Pat america Ds 350 User manual

ww.patamerica.com PAT America, Inc.

LOAD MOMENT INDICATOR

DS 350 MODULAR/GRAPHIC

for Lattice Boom Cranes

SERVICE MANUAL

P/N 031-300-190-118 REV. -, 12/18/2000

Service Manual DS 350 Modular

NOTICE

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 limited to the implied warranties

of merchantability and fitness for a particular purpose.

PAT shall not be liable for errors contained in this manual or for incidental or consequential damages in

connection with the furnishing, performance, or use of this manual. This document contains proprietary

information, which is protected by copyright. All rights are reserved.

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

written consent of PAT.

MANUAL REVISIONS

REV DATE NAME DESCRIPTION

- 12/18/00 CSH Troubleshooting Manual created.

Service Manual DS 350 Modular

TABLE OF CONTENTS

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

2WARNINGS .......................................................................................................................1

3SYSTEM DESCRIPTION...................................................................................................2

4GENERAL FLOW CHARTS...............................................................................................3

5ERROR CODES.................................................................................................................4

5.1 OPERATING ERRORS E01 THROUGH E06......................................................................................4

5.2 LOCKOUT FUNCTION ERRORS 07 AND 08......................................................................................5

5.3 ANALOG INPUT CHANNEL ERRORS................................................................................................5

5.4 ERRORS 31 AND UP.....................................................................................................................6

6FUNCTION LOCKOUT ....................................................................................................10

7NO DISPLAY....................................................................................................................11

8ANTI-TWO BLOCK PROBLEM........................................................................................13

9ANGLE SENSORS...........................................................................................................16

10LOAD READING..............................................................................................................18

11AREA DEFINITION INDICATION PROBLEM..................................................................20

12DATA TRANSFER CENTRAL UNIT <--> CONSOLE ......................................................21

13DRAWINGS .....................................................................................................................23

13.1 ELECTRICAL WIRING (DRAWING 1) PART 1................................................................................23

13.2 CENTRAL UNIT BREAKDOWN / PARTS LIST (DRAWING 2)............................................................25

13.3 CONSOLE DS350/1334 / PARTS LIST (DRAWING 3)...................................................................27

13.4 CENTRAL UNIT MAIN BOARD LAYOUT (DRAWING 4) ...................................................................28

13.5 CENTRAL UNIT ANALOG INPUT MODULE (DRAWING 5)................................................................29

13.6 CONSOLE CONNECTION BOARD (DRAWING 6) ...........................................................................30

13.7 FORCE TRANSDUCER (DRAWING 7)..........................................................................................31

13.8 AREA DEFINITION SWITCH (DRAWING 8) ...................................................................................31

13.9 BOOM JUNCTION BOX (DRAWING 9)..........................................................................................32

13.10 CABLE REEL (DRAWING 10)...................................................................................................33

14PROCEDURES................................................................................................................34

14.1 PROCEDURE 1: EPROM LOCATION AND INSTALLATION..............................................................34

14.2 PROCEDURE 2: MAIN BOARD REPLACEMENT.............................................................................35

14.3 PROCEDURE 3: ANGLE SENSOR ADJUSTMENT/REPLACEMENT....................................................36

14.4 TROUBLESHOOTING MOISTURE.................................................................................................37

14.5 THEORY 1: OPERATION OF ANGLE SENSOR...............................................................................39

General Information

1 GENERAL INFORMATION

The PAT Load Moment Indicator (LMI) DS 350 has been designed to provide the crane operator with the

essential 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 350 Load Moment Indicator will warn the operator by

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

condition.

Refer to operator’s manual 031-300-190-089 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.

Service Manual DS 350 Modular

3 SYSTEM DESCRIPTION

The PAT Load Moment Indicator DS 350 consists of a central microprocessor unit, operating console, angle

sensor, force transducer, 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 aggravating crane movements, 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 boom angle is measured by the angle sensor, mounted in the boom base. The cable reel cable serves as an

electrical conductor for the anti two-block switches and force transducer signals.

The load on the boom is measured by force transducer mounted on top of the boom, close to the tip.

The interactive user guidance considerably simplifies the input of operating modes as well as the setting of

geometry limit values. Please refer to the PAT DS350 operator’s manual for the operation of the system.

The System consists of the following main components:

1. Central Unit

2. Cable for crane power

3. Cable to cable reel

4. Cable Reel

5. Junction box

6. A2B switch with weight

7. A2B bypass plug

8. Cable to force transducer

9. Force transducer

10. Cable to main boom angle sensor

11. Main boom angle sensor

12. Operator’s console with cable assembly

13. Cable for area definition sensor

14. Area definition sensor

Fig. 1: Components of the LMI system PAT DS 350/Modular

General Flow Charts

4 GENERAL FLOW CHARTS

This section explains how to handle a problem that may arise with the PAT DS 350 Modular 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 detailed flowcharts shown in Sections 5 through 12.

The drawings and procedures that are referenced in these sections can be found in Section 13 and

14.

What’s Wrong?

Lever Lockout Activated Go to Section 6

No display

Anti-Two Block Problem

Load Reading Problem

Bad Data Transfer/Interference

Between Central Unit and Console

Area Definition Indication Problem

Go to Section 7

Go to Section 8

Go to Section 9

Go to Section 10

Go to Section 12

Angle Reading Problem

Go to Section 11

Error Code Displayed Go to Section 5

Service Manual DS 350 Modular

5 ERROR CODES

5.1 Operating Errors E01 through E06

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

Error Code Error Cause Elimination

E01 Fallen below

radius range or

angle range

exceeded

• Fallen below the minimum

radius or gone past the

maximum angle specified 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

angle 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

radius 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

configuration 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

permitted area.

E05

Boom length

not existing

• A non existing boom length has

been selected

• Correctly enter the boom

length according to the

attribution of the

operating state

• The selected boom length is not

available in the data EPROM. • Check programming of

the data EPROM

E06 Radius range

exceeded or

fallen below

angle range

with luffing jib

operation

• Maximum radius as specified in

the load chart exceeded or

fallen below minimum angle due

to luffing down the luffing jib too

far

• Luff the jib to a radius or

angle specified in the load

chart.

Error Codes

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

energized, the 2nd

contact however 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

• Processor board

defective

• Replace main board

• Replace processor 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 (4 mA)

or exceeds (E2x) the maximum (20 mA).

The analog channels are used as follows:

Sensor Pins Terminal X1 Lower Limit Upper Limit

Main Force Transducer 36 E14 E24

Angle Sensor (Main Boom) 29 E15 E25

Each channel is constantly being monitored to be within 4 mA (1.1V resp.) and 20 mA (5.5V resp.). If

it exceeds these limits, the following errors are triggered:

Error Code Error Cause Elimination

E14

Fallen below the

lower limit value in

the main force

channel

• Cable between the central

unit and force transducer

defective or water inside the

plugs

• Check cable as well as

plugs, replace, if need be.

• Force transducer is

defective. • Replace force transducer

• Electronic component in the

measuring channel is

defective.

• Replace LMI module(s).

E24 Upper limit value in

main force

transducer

measuring channel

has been exceeded

• refer to E14

E15 Fallen below lower

limit value in

measuring channel

"angle main boom"

• Cable between central unit

and the angle sensor

defective or loose. Water

inside the plugs.

• Check cable as well as

plugs, replace, if need be.

• Angle sensor defective • Replace angle sensor

Service Manual DS 350 Modular

Error Code Error Cause Elimination

• Electronic component in the

measuring channel

defective.

• Replace LMI module(s).

E25

Upper limit value in

measuring channel

"main boom angle"

has been exceeded.

• refer to E15 • refer to E15

E19

Reference and/or

supply voltage

defective

• The supply voltage is being

dragged down by one of the

sensors

• Check the voltages on the

LMI main board (AGND =

MP0). Check sensors,

plugs and cable, replace, if

need be.

• Electronic component is

defective • Replace LMI main board

• A/D converter defective. • Replace analog board

E29 Reference and/or

supply voltage

defective.

• refer to E19

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 PROM is

defective. • Replace system program

PROM (PROM No. 0)

E38

System program

and data EPROM

do not match.

• The system program in the LMI

does not match to the

programming in the data

EPROM

• Replace the system

program PROM or the

data EPROM (PROM No.

E41

Error in the internal

write/read memory

(RAM) of the

computer

component 80C537

• Computer component 80C537

defective

• CPU module defective

• Processor board defective.

• Replace computer

component 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

E45

Redundancy error

in the A/D

conversion

• The A/D converter on the

processing board and the

redundant A/D converter in the

CPU 80C537 provide different

results.

• Replace processor board.

E46

Error in the A/D

converter uPD 7004

of the processor

board.

• No acknowledgment of the A/D

converter uPD 7004 • Replace processor board.

Error Codes

Error Code Error Cause Elimination

E47 Error in the

monitored write/

read memory.

The CRC

verification of the

monitored

write/read memory

provides an

incoherent result

• The CRC sign of the monitored

write/read memory is wrong

• The buffer battery is discharged

(< 2V at 1kOhm).

• Processor board defective.

• Restart the LMI

• Replace buffer battery on

the LMI main board

• Replace processor board.

E48

Cyclic RAM test:

error in the internal

write/read memory

(RAM) of the

computer

component 80C537

• Computer component 80C537

defective

• CPU module defective

• Processor board defective.

• Replace computer

component 80C537.

• Replace CPU module

• Replace processor board

with CPU module.

E51

Error in the data

EPROM or

EEPROM.

• No valid data in the data

EEPROM.

• Memory module wrongly

bridged.

• Crane data EPROM defective

• Load data EEPROM

containing valid data.

• Bridge memory module

acc. to memory type

• Replace crane data

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

EEPROM

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

restart 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).

E60 The number of the

selected EPROM • Load chart EPROM defective • Replace load chart

EPROM

base and the

programmed value

are not identical

• Base number not programmed • Program the correct base

number (1 for base 1, 2

for base 2)

• Load chart EPROM wrongly

programmed • Check base programming

in the load chart EPROM.

E71 Faulty

acknowledgment of

relay K1 on the

connection board

• Relay K1 or main board

defective. • Replace main board.

Service Manual DS 350 Modular

Error Code Error Cause Elimination

Relay should be

energized but the

2nd contact is

signaled to be off or

the 2nd contact is

signaled to be on

whereas the relay

should be de-

energized.

• Main board is defective

• Replace main board.

E72

...

E77

Faulty

acknowledgment of

relays K2...K7 on

the connection

board.

• refer to E71

E91 No data trans-

mission form the

console to the

• 24 V supply of the console is

interrupted • Check 24 V at terminal

X1 of the console

electronics

central unit • Interruption or accidental

ground in the line between

console electronics and central

unit

• Check the connection

console electronics -

central unit. In case of an

accidental ground, the

transmitter module of the

console electronics might

be damaged. Therefore,

replaces the console

electronics.

• Transmitter/receiver module is

defective • Exchange console

electronics or LMI main

board resp.

E92 Error in the data

transmission from

console to central

unit

• Loose connection in the line

between console electronics

and central unit

• Transmitter/receiver module is

defective

• Check the connection

between console

electronics and central

unit

• Exchange console

electronics 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 trans-

mission 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

Error Codes

Error Code Error Cause Elimination

• 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

interferences by inverse

diodes 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

defective.

• The console main board is

defective.

• Replace the CPU of the

console

• Replace the console main

board.

E97

Error in the external

RAM of the console • The external RAM of the

console is defective.

• The console main board is

defective.

• Replace the external

RAM of the console.

• Replace the console main

board.

EAB Short circuit in the

A2B switch circuit • Short circuit in the A2B switch

• Short circuit in the cable to the

A2B switch

• Replace A2B switch

• Replace cable to the A2B

switch

Note:

If an error message is displayed which is not contained in above list, please contact the PAT

service department.

Service Manual DS 350 Modular

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 Sect. 14, Procedure 2.

Main board replacement.

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

warning light is lit on the console.

LED's H8, H9, and H10 are lit on the main/terminal board.

Refer to Drawing 4 in Section 13.

The fault is located in LMI, cables,

wiring, fuses, or console.

Read error code displayed on

console and go to Section 5.

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

Anti-Two Block

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 (+12/24V) and X1:2

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

Refer to Drawing 1.

Check fuses in central unit.

Replace fuses.

Measure voltage on the main board between X1:3 (+12/24V) and X1:4 (ground).

This is an output voltage to the console.

Refer to Drawing 1.

START

Check crane power supply for faulty

wiring in crane electric.

YES

Replace the main board in central unit.

Refer to Drawing 2 and Replacement

Procedure 2.

YES

Corrected

Service Manual DS 350 Modular

Console/Display is defective. Replace the console.

Refer to Drawing 1 and 3.

Check connections of the cable between

console and central unit. Replace cable if

necessary. Refer to Drawing 1 in Section 13.

END

Correct?

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

Refer to Drawing 1, 3, & 6.

YES

Anti-Two Block

8 ANTI-TWO BLOCK PROBLEM

Check by-pass plugs installed and system cables connected.

Refer to Drawing 1 and 2.

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 or system cable

connectors into socket.

Refer to Drawing 1 and 2.

Correct?

YES

Check anti-two block weight and/or flags whether installed correctly.

Refer to Operator's Manual: Pre-Operational Inspection and Calibration.

Install A2B weight or flag, if not correctly

installed.

Correct?

YES

Service Manual DS 350 Modular

Measure voltage on the main board terminal strip between X1:31 (+9V±0.5) and

X1:2(ground). This is an input voltage from the system.

Refer to Drawing 1 and 4.

Correct? Replace the main board in central unit.

Refer to Drawing 2 and Replacement Procedure 2.

YES

The A2B circuit supplies 9 volts to the circuit and a 4.7K resistor in the circuit modifies the return signal to

4.5 volts. The computer continuously monitors this signal to ensure the signal is between for a 3 to 6

volt, if the signal is:

less than 3 (open) A2B alarm and light. Check wiring for open circuit - switch not connected,

bypass plugs not installed, or sensor cables not connected

greater than 6 (short) then EAB error is given to the system. The signal is returned to the CU

unmodified; for example, a jumper wire connected between X1:31 and X1:32 in CU.

If the signal is within 3 to 6 volts or the A2B circuit is by-passed; LED H9 on the main board will be lit.

Refer to Drawing 3.

Measure voltage on the main board terminal strip between X1:31 (+9V±0.5) and

X1:32(A2B GND). This is the voltage in the A2B circuit. <3 open and >6 short in system

Refer to Drawing 1 and 4.

>6 volts<3 volts

Look for damaged cable between central unit and boom tip

junction box.

Check 4.7K resistor in boom tip junction box. Turn system power

off and measure resistance between terminal 5 in junction box and

pin A of 7 socket receptacle. measurement reading = 4.7K .

check for short between terminals 5 and 6 in boom tip junction box

or between X1:31 and X1:32 in CU.

YES

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