a wooden head stock or additional iron weights), will require a powerful motor to swing the bell. | A straight head stock, especially when not incorporated with counterweight above the bell (with either a wooden head stock or additional iron weights), will require a powerful motor to swing the bell. | ||
=== | |||
=== Mounting the stationary motor brick === | |||
The center of the motor should be mounted at a minimum 80% of the bell diameter down from the top of the bell. For straight yokes (and flying clappers), this will be the length of the reactor plate mounting arms. | The center of the motor should be mounted at a minimum 80% of the bell diameter down from the top of the bell. For straight yokes (and flying clappers), this will be the length of the reactor plate mounting arms. | ||
Motors can be mounted above the bell (at the same radius from the pivot point) if the weight of the reaction plate is taken into consideration when designing the head stock crank depth. This will also slow the ringing tempo. Do not mount the motors above the pivot on existing cranked head stocks, the bell will not ring properly. | Motors can be mounted above the bell (at the same radius from the pivot point) if the weight of the reaction plate is taken into consideration when designing the head stock crank depth. This will also slow the ringing tempo. Do not mount the motors above the pivot on existing cranked head stocks, the bell will not ring properly. | ||
The motor should be mounted to a 1/4 to 3/8 inch aluminum plate when possible to serve as a heat sink. The plate can then be spaced out from the frame with threaded rod for positioning toward the reaction plate. | |||
The motor induction housing should be painted with a polyurethane coating for UV resistance when used outside, and can be painted with the tower to match. | The motor induction housing should be painted with a polyurethane coating for UV resistance when used outside, and can be painted with the tower to match. | ||
== | === Mounting the reaction plate === | ||
The reaction plate should be centered vertically on the center line of the motor brick. | |||
Securely fasten the reaction plate to the wheel when possible, centered on the stationary motor brick. There should be about a quarter-inch gap between them and the mounting design should be rigid enough that you cannot pull them together by hand. During operation, the plate will be magnetically attracted to the motor, and the rigidity is required for sufficient swinging torque. | |||
== Low current feedback connections == | |||
[[File:MagForce-prxsw.jpg|frameless|right]] | [[File:MagForce-prxsw.jpg|frameless|right]] | ||
The motor control circuit needs some motion feedback from the bell to determine that it is swinging properly. We offer two types of feedback devices to accomplish this. The wiring requirements are the same for both | The motor control circuit needs some motion feedback from the bell to determine that it is swinging properly. We offer two types of feedback devices to accomplish this. The wiring requirements are the same for both. Four conductors of a telco or CAT5 cable usually suffice for this low current 12V signaling. | ||
=== Precision rotary motion sensor (standard) === | |||
This option is used with a MagForce motor improved motion feedback. The rotary encoder is mounted to a non-moving part (like an A-stand) with pulleys and belt to sense the precise angular movement of the swinging bell axle. A separate logic translator is supplied in a weatherproof box and may be used as a junction box at the bell location. | |||
There are four wires used in the encoder cable that connect to the translator: | |||
Green to quadrature input '''A''' on the translator | |||
Gray to quadrature input '''B''' on the translator | |||
Brown to input '''+V''' on the translator (+5VDC) | |||
White to input '''0V''' on the translator | |||
The translator outputs connect one to one to the motion controller sensor inputs: '''P''' (pulse), '''D''' (direction), '''+''' (positive power, +12VDC), '''-''' (negative power). | |||
For rotary encoder systems, verify that the label on the CPU chip of the motor control system says "SENSOR." Use the '''[[IntelliSwing_Rotary_installation#Programming_the_controller|rotary motor programming procedure]]''' and set the Transmission value to 22.8. | |||
=== Proximity sensor === | |||
These sensors are not used in recent installations. | |||
A three wire (60 inch cable) proximity sensor provides output when a bolt head or metal flag is about 1/4 inch away. Typically, a bolt is mounted to protrude from the bell wheel or head stock assembly. A stainless steel sheet metal flag is also supplied that can be mounted with dual adhesive foam tape or epoxy to the wheel or head stock. | A three wire (60 inch cable) proximity sensor provides output when a bolt head or metal flag is about 1/4 inch away. Typically, a bolt is mounted to protrude from the bell wheel or head stock assembly. A stainless steel sheet metal flag is also supplied that can be mounted with dual adhesive foam tape or epoxy to the wheel or head stock. | ||
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For proximity sensor use, verify that the motor control computer chip is labeled "PERIOD." | For proximity sensor use, verify that the motor control computer chip is labeled "PERIOD." | ||
The cable on the sensor has three wires that connect to the sensor input of the motion control computer: | The cable on the sensor has three wires that connect to the sensor input of the motion control computer (use a small screwdriver to depress spring loaded contacts): | ||
Blue (negative power) to '''-''' on the circuit board | Blue (negative power) to '''-''' on the circuit board | ||
Brown (positive power) to '''+''' on the circuit board | Brown (positive power) to '''+''' on the circuit board | ||
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If you use a cable with other colors to extend these wires, make note of the colors you splice together, so the connections to the control computer circuit board are correct. | If you use a cable with other colors to extend these wires, make note of the colors you splice together, so the connections to the control computer circuit board are correct. | ||
== System electrical connections == | == System electrical connections == | ||
Downloadable riser diagrams (pdf suitable for 11x17 paper): | Downloadable riser diagrams (pdf suitable for 11x17 paper): | ||
* [[Media:T1M1_MagForce_1Phase_Riser.pdf|1-Phase, 1-Hammer, 1-intelliSwing MagForce linear motors]] | |||
* [[Media:T1M1_MagForce_3Phase_Riser.pdf|3-Phase, 1-Hammer, 1-intelliSwing MagForce linear motors]] | |||
* [[Media:CM-RTWA3T1M3H1G3.pdf|3-Phase, 1-Hammer, 3-intelliSwing MagForce linear motors]] | * [[Media:CM-RTWA3T1M3H1G3.pdf|3-Phase, 1-Hammer, 3-intelliSwing MagForce linear motors]] | ||
* [[Media:CM-RTWA3T2M2H2G2.pdf|3-Phase, 2-Hammers, 2-intelliSwing MagForce linear motors]] | * [[Media:CM-RTWA3T2M2H2G2.pdf|3-Phase, 2-Hammers, 2-intelliSwing MagForce linear motors]] | ||
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==== Three phase ==== | ==== Three phase ==== | ||
Three power input terminals will be labeled L1, L2 and L3 in the motor control box. Separate Chime Master relay panels will use only L1 and L2 (single phase) for the controls and clapper/hammer outputs. | Three phase power when available is preferred because a smaller motor may provide the needed torque, and also because the motor does not hum as loud as single phase systems. Three power input terminals will be labeled L1, L2 and L3 in the motor control box. Separate Chime Master relay panels will use only L1 and L2 (single phase) for the controls and clapper/hammer outputs. | ||
==== Single phase ==== | ==== Single phase ==== | ||
Two power input terminals will be labeled L1 and L2 for single phase motor control boxes. | Two power input terminals will be labeled L1 and L2 for single phase motor control boxes. Internal connections to PCBs will use L1 and L3. | ||
=== Control inputs === | === Control inputs === | ||
Swinging bell control relays in the Chime Master panel are connected to an output terminal labeled Common, M1, M2, M3 etc. for each bell output. Connect a wire from the relay panel Common to the terminal marked | Swinging bell control relays in the Chime Master panel are connected to an output terminal labeled Common, M1, M2, M3 etc. for each bell output. Connect a wire from the relay panel Common to the terminal marked L3out (three phase) or L2out (single phase) terminal of the circuit breaker in the MagForce control panel. Connect the output relay panel ''Mn'' terminal for each bell to its corresponding ''Sn'' terminal in the MagForce control panel. | ||
Weather-proof toggle switches for each bell are installed on the front panel (largest bell on the left) in parallel with these control inputs for testing in the tower when the controller is disabled. | Weather-proof toggle switches for each bell are installed on the front panel (largest bell on the left) in parallel with these control inputs for testing in the tower when the controller is disabled. | ||
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=== Motor outputs === | === Motor outputs === | ||
[[File:MagForce-cable.jpg|frameless|right]] | [[File:MagForce-cable.jpg|frameless|right]] | ||
[[File:MagForceMotorTermination.jpg|frameless|right]] | |||
Three wires are required for each bell's motor to the MagForce control box. A cable (18 inch long) is permanently attached to the motor with seven wires (1-6 and ground). They are connected in the bell motor junction box as follows: | Three wires are required for each bell's motor to the MagForce control box. A cable (18 inch long) is permanently attached to the motor with seven wires (1-6 and ground). They are connected in the bell motor junction box as follows: | ||
U output to motor leads 1 and 6 | U output to motor leads 1 and 6 | ||
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==== Single phase MagForce panel ==== | ==== Single phase MagForce panel ==== | ||
The MagForce control panel for single phase will have a capacitor on the output between outputs ''U'' and ''V''. If the motor is sized to require an overload protector, the '' | The MagForce control panel for single phase will have a capacitor on the output between outputs ''U'' and ''V''. If the motor is sized to require an overload protector, the ''L1'' connection to the triac input will be routed in a serpentine fashion through the three overload circuits. This is required to prevent trips caused by the missing phase detection. | ||
== Programming Procedure == | == Programming Procedure (PERIOD proximity) == | ||
[[ | IMPORTANT: | ||
* If a rotary encoder is installed on the headstock spindles (chip on control board has a label marked '''SENSOR''') | |||
** Then go to the '''[[IntelliSwing_rotary_sensor_setup#Programming_the_controller|rotary sensor programming procedure]]''' and use the parameter options there for MagForce Linear motors. | |||
* If the bell with a proximity sensor is being serviced (chip on control board has a label marked '''PERIOD''') | |||
** Then continue to use this programming procedure | |||
=== Using the Terminal === | === Using the Terminal === | ||
The right cursor button will take you through the settings for each bell in the system. From the status window, shown below, you can cursor left to select another bell. To change settings you can increment/decrement using the up and down arrow buttons, or input the value with the numeric buttons and save it with the EXE button. | The right cursor button will take you through the settings for each bell in the system. From the status window, shown below, you can cursor left to select another bell. To change settings you can increment/decrement using the up and down arrow buttons, or input the value with the numeric buttons and save it with the EXE button. | ||
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=== Calibrate Swing Timing === | === Calibrate Swing Timing === | ||
For proximity (period) sensor systems, set the transmission value to 5.0. In order to calibrate the angle of the bell to the swinging period, set the Oscillation value as follows: | For proximity (period) sensor systems, set the transmission value to 5.0. In order to calibrate the angle of the bell to the swinging period, set the Oscillation value as follows: | ||
* Go to the 1Oscillation screen. The default value at the top of the display is 900. The bottom of the display should read "Stop" and " | * Go to the 1Oscillation screen. The default value at the top of the display is 900. The bottom of the display should read "Stop" and "180" (if not set yet) | ||
* Press the '''ON''' button - the display will say ''Measure''. | |||
* Have someone move the bell by hand so that the proximity sensor begins to blink. At this point the number beside "Stop" should begin to change and there should be a blinking asterisk to the right of "Stop." | * Have someone move the bell by hand so that the proximity sensor begins to blink. At this point the number beside "Stop" should begin to change and there should be a blinking asterisk to the right of "Stop." | ||
** If this does not happen, check the sensor connections. If the light on the sensor is on when the flag is near it, and off when the flag moves away, the sensor | ** If this does not happen, check the sensor connections. If the light on the sensor is on when the flag is near it, and off when the flag moves away, the sensor has power (through the + and - wires), but the output signal is not getting to the D input on the control board. | ||
* Swing the bell by hand (or by use the '''EXE''' key to electrically pulse the motor if you can not reach the bell) to a little more than 20 degrees. The bottom number will begin to change first, indicating what the controller estimates the maximum angle of the bell to be based on the fixed period on the top line. | * Swing the bell by hand (or by use the '''EXE''' key to electrically pulse the motor if you can not reach the bell) to a little more than 20 degrees. The bottom number will begin to change first, indicating what the controller estimates the maximum angle of the bell to be based on the fixed period on the top line. | ||
** After five consecutively similar swings, the swing period at the top of the screen should change from the default value of 900 to the actual swinging period of the bell (in milliseconds). | ** After five consecutively similar swings, the swing period at the top of the screen should change from the default value of 900 to the actual swinging period of the bell (in milliseconds). | ||
* After the bell has coasted to about 20 degrees, watch for the period to update then press the '''ON''' key to save it current period. The display will say ''Stop'' and the top period will remain static. | * After the bell has coasted to about 20 degrees, watch for the period to update then press the '''ON''' key to save it current period. The display will say ''Stop'' and the top period will remain static. The bottom right number will indicate the approximated angle that the bell is swinging. | ||
* this measurement is not critical | * this measurement is not extremely critical, but inaccuracies in the period will impact the following: | ||
#The angle that you select below will not be the true angle, but if you can get the bell to ring properly, don't be overly concerned with the number | #The angle that you select below will not be the true angle, but if you can get the bell to ring properly, don't be overly concerned with the number. | ||
#If you set the Oscillation | #If you set the Oscillation period too high, the start period will be too long and the bell may fight against the period at start up. It is better to set the oscillation period to an angle that the motor can reasonably reach with the start pulses than an accurate 20 degrees. | ||
#You can manually swing the bell and the system will display its estimated angle on the bottom line. If you can manually make the bell ring satisfactory by hand, note this | #You can manually swing the bell and the system will display its estimated angle on the bottom line. If you can manually make the bell ring satisfactory by hand, note this displayed angle and put it in the desired angle setting. Only keep this arrangement if the motor is able to start from a standstill with these settings. | ||
=== Select Swing Angle and other parameters === | === Select Swing Angle and other parameters === | ||
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Further experiments (first and second swing) must be re-run if you adjust Angle, PowerStaSwi, Pos-Impuls or Transmiss after calculations are complete. | Further experiments (first and second swing) must be re-run if you adjust Angle, PowerStaSwi, Pos-Impuls or Transmiss after calculations are complete. | ||
The ideal impulse is not written to memory unless I-regulator is zero. It will automatically go to zero when the system has finished calculating the value. If you entered your own value for | The ideal impulse is not written to memory unless I-regulator is zero. It will automatically go to zero when the system has finished calculating the value. If you entered your own value for P-regulator then you will also have to set I-regulator to zero yourself to save it in memory (manual setup mode), then swing the bell again to make sure it works. Adjustments to %Start, %Brake, PowerBrake1 and PowerBrake2 can be made at this time without having to recalculate Ideal pulses. You can test them to be sure the motor overloads do not disengage when this happens. | ||
Do not use braking with retrograde (counterbalanced) clappers. Bell damage from a severe impact may occur if the clapper gets out of phase with the bell and they collide from opposite directions. | Do not use braking with retrograde (counterbalanced) clappers. Bell damage from a severe impact may occur if the clapper gets out of phase with the bell and they collide from opposite directions. | ||
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After everything else is completed, you can adjust the motor overload (if installed on 1HP and larger motors) current setting to trip within 40 seconds of a locked rotor condition. Click the left arrow (5 clicks) from the Status screen until you get to the Test-PKZ page. Press the ON button to turn on all phases in such a fashion that the motor does not run (simulation of a locked rotor). Then adjust the overload so that it trips before the on-screen timer reaches 40 seconds. | After everything else is completed, you can adjust the motor overload (if installed on 1HP and larger motors) current setting to trip within 40 seconds of a locked rotor condition. Click the left arrow (5 clicks) from the Status screen until you get to the Test-PKZ page. Press the ON button to turn on all phases in such a fashion that the motor does not run (simulation of a locked rotor). Then adjust the overload so that it trips before the on-screen timer reaches 40 seconds. | ||
Note that on single phase systems, the load must be routed through all three circuits of the overload. | Note that on single phase systems, the load must be routed through all three circuits of the overload. The W motor lead must be wrapped around and run through each overload circuit in series so all three internal overload heaters have the same temperature. Overloads are designed to detect missing phases this way and will trip quickly if any are detected to be missing. | ||
=== Final Settings === | === Final Settings === | ||
Make a record of the following settings for future reference when setup is complete: | Make a record of the following settings for future reference when setup is complete: | ||
;Bell Number | |||
: 1 is the largest bell | |||
;Dimensions | |||
: Air gap between motor and reactor plate (typically 1/4 to 3/8 inch) | |||
: Center of bearing spindle to center of motor | |||
;Swing Angle | |||
: Intended swinging amplitude angle in degrees | |||
;Transmission | |||
: Rotary code wheel to angle ratio | |||
: ''always set to 5.0'' for proximity sensors | |||
;%Start | |||
: Percentage of swing angle for starting pulses | |||
;%Brake | |||
: Percentage of swing angle for braking pulses | |||
: 0 = No braking, 100 = brake until stopped | |||
;1Oscillation | |||
: Period in milliseconds for one complete swing cycle at 20 degrees of amplitude for proximity sensor calibration | |||
: Reset value is 900, may be less for very small bells, usually higher for most bells | |||
;Pos Option - not used | |||
;PowerStaSwi | |||
: Power reduction using soft-start current limiting 1-8 | |||
: 9=full inrush current which may trip circuit breaker | |||
;Power Brake 1 | |||
: First brake at amplitudes > 20 degrees current limit 1-8 | |||
;Power Brake 2 | |||
: Secondary braking at amplitudes < 20 degrees current limit 1-8 | |||
;StartImp | |||
: Maximum number of impulses allowed before home sensor begins to provide motion feedback | |||
: If no feedback is received after this number of tries, the system will go into safety shutdown | |||
;XtrBrakeImp | |||
: Extra brake impulses after home sensor no longer provides motion feedback | |||
: ''Should be 0'' as blind braking is not advised | |||
;MaxAmpl | |||
: Maximum swinging angle before safety shutdown | |||
: ''Set to 90'' if no obstacles are in the way of the bell swinging high | |||
;P-Regulator | |||
: Proportional regulation factor for correcting motor pulse | |||
;I-Regulator | |||
: Ideal pulse width to maintain selected angle | |||
: This is zero on the terminal when parameters have been successfully calculated and saved | |||
;Pos-Impulse | |||
: Position of the motor impulse in the sweep of the bell | |||
: 0 = home, 100 = turnaround | |||
: ''Always set to 0 for MagForce'' | |||
;Assymmetric | |||
: Proportion of motor pulse for forward/backward balance | |||
: 50 = equal pulses, 100 or 0 = unidirectional drive forward or back | |||
== After setup complete == | |||
Disconnect the programming terminal. The front panel switches and the Chime Master relays will not activate the motors while the programming terminal is connected. | |||
[[Category:Installation]][[Category:Bell automation]] | [[Category:Installation]][[Category:Bell automation]] | ||