Hirschmann qSCALE maestro User manual

HIRSCHMANN MCS
qSCALE
maestro
PLC v01.00.00
Contents
Safety instructions 1
Product description 2
Service Menus 3
Service and Maintenance 4
Appendix 5
Service Manual
Issue E – 04/2018
HMI v01.00.00
This document has the order number:
MAN-QSCA-S-0008

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qSCALE maestro (PLC v01.00.00) Service Manual / Issue E (HMI v1.0.0) 04/2018 / rbm.
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HIRSCHMANN MCS
TABLE OF CONTENTS
1  Safety Instructions...........................................................................................7 
2  Components......................................................................................................8 
2.1  Base Kit with vScale D2 or D3 (102125/102129)......................................8 
2.1.1  Junction Box, qSCALE maestro (061179).............................................9 
2.1.2  Pressure Sensor Kit (102121) .............................................................10 
2.2  Boom Upgrade (102124).........................................................................10 
2.2.1  Sensor Assembly Length Angle WGX/CAN (061185).........................11 
2.3  Boom Kit, New Cable Reel (102126).......................................................11 
2.4  Indicator Kit, Light Tower (102127) .........................................................12 
3  Description of the System.............................................................................13 
3.1  Product Identification...............................................................................15 
3.2  General Information.................................................................................15 
3.3  EC Conformity Declaration......................................................................15 
3.4  Overview of Console Elements................................................................16 
3.5  Overview Feedback Elements.................................................................17 
4  Service Menus ................................................................................................18 
4.1.1  Password Entry....................................................................................18 
4.1.2  Obtaining the Daily Password..............................................................19 
4.2  System Settings.......................................................................................20 
4.2.1  System Settings Breakdown................................................................21 
4.2.2  New Password Entry ...........................................................................23 
4.3  Sensor Calibration ...................................................................................24 
4.3.1  Calibrate Angle Sensors......................................................................25 
4.3.2  Calibrate Length Sensors ....................................................................27 
4.3.3  Luffing Cylinder Tuning........................................................................29 
4.4  Entering Measurements...........................................................................32 
4.5  Alarm Volume ..........................................................................................33 
5  Service and Maintenance ..............................................................................34 
5.1  Download Application Data......................................................................34 
5.2  Reading the Event Recorder ...................................................................35 
5.3  Reset Hour meter ....................................................................................36 
5.4  Change Date and Time............................................................................37 
5.5  Rotate Display..........................................................................................38 
5.6  Screen Capture........................................................................................39 

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HIRSCHMANN MCS
5.6.1  Taking Screen Captures......................................................................39 
5.6.2  Saving Screen Captures......................................................................39 
5.7  Mismatched DA4 .....................................................................................40 
5.8  Maintenance and Repair..........................................................................41 
6  Troubleshooting.............................................................................................42 
6.1  Identify the Problem.................................................................................42 
6.2  Initial System Inspection..........................................................................44 
6.3  Indicator Definitions .................................................................................45 
6.3.1  Indicators on Central Control Unit........................................................45 
6.3.2  Indicators on Console..........................................................................45 
6.4  Boom Angle Sensing ...............................................................................46 
6.5  Boom Length Sensing .............................................................................48 
6.5.1  Cable Reel Length Cable Replacement Procedure.............................49 
6.6  Pressure Sensing ....................................................................................50 
6.7  Load Sensing...........................................................................................51 
6.8  Anti-Two Block Switch (A2B)...................................................................52 
6.8.1  A2B Problem – Flow Chart..................................................................53 
6.9  No Console Display.................................................................................54 
6.10  CAN Bus Communications......................................................................55 
6.11  Troubleshooting Sensors With Display....................................................58 
6.11.1  Readings of CAN Bus Sensors........................................................58 
6.11.2  Readings of Digital Inputs................................................................59 
6.11.3  Readings of Digital Outputs.............................................................60 
7  Appendix .........................................................................................................61 
7.1  Technical Data.........................................................................................61 
7.2  System Layout Drawing...........................................................................62 
7.3  Junction Box Wiring Diagram ..................................................................65 
7.4  vSCALE D2 Diagram...............................................................................66 
7.5  vSCALE D3 Diagram...............................................................................67 
7.6  Error Codes Table ...................................................................................68 

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HIRSCHMANN MCS
VERSION OVERVIEW
Issue Date Description Editor
A 11/2017 Initial Release (HMI v01.00.00) RBM
B 12/2017 Updated Luffing Cylinder Calibration section and
Alarm Volume section. RBM
C 01/2018 Added backup of product files to Service section RBM
D 04/2018 Added Parts list, troubleshooting and changed
numerical entry. RBM
E 04/2018 Updated System Layout, added kit drawings RBM

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HIRSCHMANN MCS
Introduction
This manual is a component of the equipment or systems supplied by WIKA Mobile Control LP. 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. WIKA Mobile Control LP do not provide any guaran-
tee for this material, including the associated guarantee regarding marketability and suitability for cer-
tain intended purposes. WIKA Mobile Control LP 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
WIKA Mobile Control LP.
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 is 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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HIRSCHMANN MCS
Marking of Notices
Dangers and other important notices are marked as follows in this service 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.

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HIRSCHMANN MCS
1 Safety Instructions
WARNING
Imminent threat of personal injury and damage to property due to incorrect sys-
tem settings!
The correct adjustment of the RCL to the current set-up status is essential 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!

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HIRSCHMANN MCS
2 Components
Kit Name Kit Number QTY Section
BASE UPGRADE KIT W/ VSCALE D2 102125 1 Section 2.1
BASE UPGRADE KIT W/ VSCALE D3 102129 1 Section 2.1
BOOM UPGRADE (FROM EXISTING 200/208/209 REEL) 102124 1 Section 2.2
BOOM KIT, NEW CABLE REEL 102126 1 Section 2.3
INDICATOR, LIGHT TOWER, MAESTRO, 10M, 3 COLOR (RGY) 102127 1 Section 2.4
2.1 Base Kit with vScale D2 or D3 (102125/102129)
Component Name Part Number QTY Notes
SMC, POWER HARNESS, VSCALE CONSOLE, PWR ONLY, 12' 061106 1
SMC, CONSOLE, VSCALE, D2 - C1, 4.3" DISPLAY 608413 1 D2 kit only
SMC, CONSOLE, VSCALE, D3 - C2, 7", 3 CAM, 4x AI/DI, 3x DO 608416 1 D3 kit only
SMC, QSCALE MAESTRO S6, IP66/67 623029 1
JUNCTION BOX, QSCALE MAESTRO 061179 1 Section 2.1.1
0985 806 125/10M - 90 DEG BEND 900004191 1
ASBSV 4 5 P5 MCS CUSTOM 934637762 1
0935 253 103/3 10967 1
SCREW, SLOTTED PH 5mm x 16mm 002-050-206-112 11
NUT, 5MM HEX NYLON INSERT 031-300-050-468 11
WASHER, 5MM CONCAVE BELLVILLE 000-208-030-050 11
CONSOLE ACCY, KIT 2-1" BALL W/ 4.75" MTG. ARM 031-300-060-382 1 D2 kit only
CONSOLE ACCY, KIT 2 - 1.5 051170 1 D3 kit only
SMC, CONSOLE ACCY, RAM MOUNT ADAPTER, iSCOUT D2 608460 1 D2 kit only
SMC, CONSOLE ACCY, RAM MOUNT 608464 1 D3 kit only
SMC, DUMMY PLUG ASSY, 48-PIN 060980 1
BRACKET, EXTERNAL MOUNTING FEET 2/PACK, FOR MAESTRO 051309 1
SCREW M4X12MM NARROW HEAD PHILLIPS STAINLESS STEEL 051310 4
ZVK 12291 600000991 2
0909 UAC 101 600003038 2
KIT, QSCALE IX, LOAD, PSENS, DAVS, 300 BAR, SAE 6, ID 60/61 102121 1 Section 2.1.2
STRAIN RELIEF ACCY, PFLITSCH RUBBER HOLE PLUG BO 4-6.5MM 051292 7
STRAIN RELIEF ACCY, PFLITSCH RUBBER HOLE PLUG BO 9-13MM 051293 1

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2.1.1 Junction Box, qSCALE maestro (061179)
Component Name Part Number QTY
JUNCTION BOX, 160x240X81 061180 1
TERMINAL STRIP ACCY, RAIL MAESTRO 9IN 051295 1
HARNESS, QSCALE MAESTRO CONTROLLER TO JUNCTION BOX 061178 1
WASHER, LOCK 1/4 000-208-040-070 2
TERMINAL STRIP ACCY, BLOCK, PIK 4N W/BAR 051296 7
TERMINAL STRIP ACCY, BLOCK, PIK 4N WO/BAR 051297 12
TERMINAL STRIP ACCY, BLOCK PIK 4N W/DIODE 061181 1
EC, DIODE, 1N4003 200V/1A 000-430-104-003
TERMINAL STRIP ACCY, END PLATE, PIK 4N 051298 1
TERMINAL STRIP ACCY, END BRACKET, PIK 4N 051299 2
RELAY, SHUTOFF 12V 20/30A 000-304-140-112 1
EC, DIODE, 1N4003 200V/1A 000-430-104-003 2
KEYSWITCH, CENTRAL UNIT, NEW 024-350-100-768 1
CENTRAL UNIT ACCY, MEMBRANE 024-000-100-095 1
STRAIN RELIEF, PG13.5 12-15mm 021-441-161-213 1
STRAIN RELIEF, PG 9 4-6mm, 021-441-060-409 6
STRAIN RELIEF, PG 9 5.5mm, 021-441-090-709 1
TAPE, 3M, VHB 5925 1 031-300-050-765
STRAIN RELIEF, PG13.5 8-12mm 021-441-131-013 3
WIRE, HOOKUP 18 AWG BLUE 123-429-910-960 0.6 ft
WIRE, HOOKUP 20 AWG GREEN 123-429-901-830 0.6 ft
WIRE, HOOKUP 18 AWG BROWN 123-429-910-880 0.6 ft
WIRE, HOOKUP 18 AWG BLACK 123-429-907-280 3.6 ft
WIRING ACCY, CRIMP TERMINAL, 18-22AWG, INSULATED, RED 051304 4

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HIRSCHMANN MCS
2.1.2 Pressure Sensor Kit (102121)
Component Name Part Number QTY
SENSOR,PRESS,SINGLE,CAN,ID 60 061091 1
SENSOR, PRESS TRANS, CAN,ID 61 061092 1
0935 253 103/5 M 10968 2
SENSOR ACCY, CUTTING RING DKA 000-209-140-016 2
HYDR, ADAPTER, BULKHEAD 9/16- 000-214-600-093 2
HYDR, ADAPTER, 9/16-18 UNF-2B; 031-300-050-689 2
HYDR, FITTING, 1/4 NPT MALE TO 031-300-050-750 2
2.2 Boom Upgrade (102124)
Component Name Part Number QTY Notes
STRAIN RELIEF, PG13.5/PG 9 000-214-261-309 1
STRAIN RELIEF ACCY, PFLITSCH RUBBER HOLE PLUG BO 4-
6.5MM 051292 2
STRAIN RELIEF ACCY, PFLITSCH RUBBER HOLE PLUG BO 9-13MM 051293 2
0935 253 103/15 M 27866 1
STRAIN RELIEF, PG13.5 HOLE 000-214-340-013 1
STRAIN RELIEF, PG11/PG 9 000-214-261-109 1
STRAIN RELIEF, PG11 HOLE PLUG 000-214-340-011 1
SENSOR ASSY, LENGTH/ANGLE, WGX/CAN 061185 1 Section 2.2.1
SCREW, 6mm X 12mm SOCKET CAP 002-050-206-012 3
WASHER, FLAT 6MM 000-207-010-064 3
SENSOR, LENGTH POT.W/O 067-000-100-204 1

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HIRSCHMANN MCS
2.2.1 Sensor Assembly Length Angle WGX/CAN (061185)
Component Name Part Number QTY
SENSOR, ANGLE, WGX 360/3510, ACTIVATED RESISTOR, 125KBPS, CA 061194 1
CONNECTOR ACCY, JST, EH 7POS 051207 1
BOARD, LENGTH & A2B CAN -120 535950 1
RSF 5/0.5M (#5 wire GY) 600000558 1
PLATE, CABLE REEL UPGRADE, MAESTRO 051307 1
CONN ACCY, TERMINAL CRIMP, EH 051208 5
M4x30mm BOLT 051278 3
HARDWARE, LOCKWASHER, M4 051177 3
NUT, 4mm, SELF LOCKING, S.S 002-060-500-402 3
HARDWARE, STANDOFF 3mm x 12 FF 000-212-020-312 3
SCREW,3mm x 10mm PANHD PHILLIP 002-053-703-101 6
WASHER, 3mm CONCAVE BELLVILLE 000-208-030-030 9
2.3 Boom Kit, New Cable Reel (102126)
Component Name Part Number QTY Notes
CABLE REEL, KT200, STANDARD 006-820-006-002 1.00
SENSOR ACCY, GEAR WHEEL, KT200 068-000-110-038 1.00
STRAIN RELIEF, PG13.5/PG 9 000-214-261-309 1.00
0935 253 103/15 M 27866 1.00
SENSOR ASSY, LENGTH/ANGLE, WGX/CAN 061185 1.00 Section 2.2.1
SCREW, 6mm X 12mm SOCKET CAP 002-050-206-012 3.00
WASHER, FLAT 6MM 000-207-010-064 3.00
SENSOR, LENGTH POT.W/O 067-000-100-204 1.00

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HIRSCHMANN MCS
2.4 Indicator Kit, Light Tower (102127)
Component Name Part Number QTY
INDICATOR, LIGHT TOWER, 3 COLOR LED (GRN, YEL, RED) 051264 1.00
INDICATOR ACCY, POWER MODULE (FOR #051264 LIGHT TOWER) 051265 1.00
0935 253 105/10 M 15734 1.00

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HIRSCHMANN MCS
3 Description of the System
The maestro system (also referred to as ‘RCL’) is a CAN bus system comprised of a central
microprocessor unit, operating console, angle sensor, tilt sensor, load pin, and anti-two block
switch. All components and sensors are equipped with CAN bus controllers.
When limits are reached an overload warning signal is generated at the operator’s console. At
the same time, the Function Kick Out (FKO) outputs are deactivated thus ‘locking out’ the opera-
tor and stopping aggravating machine movements. The fixed data regarding the machine (ex.
capacity charts, boom weights, centers of gravity, etc.) are stored in memory chips in the central
processor unit. This data is the reference information used to calculate the operating conditions.

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HIRSCHMANN MCS
NOTE
This service manual contains information about the vSCALE D2 / D3 maestro con-
sole,
mode selection, operation, sensor calibration and maintenance.
WARNING
This service manual contains information about the vSCALE D2 / D3 maestro
console, mode selection, operation, sensor calibration and maintenance.
Although the system incorporates functions for monitoring adjustable geomet-
rical limit values with visual and audible warnings and a relay output in the event
of limit values being exceeded, the system cannot be used as an operational limit
switch.
The machine driver is responsible for the safe operation of the machine.

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HIRSCHMANN MCS
3.1 Product Identification
The type plate carries the unique identification of the operating console. It is located on the back of the
device.
Please ensure you make a note of all the information on your type plate for queries about this product.
3.2 General Information
NOTE
Knowledge of how to use a voltmeter to measure both voltage and current is as-
sumed.
HINT
For general system operation, refer to the console Operator’s Manual.
3.3 EC Conformity Declaration
The technical design and construction of the qSCALE maestro system corresponds to requirements of
the EMC directive 2004/108/EC and therefore carries the CE symbol.
The device complies with the following standards:
EN 12895:200, EN 13309:2010, EN ISO 14982: 2009
The full conformity declaration is available from the manufacturer on request.
Type plate
(Example for D3)

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HIRSCHMANN MCS
3.4 Overview of Console Elements
Function Keys F1 to F12: Calls Functions
Encoder With Pushbutton Function: For Selection and Confirmation
SET key: Selects Settings / Silences Alarm
HOME key: Returns to Main Working Screen
ESCAPE key: Aborts Function
Display with
RCL Main Menu
Rotary Encoder with
Pushbutton Function
For Selection and Con-
firmation
"Set" Key
Selects Settings /
Silences Alarm
"Home" Key
(Return to RCL Main
Operating Screen)
"Escape" Key
Aborts Function / Returns to
previous screeen
Feedback Elements
(See Section 3.5)
Function Keys F1-F8
(F1 – F12 in 7” display ver-
sion.) Function Varies by
screen
USB 2.0 interface
(used for service purposes)

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HIRSCHMANN MCS
3.5 Overview Feedback Elements
Light Sensor: Not Used
Operating Display: Green While Supply Voltage is Connected
USB Data Display: Yellow During Data Exchange via Front USB Port
Wireless Indicator: Not Used
Multi-Function Light:
/ Flashes Red/White while in error state
Blue while setting the operating mode
Green while in operation
Yellow Machine nearing operational limit

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HIRSCHMANN MCS
4 Service Menus
This chapter contains information, advice, and instructions for navigating and using the service menus.
4.1.1 Password Entry
In order to access certain menus it is necessary to enter a Service Password, Daily Password or LMI Password
(See Section 4.1.2 for information on Obtaining the daily password.)
Password entry is done by the following instructions:
Use the rotary knob to select the numbers.
Pressing the knob moves to the next digit and selects right arrow.
Pressing the right arrow when the curser is to the right of the last number confirms the entry
Use the or buttons to select the number in the chosen direction. (The selected digit turns green and will be
replaced by the next selection.)
Use the button to delete the currently selected digit.
Press to confirm the password as displayed.

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HIRSCHMANN MCS
CAUTION
Entering the Service Password will unlock all service functions on the console until it is reset.
Always reset the console when service is complete to lock access to service menus.
4.1.2 Obtaining the Daily Password
Summary In order to obtain the Daily Password you must find the Daily Password Seed in the Settings
Menu and enter it into the excel sheet to be converted into a usable password that will last the
entire day.
Finding the Daily
Password Seed The Daily Password Seed is located in the Settings Menu in the bottom center of the screen
above the Information Bar.

HOME SETTINGS
Converting the
Seed into the Daily
Password
Open the DailyPassword_maestro.xls document and enter the Daily Password Seed into the field
beside the “Console” cell and then press the TAB key.
The DailyPassword_maestro.xlsx document will then generate a daily password next to the
“Password” cell.
This password will allow access to service functions until the console’s internal clock reaches
12:00am at which time a new seed is created.
Daily Password Seed.

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HIRSCHMANN MCS
4.2 System Settings

HOME SETTINGS SYSTEM
SETTINGS
Function Keys
And
Choose option to adjust.
(See Section 4.2.1 for explanations of
each option.)
And
Adjust chosen option.
(See Section 4.2.1 for explanations of
each option.)
New Password Entry.
(See Section 4.2.2)