Schwing CPC III User manual

1
Operation
CPC III Manual
Installation Instructions...................................3
Control Panel...................................................3
Scanreco Radio ...............................................4
Oil Temperature Sensor...................................4
Rear Control Panel ..........................................4
Important Notes ...............................................5
CPC III (Concrete Pump Controller)................6
HMI (Human Machine Interface) .....................7
Navigation Pane ..............................................7
LCD Screens .....................................................8
Homepage Screen - with installed options ......8
Menu Screen ...................................................8
Module and PLC I/O Screens..........................9
INPUTS St Screen...........................................9
OUTPUTS St Screen.......................................9
INPUTS Ex Screen..........................................9
OUTPUTS St Screen.......................................9
OUTPUTS Ex Screen....................................10
System Voltage Screen .................................10
Keypad Screen ..............................................10
Radio Screen................................................. 11
Proportional Settings Screen (Display).......... 11
Proportional Settings Screen (Teach Mode)..12
Maintenance Screen - Password Prompt ......12
Maintenance Screen......................................13
Conguration Screen.....................................13
Cable/Radio Remote Box...............................14
Status LCD Display .......................................15
98465796-00
Panel Assembly:
Schematic:
98458772
98455320
Boom Harness
(PBC)
Radio A
(PRADA)
Front Harness
(PFC)
Rear Harness
(PRC)
Programming Port
(PPPT)
I/O Harness
(PIOE)
Oil Temperature
(POTS)
Power
(PPG)
Pairing Port
Maintenance Switch
(PMS)
Radio C
(PRADC)
OFF
ON
In Maintenance mode, all CPC
safety features will be disabled
WARNING
ok
CPC III Manual

2
Operation
CPC III Manual
Joystick Conguration - Example ..................15
Radio/Cable Remote Buttons/Switches.........16
Status Lights..................................................17
Pairing Transmitter to Receiver ....................18
Operator Panel Keypad..................................19
Keypad Buttons..............................................19
Teach Mode Operation...................................22
To enter teach mode:.....................................22
Adjusting Boom Functions.............................23
Adjusting Stroke Limiter.................................23
Factory Settings.............................................23
Warning Messages .........................................24
Pump Error Codes.........................................24
Loss of Rear Keypad .....................................24
Maintenance Switch:......................................24
Display Messages...........................................25
SOURCE - Input Error Codes........................26
SOURCE - Output Error Codes.....................26
SOURCE - Error Codes.................................27
CAUSE - Error Code .....................................27
98458772-Assy CPC3 Control Panel(1 of 2).29
98458772-Assy CPC3 Control Panel(2 of 2).31

3
Operation
CPC III Manual
Installation Instructions
These instructions will vary depending on the type of
unit you are replacing. They are general guidelines and
some system understanding will be needed to install
the CPC III. All of these steps need to be performed
with the vehicle shut-o󰀨.
Electrical Schematic: 98455320
Control Panel
1. Find the primary C32/CPC/CPC2 control panel.
See Figure 1.
POWER
REAR CTR
UMB CTR
RADIO CTR
ID
LINK
ALARM
E-STOP
WHEN WELDING ANYWHERE ON UNIT
POWER CABLE MUST BE DISCONNECTED
L1357-01
Figure 1
Original CPC panel
2. Remove the primary control panel and bracket
that holds it to the shock mounts.
3. The CPC III Control Panel is pre-assembled.
Remove the faceplate and disconnect the local/
remote switch and display (Figure 2). Put the
faceplate to the side for later.
Faceplate
Disconnect
Figure 2
Unplug Local/Remote switch and display, remove
faceplate
4. There are 4 holes provided to mount the CPC III
to the unit, two above the PLC and 2 below the
PDM. If your unit used the Mounting Plate and it
used the four holes on the far left and right, then
you may need to install the mounting panel to the
CPC III panel rst to match up the pattern.
CPC III Mounting Holes
Plate is only needed if the control
panel was mounted with these side holes.
Figure 3
Location of mounting holes
5. Install the CPC III Control Panel to the shock
mounts using the old hardware.
6. Connect the four cables that match the CPC III
control panel decal (PPC, PRC, PFC, PBC). The
old Radio connector is no longer needed and can
be removed.
PRC
PFC
PBC
PPG
98465796-00
Panel Assembly:
Schematic:
98458772
98455320
Boom Harness
(PBC)
Radio A
(PRADA)
Front Harness
(PFC)
Rear Harness
(PRC)
Programming Port
(PPPT)
I/O Harness
(PIOE)
Oil Temperature
(POTS)
Power
(PPC)
Pairing Port
Maintenance Switch
(PMS)
Radio C
(PRADC)
OFF
ON
In Maintenance mode, all CPC
safety features will be disabled
WARNING
ok
Figure 4
Install connected
7. Install the faceplate and connect the display and
Local/Remote Switch.

4
Operation
CPC III Manual
Scanreco Radio
1. The CPC III uses a Scanreco radio system similar
to current Schwing BPLs/TMPs. You can remove
all the old radio system components as none of it
will be used.
2. The Receiver and Antenna may be mounted any-
where externally on the unit. Mount the Receiv-
er/Antenna and run the three cables back to the
Control Panel. (Figure 5)
98465796-00
Panel Assembly:
Schematic:
98458772
98455320
Boom Harness
(PBC)
Radio A
(PRADA)
Front Harness
(PFC)
Rear Harness
(PRC)
Maintenance Switch
(PMS)
Radio C
(PRADC)
OFF
ON
In Maintenance mode, all CPC
safety features will be disabled
WARNING
ok
Figure 5
Connect receiver to panel
3. Plug Cable A and Cable C into the control panel.
If you connect these backwards, it will blow a fuse
when power is applied.
4. Cable B has a mounting bracket on it. Mount the
Bracket where the pre-drilled holes are for “Pair-
ing Port” using the 2x M4x25 bolts. (Figure 6)
Pairing Port
Figure 6
Mount pairing port
5. Mount the Battery Charger in the cab.
6. Place the radio transmitter, cable and batteries
in the cab.
Oil Temperature Sensor
1. The Oil Temp Sensor that is installed on the unit
cannot be used. Locate the current Oil Temp
Sensor and replace it with the one provided.
2. Run the Oil Temp Harness from the Oil Temp
Sensor to the CPC III Control Panel and plug in
both sides. (See Item 260 on BOM 98458427)
Rear Control Panel
1. Remove the Rear Control Panel.
2. Install the new CPC III keypad onto the CPC III
mounting bracket.
3. Install the CPC III Mounting Bracket where the
old Rear Control Panel was.
Remove old panel
Install new panel
RPM
CPC 2
C
Figure 7
Remove old panel and install new keypad
4. Concrete Pressure Sensor: Find the Concrete
Pressure Sensor which is usually located near
the rear gauges and replace the sensor with the
new CPC III sensor. If your unit did not have a
Concrete Pressure Sensor then you have the op-
tion of installing it to get additional functionality.
It is not required. (Item 280 on BOM 98458427)
5. Run the I/O-E harness from the CPC III Control
Panel to the CPC III Rear Keypad.
- Plug in the I/O-E Harness to the CPC III Con-
trol Panel.

5
Operation
CPC III Manual
Programming Port
(PPPT)
I/O Harness
(PIOE)
Oil Temperature
(POTS)
- Plug in the connector labeled “Keypad” to the
Rear Keypad.
- If Installed: Concrete Pressure Sensor: Plug in
the M12 connector to the Concrete Pressure
Sensor.
- One of the connectors you disconnected from
the Rear Control Panel will plug into the I/O-E
Harness (PIOC).
Note: On the early C32 rear panels, only one
connector was used. I this case PIOC will not be
used.
6. Connect the supplied connector jumper to the
remaining connector from the old Rear Control
Panel. (Item 60 on BOM 98458427)
Clean up the harnesses and nish securing all equip-
ment. (Item 270 on BOM 98458427)
Initial Setup
1. Turn on PTO but do not run the engine.
2. Turn on the Maintenance Switch. Inspect F9 fuse
in the PDM. If F9 fuse blows (or is already blown)
then nd the Quick Disconnect (PQD1) on the
harness located next to Cable C and disconnect
it. Tape the connector ends.
- Reset the circuit breaker by cycling the power.
- Turn o󰀨 the maintenance switch.
Maintenance Switch
(PMS)
OFF
ON
Figure 8
Maintenance switch
3. Ignore all error messages for now. Go to the
Conguration screen using the system password
and adjust the system settings.
Screen Settings
1Channel E-stop Only select this option if the system you are
replacing had single channel E-Stops.
CPC2 Compatible Only select this option if the system you are
replacing was a CPC2 type machine.
Stroke Counter Select if the unit has a Stroke Counter.
Oil Pressure Sensor Select if the unit has an Oil Pressure Sensor
Agitator Disable Select this option if the unit does NOT have
an electrically controlled agitator.
Boom Horn Disable Select this if the unit does NOT have a
Boom Horn.
Boom Type Choose the Boom Type: 3 Section, 4 Sec-
tion, etc.
Max Engine RPM Max engine RPMs allowed.
Important Notes
1. On some units the Agitator Forward and Reverse
buttons may be backwards. If yours is backwards,
swap the agitator forward and reverse connec-
tors at the valve.
2. All agitator forward and reverse buttons will need
to be removed from the unit as they will no longer
work. Use the rear keypad or radio remote.
3. If fuse F9 blows go to the initial setup instructions.
Fully test the system and Teach the boom using the fac-
tory login.

6
Operation
CPC III Manual
CPC III (Concrete Pump Controller)
CPC III is a drop-in replacement of the previous CPC/
C32 systems. CPC III system is an upgraded system for
C32, CPC and CPC2, as well as all the variations and
revisions of each one. Due to this, CPC III may vary
depending on what the original system was and how
it was changed over the years and what options were
originally installed.
CPC III controller contains the following item:
A. HMI (Human Machine Interface)
B. Local / Remote Switch
C. Maintenance Switch
Radio/Cable Remote
Rear Control Panel
98465796-00
Panel Assembly:
Schematic:
98458772
98455320
Boom Harness
(PBC)
Radio A
(PRADA)
Front Harness
(PFC)
Rear Harness
(PRC)
Programming Port
(PPPT)
I/O Harness
(PIOE)
Oil Temperature
(POTS)
Power
(PPG)
Pairing Port
Maintenance Switch
(PMS)
Radio C
(PRADC)
OFF
ON
In Maintenance mode, all CPC
safety features will be disabled
WARNING
o
k
A
BC

7
Operation
CPC III Manual
HMI (Human Machine Interface)
The HMI is the interface between the operator and CPC
III Controller. From the HMI, operators can view and set
machine parameters.
The HMI contains the following:
A. LCD Screen
B. (F1) Function Button
C. (F2) Function Button
D. (F3) Function Button
E. (F4) Function Button
F. OK Button
G. Navigation Arrows Button
ok
A
E
D
BCF
G
Navigation Pane
The Navigation Pane displays the available functions
and menu actions for each screen. If a function symbol
appears on the Navigation Pane, the operator can push
the corresponding function button below that symbol to
execute a menu action.
Example: The stroke counter reset symbol appears
above the (F4) Function Button. Press and hold this
button for 2 seconds to reset the stroke counter.
Navigation Pane
Avaliable
Function Symbol
(F4) Function Button
Arrows in the center of the Navigation Pane, repre-
sent which direction you can push the Function Arrows
button. The Function Arrows button can be pushed in
four directions. Not all directions are available on ev-
ery screen. These buttons are used to navigate to other
screens and scroll through menu items.
To assist the reader, we will represent the symbols as
follows:
ok = OK
= Function Arrows Left/Right
= Function Arrows Up/Down

8
Operation
CPC III Manual
LCD Screens
Homepage Screen - with installed options
When the ignition switch is engaged, power will be sup-
plied to the CPC III Controller. The Homepage screen
will appear on the HMI LCD display.
BN
M
C
D
E
FGL
A
HIJK
Displays:
A. Status Message Display
B. RPM
C. Hydraulic Oil Temperature
D. Oil Pressure PSI (if equipped)
E. Stokes Per Minute (if equipped)
F. Silent Alarm Symbol
G. Estop Reset Symbol (if keypad disconnected)
H. Dirty Oil Filter Indicator Symbol
I. Oil Cooler ON Symbol
J. E-Stop Pressed Symbol
K. Local / Remote Indicator Symbol
L. Stroke Counter Reset Symbol
M. Stroke Counter Indicator
N. Comms Link Indicator
Functions:
- Press ok to go to the Menu screen.
- Press (F1) button to silence the alarm
- Press (F2) button
Reset
to reset the E-stop (if
keypad is disabled)
- Press and hold (F4) button
R
to reset the
stroke counter
Menu Screen
The Menu Screen displays additional status, parameter
settings screens and software version:
• PLC I/O Status
• Local Keypad
• Radio
• Prop Settings
• Maintenance
• Conguration
• HMI Software Version
• PLC Software Version
A small Schwing logo indicates which menu item is
currently selected. Menu items with an orange outline
around them, don’t require a password to access. Use
the to scroll up and down the menu items. When
you have moved the to the screen you would like to
access, press the ok button.
Software versions for the HMI and PLC are displayed
in the lower corners of the screen. This information is
useful for troubleshooting.
Functions:
- Press (F4) button Esc to return to the Homep-
age Screen.
- Press (F1) button
Log
out
to log out of Mainte-
nance Access
- Use the to scroll up/down menu items
- Press the to enter a password, if required.

9
Operation
CPC III Manual
Module and PLC I/O Screens
Displays the electronic input and output signals. Active
input or output signals will be indicated with a green
circle. Supply voltage indicators and PLC temperature
are displayed below the input/outputs.
This screen can be used to assist in troubleshooting
electrical issues.
INPUTS St Screen
Functions:
- Press (F4) button Esc to return to Menu Screen.
- Press the to go to next or previous PLC I/O
screen
OUTPUTS St Screen
Functions:
- Press (F4) button Esc to return to Menu Screen.
- Press the to go to next or previous PLC I/O
screen
INPUTS Ex Screen
Functions:
- Press (F4) button Esc to return to Menu Screen.
- Press the to go to next or previous PLC I/O
screen
OUTPUTS St Screen
Functions:
- Press (F4) button Esc to return to Menu Screen.
- Press the to go to next or previous PLC I/O
screen

10
Operation
CPC III Manual
OUTPUTS Ex Screen
Functions:
- Press (F4) button Esc to return to Menu Screen.
- Press the to go to next or previous PLC I/O
screen
System Voltage Screen
Functions:
- Press (F4) button Esc to return to Menu Screen.
- Press the to go to next or previous PLC I/O
screen
Keypad Screen
Displays active functions on the Operator Keypad.
When a button is pressed on the keypad, the corre-
sponding button on the screen will light up green. Ex-
ample, horn button activated.
This screen also shows your communications link
(Comms), Green dot = connected, Red dot = not con-
nected.
Functions:
- Press (F4) button Esc to return to Menu Screen.