Airpes ALE-100/T User manual

MANUAL OF INSTRUCTIONS
ELECTRONIC LIMITER
MODEL “ALE-100/T”
Version “M-37”
AIRPES Sistemas Integrales de Manutención y Pesaje S.L.
Polígono Industrial Can Roqueta II
C/ Can Lletget, 3
08202 Sabadell (Barcelona) SPAIN
Tel.: [phone] Fax: [phone]
Email: [e-mail]
internet: http://www.airpes.com
ALE-100T.VM37.L.S.EN.18-10.0

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INDEX
PAG.
DESCRIPTION 3
CHARACTERISTICS 4
1. BASIC FUNCTIONS 5
1.1 START UP (ALE-100/T) 5
1.2 EXTERNAL TARE 5
1.3 WEIGHT ADJUSTMENT WITH PUSH-BUTTON (ALE-100/T) 5
1.4 MENU DIAGRAM OF WEIGHT ADJUSTMENT WITH PUSH-BUTTON
(ALE-100/T) 7
1.5 WARNING OF OVERLOAD, SLACK CABLE AND ALARMS 8
1.6 PROTOCOLO CONFIGURATION 9
1.7 LANGUAGE CONFIGURATION TO SEND TO REMOTE CONTROL 11
1.8 START UP (AMM-40S) 13
1.9 WARNING MESSAGES (AMM-40S) 13
2. MENU DIAGRAM (TERMINAL AMM-40S V5.5) 14
3. OPERATIONS WITH THE TERMINAL AMM-40S 15
3.1 WEIGHT ADJUSTMENT AND CONFIGURATIONS 15
3.2 DELAYS 21
3.3 REQUEST OF THE PASSWORD 23
3.4 DATA AND INCIDENTS DIAGRAM 24
3.5 VISUALIZATION OF DATA AND INCIDENTS 25
3.6 DATE AND HOUR ADJUSTMENT 29
3.7 CONFIGURATION OF THE PASSWORD 30
3.8 CONFIGURATION OF DATE/HOURS FOR THE NEXT CHECK 31
3.9 PROGRAMMATION OF THEORICAL HOURS OF SAFE OPERATIONS 34
3.10 PROGRAMMATION OF LONG OVERLOAD 36
3.11 PROTOCOL 36
4. INPUTS/OUTPUTS MANEUVERS 37
5. OVERLOAD AND INTERMEDIATE LIMIT OUTPUTS 37
6. DETECTION OF OVERHEATING IN THE ENGINES 38
7. DOWNLOAD DATA FROM ALE-100/T TO COMPUTER 39
7.1 DATA TRANSMISSION PROTOCOL 40
8. RESETTING THE ALE-100/T 41
9. FIRMWARE VERSION OF ALE-100/T 41
10. CONNECTION OF THE LIMITER ALE-100/T 42
CONDITIONS OF GUARANTEE 46
DECLARATION OF CE CONFORMITY 47

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DESCRIPTION
The electronic limiter model ALE-100/T with delays (for liftings and lowerings
operations) and black box functions has been designed to control the overload and a
intermediate limit (or slack cable) well as the overheating in the engines and to
register the espectrum of loads of machines of lifting (hoist) according to the norm
UNE 58 919.
It can connect on any sensor of weight located in fixed rope, pulley, trolley, etc.
Besides of the control of Safe Working Period “SWP” established in the norm, it
has several registers to the control of:
-Number of maneuvers of lifting.
-Number of maneuvers of lifting to impulses.
-Time of maneuver of lifting.
-Number of overloads.
-Use of the crane.
-Use of the troley.
-Activation of alarm by hours or date to check.

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CHARACTERISTICS
-Power supply of 48V, 110V or 220V AC.
-Adjustment with push-buttons of the zero and full scale (nominal capacity).
-Load cell input.
-Inputs and outputs for maneuvers of movement.
-Probe PTC input.
-Outputs relays.
-Indicator by leds of the percentage of the applied load (led 25%, led 50%, led
75%, led 100%, led of OVERLOAD, led of slack cable).
-Indicator by leds of the movements of outputs (LIFTING, LOWERING, FAST
and BRAKE).
-Configurable parameters by means of terminal AMM-40S ver. V-ALE.
-Actualization of firmware through laptop
-Download of data in manual mode or through laptop.
-Temperature -10º C … +50º C
-Humidity 15% - 85%.

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1. BASIC FUNCTIONS
1.1 START UP (ALE-100/T)
Connect the equipment to its power supply (48V, 110V or 220V AC).
The equipment will realize a test by means of a sweep of all the leds, to stay
finally in the normal mode of work.
1.2 EXTERNAL TARE (ALE-100/T)
Possibility of holding the weight to 0 in a repeater or radio.
Connect the equipment to its working power (48V, 110V or 220V AC).
1.3 WEIGHT ADJUSTMENT WITH PUSH-BUTTONS (ALE-100/T)
Connect the limiter to its power supply (48V, 110V or 220V AC).
During the sweep of the leds, press the [ENT] and [SALTO] keys simultaneously.
(See “Weight adjustment menu diagram with push-buttons”).
Immediately the 25%, 50%, 75% and 100% leds will make three blinks.
Later the 25% CERO led will blink, showing that it is possible to realize the
adjustment of ZERO.
Adjustment of ZERO:
If we want to realize it, we will unload the crane (if it is loaded) and wait until
the 25% CERO led remains illuminated (the flashing led indicates unstable weight,
permanent led indicates stable weight), in this moment we will press the [ENT] key,
the 25% CERO led will turn off and the zero will be memorized.
If we do not want to make the adjustment of ZERO, it will be enough to press the
[SALTO] key and automatically we will go to adjustment of F.E. (full scale).
Later the 100% F.E. led will blink, indicating that it is ready to make the
adjustment of the F.E. (full scale).

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Adjustment of the F.S. (full scale):
If we want to realize it, we will load the crane with an equal weight on the
nominal capacity with this one (having external terminal of configuration will not be
necessary the nominal capacity), and will wait until the 100% F.E. led remains
illuminated (the flashing led indicate unstable weight, permanent led indicate stable
weight), in this moment we will press the [ENT] key, the 100% F.E. led will turn off
and the full scale will be memorized.
Later the equipment will be restarted.
If we do not want to make the adjustment of F.E., it will be enough to press the
[SALTO] key and automatically the equipment will be restarted.

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1.4 MENU DIAGRAM OF WEIGHT ADJUSTMENT WITH PUSH-BUTTONS (ALE-100/T)
CONNECT THE LIMITER
TO THE SUPPLY
THREE BLINKINGS
LED 25% - LED 50%
LED 75% - LED 100%
UNLOAD THE CRANE
LED CERO IS ON
STABLE WEIGHT
ZERO IS MEMORIZED
LED CERO IS OFF
BLINKING LED F.E.
ADJUSTMENT OF
FULL SCALE
LOAD THE CRANE
LED F.E. IS ON
STABLE WEIGHT
F. S. IS MEMORIZED
LED F.E. IS OFF
BLINKING LED CERO
ADJUSTMENT OF ZERO
TEST OF THE LEDS
S IMULTAN EOUSLY
[ENT] + [SAL]
PUSH [EN T]
PUSH [ENT]
PUSH
[SAL]
PUSH
[SAL]
NORMAL MODE
WHEIGHT - LIMITER

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1.5 WARNING OF OVERLOAD, SLACK CABLE AND ALARMS
LED ESTADO DEFINICION
-------------------------------------------------------------------------------------------
SOBR. On Overload
-------------------------------------------------------------------------------------------
C.F. On Slack cable
-------------------------------------------------------------------------------------------
SOBR. On
+75% Blink Temperature alarm
-------------------------------------------------------------------------------------------
50% Blink Alarm revision
-------------------------------------------------------------------------------------------
C.F. Show blink SWP < 10%
-------------------------------------------------------------------------------------------
C.F. Blink SWP Alarm
-------------------------------------------------------------------------------------------
C.F. Blink SWP Alarm
+ 100% On
+ SOBR. On Overload
-------------------------------------------------------------------------------------------
C.F. Blink SWP Alarm
+ SOBR. On Slack Cable
-------------------------------------------------------------------------------------------
SOBR. On Data view…
+ CF. On … mode
-------------------------------------------------------------------------------------------
100% Blink Error clock and
+25% Blink data memory

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1.6 PROTOCOL CONFIGURATION
In the ALE100-T limiters with firmware version "M37", the RS485 communication
protocols available are:
-IKUSI
-AUTEC (mod. LK)
-AUTEC (mod. NEO)
-AIRPES (RP). Compatible with AMR-XXX “RP-nn” and 1200 Bds.
-AIRPES (ST). Compatible with AMR-XXX “ST-nn” and 9600 Bds.
-JAY (04). Sending weight in the direction 04 (Modbus).
-JAY (05). Sending weight in the direction 05 (Modbus).
-JAY (WHC). Sending black box data and weight as messages (Modbus).
The default protocol is IKUSI.
In order to communicate with a radiocontrol different (AUTEC or JAY) or with
AIRPES repeaters, we will perform the following steps:
- With the limiter in normal mode, press (SAL) and without releasing, press
(ENT).
- Release both buttons when the display:
SOBR. -
100% -
75% -
50% -
25% O
C.F. O
As a result, leds are turned off and after 1” is displayed:
SOBR. -
100% O
75% O
50% O
25% O
C.F. -
Indicating that the protocol AUTEC (mod. LK) is selected.
To set a specific protocol, we follow the same procedure to select the desired
option.

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The relationship of protocols with LED indication shown in the following table:
IKUSI AUTEC(LK) AUTEC(NEO) AIRPES(RP) AIRPES(ST) JAY(04) JAY(05) JAY(WHC)
SOBR. - --- - -- -
100% -O O - O -- -
75% -O O O O -- O
50% O O -O O -O -
25% O O O O - O - -
C.F. ---- - -- -
In the case of AUTEC, IKUSI or JAY (WHC) protocols, if the remote control is
operating, the selected protocol is displayed:
PROTOCOL or PROTOCOL or PROTOCOL
AUTEC IKUSI JAY
You can check the current protocol configured by pressing from the normal working
mode, the (SAL) key for approx. 5" in order to display the combination of LEDs
indicated in the table.
Note 1: If you select the protocol AIRPES, JAY(04) or JAY(05) the black box data
can not be displayed on the radio control.
Note 2: If you select a protocol of radio control and you need see the weight in the
AMM-40S, will be necessary go to option [PESO] (weight) in the menu and
confirm with (ENT).
Note 3: When connecting the AMM-40S for any query, set, etc…, the sending data to
the radio control will be temporarily canceled, re-establish itself once the
limiter ALE100-T is turn off an turn on.

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1.7 LANGUAGE CONFIGURATION TO SEND TO REMOTE CONTROL
The default language in the limiter ALE100-T, if we select the protocol IKUSI,
AUTEC o JAY(WHC), will be “Spanish”.
To change the language of messages displayed on the remote control, follow these
steps:
- With the limiter in normal mode, press (SAL) and without releasing, press
(ENT).
- Release both buttons when the display:
SOBR. -
100% -
75% -
50% -
25% -
C.F. O
As a result, leds are turned off and after 1” is displayed:
SOBR. -
100% -
75% -
50% O
25% -
C.F. -
Indicating that the language “English” is selected.
To select a different language, follow the steps above, then the leds turn on at the
end of the selection depending on the selected language:
“Español” “English” “Française” “Portugues”
SOBR. -SOBR. -SOBR. -SOBR. -
100% -100% -100% -100% O
75% -75% -75% O75% -
50% -50% O50% -50% -
25% O25% -25% -25% -
C.F. -C.F. -C.F. -C.F. -

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In all previous cases if we have the remote control in operation, show the selected
language:
IDIOMA or LANGUAGE or LANGAGE or IDIOMA
ESPANOL ENGLISH FRANCAISE PORTUGUE
Note: This function has no effect if the protocol AIRPES, JAY(04) or JAY(05) is
selected.

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1.8 START UP (AMM-40S)
Press the (ON/OFF) key to turn on:
[ AMM40]
[ VX.X] Firmware version of the AMM-40S.
[ CONEC]
[ M-XX] Firmware version of the ALE-100T.
[ 0] Current weight.
Press the (ON/OFF) key to turn off:
[ OFF]
1.9 WARNING MESSAGES (AMM-40S)
[ MENU] The terminal AMM-40S is not connected to limiter
ALE-100/T or information of the weight is not received.
If this condition is kept, every 10 " it realizes a blink and
continues to the wait of receiving information.
[ HIGH ] The gross weight is higher than the maximum capacity of
the equipement.
[ LOW ] The negative gross weight is higher than the maximum
capacity of the equipement.
[ OVER ]Failure in the weight system.
[ ooooo] Failure in the weight system.
[ CELL ] Failure in the weight system.

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2. MENU DIAGRAM (TERMINAL AMM-40S V5.5)
EXIT
CURRENT WEIGHT
ON THE LIMITER
ENT
WEIGH
ADJUS
Vx.X
0
CONEC
MESSAGES OF COMMUNICATION
SEND
ERROR
N-ECO
READ
TIMER ENT
ESC
ESC
ESC
ESC
ESC
ESC
ESC
ESC
ESC
ESC
ESC
ENT
ENT
ESC
ENT
ENT
ENT
ENT
ENT
ZERO
CAPAC
FRACT
FS
PERCE
OVERL
DELAY
HYSTE
10%
UP
DOWN
H-YES
H-NO
UP0.0
DOW0.0
0
03000
ESC
CAPAC FR 2
PLR
RLP
LPL
RLR
MIR
FRE
PLR1.0
RLP0.5
LPL1.0
RLR1.1
MIR0.4
FRE1.0
ENT ENT
ESC
SAMPL
ENT 02200
ESC
ENT
ENT
PLR -> stop-slow-fast
RLP -> fast-slow-stop
LPL -> slow-stop-slow
RLR -> fast-slow-fast
MIR -> minimum fast
FRE break->
TIMERS (sg.)
(1)
ENT
ENT
B-BOX ENT
ENT
DatA
CLOCK
KEY
CHECK
SWP
SEEDIAGRAM
DATA AND
INCIDENTS
ENT SELECTLINE
AND GROUP
AS TABLE V2
SEEDATE/TIME
ADJUST
SEEKEY
CONFIGURATION
SEECONFIGURATION
DATE/HOURS
UP NEXTREVIEW
ENT
ENT
ENT
(1)
ESC ESC
ENT
ENT
READI REA08
Reset
(2)
(3) VERSI
Reset limiter
ALE-100/T
Firmware version
request to the limiter
ALE-100/T
AMM40
ENT
ENT
MENU
OVER
LONG ENT SEE CONFIGURATION
LONG OVERLOAD
PROTOENT SEE PROTOCOL
CONFIGURATION
ENT
READ2 R2 01ENT
M-07
LANGU
ESC ESC
ESC
ESC
ESC
ESC
ENT ENT
ENT
ENT
LIMI2 POSIT
NEGAT
00750 UP
DOWN
UP0.0
DOW0.0
HYST2 00300
ESC
ENT
ENT
ESC
ENT
ESC
(2)
(3)

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3. OPERATIONS WITH THE TERMINAL AMM-40S
3.1 WEIGHT ADJUSTMENT AND CONFIGURATIONS
From the normal mode of work of the ALE-100/T we will be able to realize a
normal adjustment of the weight (CERO, CAPACIDAD and F.E.) and equally we will have
acces to differents parameters configurables (see “Menus diagram”).
Connect the terminal AMM-40S in the conector AMP ref. J5 (to see figure):

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With both equipments already connected and put in on, the visor of the terminal
will visualize the current weight (in case of visualizing "MENU", we will wait for
approximately 10 " and after a blink the weight will be visualized).
[ CONEC] Press (ENT).
[ M -XX] Firmware version.
[ 0] Current weight of limiter.
[ WEIGH] Press (  ).
[ ADJUS] Press (ENT).
[ READ]
[ ZERO] Option of setting to zero the weight.
Press:
(  )to pass to next parameter.
(ESC) to exit.
(ENT) to realize the setting to zero of the weight.
In this case it is necessary to make the scale free
of load and to wait until the weight is stable
before pressing the key.
[ 0]
[ SEND]
[ CAPAC] Option to choose a CAPACITY and FRACTION.
(  )to pass to next parameter.
(ESC) to exit.
(ENT) to enter in the option.
[ 03000] With the (  ,  , → )
keys, introduce the capacity.
(ESC) to exit.
(ENT) to validate with automatic fraction
( * ) to enter a special fraction.
[ FRACT]
[ FRA 2] With (  ,  )
introduce the fraction (1, 2, 5, 10, 20 or 50).
(ESC) to exit.
(ENT) to validate.

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[ SEND]
[ FS ] Option to realize an adjustment of the FULL SCALE by
means of a sample weight.
(  )to pass to next parameter.
(ESC) to exit.
(ENT) to enter in the option.
[ SAMPL]
[ 02200] With the (  ,  , → )
keys, introduce the value of the
sample.
Arrange a known load (if it is possible >50% the total
capacity of the equipment) and wait until the weight
become stable.
(ENT) to validate.
(ESC) to exit without adjusting.
[ READI]Option to get more or less speed in the response of the weight in the
maneuvers of lifting/lowering bear in mind that to more readings (minor
speed) the weight will be stable (8 by default).
[ REA08] With (  ,  , → )
introduce the value (1...50).
(ESC) to exit.
(ENT) to validate.
[ LECT2] Option to program a number of readings for more or less rapid response
during maneuvers weight lifting/lowering, given that more readings (less
rapidly) the weight will be more stable (1 by default).
[ L2 01] With keys (  ,  y → ) enter the value (1 ... 50).
(ESC) to exit.
( (E EN NT T) ) t to o c co on nf fi ir rm mr r. .
[ PORCE]
[ OVERL]Option to change the percentage to apply overload (10% by default).
[ 10%] With (  ,  , → )
introduce the value (0%...25%).
(ESC) to exit.
(ENT) to validate.of programming a nº of readings
[ DELAY] Possibility of programming a delay in the deactivation of the OVERLOAD
relay, on having reached the value of the overload programmed on the
lifting or lowering of the load (0 sec. by default).
(ESC) to exit.
(ENT) to enter in the option.

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[ UP ]The delay will act on lift the weight, and only if this one
exceeds the overload percentage programmed for x.x s.,
then the OVERLOAD relay will be deactivate and the led
SOBRE will be on.
[ DOWN ]The delay will act when, once the OVERLOAD relay is
deactivated, the weight is lower than the overload
percentage programmed or from the nominal capacity of
the equipment (see the hysteresis configuration) for x.x s.,
then the OVERLOAD relay will be allowed and the SOBRE
led will be off.
(  ),(  )to change the option.
(ESC) to exit.
(ENT) to enter in the option.
[ UP 00]/[ DOW00]
With (  ,  , → )
introduce the value (0.0 … 3.0 s).
(ESC) to exit.
(ENT) to validate.
If the delay is equal to “0”, we will cancel this time of
shot and the activation/deactivation of the OVERLOAD
relay will be instantaneous.
[ HYSTE] Possibility of programming a hysteresis or window of rearmament fore,
once deactivated the OVERLOAD relay (because of an overload of weight)
this one couldn’t be reactivated until the weight in the scale is not equal
or lower than the nominal capacity. (“YES” by default).
(ESC) to exit.
(ENT) to enter in the option.
[ H-YES] Hysteresis activated.
[ H- NO] Hysteresis cancelled. The activation/deactivation of the
OVERLOAD relay will be realize in the value of the
percentage of overload programmed.
With the (  ), (  ) keys change the option.
(ESC) to exit.
(ENT) to validate.

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[ LIMI2] Possibility to program an intermediate limit to disable the second relay,
when the weight reaches the programmed positive (or negative) value.
Its default value is 25% of the programmed capacity.
(ESC) to exit.
(ENT) to enter in the option.
[ POSIT] Choose the limit sign (“POSITIVE” or “NEGATIVE”) with keys
[ NEGAT] (  ) / (  )and press (ENT) to validate.
[ 00750] Enter the desired value of the limit.
(  ) / (  ) to change the value.
( → ) to skip to next digit.
(ENT) to validate.
[ UP ]The delay acts on the lifting of the weight and only if it exceeds the
programmed value for x.x s, then it is activated the second relay.
[ DOWN ]The delay will act when, after the second relay is deactivated,
the
weight is equal to or lower than the programmed value for x.x s.
(  ) / (  )to change the option.
(ESC) to exit.
(ENT) to enter in the option
[ UP00]/[ DOW00]
With (  ,  , → )
introduce the value (0.0 … 3.0 s).
(ESC) to exit.
(ENT) to validate.
[ HIST2] Possibility to program a value of hysteresis for the limit 2 and reactivate
the second relay when the weight reaches the programmed value.
Its default value is 10% of the programmed capacity.
(ESC) to exit.
(ENT) to enter in the option.
[ 00300] Enter the desired value.
(  ) / (  ) to change the value.
( → ) to skip to next digit.
(ENT) to validate.
[ EXIT] Exit to normal mode of work.

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CONFIGURE POSITIVE VALUES IN THE INTERMEDIATE LIMIT FOR AMM-40
PROGRAMMING UNITS WITH PREVIOUS FIRMWARE VERSIONS TO V5.5:
Since the controls AMM-40 with firmware version earlier than V5.5 only have the
function of "slack cable" (negative limits), it is possible to enter positive values for the
intermediate limit, following these examples:
EXAMPLE 1 Introduce a negative limit (or SLACK CABLE) of -400.
[ SLACK]
[ CABLE]
[ 00400] Introduce the value.
Validate by pressing (ENT) of AMM-40.
[ SEND] Result:
Limit 2 = -400
Hysteresis 2 = -400
(without hysteresis)
EXAMPLE 2 Introduce a positive limit of +400.
[ SLACK]
[ CABLE]
[ 00400] Introduce the value.
Press (ENT) in the limiter and without release it validate by
pressing (ENT) of AMM-40.
[ SEND] Result:
Limit 2 = +400
Hysteresis 2 = +400
(without hysteresis)
EXAMPLE 3 Introduce a positive limit of +1000 with hysteresis of +400.
[ SLACK]
[ CABLE]
[ 01000] Introduce the value.
Press (ENT) + (SAL) in the limiter and without release them
validate by pressing (ENT) of AMM-40.
[ SEND] Result:
Limit 2 = +1000
Hysteresis 2 = +400
(in this case the last value of the
hysteresis is retained)