Hirschmann Pat ds 160 User manual

DS 160

System

DS 160 /0005

DS 160 /0006

Service Manual

Issue 6/2005 Rev. D

This Document has the part-no.

24 160 19_0106e

Contents

General Information

Warnings

System Description

General Troubleshooting

Information

Error Codes

Function Lockout

No Display

…

PRELIMINARY ISSUE

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CONTENTS

1. GENERAL INFORMATION......................................................2

2. WARNINGS .............................................................................2

3. SYSTEM DESCRIPTION.........................................................3

4. GENERAL TROUBLESHOOTING INFORMATION.................4

4.1 GENERAL FLOW CHARTS.............................................................. 5

5. ERROR CODES ......................................................................6

5.1 Operating Errors E01 through E05.................................................... 6

5.2 Lockout Function Errors 07 and 08 ................................................... 7

5.3 Analog Input Channel Errors............................................................. 7

5.3.1 Troubleshooting a Sensor Problem using the Display ...................... 8

5.3.2 Error Codes for the Analog Inputs..................................................... 9

5.4 Errors 31 and up ............................................................................. 11

6. FUNCTION LOCKOUT ..........................................................13

7. NO DISPLAY .........................................................................14

8. ANTI-TWO BLOCK PROBLEM .............................................16

9. LENGTH READING PROBLEM ............................................19

10. ANGLE READING PROBLEM...............................................21

11. LOAD READING PROBLEM .................................................23

12. DATA TRANSFER CENTRAL UNIT <--> CONSOLE............25

13. PROCEDURES......................................................................27

13.1 EPROM Location and Installation Procedure.................................. 27

13.2 Main Board Replacement Procedure .............................................. 28

13.3 Calibration of Sensors Procedure ................................................... 29

13.3.1 Pressure Transducer Calibration Procedure ................................... 29

13.3.2 Length Sensor Calibration Procedure ............................................. 30

13.3.3 Angle Sensor Calibration Procedure............................................... 31

13.4 Cable Reel LWG308/0001 Adjustment Procedure.......................... 32

13.5 Cable Reel Length Cable Replacement Procedure ........................ 33

14. TROUBLESHOOTING MOISTURE .......................................34

14.1.1 Water Ingress.................................................................................. 34

14.1.2 Condensation .................................................................................. 35

The information in this document is subject to change without notice. PAT makes no warranty of any kind with regard to this

material, including, but not limeted to the implied warranties of merchantability and fitness for a particular purpose. PAT shall

not be liable for errors contained herein or for incidental or consequential damages in connection with the furnishing, per-

formance, or use of this manual. This document contains proprietary information which is protected by copyright. All rights

reserved. No part of this document may be photocopied, reproduced, or translated to another language without the prior

written consent of PAT

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1. GENERAL INFORMATION

The PAT Load Moment Indicator (LMI) DS 160 has been designed to provide the crane operator with the essen-

tial information required to operate the machine within its design parameters.

Using different sensing devices, the Load Moment Indicator monitors various crane functions and provides the

operator with a continuous reading of the crane’s capacity. The readings continuously change as the crane

moves through the motions needed to make the lift.

The LMI provides the operator with information regarding the angle of the boom, working radius, rated load and

the total calculated weight being lifted by the crane.

If non permitted conditions are approached, the DS 160 Load Moment Indicator will warn the operator by sound-

ing an audible alarm, lighting a warning light and locking out those functions that may aggravate the crane’s

condition.

Refer to operator’s manual for console operating instructions.

2. WARNINGS

The LMI is an operational aid that warns a crane operator of approaching overload conditions and of over hoist

conditions that could cause damage to equipment and personnel.

The device is not, and shall not, be a substitute for good operator judgment, experience and use of accepted

safe crane operating procedures.

The responsibility for the safe crane operation shall remain with the crane operator who shall ensure that all

warnings and instructions supplied are fully understood and observed.

Prior to operating the crane, the operator must carefully and thoroughly read and understand the information in

this manual to ensure that he knows the operation and limitations of indicator and crane.

Proper functioning depends upon proper daily inspection and observance of the operating instructions set forth

in this manual. Refer to Section Pre-Operation Inspection and Calibration Verification of the operator’s manual.

The LMI can only work correctly, if all adjustments have been properly set. For correct adjustment,

the operator has to answer thoroughly and correctly all questions asked during the setup procedure

in accordance with the real rigging state of the crane. To prevent material damage and serious or

even fatal accidents, the correct adjustment of the LMI has to be ensured before starting the crane

operation.

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3. SYSTEM DESCRIPTION

The PAT Load Moment Indicator DS 160 consists of a central microprocessor unit, operating console,

length/angle sensor, pressure transducers, and anti-two block switches.

The system operates on the principle of reference/real comparison. The real value, resulting from the load

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 crane functions, such as hoist up 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 information used to calculate

the operating conditions.

The length/angle sensors inside the cable reel, which is mounted on the boom, measure the boom length and

angle. The boom length is measured by the cable reel cable that 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 sides of the hoist cylinders.

1. A2B Switch(-es)

2. Pressure Transducers

3. Cable Reel

4. Console

5. Central Unit (in cab or outside)

Fig. 1: Components of the LMI

System PAT DS 160

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4. GENERAL TROUBLESHOOTING INFORMATION

This section explains how to handle a problem that may arise with the PAT DS 160 System. The procedures are

given in flowchart format for the following sections. Start with the general flowchart below that will guide you to

one of the noted detailed sections. Use the Table of Contents to find the drawings and procedures that are ref-

erenced in these sections.

The system wiring diagram and central unit spare parts list are machine specific and can be found in the

central unit lid. The system wiring diagram in the central unit lists component part numbers.

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4.1 GENERAL FLOW CHARTS

What’s Wrong?

Function Lockout Go to Section 6

No display

Anti-Two Block Problem

Angle Reading Problem

Bad Data Transfer/Interference

Between Central Unit and Console

Load Reading Problem

Go to Section 7

Go to Section 8

Go to Section 9

Go to Section 10

Go to Section 12

Length Reading Problem

Go to Section 11

Error Code Displayed Go to Section 5

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5. ERROR CODES

5.1 Operating Errors E01 through E05

These errors are usually caused by operating in a way that is not allowed per the load charts.

Note: If an error message is displayed which is not contained in the following list, please contact the

PAT service department.

Error Code Error Cause Elimination

E01 Fallen below

radius range or

angle range ex-

ceeded

•Fallen below the minimum radius or

gone past the maximum angle spe-

cified in the respective load chart

due to hoisting up the boom too far

•Hoist the boom down to a

radius or angle specified in

the load chart.

E02 Radius range

exceeded or

fallen below an-

gle range

•Gone past the maximum radius or

fallen below the minimum angle

specified in the respective load

chart due to hoisting down the

boom too far

•Hoist the boom up to a ra-

dius or angle specified in the

load chart.

E04

Operating mode

not existing or

non permitted

slewing zone

•A non existing operating mode has

been selected

•Set the correct operating

mode for the crane configu-

ration in question

•The selected operating mode is not

available in the data EPROM or

blocked.

•Check programming of the

data EPROM

•The boom is in a non-permitted

slewing zone

•Slew the crane into a permit-

ted area.

E05

Forbidden length

range of the main

boom

•Boom has been extended too far or

not enough, e.g. the boom length

has been moved out of the permit-

ted range for load charts.

•The length sensor adjustment was

modified, e.g. cable slid off the

length sensor reel.

•Clutch between length sensor pot

and drive is defective

•Failure of the +5V-supply for the

analog part of the LMI-analog

board.

•Length potentiometer defective.

•Retract or extend boom to

the correct length.

•Retract the boom. Check the

pretention on the cable.

Open the length sensor and

carefully turn the length pot

counterclockwise to the de-

tent with a screwdriver.

•Completely replace the

clutch with the drive wheel

and adjust length sensor pot

•Check +5V-voltage. If there

is no voltage or break down

at a charge of 50 ohm ap-

proximately, exchange LMI

board.

•Replace length potentiome-

ter.

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5.2 Lockout Function Errors 07 and 08

These errors are caused by defects around the function lockouts.

Error Code Error Cause Elimination

E07 Faulty acknowledgment of

the overload relay on the

connection board.

The relay should be ener-

gized, the 2nd contact how-

ever is indicated to be off, or

the 2nd contact is indicated

to be on while the relay

should be de-energized.

•Overload relay or main

board are defective

•LMI board defective

•Replace main board

E08 No acknowledgment from

the anti-two-block relay

•refer to E07 •refer to E07

5.3 Analog Input Channel Errors

These errors occur if the input signal of an analog input channel falls below (E1x) the minimum (0.5V)

or exceeds (E2x) the maximum (4.5V) as measured on the troubleshooting display.

The analog channels are as follows (Use theory section to define voltage or current at terminal strip):

Sensor Pins Terminal X1 Lower Limit Upper Limit

Piston Pressure Transducer 32 E12 E22

Rod Pressure Transducer 33 E13 E23

Length Sensor 34 E11 E21

Angle Sensor 35 E15 E25

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5.3.1 Troubleshooting a Sensor Problem using the Display

For a sensor error or problem with a sensor, look at the output voltage of the pressure transducer,

length, and angle sensors and compare the reading with the following:

Pressure transducers (piston and rod), 500 mV @ 0 psi

Length sensor, 500 mV @ retracted boom length

Angle sensor, 4500 mV at 0°, 2000 mV at 45°, or 500 mV at 90°

To access the analog output screen use the following procedure.

1. From the operating screen, press and held both the ⇑- button and the “OK”-button for 5 sec-

onds to display the maintenance screen.

2. The screen show the following selections:

•calibrate sensors

•sensor outputs

•exit

3. Use the ‘UP’ and ‘DOWN’ arrows to high light (text flashes) sensor outputs, and then press

‘OK’ to display a similar screen as shown below:

All Analog input voltages (shown in millivolts), received from the sensors will be displayed here as

described below. The minimum values are show in the screen pictured.

PIS 2047 mV 1686 PSI

ROD 698 mV 215 PSI

LEN 503 mV 32.9 FT

ANG 1236 mV 73.4 DEG

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5.3.2 Error Codes for the Analog Inputs

If it exceeds these limits, the following errors are triggered:

(NOTE: the upper limit follows the lower limit error, i.e. 11 and 21, 12 and 22, 13 and 23…)

Error Code Error Cause Elimination

E11

Fallen below limit for

the measuring chan-

nel "Length telescopic

boom".

•Length sensor pot defective.

•Electronic board in the meas-

uring channel defective.

•Replace length sensor poten-

tiometer.

•Replace LMI board.

E21

Upper limit value for

measuring channel

"length telescopic

boom" exceeded.

•Length sensor pot defective.

•Electronic part in the measur-

ing channel defective.

•Replace length sensor poten-

tiometer.

•Replace LMI board.

E12

Fallen below the lower

limit value in the

measuring channel

"pressure piston side"

•Cable between the central unit

and pressure transducers de-

fective or water inside the

plugs

•Check cable as well as plugs,

replace, if need be.

•Pressure transducer is defecti-

ve.

•Replace pressure transducer

•Electronic component in the

measuring channel is defec-

tive.

•Replace LMI main board or

processor board.

E22

Upper limit value in

measuring channel

"pressure piston side"

has been exceeded

•refer to E12

E13

Fallen below lower

limit value in the

measuring channel

"pressure rod side"

•refer to E12 •refer to E12

E23

Upper limit value in

measuring channel

"pressure rod side"

has been exceeded.

•refer to E12

E15

Fallen below lower

limit value for the

measuring channel

"angle main boom".

•Angle sensor defective.

•Electronic part in the measur-

ing channel defective.

•Replace angle sensor.

•Replace LMI board.

E25

Upper limit value in

measuring channel

"angle main boom"

exceeded

•refer to E15 •refer to E15

E16

Fallen below lower

limit value for the

measuring channel

"middle section".

•Angle sensor defective.

•Electronic part in the measur-

ing channel defective.

•Replace angle sensor.

•Replace LMI board.

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Error Code Error Cause Elimination

E26

Upper limit value in

measuring channel

"middle section" ex-

ceeded

•refer to E16 •refer to E16

E17

Fallen below lower

limit value for the

measuring channel

"telescopic jib".

•Angle sensor defective.

•Electronic part in the measur-

ing channel defective.

•Replace angle sensor.

•Replace LMI board.

E27

Upper limit value in

measuring channel

"telescopic jib" ex-

ceeded

•refer to E17 •refer to E17

E19

Reference and/or

supply voltage defec-

tive

•The supply voltage is falsified

by one of the sensors (DAV,

LWG)

•Check the voltages on the LMI

main board (AGND = MP0).

Check sensors, plugs and ca-

ble, replace, if need be.

•Electronic component is defec-

tive

•Replace LMI board

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5.4 Errors 31 and up

Miscellaneous Errors, most of them caused by electronics.

Error Code Error Cause Elimination

E31

Error in the system

program

•The system program EPROM is

defective.

•Replace system program

PROM (D13)

E38

System program and

data EPROM do not

match.

•The system program in the LMI

does not match to the program-

ming in the data EPROM

•Replace the system pro-

gram EPROM (D13) or the

data EPROM (D1)

E41

Error in the internal

write/read memory

(RAM) of the com-

puter component

80C537

•Computer component 80C537

defective

•CPU module defective

•Processor board defective.

•Replace computer compo-

nent 80C537.

•Replace CPU module.

•Replace processor board

with CPU module.

E42

Error in the external

write/read memory,

1st part (RAM)

•Write/read memory (CMOS RAM)

or processor board defective.

•Replace processor board

with CPU module.

E43 Error in the external

write/read memory,

2nd part (RAM)

•refer to E42 •refer to E42

E48

Error in the internal

write/read memory

(RAM)

•Computer component 80C537

defective

•Processor board defective.

•Replace processor board

(main board)

E51

Error in the data

EPROM or EEPROM.

•No valid data in the data EE-

PROM.

•Memory module wrongly bridged.

•Crane data EPROM defective

•Load data EEPROM con-

taining valid data.

•Bridge memory module acc.

to memory type

•Replace crane data EPROM

E52

Error in load chart

PROM.

•Memory module wrongly bridged.

•Load chart EPROM defective.

•Bridge memory module acc.

to memory type.

•Replace load chart

EPROM

E56

Error in the data

EEPROM.

•Memory module wrongly bridged.

•Crane data EEPROM defective

•Bridge memory module acc.

to memory type

•Replace crane data EE-

PROM

E57

Error in serial crane

data EEPROM.

•Serial crane data EEPROM does

not contain valid data.

•Memory module defective

•Write data on the serial

crane data EEPROM (by

means of test program or

on-line function), then re-

start the LMI

•Replace memory module.

E58

Error in the serial

analog data

EEPROM.

•No valid data in the serial analog

data EEPROM.

•LMI module(s) defective.

•Write data on the serial

analog data EEPROM by

means of the test program,

then, restart the LMI

•Replace LMI module(s).

E83 Error in Telecode •The selected telecode is not

available

•Select an available tele-

code

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Error Code Error Cause Elimination

E85 Error in the radius

determination

•The computed radius is too small

(negative deflection)

•Check the programming in

the data EPROM.

E91 No data transmission

form the console to

the central unit

•24 V supply of the console is inter-

rupted

•Check 24 V at terminal X1

of the console electronics

•Interruption or accidental ground in

the line between console electron-

ics and central unit

•Check the connection con-

sole electronics - central

unit. In case of an acciden-

tal ground, the transmitter

module of the console elec-

tronics might be damaged.

•Transmitter/receiver module is

defective

•Exchange console electron-

ics or LMI main board resp.

E92 Error in the data

transmission from

console to central unit

•Loose connection in the line be-

tween console electronics and

central unit

•Transmitter/receiver module is

defective

•Check the connection be-

tween console electronics

and central unit

•Exchange console electron-

ics or LMI main board resp.

E93 Error in the data

transmission from the

central unit to the

console

•refer to E92 •refer to E92

E94

No data transmission

from the central unit

to the console

•Interruption or accidental ground in

the cable between central unit and

console

•Check wiring to the console

(in case of accidental

ground, replace console

electronics, too).

•5 V supply of the computer in the

central unit is missing

•Check connection to the

power unit

•5 V supply is too low •Exchange the LMI main

board

•Transmitter/receiver module is

defective

•Replace console electronics

or LMI main board

•Computer module is defective •Replace processor board.

•Electro-magnetic interferences

(e.g. when switching contactors or

valves)

•Eliminate the source of in-

terferences by inverse di-

odes or varistors.

E95

Error in the console

EPROM

•The console EPROM is defective. •Replace the console

EPROM

E96

Error in the internal

RAM of the console.

•The CPU of the console is defec-

tive.

•The console main board is defec-

tive.

•Replace the CPU of the

console

•Replace the console main

board.

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6. FUNCTION LOCKOUT

Fault in crane electric, hydraulic system, or

electronic board.

PROBLEM: The lever lockout system of the crane is activated. Crane movements “hoist up” and (optional)

“boom down” are stopped. Only if the crane is not in overload or two-block condition continue with flow chart.

WARNING: If overload or A2B condition exists, use extreme caution and move the crane out of the

condition.

If Error Code is displayed goto Section 5.

Corrected

Check lever lockout

system in crane

service manual.

Relay defective on the main

board. Replace main board.

Refer to main board

replacement procedure.

The LMI by-pass warning light and/or anti-two-block

warning light is lit on the console.

LED's H1, H2, and H3 are lit on the main/terminal board.

The fault is located in LMI, cables,

wiring, fuses, or console.

Read error code displayed on console

and go to error code section.

Start

Use the console key switch and the LMI by-pass button or the central unit key switch to override the overload.

When by-passing the system, the following instructions must be obeyed:

The by-pass function shall be used with discretion, as unwarranted use of it to override the control lever

lockout system can result in harm to the crane and danger to property and persons.

Never use the by-pass function to either overload or operate the crane in a non-permissible range.

YES

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7. NO DISPLAY

PROBLEM: Blank console display with no warning light shown. All crane moments have

been stopped.

Measure voltage on the main board terminal strip between X1:1 (10-30V) and X1:3

(ground). This is an input voltage from the crane.

Refer to system wiring diagram.

Check fuses in central unit.

Replace fuses.

Measure voltage on the main board between X1:5 (+UB) and X1:6 (ground). This

is an output voltage to the console.

Refer to system wiring diagram.

START

Check crane power supply for faulty

wiring in crane electric.

YES

Replace the main board in central unit.

Refer to system wiring diagram and main

board replacement Procedure.

YES

Corrected

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Console/Display is defective. Replace the console.

Refer to system wiring diagram.

Check connections of the cable between

console and central unit. Replace cable if

necessary. Refer to system wiring diagram.

END

Correct?

Measure voltage in the console between X1:1 (+12/24V) and X1:2 (ground).

Refer to system wiring diagram.

YES

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8. ANTI-TWO BLOCK PROBLEM

Check Bypass plug installed, if necessary

Refer to system wiring diagram.

PROBLEM: Function of Anti-Two-Block System is faulty.

START

Check to see whether or not crane is in two-block condition.

Correct? Lower hook down into safe position

Plug appropriate bypass plug into socket of

junction box.

Turn power off or disconnect wire from connection board X1:9 in central unit. Check wire

connections in boom nose box and measure the resistance at the boom nose box between

terminals 1 and 2 with a ohmmeter. This checks the function of the Anti-Two Block switch.

Switch closed = 0Ohms (weight installed)

Switch open => 1 Megaohm (weight removed)

Pug the bypass plug into the boom nose box.

Refer to system wiring diagram.

Replace Anti-Two-Block switch.

Refer to system wiring diagram.

Correct?

Yes

YES

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Fault in wiring between boom nose box and cable reel. Check

for damaged length cable and wiring. Refer to system wiring

diagram. If broken length cable, Refer to length cable

replacement procedure.

Ensure the A2B switch is closed (weight or flag installed) and, if necessary, the byass plug is

plugged into the boom nose box. Measure the A2B signal in the cable reel

between X1:Brown and X2:Red wires on the slip ring with an ohmmeter.

Switch closed =4700 ±500Ohms

Switch open => 1 Megaohm

Reconnected slip ring wires.

Refer to system wiring diagram.

Correct?

Measure the A2B signal in the cable reel between terminal 7 and 8 with an ohmmeter.

Switch closed =4700 ±500Ohms

Switch open => 1 Megaohm

Reconnected slip ring wires.

Refer to system wiring diagram.

Replace slip ring

Refer to system wiring and cable reel diagram.

Correct?

Disconnect boom base connector, measure the A2B signal in the boom base connector on

cable reel cable assembly between terminals 5 and 6 with an ohmmeter.

Switch closed =4700 ±500Ohms

Switch open => 1 Megaohm

Reconnected slip ring wires.

Refer to system wiring diagram.

Fault in 7 conductor cable between cable reel and

boom base connector. Check connections and

replace cable if necessary.

Refer to system wiring diagram.

Correct?

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Defect on main board. Replace main board.

Refer to system wiring diagram and main board

replacement Procedure.

Connect the boom base connector. Connect wire #5 back to the terminal

X1:9 on the connection board. Refer to system wiring diagram.

Correct? Faulty wiring between boom base connector and central

unit. Check connections and replace cable if necessary.

Disconnect X1:9 and X1:10. Check main board function by installing a temporary

resistor, 4700 Ohms between X1:9 and X1:10 in central unit. With resistor connected

alarm should be inactive.

Refer to system wiring diagram.

Correct?

End

YES

Turn system power off. Check Anti-Two-Block signal in central unit with ohmmeter

measure between X1:31 and X1:32.

Anti-Two-Block switch closed = 4700 Ohms ±50 0Ohms

Anti-Two-Block switch open => 1 Megaohm.

Refer to system wiring diagram.

Reconnect Wire #5 to X1:9 and Wire #6 to X1:10

Refer to system wiring diagram.

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9. LENGTH READING PROBLEM

Check out clutch in big gear wheel of length transducer. Extend and retract boom

to ensure that clutch is not slipping on potentiometer axle.

Refer to system wiring diagram and sensor adjustment procedure.

Replace length potentiometer assembly, Refer to Drawing 6 in Section 4.

Remove slip ring body from shaft and remove gear wheel from potentiometer

axle. Unscrew mounting plate and remove potentiometer assembly from

mounting plate. Remove assembly wires form terminal block. Connect new

assembly to terminal block. Reinstall mounting plate, gear wheel and slip

rings. With boom fully retracted, reset potentiometer by turning it slowly

counter-clockwise until it reaches a soft stop. Refer to system wiring diagram

and sensor adjustment procedure.

Check mechanical adjustment of length potentiometer in cable reel. With boom fully retracted, reset

potentiometer by turning it slowly counter-clockwise until it reaches a soft stop.

Refer to system wiring diagram and sensor adjustment procedure.

START

PROBLEM: Length displayed incorrect. Crane is not in “out of load chart” condition.

Replace the gear wheel, clean potentiometer axle. Reset

length potentiometer.

Refer to system wiring diagram and sensor adjustment

procedure.

Check power supply to length transducer on main board,

terminal X1:31 (+UB) and X1:39 (GND)

Refer to system wiring diagram.

Main board defective. Replace main board.

Refer to system wiring diagram and main borad

replacement procedure.

Correct?

YES

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