The Big Red Mechmate in Aus

[ozspeedway]

Thought I would start a build log for my Mechmate as I now have a few electrical questions. To the Big Red MM...

I am pretty much done with the construction side, a few things to finish off but it is actually looking like a Mechmate now:



I got to this point and noticed a few problems so it was rebuilt slightly and then put back to pretty much this state. I have the first layer of spoilboard to attach, fit the racks and start wiring from here on in.

I have moved onto getting my control box working utilising drawings from the Mechmate plans and Eddy Currents major safety circuit and this is where I have hit a wall. For some reason my PNOZ1 is not playing ball and is throwing everything else out as it is a major centerpiece of the safety circuit.

It went like this.... I first got 240V working via disconnects, pushbuttons and LED indicators - all good with that side. I had previously built a couple of power supplies, one 50VDC for my AM882's and a 24VDC one for my safety circuit, both of them made from toroids and capacitors. Trying the 24V circuit first I wired up my second hand PNOZ1 as per the tech doc I located on the net....... and nothing happened. It didn't matter what I tried I could not get it to activate. Thinking it could be my unregulated power supply I bougght a Din rail Meanwell 24VDC supply that seems to be putting out a constant 24.1VDC. Still no joy from the PNOZ. So I contact the seller telling him of my issues and he gladly sends me another one, this time it is brand new and even had the original docs on the box.

I disconnected the first PNOZ and wire in the second one but I still have NO ACTIVATION. This is getting really frustrating and I am thinking either both PNOZ units are stuffed or something in my wiring is dodgy. So I directly wire the the safety relay to the PS bypassing everything else in the box but still nothing. I include 2 images here, one of the power supply and one of the PNOZ as I have it wired. Can anyone see anything I can't (have been trying to get this thing working for hours!)

Power Supply:



Input 3 wires - L, N Earth
Output 2 wires V+ & V-

PNOZ 1


V+ from PS to A1
V- from PS to A2
X1 bridged to X2
T11 bridged to T12
T11 bridged to T22
T33 - T34 left open to bridge for activation.

I tried connecting a single NC E-stop to T11 - 12 and bridging T12 - T22, as per the docs for single channel - nothing
I tried connecting both NC contacts (2 separate contacts) on the E-stop to T11-12 & T11 - T22, as per the docs for dual channel - nothing
I tried bridging T33 and T34 as per the docs for auto reset - nothing
I tried connecting an NO button between T33 & T34 - nothing

The nothing part is happening to BOTH PNOZ units I have so something is very wrong somewhere. Any help diagnosing my issue for would greatly appreciated.

Cheers
Bruce

[ozspeedway]

One other thing with this/these damn safety relays, it says in the tech docs; DC: Connect terminal A2 (-) with the earthed side of the operating voltage. What the hell does that mean? And what is that terminal marked (-) with the ground symbol on it used for?

WHat worries me in all this is that the description for the PNOZ 1 says "earth faults are detected in the emergency stop circuit" whereas something like a PNOZ 4 does not say that. Could this be part of my problems? Very tempted to buy a PNOZ 4 instead but not until I have exhausted all avenues with these PNOZ 1's

[Web Goblin]

The terminal marked (-) with the ground symbol is connected to ground. Are you sure the relay you have is the correct supply voltage?
With the supply voltage on you should be able to measure voltage between T11 or T33 and (-) ground symbol connector. As you say linking T11 to T12 and T22 should supply power to the relay coils. Linking X1 and X2 provides the link for the reset. So you should be able to press the reset button, link between T33 and T34, with the power on and the relay should work.
More info here : http://www.google.co.uk/url?url=http...nN3ImeJyLyD7tw

[ozspeedway]

Web Goblin... you have solved it! The stupid hat goes to me. I have infact now got 2 PNOZ 1 relays that require 24VAC not 24VDC and that puts both of them totally useless to me. I will contact the ebay seller once again and see if I can send them both back and get a 24VDC PNOZ 4. Barrring that a quick toroid supply making 24VAC just for the PNOZ might be in order.

[ozspeedway]

OK, it is cheaper for me to just go buy a 12VAC + 12VAC toroid and use that for the relay plus it will allow me to continue the control box this weekend rather than next week sometime. I can get either a straight toroid or a PCB mounted 24VAC supply, will decide which when I get to the store.

More updates to follow once I have the relay powered off the correct voltage type :)

[Web Goblin]

Glad it helped you out, we all get a shot of the hat sometimes . I would go for the 24VAC option for the relay supply.
As you say it will let you continue with your build.