FABER-COM CLG-SL User manual

MAP2 / MAP2LCLG-SL
FABER-COM srl - Via Romana 36/1 - 42028 Poviglio (RE) - Italy Tel. [phone] Fax. [phone] - www.fabercom.it
\Prodotti\Limitatore CLG\PCLG-LxE[CLG-SL- Barra LED]\Documenti\SM#Limitatore CLG-SL_v102 - 19/04/2017
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Overall dimensions: 138 x 110 (147 with connector) x 38 mm
Drilling interaxis: 119 x 99 mm (n° 4 screw M5)
A1 - Power supply
A2 - +V transducer supply
A3 - not used
A4 - +V switch supply
A5 - +V switch supply
A6 - not used
A7 - DV input
A8 - Emergency input
B1 - RX serial comm.
B2 - +V PRG2 supply
B3 - ground for 90% signal
B4 - +ELV1 signal
B5 - ELV1 ground
B6 - input TRANSD. 1 (P)
B7 - input DECREMENT
B8 - Emergency output
C1 - TX serial comm.
C2 - PRG2 ground signal
C3 - ground for 100% signal
C4 - not used
C5 - not used
C6 - input RESET
C7 - not used
C8 - GND
Pinout FCI connector (24 ways)
04/01/2017 - v100: Prima stesura [VA] a cui il 24/02/2017 seguono piccole correzioni. Il documento fino ad allora è stato ad uso interno
27/03/2017 - v101: rivista un po' la grafica [VA]
CLG-SL Load limiter is an electronic device able to control the load of the crane (or another machine) through a
pressure transducer, and limits the operations that would cause an overloading and/or an overturning of the
machine, acting on the bypass valve.
Load limiter for crane

MAP2 / MAP2LCLG-SL
FABER-COM srl - Via Romana 36/1 - 42028 Poviglio (RE) - Italy Tel. [phone] Fax. [phone] - www.fabercom.it
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FEATURES
Power supply range: from 10Vdc, up to 30Vdc.
Connector FCI, 24 ways, IP68, mechanical polarization, easy locking cam.
Maximum output current supply: 3A
In the respect of EN 954-1 the safety features belongs to category 2
Two differnet working areas with two different load limits.
Fast and easy programming sequence.
HUMAN MACHINE INTERFACE
The green led on the board, in normal operation mode, is lighten to show the power supply.
When faults are present, the green led blinks following a particular sequence related to the fault
reasons. (look at the last page for a detailed blinking sequence meaning).
Leds placed into the emercency button box (red colour and yellow colour), are lighten in the
floowing situation:
- When emercy button is pressed, the red button and the yellow butto blink together.
- When the load exceed the 90% of the limit, yellow led is ON.
- When the load exceed the 100% of the limit, red led is ON.
INPUT
- RESET: That input allow the load limiter to power the valve for a short period, even if the
load value exceed the load limit.
- LIMIT REDUCTION: It is used to set the working area. When it is low value, then the load
limiter compare the pressure from the transducer with a reduced threshould.
- PRESSURE transducer input: 4÷20 mA.
- INPUT DV: It allow to connect the load limiter to a remote control in a safety way.
- DIFFERENT POWER SUPPLY for logic control unit and powered OUTPUT.
OUTPUT
- Powered output to drive bypass valve coil. The board implements a feedback current control
on the mentioned output.
- Two powered output to drive external optional lamps. The mentoned outputs are driven as well
as the leds into emergency button box (90% and 100%).
SETTING PARAMETERS
The load limiter's threshoulds are programmed using an exernal, little, 4 bottons, keyboard. The
keyboard is an optional. His name is "PRG2_CLG". When it is connected the green led blinks
for time in a second.
In order to set whole the load limiter's parameters and download the working configuration, an
optional serial interface can be used to connect the PC to the load limiter. The program interface
is named SepSim.
HARDWARE KEY TO INCREASE THE LOAD LIMIT THRESHOLD
The PRG2_CLG can be used even to increase the load limit thresold up to 125%, for a brief
period of time.
In order to increase the limit: when you connect the PRG2_CLG, the "+" button has to be
pressed within 5 seconds then kept pressed till the green led blinking will becomes slower.
Features
Human machine interface
Power supply range: from 10Vdc, up to 30Vdc.
Connector FCI, 24 ways, IP68, mechanical polarization, easy locking cam.
Maximum output current supply: 3A
According to EN 954-1 Safety Standards: Category 2
Two different working areas with two different load limits.
Fast and easy programming sequence.
The green led on the board, in normal operation mode, is lighten to show the power supply.
When faults are present, the green led blinks following a particular sequence related to the fault reasons. (look at
the last page for a detailed blinking sequence meaning).
Also, it is present a LED bargraph to show the load percentage in real time, compared to the maximum load. When
the load exceedes the 100% of the limit, red LED of the bargraph blinks.
Leds placed into the emergency button box (red colour and yellow colour), are lighted in the following situations:
- When emergency button is pressed, the red and the yellow blink together.
- When the load exceedes the 90% of the limit, yellow led is ON.
- When the load exceedes the 100% of the limit, red led is ON.
The CLG-SL load limiter is able to control a Bar LED in order to signal when load exceed the 90% and 100% of
maximum permitted load.
For this purpose, it is necessary open the box of secondary emergency push button and connect a cable as
instructed below.
CARATTERISTICHE TECNICHE
Tensione di alimentazione unica da 10Vdc a 30Vdc
Connettore a 24 poli IP68 con aggancio rapido a slitta.
Corrente massima uscite di potenza: 3A
Classificazione sicurezza secondo norme EN954-1: Categoria 2
Interfaccia utente con 1 LED (led mode) per mostrare lo stato di
- Presenza tensione di alimentazione
- Segnalazione allarmi e anomalie (in ultima pagina è presente l'elenco delle segnalazioni)
I led presenti sul cablaggio, posti nella scatola dei funghi di emergenza, svolgono diverse segnalazioni
- Carico al 90% (quando la luce gialla è accesa fissa)
- Carico al 100% (quando la luce rossa è accesa fissa)
- Fungo di emergenza premuto (quando entrambe le luci lampeggiano)
INGRESSI
- RESET (riarmo con temporizzazione opzionale)
- Decremento portata (zona di lavoro)
- Lettura di un trasduttore di pressione a due fili 4÷20 mA con controllo del range di
funzionamento, segnalazione del guasto e blocco delle uscite.
- Predisposizione per l'ingresso DV dell'eventuale radiocomando installato sulla gru.
- Ingresso separato per l'alimentazione delle uscite di potenza (positive) con relè sezionatore
generale controllato in retroazione. A tale ingresso sarà collegato il positivo della serie dei funghi di
emergenza.
USCITE
- Uscita di potenza per il comando elettrovalvola di bypass (controllata in retroazione).
- n° 2 uscite di potenza (negative) per il comando delle lampade esterne di segnalazione del
carico al 90% e al 100%.
PROGRAMMAZIONE DA PARTE DEL COSTRUTTORE
La programmazione delle soglie di intervento è impostabile, in modo veloce e intuitivo, attraverso un
tastierino esterno (opzionale) denominato "PRG2-CLG".
Per mezzo di un adattatore di interfaccia seriale e di un apposito cablaggio di adattamento è possibile
collegare la scheda ad un Personal computer per la configurazione dei parametri di funzionamento più
delicati (ritardo del RESET, variazioni delle soglie associate agli ingressi di incremento e decremento
portata, configurazione di un trasduttore di pressione con scala diversa, ecc, ecc).
PROGRAMMAZIONE DA PARTE DELL'INSTALLATORE
L'installatore ha a disposizione un tastierino differente da quello del costruttore (PRG2-DEC), per il
declassamento della gru. L'installatore può variare le soglie di intervento, ma solo per valori al di sotto di
quelli impostati dal costruttore. Il tastierino permette di richiamare, in caso di necessità, i dati di fabbrica.
CHIAVE HARDWARE DI INCREMENTO DELLA SOGLIA DI INTERVENTO
Il tastierino PRG2 (sia DEC che CLG) permette inoltre di incrementare la soglia di intervento al 125%.
Per attivare questa funzione si deve premere per 5 secondi il tasto "+", entro 5 secondi da quando è
stato collegato il tastierino alla centralina.
Quando si estrae il tastierino, o dopo un'ora dall'inserimento, la soglia di intervento del blocco momento
torna al valore normale di lavoro.
La centralina CLG permette la limitazione del carico di una gru.
Il carico viene misurato mediante un trasduttore di pressione 4÷20 mA sul martinetto del primo braccio.
Quando il limite di sollevamento della gru viene superato la gru viene bloccata spegnendo l'uscita ELV1 che sarebbe, in condizioni normali di lavoro, sempre accesa.
+ (blue)
90% (brown)
100% (grey)

MAP2 / MAP2LCLG-SL
FABER-COM srl - Via Romana 36/1 - 42028 Poviglio (RE) - Italy Tel. [phone] Fax. [phone] - www.fabercom.it
\Prodotti\Limitatore CLG\PCLG-LxE[CLG-SL- Barra LED]\Documenti\SM#Limitatore CLG-SL_v102 - 19/04/2017 Page 3 / 6
Inputs
Outputs
-RESET: That input allows the load limiter to power the valve ELV1 for a short period, even if the load value
exceedes the load limit. During this time, the user is able to move the machine in order to return into a safety
position. Working conditions are not monitored when reset functionality is enabled, user is responsible for possible
machine damage.
- LIMIT REDUCTION (critical working area): It is useful when a working area is more critical than other: when its
value is low, a reduced pressure threshold is used.
- INCREASE THRESHOLD (optional): that input has to be coupled with first boom descent manoeuvre. When input
value goes high, the load limit threshold is increased by a fixed value (specified in a configuration parameter), in
order to offset the pressure increase due to overcenter valves which operate during this manoeuvre.
- PRESSURE transducer input: 4÷20 mA.
- INPUT DV: It allows to connect the load limiter to a remote control in a safety way.
- DIFFERENT POWER SUPPLY for powered outputs, which includes a disconnect relay with feedback control.
Emergency button can be connected to this input.
- Powered output to drive bypass valve coil. The board implements a feedback current control on the mentioned
output.
- Two powered output to drive external optional lamps. The mentioned outputs are driven as well as the leds into
emergency button box (90% and 100%).

MAP2 / MAP2LCLG-SL
FABER-COM srl - Via Romana 36/1 - 42028 Poviglio (RE) - Italy Tel. [phone] Fax. [phone] - www.fabercom.it
\Prodotti\Limitatore CLG\PCLG-LxE[CLG-SL- Barra LED]\Documenti\SM#Limitatore CLG-SL_v102 - 19/04/2017
COM
FABER -
PRG2-DEC
NEXTNEXTPREVPREV
COM
FABER -
RS-232 Adapter
CLG
Serial cable
Ordering code: PISPM
programming
connector
Page 4 / 6
Setting parameters by final user
Hardware key to increase the load limit threshold
The load limiter's thresholds are programmed using an external, little, 4 buttons,
keyboard. The keyboard is an optional. Its name is "PRG-CLG". When it is
connected the green led blinks four times in a second.
The PRG2 (either CLG version or DEC version) can be used even to increase
the load limit threshold up to 125%, for a brief period of time.
In order to increase the limit: when you connect the PRG2, the "+" button has to
be pressed within 5 seconds then kept pressed till the green led blinking will
becomes slower.
In most cases, CLG load limiter doesn't need to be connected to PC:
- thresholds are programmed by means of PRG 2 keyboard
- fault analysis is done by means of the green LED placed near connector
It is possible to connect CLG card to PC with serial port using the special serial adapter AISM (code: PISPM) and
free SepSim Windows® program.
PC connection is required in the following cases:
- to set whole the load limiter's parameters
- upload/download the working configuration
- to monitor some working parameters when fault occurs
- to update the firmware
PC connection

MAP2 / MAP2LCLG-SL
FABER-COM srl - Via Romana 36/1 - 42028 Poviglio (RE) - Italy Tel. [phone] Fax. [phone] - www.fabercom.it
\Prodotti\Limitatore CLG\PCLG-LxE[CLG-SL- Barra LED]\Documenti\SM#Limitatore CLG-SL_v102 - 19/04/2017
COM
FABER -
PRG2-DEC
NEXTNEXTPREVPREV
COM
FABER -
PRG2-CLG
NEXTNEXTPREVPREV
123
3
2
1
ELV1
FUSE-5A
1
2P+T
2x1+2x0,5
L=1.1m
2x1+2x0,5
L= 2,5 m 3x0,75
2x0.75
L=1.2m
2x0.75 L=2.0m
(protection conduit ø ext.=11 mm)
2x1
L=1.0m
2x1.5
L=1.5m
÷20 mA
4
2 fi ia l
÷20 mA
4
2 fi ia l
2
3
4
90%
100%
5
Power
20
40
60
80
90
100%
CLG-SL
!
123
3
2
1
EMERGENZE
con LED 90% e 100%
ALIMENTAZIONE
ELV1
FUSE
CABLAGGIO
Riarmo
Incremento
Decremento
1
+ (1)
- (2)
2P+T
Connettore per
il collegamento
del programmatore
Trasduttore di pressione
a 2 fili 4÷20 mA (NON INCLUSO)
4x0,75
L=0.4m
4x0,75
L= 3 m
2x1
L=1.3m
2x1
L=1.3m
2x1 L=5.0m
(in guaina corrugata ø est.=11 mm)
2x1
L=1m
2x1.5
L=1.5m
2x0.75 L=5.2m
(in guaina corrugata øest.=11mm)
3x0.75
L=0.25m
2x1
L=0.20m
4÷20 mA
2 ia fil
4÷20 mA
2 ia fil
cavetto sez. 0,5 - L.: 30 cm.
per collegamento DV dal radio
(all' interno della guaina)
2
6
3
7
4
5
+ (blu)
90% (marrone)
100%(grigio)
1234
4
3
2
1
Power
20
40
60
80
90
100%
CLG-SL
!
2x1
L=1.3m
6
7
123
3
2
1
F E AUS -5
1
2
7
3
4
L=5m
L=0,5m
L=0,5m
4÷20 mA
a 2 il
f i
L=3m
6
COM
FABER -
PRG2-DEC
NEXTNEXTPREVPREV
COM
FABER -
PRG2-CLG
NEXTNEXTPREVPREV
COM
FABER -
PRG2-CLG
NEXTNEXTPREVPREV
2x0.75
L=1.2m
2x1
L=1.3m
+ (1)
- (2)
2x1.5
L=1.5m
ELV1
Power
20
40
60
80
90
100%
CLG-SL
!
Page 5 / 6
ELECTRONIC BOARD
CLG
POWER SUPPLY
Connector to plug
the PRG2_CLG
EMERGENCY BUTTONS
with LED 90% and 100%
wire 0,5mm - L.: 30 cm.
to connect the remote control DV
(hidden under the conduit)
Programming
keyboard
PRG2-CLG
2x0.75 L=5.0m
(protection conduit
øext.=11mm)
RESET
LIMIT REDUCTION
2
Code PASMLMxxx : Control unit CLG + cabling
Code PCLG-LyE : Only control unit
Code A1003720022 : 400bar Pressure transducer
Code A1003720021 : 250bar Pressure transducer
Code PPRG2MC:programming keyboard
Ordering code of system shown in figure :
Code PASMLM0027 : Control unit CLG + cabling
Code A1003720022 : 400bar Pressure transducer
Pressure transducer,
4÷20 mA, M12 connector
INCREASE
THRESHOLD
(optional)
2x0.75 L=5.0m
(protection conduit øext.=11mm)
Ordering code
It is possible to connect a
LED bar which signals when
load exceed the 90% or 100%

MAP2 / MAP2LCLG-SL
FABER-COM srl - Via Romana 36/1 - 42028 Poviglio (RE) - Italy Tel. [phone] Fax. [phone] - www.fabercom.it
\Prodotti\Limitatore CLG\PCLG-LxE[CLG-SL- Barra LED]\Documenti\SM#Limitatore CLG-SL_v102 - 19/04/2017
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Here below you can see a table to summarize the green led blinking and a brief description of the related error.
Error code
CLG STATE
CLG STATE
DESCRIPTION
DESCRIPTION
BLINKING
BLINKING
WORKING
STATE
AUTOTEST
ANY TIME
Slow sequence Fast sequence
Input from transducer 1 exceedes the
maximum working limit.
Input from transducer 2 exceedes the
maximum working limit.
Input from transducer 1 is lower than
minimum working value.
Input from transducer 2 is lower than
minimum working value.
The current value on the valve 1 is outside
the normal working range.
The current value on the valve 2 is outside
the normal working range.
The input transducer 1 is in protection mode.
The input transducer 2 is in protection mode.
Relay broken because of the welded
contacts.
FLASH MEMORY ERROR.
It is not possible to close the relay. The
outputs are not powered.
There is current flowing on the valve coil
even though the CLG is not driving the
related output.
There is current flowing on the transducer
even though the CLG gives no power to it.
There is current flowing on switches
even though the CLG gives no power to it.
LED 100% + LED 90% blinking together Emergency button pressed