ds350 (rcl) - skyazulskyazul.com/wp-content/uploads/2016/05/ds350-linkbelt...• the pat ds 350...

SIGALARM MODEL 210

DS350 (RCL) For Lattice Boom Cranes

SERVICE MANUAL

Service Manual – 1225/1229 Console

SkyAzúl, Equipment Solutions www.skyazul.com 301-371-6126

NOTICE

SkyAzúl makes no warranty of any kind with regard to this material, including, but not limited to, the implied warranties of merchantability and/or its fitness for a particular purpose.

SkyAzúl will not be liable for errors contained in this manual or for incidental or consequential damages in connection with the furnishing, performance, or use of this manual. This document contains proprietary information, which is protected by copyright, and all rights are reserved.

No part of this document may be photocopied, reproduced, or translated to another language without the prior written consent of SkyAzúl.

SkyAzúl reserves proprietary rights to all drawings, photos and the data contained therein. The drawings, photos and data are confidential and cannot be used or reproduced without the written consent of Hirschmann. The drawings and/or photos are subject to technical modification without prior notice.

All information in this document is subject to change without notice.

MANUAL REVISIONS

REV DATE NAME DESCRIPTION

- 05/10/11 SC DS350 LS108 Service Manual (SkyAzúl) Rev 12/2000

SkyAzúl, Inc. 16 Walnut Street Middletown, MD 21769 Fax 301-371-0029 [email protected]

DS350 Rated Capacity Indicator System


TABLE OF CONTENTS

NOTICE

GENERAL INFORMATION...................................................................................1

WARNINGS..........................................................................................................1

1.0 ERROR CODE CHART ..................................................................................2

2.0 SYSTEM COMPONENT LAYOUT .................................................................6

3.0 ANGLE SENSOR ADJUSTMENT ..................................................................7

3.1 ANGLE CIRCUIT (WG203)......................................................................83.2 ANGLE CIRCUIT (WG206)......................................................................9

4.0 LINERIDER SETTINGS AND ADJUSTMENTS............................................10

4.0 General Information................................................................................10 4.1 Linerider Zero Point Adjustment.............................................................11 4.2 Linerider Output Adjustment...................................................................12 4.3 Linerider Circuits ...................................................................................13 4.4 Linerider Cannon Connection.................................................................14

5.0 DIGITAL INPUTS..........................................................................................15

6.0 ANTI-TWO BLOCK.......................................................................................16

7.0 BOOM BASE CABLE REEL DIAGRAM .......................................................16

8.0 MAIN BOOM / JIB JUNCTION BOX DIAGRAMS .........................................17

9.0 LUFFING JIB JUNCTION BOX DIAGRAMS.................................................18

10.0 SYSTEM ( 12 VOLT ) WIRING DIAGRAM .................................................19

10.1 Vertical Console Diagram ....................................................................20

11.0 SYSTEM ( 24 VOLT ) DIAGRAM................................................................21

11.1 Horizontal Console Diagram ................................................................22

12.0 TERMINAL BOARD DESIGNATIONS........................................................23

13.0 MAIN BOARD MEASURING POINTS ........................................................24


Service Manual – 1225/1229 Console


GENERAL INFORMATION

This handbook defines the error codes, cause, and actions to troubleshoot thePAT DS 350 Rated Capacity Limiter (RCL) System for Link-Belt Lattice-Boom Cranes.

Refer to the operating handbook for operation and maintenance of the PAT DS 350Rated Capacity Limiter (RCL).

This system assists the crane operator in promoting efficient operation by monitoringcrane loads and by warning the operator of approaching overload conditions. Alwaysrefer to operational instructions and load charts provided by the crane manufacturer forspecific crane operation and load limits.

WARNINGS

• The operator is always responsible for operating the crane within the manufacture’sspecified parameters.

• The PAT DS 350 Rated Capacity Limiter (RCL) is an operational aid which warns a

crane operator of an approaching overload and over hoist condition which couldcause damage to equipment, property, and/or injury to the operator or bystanders.

• This device is not, and shall not be a substitute for good judgment, experience, and

the practice of accepted safe crane operation. • The operator is solely responsible for the safe operation of the crane and must

observe and obey all warnings and instructions supplied by PAT and the cranemanufacturer.

• Prior to operating a crane, the operator must carefully and thoroughly read and

understand the information in operator’s handbook and the crane manufacturer’smanual to ensure that the operator understands the function and limitations of theRCL system and the crane.

• Proper operation of the RCL System is dependent upon proper inspection,maintenance, and observance of the operating instructions.

Service Manual - 1225/1229 Console DS350 Rated Capacity Limiter System

SkyAzúl, Equipment Solutions www.skyazul.com Page 1

301-371-6126

1.0 ERROR CODE CHART

ERRORDISPLAY

ERROR CAUSE ACTION

E 01 Fallen below radius orangle range

Fallen below the minimum radius orangle given in the load chart due torising the boom too far.

Put boom back to a radius orangle given in the load chart.

E 02 Radius or angle rangeexceeded.

The maximum radius or angle given inthe load chart was exceed due tolowering the boom too far.

Raise boom back to a radiusor angle given in the loadchart.

E 03 Prohibited slewingrange (no load area).

Slewing range prohibited with load. Slew back into permissiblerange.

E 04 Operating mode notavailable.

Operating mode switch on the consoleset incorrectly.

Set operating mode switchcorrectly to the codeassigned to the operatingmode of the machine. (seeSection 9 operator’shandbook)

E 06 Angle luffing jibexceeded.

The minimum angle given in thecorresponding load chart wasexceeded due to lowering the luffingjib too much.

Raise luffing jib to an anglegiven in the load chart.

E 07 No acknowledgesignal from overloadrelay.

Over load limit switch relay is stuck,defective, or not being selected.

Replace relay

E 08 No acknowledgesignal from hoist limitswitch relay

Hoist limit switch relay is stuck,defective, or not being selected.

Replace relay

E 09 No acknowledgesignal from relay 2.

Relay 2 is stuck, defective, or notbeing selected.

Replace relay

E 13 Fallen below lowerlimiting value for themeasuring channel“auxiliary force”.

Cable from central unit to the forcetransducer defective or water in theplugs.

Electronic component in themeasuring channel defective.

Check cable and plugs;replace items as necessary.

See Section 3, forcetransducer adjustments.

E 14 Fallen below lowerlimiting value for themeasuring channel“force-main hoist”.




See Section 3, forcetransducer adjustments.

E 15 Fallen below lowerlimiting value for themeasuring channel“angle main boom”.

Cable from central unit to the anglesensor defective or loose, or water inthe plugs.

Electronic component the measuringchannel defective.


See Section 2, angle sensoradjustments.



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1.1 ERROR CODE CHART - continued

ERRORDISPLAY

ERROR CAUSE ACTION

E 16 Fallen below lowerlimiting value for themeasuring channel“angle luffing jib”.





E 18 Error in the referencevoltage.

Electronic component on main boarddefective.

Replace main board & resetforce transducers as shownin Section 3.2.




E 20 No analog voltage. Crane voltage to low

Short in supply voltage from crane tocentral unit.

Voltage converter is defective on mainboard

Check crane voltage

Check wiring


E 23 Upper limiting valuefor the measuringchannel “auxiliary-force” exceeded.





E 24 Upper limiting valuefor the measuringchannel “force - mainhoist” exceeded.





E 25 Upper limiting valuefor the measuringchannel “angle mainboom” exceeded.





E 26 Upper limiting valuefor the measuringchannel “angle luffingjib” exceeded.







301-371-6126


ERRORDISPLAY

ERROR CAUSE ACTION




E 31-34 Error in systemsoftware.

Eprom’s with system softwaredefective.

Replace system Eprom


E 37 Error in systemsoftware.

Eprom’s with system softwaredefective.



E 38 Wrong system ordata Eprom.

Eprom’s with system software doesnot correspond with data Eprom.


E 41-42 Error on the ram. Ram range on the main boarddefective.


E 45 Error in internalcommunications

Error in read/writememory.


Electronic component on main boarddefective


E 51-59 Error in data memory. Data Eprom's defective


Replace data Eprom


E71 Incorrectacknowledgment ofthe 1. Relay on theterminal board a101.

Anti two-block relay is stuck ordefective.

Anti two-block relay is not beingselected due to a break on theterminal board a101, main board orribbon cables.

Replace 1. Relay.

Check terminal board a101,main board and ribboncables as well as replacedefective part, if necessary.

E72 - 77 analogous to E71 forthe relays 2...7.

Analogous to e71 for the relays 2...7. Analogous to E71 for therelays 2..7.

E89 Change of theoperating code duringlifting a load.

The operating mode switch in theconsole was used during lifting a load.

Lower the load and set theoperating mode switchcorrectly to the codeassigned to the actualoperating mode of the crane.



301-371-6126


ERRORDISPLAY

ERROR CAUSE ACTION

E 91-92 No data transmissionfrom console.

Plug on console loose; cabledefective.

Check cable and plug;replace console, asnecessary.

E 93-94 Error in the datatransmission to theconsole.

Cable to the console not plugged in orinterrupted.

Eprom not installed or defective

Defect in the central electronics (mainboard).

Check cable; attach plugproperly.

Replace Eproms


E-19/20/29 Error in reference supply voltage. Identify supply voltage that is beingshorted, (+/-5 or + -9) disconnect ribbon cable. If power supply returns then problem isexternal. Reconnect ribbon cables and disconnect all components individually to identifythe location of the short.



301-371-6126

2.0 SYSTEM COMPONENT LAYOUT



301-371-6126

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3.0 ANGLE SENSOR ADJUSTMENT

The angle φ shown in Figure 1 needs to be within +0, -0.4 of the actual angle of theboom. Check boom angle at base/heel Section only. After adjustment, compare theactual boom angle with the displayed angle at about 0°, 30° and 60°. To comply with theSAE J375 standards the displayed angle must be +0.0° to -2.0° of the actual angle.

WG 203

φ φ

Figure 1. Angle Sensor Adjustment.

The supply voltage can be checked directly at the cannon connection. Using adigital volt meter measure between pins A and C, (A=GND, C= - 5V). If this voltage isnot correct refer to the system wiring diagram and verify all cable connections. You mayneed to start at the main board and check the supply voltages at their proper measuringpoints.

The following 2 drawings show the theory of operation for the main and luffing anglesignals.



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3.1 ANGLE SENSOR CIRCUIT (WG203)

DRAWING # - LKB24-03



301-371-6126

BOOM ANGLE SENSOR PENDULUM

~ --WG 203 FIXED RESIST OR +90" (PART OF THE ANGL E

~5" POTENTIOMETER)

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RESIST OR

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AM P:::e-...... ----1~

MP 8 TEST POINT

CH. #5 (PART OF THE ANGL E OPERATING POTENTIOMETER)

WINDOW I ERROR CODE

ERROR CODE

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WORKING RANGE

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MP 8 VOLTAGES +90' ANGLE MIN. SIG. = +SOOmV (.SOOY)

+45' ANGLE = +2.50V

O' ANGLE MAX. SIG. = +4.S0V

NOTE: ALL VOLTAGES ARE MEASURED WITH REFERENCE TO GND (TERMINAL Xl-16 OR MP15)

ON MAIN BOARD

C --D---- 3 ----lI2l -5. 0 V

1U

-#-WIRE NUMBER

1U --D-- CENTAL UNIT

TERMINAL BOARD

-0- TEST POINT ON MAIN BOARD

3.2 ANGLE SENSOR CIRCUIT (WG206)




301-371-6126

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NOTE: ALL VOLTAGES ARE MEASURED WITH REFERENCE TO GND (TERMINAL Xl-12 OR MP15)

ON MAIN BOARD

C D-3~-5.0V

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-0- TEST POINT ON MAIN BOARD

4.0 LINERIDER SETTINGS AND ADJUSTMENTS

4.1 GENERAL INFORMATIONCalibration of a linerider will require the hoist rope line pull information, which should beprovided by the manufacturer. Use single part line when calibrating the linerider.Lineriders require specific wire rope size, see Table 2 to insure your rope size matchesyour linerider provided.

NOTE: A new wire rope is normally over sized, the amount oversize will depend on thediameter of the rope. With normal wear the inter core breaks down and diameterdecreases, See your manufactures guide lines for wire rope replacementconditions.

Table 2. Lineriders should match the wire diameter of your hoist rope.

ITEM NUMBER DESCRIPTION WITH WIRE ROPE SIZEWIRE ROPEDIAMETER

ADVISED RANGE048-500-060-005 SENSOR, LINERIDER SKM500 7/8" ±3/64

048-500-060-006 SENSOR, LINERIDER SKM500 1" ±3/64

048-500-060-012 SENSOR, LINERIDER SKM500 1-1/8 2 TON KMD ±3/64

048-500-060-013 SENSOR, LINERIDER SKM500 1-1/4 2 TON KMD ±1/16

The linerider requires a load sheave adjustment to maximize the voltage output of theamplifier and minimize the line angle through the linerider. The linerider maximumoutput of 2.5 volts should be equal to the maximum hoist rope line pull. The load sheavemay need to be adjusted by turning the eccentric wheel on the load sheave of theSKM500 linerider, see figure below.

P

L o ad S h eav e



301-371-6126

4.1 LINERIDER ZERO POINT ADJUSTMENT

NOTE: Complete the following processes before placing cable through the linerider.

ZERO POINT SETTINGS

a.) Check that the differential output of the main and auxiliary linerider is within±25millivolts at zero force:

• Main Linerider: central unit terminal connection X1-#33 and X1-#34.• Auxiliary linerider: central unit terminal connection X1-#23 and X1-#24.

b.) Adjust the linerider voltages on the main board, Refer to Figure 2 below.

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MP-2

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X6

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MP-9MP-8

MP-15MP-19

MP-1

Figure 2. Main Board

• Adjust the main linerider zero point by placing your positive volt meter lead onMP 3 (measuring point 3) with your ground lead on MP 11. Turn the screw onpotentiometer P3 so the volt meter reads a value of 0.500 volts.

• Adjust the auxiliary linerider by placing your positive volt meter lead on MP 5 withyour ground lead on MP 11. Turn the screw on potentiometer P5 so the voltmeter reads a value of 0.500 volts.

• After completing this adjustment run the hoist rope through the lineriders.



301-371-6126

4.2 LINERIDER OUTPUT ADJUSTMENT

LINERIDER OUTPUT ADJUSTMENTS

a) Calculate the output voltage required from the linerider using the known thetotal load and maximum line pull information. The tolerance for the outputvoltage “X” is +0.0, -0.2 volts.

NOTE: The total load includes the load, rigging, cables, and hook block. Testload should be 80% of maximum rated load for the cranes configurationor condition. To comply with the SAE J376 standards the test load mustbe to a known accuracy of ±1%.

TEST LOAD x 2.5 = ÷ PARTS OF LINE = X LINE PULL

23.600 x 2.5 = 2.0 ÷ 1 = 2.0 29.500

“X” is equal to the to optimum output voltage of the linerider. The outputvoltage required in this example is 1.8 to 2.0 volts.

WARNING: THE OPERATOR IS RESPONSIBLE FOR OPERATING THE CRANEWITHIN THE MANUFACTURE’S SPECIFIED PARAMETERS.

b) Pick the test load used in the calculation for the output voltage with a singlepart of line.

c) Take a voltage reading with a voltmeter and compare the reading with the

calculated voltage and decide if a mechanical adjustment of the linerider isneeded.

• Main Linerider: central unit terminal connection X1-#33 and X1-#34.• Auxiliary linerider: central unit terminal connection X1-#23 and X1-#24.

d) If a mechanical adjustment is necessary follow steps below, if no mechanical

adjustment is necessary proceed to next Section and begin calibration. • Before and after you set the mechanical adjustment, scribe a line on the

side of the eccentric wheel to show the amount of change.• Loosen the adjustment nut, see Figure 3. Note that there is a single lockout

nut on one side and a double on the other. These both should be loosenedto some degree. Adjustment from the double nut side seems to work thebest after tightening the 2 nuts together.

• Depending upon the output voltage you can look at the eccentric nut fromthe side of the linerider and determine the direction you should turn.Increasing the height of the load sheave will increase the output voltage.

• Tighten all lock nuts insuring not to move the wheel. e) Return and repeat step ‘c’.



301-371-6126

4.3 LINERIDER CIRCUIT (MAIN LINERIDER)





301-371-6126

4.4 LINERIDER CANNON CONNECTION LINERIDER CANNON CONNECTION

The supply voltage can be checked directly at the cannon connection. Using adigital volt meter measure between pins A and B, (A= + 9v) + (B= - 9v) = 18volts. Ifthis voltage is not correct refer to the system wiring diagram and verify all cableconnections. You may need to start at the main board and check the supply voltages attheir proper measuring points.



301-371-6126

5.0 DIGITAL INPUTS




301-371-6126

9 I

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6.0 ANTI-TWO BLOCK CIRCUIT

7.0 BOOM BASE CABLE REEL DIAGRAM

DRAWING # - 031-300-100-424



301-371-6126

8.0 MAIN BOOM / JUNCTION BOX DIAGRAMS

MAIN BOOM NOSEDRAWING # - 031-300-100-446

JIB NOSEDRAWING # - 031-300-100-522



301-371-6126

9.0 LUFFING ATTACHMENT / JUNCTION BOX DIAGRAMS

LUFFING LIMIT BASEDRAWING # - 031-300-100-679

LUFFING JIB NOSEDRAWING # - 031-300-100-535



301-371-6126

10.0 SYSTEM ( 24 VOLT ) DIAGRAM



301-371-6126

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OPERATING VOLTAGE

INPUT VOLTAGE

SkyAzúl, Soluciones de Equipos www.skyazul.com 301-371-6126


SkyAzúl, Inc. 16 Walnut Street Middletown, MD 21769 Phone 301-371-6126 Fax 301-371-0029 [email protected] www.skyazul.com

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