Alimak OSD 5 User manual

Users manual
ALIMAK OSD 5
Original instructions

Overload Sensing Device
type OSD 5
User’s Manual
Manufacturing No.: Year: Part No. 9081 804 - 010 I
2019 - 10 - 31
This manual is only applicable if the manufacturing number indicated below corresponds to the manufacturing number stamped on the
identification sign of the equipment. Where there is a conflict contact Your ALIMAK representative.
Valid mainly for OSD software version OSD-5 1.09 and later versions!

Document revision:
Rev Date By Comments Approved by
– 2014-06-18 JoLu Created
A 2014-08-28 JoLu
B 2016-02-02 JoLu Updated for v 1.05
C 2016-03-15 JoLu Quick Guide
D 2016-06-08 JoLu Updated with "Func" page 3, 6 and 8
E 2017-02-07 JoLu Updated with Extra functions. Edits of setup.
F 2017-11-08 JoLu Min weight 400 kg, 30 % full load
G 2018-11-06 JaSv Added a new front and back page with
an updated Alimak-logo.
H 2019-06-28 JoLu Updated for measuring trailing cable
weight. Software update v.1.09
This manual contains information protected by copyright and intellectual property laws. No part of the manual may be copied or
transmitted, in whole or in part. Pictures are illustrative only and do not necessarily show the configuration of products on the
market at a given point in time. Products must be used in conformity with safe practice and applicable statues, regulations, codes
and ordinances. Specifications of products and equipment shown herein are subject to change without notice.

– 1 –
CONTENT
Overload Sensing System..................................................3
Calibration mode – System Set up.....................................5
Calibration mode – Zero Calibration...................................6
Calibration mode – Load Calibration ..................................7
Calibration mode – Load Calibration with default values ...8
Work mode – View current system parameters..................9
Work mode – System test and Zero functions..................10
Software Update............................................................... 11
Failsafe mode................................................................... 11
Relay function................................................................... 11
Trailing Cable Compensation ........................................... 11
Verification........................................................................12
Extra functions..................................................................12
Function information.........................................................12
Connection difference between OSD 4 and OSD 5 ......... 13
Debug information ............................................................16
Circuit diagram industrial lift relay control.........................17
Circuit diagram industrial lift ALC II...................................17
Circuit diagram construction hoist relay control................18
Circuit diagram construction hoist ALC II..........................18
Signs.................................................................................21

– 2 –

Optional Overload Sensing System
The hoist can be equipped with an overload sensing
system, OSD 5. The system indicates when the car is fully
loaded and prevent operation in an overload condition.
Load cells are built into the pull rods connecting the
machinery to the car structure.
When the rated load is exceeded the control circuit will be
switched off to prevent the use of the hoist. At the same
time a red LED light is activated.
When an ALC is installed, fault code F4 will be displayed
in case of overload.
Note that software of at least version 3.50 must be used
for ALCII functionality.
If software is older than version 3.50 on ALCII, it must be
connected as relay control, and not as CAN.
Read more on page 10.
Indication light ”Overload” in car
Signals from the load cells are transferred
to the OSD 5 amplifier located in M-panel.
Art.No. 3002 121-080
Gearbox rear side
Pull rod
Load cell
OSD 5 Overload Sensing System
– 3 –

Setting of Payload and Alarm Limits
Payload 400 kg – 30000 kg
Overload (R1) 100 – 120 %
Full load (R2) 30 – 100 %
Underload (R3) Absolute values cannot be less than hysteresis (Hst)
Hysteresis (Hst) Can not be less than 75 kg and not more than 10 % of payload,
if the hysteresis is bigger than 80 kg
Load Calibration 50 – 120 %
Trailing cable compensation
Cable weight can be set between 0,9 - 4,8 kg/m
Maximum compensation is 250 kg for each load cell or 10 kg/m.
Quick guide for OSD 5 settings
Standard values:
Payload 1000 kg
Overload 1100 kg
Full load 900 kg
Setting of Zero Calibration value ZERO
Empty car.
Prog. + Zero
Zero
Cal.
Counts down to 0 on the display and weights.
Setting of Load Calibration value LOAD
Load at least 50 % of payload. To get the best result load 100 % of
payload.
Prog. + Zero
Load
Cal.
Set weight, for example payload 800 kg
Zero till 8
Load
Load 800 on the display
Cal.
Counts down to 0 on the display and weights.
– 4 –

To set System parameters for OSD 5,
press the "Prog." and (+) "Zero" buttons.
Alarm limits can be set according to separate table.
Finish by pressing the "Prog." button or wait for 10
seconds.
Use the "Cal." button to enter the System Menu.
Use the "Cal." button to cycle through parameter(s) to be adjusted.
The example shows how to adjust the Lift capacity from 1000 kg to
2000 kg.
Example:
OSD 5 Calibration mode – System Set up
Use the “Cal.” button to enter the system menu.
Cycle through to select the parameter(s) to be adjusted,
using the "Cal." button.
Use the "Zero" button to re-set the displayed value to zero.
The first digit is increased by pressing the "Zero" button.
Use the "Load" button to select the second, third and
fourth digit respectively.
If required, adjust the second, third and fourth digit by
using the "Zero" button.
When the correct value has been set – cycle through to
the next parameter or return to the Weight display using
the "Cal." button.
Note: To ensure ALL changed parameters are stored,
the operator MUST tab through all the parameters
before returning to the Weight display.
– 5 –

To start Zero Calibration press the "Prog."
and "Zero" buttons.
Note: The lift/hoist must be empty
(no load).
Zero Calibration: Activate the Zero Calibration menu by pressing the
"Zero" button.
Press the “Cal.” button and the display counts down from 10 to 1. This
allows time for the operator to leave the car to ensure the lift/hoist car
is empty, without load.
On return to display function the "Zero" point is automatically
calibrated and stored.
If no changes are made in Menu mode, the overload sensing system
will automatically return to Weight mode after 10 seconds.
OSD 5 Calibration mode – Zero Calibration
– 6 –

Begin the Load Calibration procedure by
placing a calibration weight with known
weight in the car.
Weight should be between 50 – 120 % of
the lifts/hoists rated load.
To be able to perform Load Calibration –
press buttons “Prog.”- and “Zero”.
Load Calibration: Activate the Load Calibration menu by pressing the
"Load" button.
Use the "Cal." button to display the stored weight value. Adjust the value
so it matches the required calibration weight using both the "Zero" and
"Load" buttons.
Note: Use the "Zero" button to re-set the stored weight value to zero and
to increase the value of the digit(s). Use the "Load" button to select
additional digits as required.
Press the "Cal." and the display counts down from 10 to 1. This allows
time for the operator to leave the car to ensure that the correct
calibration weight is stored.
On return to display function the calibration weight is automatically
stored.
If no changes are made in Menu mode, the overload sensing system will
automatically return to Weight mode after 10 seconds.
OSD 5 Calibration mode – Load Calibration
– 7 –

Begin the Load Calibration procedure by
emptying the car.
To be able to perform Load Calibration –
press buttons “Prog.”- and “Zero”.
Load Calibration: Activate the Load Calibration menu by pressing the
"Load" button.
Use the "Cal."button to display the stored weight value. Adjust the value
so it matches the required calibration weight using both the "Zero" and
"Load" buttons.
To do an automatic calibration:
Use the "Zero" button to re-set the stored weight value to zero and to
increase the value of the digit(s). Use the "Load" button to select
additional digits as required.
Set the value:
31 for Scando 650 (30 with +5 % adjust) (3 ton load cell with 1 mV/V)
22 for Scando 450 (20 with +5 % adjust) (2 ton load cell with 2 mV/V)
61 for 6 ton load cell (60 with +5 % adjust) (6 ton load cell with 1 mV/V)
This sets both load and zero values.
Press "Cal." and the display counts down from 10 to 1. This allows time
for the operator to leave the car to ensure that the correct
calibration weight is stored.
Remember to exit the cage before the counter reaches 0.
On return to display function the calibration weight is automatically
stored.
If no changes are made in menu mode, the overload sensing system will
automatically return to Weight mode after 10 seconds.
OSD 5 Calibration mode – Load Calibration with
default values
Warning: Use with extra consideration.
– 8 –

The stored system parameters can be
recalled via the front panel as the flowchart
example shows.
Use the "Cal." button to cycle through
the system parameters.
Note: Values marked with * can be altered
via the "Cal. mode".
If no changes are made in Menu mode, the
overload sensing system will automatically
return to Weight mode after 10 seconds.
OSD 5 Work mode – View current system
parameters
– 9 –

System test – Activate the "system test" by pressing
the "Load" button. The self diagnostic function
activates in sequence the instrument's hardware
components to ensure they are operational.
S 1.xx = software version.
Display indicates "CAn" if the device is wired to ALC
II CAN interface. If not "RELAY" is indicated.
OSD 5 Work mode – System test and Zero functions
System test
Test function
Testing inputs and outputs.
I = Input
O = Output
Push "Prog." button and keep it pressed:
Display indicating "- - - - "
Input 1 indicating ex. "I - - - "
Input 2 indicating ex. "- I - - "
Output 1 indicating ex. "- - - O" (no overload)
Output 2 indicating ex. "- - O -" (full load)
Output overload is normally closed when Overload
situation does not occur.
If the OSD 5 has been wired to ALC II with CAN
interface and should be reconnected to Relay without
CAN interface, a new payload programming must be
performed, even if the Payload value is the same.
The display can indicate "tESt" as well. Then the
device is in production mode for testing. (Can be
removed by performing a Zero Calibration followed
by a Load Calibration.). – 10 –

OSD 5 Failsafe mode
This function is used in case of over or under load, for example
by running against buffer springs or during drop test.
Press the "Zero" button for 5 seconds.
The display shows "InSP" if the system is in Inspection mode,
otherwise it shows " – – – – – ".
If the device is connected to CAN interface, five trips can be
made, otherwise a maximum of 2 trips are possible.
OSD 5 Software Update
OSD 5 Relay function
If the device has only boot software or when updating the device to the
latest version:
Software can be downloaded from the A3 web site – if the ALC II is used and has the latest
software (version 3.50 or later). Note: This is for certified personnel ONLY!
1. Put latest version of software in boot mode in A3 for OSD 5 on device with correct
serial number.
2. Restart ALC II (power OFF/ON).
3. Load software. Before the booting starts, three or two dots flash alternately. While the
device updates, ALL dots flash rapidly.
4. When the OSD 5 is started the first time after software update the display may show
error code "Err 71.1".
5. Restart ALC II and wait until error code "Err 7.1" disappears.
2 digital inputs +24VDC.
Function: Set/Reset function for measuring.
When the lift/hoist is standing still and the brakes are engaged, input (DI1) is activated.
When the door/s are closed, input DI2 is activated and measurement takes place,
and operation is possibly accepted, depending on weight.
After a power failure, 10 % extra weight is approved for the first trip.
This is indicated by:
Left and right dot flash in sync during the first trip.
During the subsequent trip, the left and right dots flash out of sync.
OSD 5 Trailing Cable Compensation
Set the function bit.
To activate this function, do a normal Zero Calibration on the bottom floor.
Then, travel up as high as possible and do a new Zero Calibration. See chapter OSD 5
Extra functions.
– 11 –

OSD 5 Extra functions
Func0.
Default.
Normal function for full load and overload.
Func1. 1 = Bit 0 (Used for permanent lift with special requirements)
At full load, relay 2 is activated and remains active for 5 seconds.
Payload activates relay 1.
Overload enables function that ALCII activates alarm F4.
Func2. 2 = Bit 1 (Used for lift with sensor in floor)
(Input used instead of weight)
Input 2:1 = Full load
Input 2:2 = Overload
(Output same as normal use)
Func4. 4 = Bit 2 (Used for special lifts where an empty car weighs too
much relation to payload)
This function deactivates the alarms for 6.1 – 6.2 error (software version 1.08).
This function deactivates the alarms for 1.x and 6.x error (software version 1.09 and
higher)
Func8. 8 = Bit 3 (Used for lift with low payload and high lift height)
Trailing cable compensation.
Note:
Bits can be added binary for multiple functions.
OSD 5 Function information
1. The dot on the right display is a run indication.
2. The dot on the left display flashes in sync with the dot on the right display when it is
the first travel with 10 % extra weight.
3. The dot on the left display shines with a steady light of digital input is blocked for
Extra Function 2, or if the lift/hoist is moving.
– 12 –
OSD 5 Verification
• The difference between the load cells is shown in "Work mode" by pressing the "Zero"
button.
• Temperature display: Press "Prog." followed by "Zero", and temperature will be shown
in the display.

Connection difference between OSD 4 and OSD 5
OSD 4 OSD 5
Load cell connection Pin 1 Pin 2
4:1 Screen = 4:5 3:5
4:2 -Exc. = 4:4 3:4
4:3 -Signal = 4:3 3:3
4:4 +Signal = 4:2 3:2
4:5 +Exc. = 4:1 3:1
Supply voltage
3:1 0 VDC = 1:3
3:2 24 VDC = 1:1
Note:
R3 = underload is used in parallel with the signal overload.
The "Control Signal" connection 1:1–1:2 is removed for safety reasons.
Circuit diagram load cell
EXC + = RED
SIG + = GREEN
EXC – = BLUE
SIG – = YELLOW
– 13 –
RD – BU ~ 410 Ohm
GN – YE ~ 350 Ohm

Wrong inclination Pin 1
OSD 5 Information and fault indications on the display
Non/Incorrectly programmed Payload, min. 400 kg
max 30000 kg
Calibration values
Alarm limits
Abnormal values Pin 1 For example: Payload = 3000 kg
Value is less than minus payload/4 Value cant be less than -750 kg
Abnormal values Pin 2
Value is less than minus payload/4
Reversed position Pin 1
Reversed position Pin 2
No communication with ALC II
Id tag missing Doesn't give overload
Id tag error Doesn't give overload
ROM check sum wrong
Ratio between the loadcells'
constant-value is more than 20 %.
Wrong inclination Pin 2
A/D Converter error
– 14 –
Both pins reversed position
Calibration or cable measurement not performed.
Serial No. wrong
Too little difference between Zero
Calibration and Load Calibration.
Check setup
values
}
}
}
}
Heavy car weight
and low payload
Yellow and green can be shifted or
that the cell is in the wrong way. Use
the debug menu to check values.
Ratio between Empty car weight
and Payload is more than 4/1 on Pin 1
Ratio between Empty car weight
and Payload is more than 4/1 on Pin 2

– 15 –
Solenoid 1 activated Overload
Solenoid 2 activated Full load
Solenoid 1 activated Under load
More than 500 kg.
Compensation error
More than 10 kg/m.
Compensation error
Compensation more than three times on weight compensation.
These errors doesn't give overload.
Trailina Cable
compensation weight error
Perform a new cable calibration in base
weight error and top. See chapter
"OSD 5 Trailing Cable Compensation".

OSD 5 Debug information
Use this to get important information from the OSD 5. This is for troubleshooting or for
viewing current system parameters.
In normal operation.
Press "Cal" then "SYS" is shown
Press "Load" it shows = X3 Weight.
Press "Zero" it shows = X4 Weight.
Press "Cal" twice then "R1" is shown
Press "Load" it shows = X3 Empty car Weight.
Press "Zero" it shows = X4 Empty car Weight.
Press "Cal" twice then "R2" is shown
Press "Load" it shows = X3 Compensation in kg. at top Zero Calibration.
Press "Zero" it shows = X4 Compensation in kg. at top Zero Calibration.
Press "Cal" twice then "R3" is shown
Press "Load" it shows = Bottom floor position (should always be 0).
Press "Zero" it shows = Position on top Zero Calibration position.
Press "Cal" twice then "Hyst" is shown
Press "Load" it shows = Current position.
Press "Zero" it shows = Programmed position.
Press "Cal" twice then Func" is shown
Press "Load" it shows = Distance between the Zero Calibrations.
Press "Zero" it shows = Current value in % from the "R2" value.
– 16 –