Hirschmann qSCALE i2 User manual

qSCALE i2
qSCALE i2 System
Tool Version 3.0.34
Contents
Safety Instructions
1
General Information
2
Troubleshooting
3
Commissioning
4
Maintenance and Repair
5
Appendix
6
Service Manual
Issue B –11/2017
This document has the order number:
MAN-QS12-S-0004

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TABLE OF CONTENTS
1Safety Instructions...........................................................................................7
2General Information .........................................................................................8
2.1 Description of the System...............................................................................9
2.1.1 Description of System Function.............................................................9
2.1.2 Description of the CAN Bus System....................................................10
2.1.3 Description of the System Components ..............................................11
3Troubleshooting .............................................................................................14
3.1 Troubleshooting with Display...................................................................14
3.1.1 Op-Mode Confirm Screen....................................................................15
3.1.2 Information Selection Menu.................................................................16
3.1.3 Error Codes..........................................................................................27
3.2 Hardware Troubleshooting ......................................................................29
3.2.1 What is Wrong? ...................................................................................29
3.2.2 Initial System Inspection......................................................................31
3.2.3 Simple Corrective Actions....................................................................33
3.2.4 Indicator Definitions .............................................................................34
3.2.5 Boom Angle Sensing ...........................................................................35
3.2.6 Boom Length Sensing .........................................................................38
3.2.7 Pressure Sensing ................................................................................44
3.2.8 Load Sensing.......................................................................................45
3.2.9 A2B Switch Overview ..........................................................................46
3.2.10 Slew Sensing Overview...................................................................48
3.2.11 Tilt Sensing......................................................................................49
3.2.12 No Console Display .........................................................................51
3.2.13 CAN Bus Communications..............................................................52
4Commissioning...............................................................................................55
4.1 Adding Wireless Sensors..............................................................................55
4.2 Sensor Calibration..........................................................................................57
4.2.1 Sensor Calibration Selection ...............................................................60
4.2.2 Boom Length Calibration.....................................................................61
4.2.3 Boom Angle Calibration.......................................................................63
4.2.4 Slew Sensor Calibration ......................................................................66
4.2.5 Tilt Sensor Calibration .........................................................................68
4.2.6 Analog Outrigger Calibration ...............................................................71
5Maintenance and Repair................................................................................73
5.1 Maintenance ............................................................................................73
5.2 Cleaning...................................................................................................73
5.3 qSCALE i2 Console Software Upload .....................................................74

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6Appendix .........................................................................................................76
6.1 Password Entry........................................................................................76
6.2 Error Code Tables ...................................................................................77
6.2.1 General Errors –00xx, 1Fxx, 2xxx, & 3xxx .........................................78
6.2.2 Limit Error Codes –01xx, 02xx, 03xx, 04xx, & 05xx...........................82
6.2.3 Kinematic Error Codes –0Axx.............................................................90
6.2.4 CAN and I/O Error Codes –11xx-1Bxx...............................................95
6.3 Drawings................................................................................................157

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VERSION OVERVIEW
Issue
Date
Description
Editor
A
6/2015
Initial Release
AC
B
6/2016
Updated images and sections
AC

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Introduction
This manual is a component of the equipment or systems supplied by Hirschmann Automation and
Control GmbH. Keep this manual in a safe place and ensure that it is available to all users.
The contents of this manual are subject to change. Hirschmann Automation and Control GmbH do not
provide any guarantee for this material, including the associated guarantee regarding marketability and
suitability for certain intended purposes. Hirschmann Automation and Control GmbH accept no liability
for errors in the contents of the manual or for direct or indirect damage in connection with the provision
and use of the manual.
This manual is protected by copyright. All rights reserved. The manual may not be duplicated, repro-
duced or translated into another language, either wholly or partly, without the prior written permission of
Hirschmann Automation and Control GmbH.
The rendition of common names, trade names, trademarks etc. in this documentation should not be
construed to mean that such names, even without special identification, are free in the sense of trade-
mark and trademark protection legislation and hence usable by anyone.
This device / system are intended exclusively for the tasks described in this manual. Any other use shall
be construed as being inappropriate. The manufacturer accepts no liability for damage caused by inap-
propriate or impermissible use. This device / system may only be used if it is in perfect technical condi-
tion.
Only appropriately qualified personnel may work with this device / system, i.e. persons:
who are familiar with the operation or installation and commissioning
who know the current regulations for the prevention of accidents
About this Manual
Liability Disclaimer
Copyright
Notice
Trademarks
Use for the Intended
Purpose
Qualification of the
Operating Personnel

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Marking of Notices
Dangers and other important notices are marked as follows in this manual:
WARNING
Warning of direct threat of personal injury and damage to property.
Instructions on precautions to avert the danger.
CAUTION
Warning of dangerous situations. Also warns of damage to property.
Instructions for averting the danger.
IMPORTANT
Warning of possibly damaging situation for the product.
Instructions for avoiding the possibly damaging situation.
NOTE
Usage instructions and information, but no dangerous situation
HINT
Supplementary comments and recommendations for the user.

Safety Instructions
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1 Safety Instructions
WARNING
Imminent threat of personal injury and damage to property due to incorrect system settings!
The correct adjustment of the Rated Capacity Limited (RCL) to the current set-up status is es-
sential for the correct function of the system and of the machine.
The RCL can only operate correctly if all settings are entered correctly according to the current
set-up status during the SETUP procedure.
The settings can only be carried out by operators who are completely familiar with the operation
and functions of the machine and the RCL.
The correctness of these settings must be guaranteed before starting the machine operations!
IMPORTANT
Connection to the wrong power supply will cause damage to the device.
The device may only be connected to a DC voltage source of 10 V to 30 V!

General Information
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2 General Information
This service manual is designed to assist a service or maintenance person in identifying system prob-
lem areas or malfunctions. A digital voltmeter with the capability to measure current will be required,
along with standard maintenance and service tools.
NOTE
Knowledge of how to use a voltmeter to measure both voltage and current is assumed.
NOTE
The qSCALE i2 contains several menus where queries and settings can be made only after en-
tering a password.
HINT
For system operation, refer to the console Operator’s Manual.

Description of the System
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2.1 Description of the System
2.1.1 Description of System Function
The qSCALE i2 system is a CAN bus system comprised of an operating console, digital input/output
(DIO) extension box, length/angle cable reel, pressure transducers, and an anti-two-block switch. All
components and sensors are equipped with CAN bus controllers.
The Hirschmann Automation and Control system operates on the principle of reference/real compari-
son. The real value resulting from the pressure measurement is compared with the reference data
stored in the central processor memory and evaluated in the microprocessor. When limits are reached,
an overload warning signal is generated at the operator’s console. At the same time, the aggravating
crane movements, such as hoist up, telescope out, and boom down, will be stopped.
The fixed data regarding the crane, such as capacity charts, boom weights, centers of gravity, and
dimensions are stored in memory chips in the central processor unit. This data is the reference infor-
mation used to calculate the operating conditions.
Boom length and boom angle are registered by the length/angle sensor mounted inside the cable reel
which is mounted on the boom. The boom length is measured by the cable reel cable, which also
serves as an electrical conductor for the anti-two block switches.
The crane load is measured by pressure transducers attached to the piston and rod side of the hoist
cylinders.
The interactive user guidance considerably simplifies the input of operating modes as well as the setting
of geometry limit values.

Description of the System
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2.1.2 Description of the CAN Bus System
CAN stands for “Controller Area Network” and is intended to be used as a serial bus system for a net-
work of controllers. Each controller connected through a CAN chip is called a "node" and is mostly used
to acquire data from a sensor. All nodes are connected to a common bus and all nodes are able to
simultaneously read the data on that bus. Also, all nodes are able to transmit data on that bus, but only
one node at a given time has write access to the bus. If the message is relevant, it will be processed;
otherwise, it is ignored. The unique identifier also determines the priority of the message. The lower the
numerical value of the identifier, the higher the priority.
The cable bus is a twisted pair of shielded wire. Data can be transmitted in blocks from 0-8 bytes at a
maximum transfer rate of 1 Mbit/s for networks up to 40 meters. For longer network distances, the max-
imum transfer rate must be reduced to 50 Kbit/s for a 1 km network distance. CAN will operate in ex-
tremely harsh environments and the extensive error checking mechanisms ensure that any transmis-
sion errors are detected.

Description of the System
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2.1.3 Description of the System Components
The qSCALE i2 system is comprised of various components. The typical relative locations of these
components are shown in the photo below.
2.1.3.1 Console (qSCALE i2)
The graphic display console houses the CPU and also displays pertinent information
regarding the RCL configuration. Refer to the Operator’s Manual for detailed opera-
tion of the console.
cSCALE Ix consoles are available in 4.3” (I2) and 7” (I3) sizes. The graphic display console displays
pertinent information regarding the RCL configuration. Refer to the Operator’s Manual for detailed oper-
ation of the console.
2.1.3.2 cSCALE DIO
The DIO module is an I/O module for the decentralized detection of analog and digital
sensor signals as well as for driving actuators and proportional valves. The DIO mod-
ule is able to communicate with programmable logic controllers using the CANOpen
protocol.

Description of the System
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2.1.3.3 Pressure Transducers
The pressure transducers convert hydraulic pressure into an electric signal. The
pressure transducers are connected to the CAN bus junction box. One pressure
transducer is connected to the piston side of the lift cylinder and the other to the rod
side.
2.1.3.4 Cable Reel (Length-Angle Sensor)
The length-angle sensor (LWG), often referred to as the “cable reel”, is installed on
the base section of the boom can measure the length and the angle of the boom
along with transmitting signals to the boom tip.
A reeling drum drives either a potentiometer or rotary encoder to measure the length
of the boom. The length cable on the drum connects to the boom tip and can transmit signals from the
chassis through a slip ring within the LWG housing through the length cable to the boom tip.
The angle sensor is either a liquid capacitive angle sensor (WGC) or a MEMS based angle sensor
(WGX). Both length and angle sensor are connected to a CAN bus board which is connected to the bus
system.
2.1.3.5 Anti-Two-Block (A2B) Switch
The anti-two-block switch monitors the load block and its relationship with the head of
the boom. In working condition, the switch is closed. When the load block strikes the
weight, the circuit opens, disengaging a relay output. To check the cable for damage
(short circuit to ground) there is a 4.7k resistor between ground and the contact of the
switch to give a signal back to the central unit. The weight at the anti-two-block
switch keeps the switch closed until the load block strikes it.

Description of the System
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2.1.3.6 Slew (Angle of Rotation) Sensor
This component is an absolute rotary encoder. This slew angle is the angle (rotational
positioning) of the crane boom relative to the truck.
2.1.3.7 Tilt Sensor
This component is a MEMS based inclination sensors, applicable for all kinds of angle and
position measurements on mobile machines. Typical applications include determination of
a crane boom angle, the leveling of an undercarriage, and alignment tasks on mobile
machines.

Troubleshooting
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3 Troubleshooting
3.1 Troubleshooting with Display
The main working screen displays error codes and symbols in the status bar. The error code cause and
recommended solution can be found using the displayed code in Section 3.1.3. The status of all inputs
and outputs of the system can be checked using several screen displays on the RCL console.
When there are communication errors with safety critical sensors the system will default to maximum
system utilization. Sensors in error state will have their values turn red.
.
User Limits
(see Operators Manual)
Operation Confirm Screen
(see Section 3.1.1)
Display Day/Night Switch
(see Operators Manual)
System Event Information
(see Section 3.1.3)
Silence Alarm
(see Operators Manual)
Function
Keys
Load Capacity
(bar chart)
% Utilization
Operation
Mode
Event code,
as required
(Section
3.1.3)
Lifting Capacity
Date
Time
Warning Symbols
as required
Actual Load
Heartbeat

Troubleshooting
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3.1.1 Op-Mode Confirm Screen
The Op-Mode Confirm screen is the starting point to access diagnostic screens

MAIN
WORKING
SCREEN
OP-MODE
CONFIRM
Setup
(see Operator’s Manual)
Operation Mode Selection
(see Operator’s Manual)
Information Selection
(see Section 3.1.2)
Select Reeving
(see Operator’s Manual)
Graphic Tilt Screen
(see Operator’s Manual)
System Event Information
(see Section 3.1.3)
Function Keys

Troubleshooting
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3.1.2 Information Selection Menu
The Information Selection Menu allows the user to view crane, sensor, and software version information
and is the starting point for diagnostic information.


MAIN
WORKING
SCREEN
OP-MODE
CONFIRM
INFORMATION
SELECTION
Sensor Information Screen
(see Section 3.1.2.1)
Crane Information
(see Operators Manual)
Information Selection (extended)
(see Section 3.1.2.2)
Version-Info
(see Operators Manual)
Function Keys

Troubleshooting
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3.1.2.1 Sensor Information Menu
In this menu different information can be displayed about the defined input sensors on the crane.



MAIN
WORKING
SCREEN
OP-MODE
CONFIRM
INFORMATION
SELECTION
SENSOR
INFORMATION
Digital Input Information
(see Section 3.1.2.1.1)
Analog Input Information
(see Section 3.1.2.1.3)
Digital Output Information
(see Section 3.1.2.1.2)
Not available for this project
NOTE
Available screens will vary depending upon system configuration!
Function Keys

Troubleshooting
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3.1.2.1.1 Digital Input Screen
The Digital Input Screen shows all of the configured digital inputs for the system, including the A2B
signal. These inputs are wired to the DIO Box; refer to your crane system wiring diagram for details.
Use the rotary knob to scroll between all available inputs.




MAIN
WORKING
SCREEN
OP-MODE
CONFIRM
INFORMATION
SELECTION
SENSOR
INFORMATION
DIGITAL
INPUTS
Additional Information
The following information can be found on this screen:
Value Current Value of the Input (False = Low, True = High)
Fault Indication whether an error has occurred
State Current Status of value
Substitute According to Project File Configuration
Debounce Time According to Project File Configuration
Error Base Base error priority of the error when error occurs
Raw Source Available in Additional Information
Function Keys

Troubleshooting
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3.1.2.1.2 Digital Output Screen
Digital Output Screen shows all of the configured digital outputs for the system (if there are no digital
outputs then this screen will not exist). These outputs are wired from the DIO Box; refer to your crane
system wiring diagram for details. Use the rotary knob to scroll between all available outputs.




MAIN
WORKING
SCREEN
OP-MODE
CONFIRM
INFORMATION
SELECTION
SENSOR
INFORMATION
DIGITAL
OUTPUTS
Additional Information
The following information can be found on this screen:
Value False = Low, True = High
Fault Indication whether an error has occurred calculating this value
State Current Status of value
Substitute Not Configurable
Debounce Time According to Project File I/O configuration
Error Base Base error class and priority of the sensor when an error occurs
Raw Source Available in Additional Information
Function Keys

Troubleshooting
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3.1.2.1.3 Analog Input Screen
Analog Input Screen shows all of the configured analog inputs for the system, including CAN sensors.
These outputs are wired from the DIO Box; refer to your crane system wiring diagram for details. Use
the rotary knob to scroll between all available outputs.




MAIN
WORKING
SCREEN
OP-MODE
CONFIRM
INFORMATION
SELECTION
SENSOR
INFORMATION
ANALOG
INPUTS
Delete Sensor Calibration
Set Zero Point Offset
Set Current Sensor Raw Value as
Raw-Value Scale Start
Inverts Raw Value
(100% minus raw value)
Set Current Sensor Raw Value as
Raw-Value Scale End
Additional Information
(see Section 3.1.2.1.4)
The following information can be found on this screen:
Value Current Value
Fault Indication whether an error has occurred calculating this value
State Current Status of value
Substitution According to Project File Configuration
Scale Scaled values are defined in the configurator
Raw Value Scaling: The start of a raw value scaling is assigned to the scale start value and
changes after sensor calibration
Deviation Offset changes after sensor calibration
Gain Filter amplification factor
Lag Filter delay
Error Base Base error class and priority of the sensor when an error occurs
Function Keys