BROSA 0656 FlexLim User manual

BROSA AG
Dr. Klein Straße 1
D-88069 Tettnang
Phone: [phone]
Fax: [phone]
[e-mail]
www.brosa.net
BROSA Pte Ltd
5 Lorong Kilat #0 -01
Singapore 5981 6
Phone: [phone]
Fax: [phone]
[e-mail]
BROSA B.V.
Galliershof 38
NL - 5349 BV Oss, Holland
Phone: [phone]
Fax: [phone]
[e-mail]
BROSA (Nanjing) Co., Ltd.
Jinma Lu 3, Maqun Scientific Park, Qixia District
10049 Nanjing
Phone: +86 ( 5)8 4639
Fax: +86 ( 5)8 4639
[e-mail]
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© 2018 BROSA AG, Tettnang, Ge many
Ope ating Manual
0656 FlexLim (Safe) system
Manual version: 2.3
Revision: 05/ 019

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Notes

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Contents
1 General information ................................................................................................ 5
1.1 About this manual ............................................................................................ 5
1. Safety instructions and warning symbols ........................................................... 6
1.3 Warnings and important information ................................................................. 7
1.4 Purpose of the system ..................................................................................... 7
1.5 Qualification and responsibility of the operating staff ......................................... 7
1.6 Disclaimer ....................................................................................................... 8
System description ................................................................................................. 8
3 System calibration and parameter setting .............................................................. 1
3.1 General ......................................................................................................... 1
3. External display 0680 ..................................................................................... 14
3.3 4.3 "or 7" external display ............................................................................... 17
3.4 Computer with PuTTY terminal emulation ....................................................... 17
4 General System Information (VT 100) ................................................................... 1
4.1 Menu structure ............................................................................................... 1
4.1.1 System ................................................................................................... 1
4.1. System information .................................................................................. 1
4.1.3 Protocols .................................................................................................
4.1.4 Service ...................................................................................................
4.1.5 System restart ......................................................................................... 4
4.1.6 Language ................................................................................................ 4
4.1.7 Metrics .................................................................................................... 4
5.1.1 Machine set-up ........................................................................................ 5
5.1. CANopen inputs ...................................................................................... 6
5.1.3 Configuration........................................................................................... 6
5.1.4 Analogue outputs .................................................................................... 7
5.1.5 Constants ( ) .......................................................................................... 9

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5.1.6 Constants ............................................................................................... 30
5.1.7 Comparators ........................................................................................... 30
5.1.8 Changing the PIN .................................................................................... 31
5.1.9 Service ................................................................................................... 3
5.1.10 Baud rate ................................................................................................ 3
5.1.11 Tool block ............................................................................................... 3
5.1.1 Bootloader .............................................................................................. 33
5.1.13 Integration of new sensors during replacement ......................................... 33
6 Technical data of 0656 electronic system .............................................................. 35
7 List of error codes and troubleshooting .................................................................. 37
7.1 CANopen input .............................................................................................. 37
7. D curve ........................................................................................................ 39
7.3 Multifunctional block (weighing) ...................................................................... 39
7.4 System errors ................................................................................................ 40

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Gene al info mation
1.1 About this manual
This manual is designed to explain the features and operation of the BROSA 0656 electronic
system when used as an overload or weighing system. In addition, it is intended as a manual
for qualified and authorised personnel which describes the calibration of a BROSA 0656
system.
The manual is an integral part of the BROSA 0656 electronic system and the FlexLim (Safe)
operating system software from the manufacturer:
BROSA AG
Dr. Klein Strasse 1
D-88069 Tettnang
Telephone [phone]
Fax [phone]
E-mail [email protected]
Internet www.brosa.net
The manual describes the functions, general settings and calibration as well as troubleshooting
for the BROSA 0656 overload protection system using the FlexLim (Safe) operating system
software.
It describes the possible uses of the system as well as the required qualification of the technical
staff.
The manual and the examples given are copyright protected. All rights reserved. This manual
may not be copied or duplicated, in whole or in part, without prior written consent of the
manufacturer.
The manufacturer reserves the right to change the content and form of this manual without
further notice. There is no distribution list for this manual.
The manufacturer accepts no liability for content or printing errors in this manual and for
damages that directly or indirectly arise from the use of this manual.

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1. Safety instructions and warning symbols
For the sake of clarity and readability, icons are used to alert readers to important
information:
Warning of an immediate danger. Neglect leads to serious injury or
death
Warns of possible danger. Neglect could result in serious injury or
death.
Indication of a possible danger. Non-observance may result in minor
injury or property damage.
Indication of a potentially harmful situation. Non-observance could
result in property damage to devices and equipment.
Indication of a possible risk of electric shock. Parts marked with this
symbol must never be touched.
Indication of a section with additional information and useful tips.
The sections labelled with the icons shown above contain important information and
deserve special attention as you read this manual. Failure to observe the icons or
recommendations will result in a significantly increased potential for risk.
DANGER
WARNING
ATTENTION
CAUTION

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1.3 Warnings and important information
Depending on the individual configuration, some systems can also be
equipped with a 30V AC power supply (details can be found in the system
documentation). This is indicated by a corresponding warning symbol on the
voltage transformer and the relays. Although these parts are protected against
direct contact, special caution should be exercised near them.
1.4 Purpose of the system
The BROSA 0656 electronic system is an overload protection and weighing
system for crane systems, an important aid for the operation of cranes. The
device provides the operating staff with all the information required for safe
operation within target values when lifting. The system is designed and
constructed to comply with all applicable safety standards.
The system may not be used for purposes other than those mentioned above.
Improper use of the system endangers the life of the operating staff and other
persons and may result in damage to the machine or property.
It is crucial that the system is always in perfect condition. In systems that consist
of a large number of electronic and mechanical components, the occurrence of
errors can never be completely ruled out. Such errors constitute a potential
security risk and must therefore be remedied promptly by qualified technical
staff.
An overload protection system is no substitute for good judgement, for
experienced operating staff or for the necessary safety regulations during
operation and the system should therefore also not be misused for this purpose.
1.5 Qualification and responsibility of the operating staff
To ensure safe operation of the system and crane, calibration and adjustment
of the system by a qualified technician is mandatory. The technician must meet
the following requirements:
DANGER
WARNING

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 He/She has the necessary authorisations and has been
sufficiently trained.
 He/She has read and understood this manual or received
appropriate instruction or training.
 He/She is familiar with the operation of the system.
 He/She knows the relevant safety standards and accident
prevention regulations.
A person's knowledge regarding the operation of the system does not
automatically mean that this person is authorised to operate the system.
Responsibility for safe operation of the system and the crane lies with the
operating staff. It must be ensured that the operating staff has understood all
the information given here about operating safety and also follow it.
1.6 Disclaimer
The manufacturer assumes no liability for damage or injury resulting from
impermissible or improper use of the system. This risk is the sole responsibility
of the user.
The manufacturer has checked the contents of this document for compliance
with the hardware and software described.
Nevertheless, deviations cannot be ruled out, and the manufacturer assumes
no responsibility for complete compliance. The information in this publication is
checked regularly and necessary corrections will be included in later issues.
System desc iption
The BROSA 0656 electronic system together with the BROSA "Flexible Limiter" (FlexLim
(Safe)) operating system software is a flexible overload protection system for crane
systems. The system continuously monitors the various functions and operating
conditions of a crane using a wide variety of external sensors (e.g. force sensors, angle
sensors). An external display can be added to the system. The operator then receives
permanent feedback (both visible and audible) about the operating status of the crane
WARNING

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during lifting operations. The outputs on the display (sensor data, calculated values,
utilisation percentage values, etc.) are adapted to the existing crane system and the
configuration of the application.
Optionally, the BROSA 0656 electronic system can be used as a weighing system in
accordance with SOLAS. Handling essentially corresponds to use as an overload
protection, which is why explicit mention of this is omitted in the following.
The BROSA overload protection system is based on the 0656 electronics platform with
the following features:
• 8 (typ.) CANopen nodes (ID 11 - ID 18)
• analogue outputs
• 8 digital inputs
• 8 digital outputs + 1 system error output
• RS 3 interface
• RS485 interface
• PROFINET interface (slave)
• PROFIBUS interface (slave)
• CANopen interface (slave)
For additional technical details, see chapter 5
Each system can be adapted to the specific needs of a customer using BROSA's FlexLim
Safe operating system software. As the name implies, FlexLim Safe flexibly allows for the
creation of customised load limiting applications. Depending on the version, the system
achieves SIL (PLd)
The software consists of predefined modules (inputs, outputs, comparators, mathematical
operators, etc.) that can be combined appropriately to achieve the desired functionality.
Each module has a number of specific parameters which can be changed either directly

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in the system (display) or by means of a PC connected via the RS 3 interface. The
function of these parameters is application-dependent and is explicitly listed in a separate
software description.

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The following sketches illustrate the system principle and the FlexLim program structure:
Figure 1: Standard system layout
Figure : FlexLim program structure

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System calib ation and pa amete setting
3.1 General
The system offers different methods for calibration and setting of system
parameters:
• PC with VT100 emulation (e.g. Putty in MS Windows) via the RS 3
interface.
• Android app via Bluetooth (planned)
The menu structure differs depending on the interface used. Input and menu
guidance also depend on the periphery used.

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The selection menus for:
• CANopen inputs
• Digital inputs / outputs
• Constants ( ) and (3)
• Load spectrum counter
• Comparators
are so-called dynamic menus. This means that the menus may be different
depending on the system configuration. Only the options defined in the system
configuration are displayed. For example, in a system configured with 3
CANopen inputs, only the inputs actually used by the program will be available
for selection (though the BROSA 0656 system supports more channels on the
software side). If there is no configuration available for the selected option, the
system will indicate this by the "Nothing to select" indicator.
Each parameter can also be assigned its own units of measure. For example,
in the block diagram above, the CANopen inputs are load sensors. They
therefore record signals in tonnes [t]. Depending on the application, these could
just as well be configured to output values in metres, kilonewtons or degrees.
Although the parameter values can be changed at any time by changing to the
machine setting input mode (see description below), the units of measure are
application-specific. They can therefore only be set in the phase of program
implementation.

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3. External display 0680
An external display uses the built-in navigation keys to select menus and to
enter parameter values.
Selecting the se vice menu
Press the "ESC" key to open the service menu.
Sc olling th ough the menu
The display can only show 4 lines at a time. If the menu consists of more
lines, you can scroll up or down using the corresponding arrow keys.
Making a menu selection

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Press the "ENTER" key. The menu then scrolls to the "select" option and a "1"
is displayed in the first input field.
You can change this value to that of the menu to be selected by pressing the
corresponding arrow keys (up or down).
Press the "ENTER" key to confirm your selection.
If the selected menu is incorrect, press the "ESC" key to return to the previous
menu.
Ente ing a pa amete value
Press the "ENTER" key. A "1" is displayed as a default in the first input field.
Change this by pressing the up and down arrow keys on the first digit of the
parameter value.
The arrow key to the right moves the cursor to the next input field and a preset
"1" is displayed.
Repeat this process with the remaining digits.
The left and right arrow keys can be used to move between the input fields.
Press the "ENTER" key to confirm the input value.
If you do not want to change the parameter value, press the "ESC" key to exit
value entry and go to the next parameter or return to the previous menu.
Display set-up
From display software V1.0. , there is a "Set-up menu" to select the following:
 Display test
 Baud rate selection
 Bootloader mode
OK
OK
OK
OK

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Selection of the "Set-up menu" display
Press the "ESC" key and turn on the display.
Display test
Press the left arrow key to scroll through the display test routine. The software
version is displayed and the display goes through a test cycle.
Baud rate selection (conversion)
Press an arrow key to change the baud rate.
Press the arrow key to the left for 9600bd
Press the arrow key to the right for 38400bd
Note: This option changes the baud rate of the display. To ensure functioning
communication with the system, the baud rate of the system must first be
switched.
Bootloade
Only for internal application for BROSA.
Setup menu:
←: Display test
→: Baudrate
↓: Bootloader
Change baud rate:
Old baud rate: xxKx
Baud rate: 9K6/38K4
Press key:
←
/
→

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3.3 4.3 "or 7" external display
The display is addressed via the CAN interface (CAN ). The values are sent
to the display via defined COB-IDs and shown according to the programming
of the display.
Display example
3.4 Computer with PuTTY terminal emulation
Requi ed tools:
• Notebook with RS 3 interfaces or USB with corresponding interface
cable (USB to RS 3 )
• Terminal emulation program (e.g. PuTTY in MS Windows)
Connection of a PC to the 0656 elect onic system

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Connect a serial port of your PC to the 0656, as shown below:
Contacts:
Configu ation of the VT100 te minal
Most VT100-capable terminal emulations should be compatible with FlexLim.
However, you must make sure that the following parameters are set correctly.
(Please refer to the documentation of your emulation program to see which
parameters are named and how to set them):
COM po t: Set to the port to which the RS 3 cable is connected.
Te minal emulation: You may need to specify this explicitly. If so, specify
VT100.
Designation:
Plugs:
Contact:
RS232_TXD_ UT
M DICE30_L
FL3
RS232_RXD_IN
M DICE30_L
GL1

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Baud ate: 115 00 bps
Data bits: 8
Parity: None
Stop bits: 1
Flow control: None
You need a terminal program for configuration. The following examples were
created with the free terminal program PuTTY.
Selection of the connected
COM port
Set as shown

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Select VT100 terminal emulation
Selecting the service menu
Press the "ESC" key to open the service menu.
Making a menu selection
Select the desired menu by pressing the corresponding number on the
numeric keypad.
Press "ENTER" twice to select the menu corresponding to the input.
If the selected menu is incorrect, press the "ESC" key to return to the previous
menu.
Entering a parameter value
Enter the full parameter value on the numeric keypad.
Press the "ENTER" key twice to confirm.
If you do not want to change the parameter value, press the "ESC" key to exit
value entry and go to the next parameter or return to the previous menu.