PAT DS 150 User manual

www.patamerica.co PAT America, Inc.
LOAD MOMENT INDICATOR
DS150
SERVICE MANUAL
P/N 031-300-100-753 REV B 03/08/02

Service Manual
DS150
REV DATE NAME DESCRIPTION
A 10/16/01 CSH ECN 01-283
B 03/08/02 CLC ECN 02-087
NOTICE
PAT America, Inc. makes no warranty of any kind with regard to this material, including, but not limited
to, the implied warranties of merchantability and/or its fitness for a particular purpose.
PAT America, Inc. will 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
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No part of this document may be photocopied, reproduced, or translated to another language without
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The drawings, photos and data are confidential and cannot be used or reproduced without the written
consent of PAT America, Inc. The drawings and/or photos are subject to technical modification
without prior notice.
All information in this document is subject to change without notice.
MANUAL REVISIONS

Service Manual
DS150

Service Manual
DS150
TABLE OF CONTENTS
1 MECHANICAL DESCRIPTION OF THE SYSTEM COMPONENTS ..............................................1
2 MECHANICAL AND ELECTRICAL DESCRIPTION OF THE CENTRAL UNIT.............................2
BASIC SYSTEM COMPONENT LAYOUT..........................................................................................................3
BASIC ADJUSTMENT OF THE COMPONENTS...............................................................................................4
3 DEFINITIONS ................................................................................................................................5
4 DRAWINGS...................................................................................................................................6
SYSTEM ELECTRICAL DIAGRAM..................................................................................................................6
CENTRAL UNIT 024-150-060-002 SPARE PARTS LIST .............................................................................7
CONSOLE 050-150-060-006 SPARE PARTS LIST......................................................................................9
CONSOLE 050-150-060-008 SPARE PARTS LIST....................................................................................11
CABLE REEL 068-208-060-013 LWG208 SPAREPARTS LIST............................................................. 13
CENTRAL UNIT BOARD LAYOUT AND MEASURINGPOINTS 024-150-300-001 ..............................15
5 PROCEDURE..............................................................................................................................16
EPROM REPLACEMENT IN CENTRAL UNIT................................................................................................16
PISTON & ROD PRESSURE CHANNEL ZEROPOINT ADJUSTMENT......................................................... 16
LENGTH & ANGLE ADJUSTMENTS...............................................................................................................17
MAIN BOARD REPLACEMENT.......................................................................................................................18
6 THEORY......................................................................................................................................19
ANTI-TWO BLOCK & SHUTOFF CIRCUIT.....................................................................................................19
LENGTH MEASURING CHANNEL...................................................................................................................19
PISTON SIDE PRESSURE MEASURING CHANNEL......................................................................................20
ROD SIDE PRESSUREMEASURING CHANNEL...........................................................................................20
MAIN BOOM ANGLE MEASURING CHANNEL...............................................................................................21
SECOND ANGLE MEASURING CHANNEL.....................................................................................................21
7 TROUBLESHOOTING FLOW CHARTS......................................................................................22
GENERAL FLOWCHART.................................................................................................................................22
LEVER LOCKOUT ACTIVATED.......................................................................................................................23
BROKEN LENGTH CABLE..............................................................................................................................24
NO DISPLAY...................................................................................................................................................25
ANTI TWOBLOCK PROBLEM........................................................................................................................27
LENGTH READING PROBLEM.......................................................................................................................30
LOAD READING PROBLEM............................................................................................................................33
BAD DATA TRANSFER BETWEEN CONSOLE & CENTRAL UNIT............................................................... 36
INTERFERENCE PROBLEM............................................................................................................................38
ANGLE PROBLEM..........................................................................................................................................39
8 ERROR CODE TABLE................................................................................................................40
ADDENDUM A BASIC ADJUSTMENT AND VOLTAGE CHECKS ...................................................46
ADDENDUM B REFERENCE TABLES FOR MEASURING SUPPLY AND SIGNAL VOLTAGES FOR
SENSOR CHANNELS .......................................................................................................................47

Service Manual
DS150

Mechanical Description Of The System
1
1 MECHANICAL DESCRIPTION OF THE SYSTEM COMPONENTS
Pressure Transducer: The pressure transducer transforms hydraulic pressure into an electric analog
voltage signal. Two pressure transducers are connected, one to the rod side and one to the piston
side of the lift cylinder. The pressure transducer is connected to the central unit with a four-conductor,
double-shielded cable.
The power supply voltage is 5V.
The output signal is 0.00V under 0 pressure to -1.00V at max. pressure (4410psi)
The Length-Angle Transducer: The length-angle sensor (LWG) is a combination of two transducers
in one box, fitted at the base section of the boom. It measures the length and angle of the boom.
A reeling drum drives a potentiometer, which is the length transducer. Part of the length transducer is
the length cable on the drum, which is a two-conductor cable (screen and live). It is connected to the
anti-two-block switch at the boom head and to a slip ring body in the reel. The angle transducer is
fitted into a small box filled with oil. A pendulum drives the axle of the angle potentiometer.
The power supply voltage for both is -5.00V
The output signal for the length transducer is: -0.500V up to -4.500V
The output signal for the angle transducer is: -1.875V up to -3.125V
Anti-Two-Block 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 hook block strikes the
weight, the circuit opens, disengaging a relay output to the lockout solenoid valves, where applicable.
To check the cable for damage, (short circuit to ground) there is a 4.7k resistor between ground and
the contact of the switch. The weight at the anti-two-block switch keeps the switch closed until the
hook block strikes it.
Console: The console displays the geometrical information such as length and angle of main boom,
working radius and head height of the boom. It also displays the actual load and the maximum load
permitted by load chart. Furthermore, it has an alarm horn and a warning light for overload, and a pre-
warning light. The analog instrument shows a percentage of the total permissible moment. The
console has a switch for the operating modes (duty-selection switch for crane configurations) and a
switch for the Reeving of the hook block. It also has a warning light for anti-two-block conditions and
an override switch for overload or anti-two block condition.
Duty Selection Switches (Digital Inputs): The system has to be programmed for the lifting area
configuration. The crane is going to be worked in (e.g. main boom) on outriggers over front, or rear, or
over the side for 360 degrees. For obtaining this information from the crane, micro switches are
installed in the electrical swivel that tells the system the exact location of the boom. Micro switches
are also located on the counterweight which tells the system if the counterweight is installed or not,
where applicable.

Mechanical Description Of The System
2
2 MECHANICAL AND ELECTRICAL DESCRIPTION OF THE CENTRAL UNIT
All the data of the crane is stored inside the central unit in EPROM‟s. The central unit receives all
actual information of the crane. This is computed against the reference data and the crane status is
continuously monitored.
Description of the Housing: The central unit DS150 is a rugged, waterproof sheet steel housing. It is
mounted on the left side of the turn table weldment or on the counterweight. The cables are led into
the central unit via strain reliefs and connected with fast-ons. An override switch is mounted on the
housing, which overrides the LMI function. The system is protected by a 2-AMP fuse, which is
mounted on the lower right side. The output signal is protected by a 10-AMP fuse, mounted on the
lower mid.
Description of the Boards: Inside the central unit (CU) there is a main board. The main board and
CPU is the heart of the system, and it contains the processor and the system and data EPROMs. The
system EPROM holds the operating system and data EPROM hold the crane and calibration
information. The wires from the various components are connected with fast-ons to the main board.
The main board holds the electronics necessary to receive, evaluate, and direct the continuous flow of
data from the sensors to the processor.
Main board components:
Power supply: Provides all the necessary voltages for the transducers and the electronics on the main
board.
Analog input part: Receives and prepares all the signals from the transducers for further processing.
Relays, an overload and anti-two-block relay: Controls the Bosch relay for lever lockout.
Incoming Signals: Signals from the transducers are connected to the main board. The signals vary
depending on the sensor:
Angle transducer signal is between -1.875V and -3.125V.
Length transducer signal is between -0.500V and -4.500V.
Pressure transducer signals are between 0.00V and -1.00V. (measured between the negative and
positive outputs)
Anti-two-block switch resistance is 4.7Kohms.
Digital inputs for the duty selection switches are on or off.
Outgoing Signal: The outgoing signal of the main board is the signal for lever lockout of connection
#48. In normal working conditions there are 12 volts at this connection. If there is an overload or anti-
two-block condition the signal becomes 0 volts. Furthermore, all voltages for the transducers are going
out through the main board.

Mechanical Description Of The System
3
Basic System Component Layout