SkyAzúl HC3900 Manual

HC3900
(DS380)
Installation, Operation & Service Manual

HC3900 Installation, Operation & Service Manual
SkyAzúl, Equipment Solutions www.skyazul.com 301-371-6126
NOTICE
SkyAzúl 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.
SkyAzúl 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 document
contains proprietary information, which is protected by copyright, and all rights are reserved.
No part of this document may be photocopied, reproduced, or translated to another language without
the prior written consent of SkyAzúl.
SkyAzúl reserves proprietary rights to all drawings, photos and the data contained therein. The
drawings, photos and data are confidential and cannot be used or reproduced without the written
consent of SkyAzúl. The drawings and/or photos are subject to technical modification without prior
notice.
All information in this document is subject to change without notice.
SkyAzúl, Inc.
16 Walnut Street
Middletown, MD 21769
Fax [phone]
[email protected]

CONTENTS
1System components...............................................................................................................1
2SYSTEM OPERATION.............................................................................................................2
2.1 content of display .....................................................................................................2
2.2 Operation description...............................................................................................3
2.2.1 Setting the operating mode ...............................................................................3
2.2.2 Setting the reevings ...........................................................................................5
2.2.3 Setting time.........................................................................................................5
2.3 Alarm stop .................................................................................................................5
2.4 Description of indication light..................................................................................6
2.4.1 A2B indication light............................................................................................6
2.4.2 Pre-warning light ................................................................................................6
2.4.3 Overload alarm light...........................................................................................6
2.5 Setting of upper and lower limit...............................................................................7
2.5.1 Setting of upper limit angle ...............................................................................7
2.5.2 Setting of lower limit angle................................................................................7
2.5.3 Delete of angle limit............................................................................................7
3HC3936 SYSTEM FUNCTIONS...............................................................................................8
4SERVICE AND MAINTENANCE ..............................................................................................9
4.1 Content of maintenance ...........................................................................................9
4.2 Length sensor adjustment........................................................................................9
4.3 Adjustment for angle sensor....................................................................................9
4.4 The reason for buzzer keeping sound alarm.........................................................10
4.5 Cable retract not smoothly.....................................................................................10
5Trouble shooting ..................................................................................................................11
5.1 Length sensor .........................................................................................................11
5.2 Angle sensor ...........................................................................................................12
5.3 Pressure transducer ...............................................................................................13
5.4 A2B...........................................................................................................................14
5.5 No console display .................................................................................................15
6DS380 Tool............................................................................................................................15
6.1 Software Installation ...............................................................................................15
6.2 Software introduction .............................................................................................16
6.2.1 Welcome window..............................................................................................16
6.2.2 Main window .................................................................................................17
6.2.3 File -> Load hex file [F2]...................................................................................18
6.2.4 File ->Save as binary file..................................................................................18
6.2.5 File ->Exit ..........................................................................................................18
6.2.6 Edit -> Buffer.....................................................................................................18
6.2.7 Communication -> Connect [F5]......................................................................19
6.2.8 2．6 Communication ->Upload [F6] ................................................................19
SkyAzúl, Equipment Solutions
www.skyazul.com
301-371-6126

6.2.9 Setup -> Chip Select.........................................................................................21
6.2.10 Setup -> Com port ............................................................................................21
6.2.11 Setup -> Baud rate............................................................................................21
6.2.12 Setup ->language .............................................................................................21
6.2.13 Help ->About DS380 Tool.................................................................................22
6.3 Appendix：..............................................................................................................22
7ERROR CODE.......................................................................................................................23
SkyAzúl, Equipment Solutions
www.skyazul.com
301-371-6126

1 SYSTEM COMPONENTS
1. Central unit
2. LCD Graphic Display
3. Pressure transducer
4. Length/angle sensor
5. Anti-Two-Block switch
SkyAzúl, Equipment Solutions
www.skyazul.com
1
301-371-6126

2 SYSTEM OPERATION
2.1 CONTENT OF DISPLAY
1. indication light of A2B switch
2. pre-warning light
3. overload warning light
SkyAzúl, Equipment Solutions
www.skyazul.com
2
301-371-6126

a) bargraph (load moment percentage indication)
b) OM display
c) Reeving display
d) Actual load display
e) Rated capacity display
f) Function key
g) Upper limit angle setting
h) Lower limit angle setting
i) Alarm stop
j) Net weight
2.2 OPERATION DESCRIPTION
2.2.1 Setting the operating mode
The OM setting is used for to adjust the LMI parameter according to the actual crane’s condition. When
operate the crane please make sure the displayed operation mode is the same with the actual operation
mode.
Before operate the crane please check the corresponding OM code according to your crane type and
actual mode and then adjust the OM to be the same with the actual OM.
WARNING
The correct setting is of utmost importance for the proper function of the system and the crane.
Therefore only operators who are thoroughly familiar with use and operation of the system shall
set this function.
Way for correctly setting the operating mode:
When it is need to adjust the operating mode please press the button under the Function interface
(see pic.1), and press the button to change the language between English and Chinese
You should do as the following procedures:
SkyAzúl, Equipment Solutions
www.skyazul.com
3
301-371-6126

( pic.1)
Pressing the key of number “1” enter into pic.2 “ Set operation mode”. (see pic.2)
( pic.2)
By pressing the number key the actual OM can be input. Let’s take a example: if you want to enter OM
02, you can press the key “0” to input the number key of “0”and press the function key to next
digital. And press the number key of “2” for input 2, then press the function key to confirm this
time’s operation. If needn’t OM setting operation, please press the function key for return to the
SkyAzúl, Equipment Solutions
www.skyazul.com
4
301-371-6126

upgrade interface.
2.2.2 Setting the reevings
This function is for to setting the number of the rope for LMI system. Before operate the crane the
operator is asked to adjust the displayed reeving to be same with the actual one.
The relationship between the actual reeving and displayed one is as following:
Displayed value: 1 ----------16
Number of parts in line of the ropes: 1 ----------16
Way for correctly setting the reevings:
Press the number “2” button under the function interface and enter into “Set reev” (see pic.3)
(pic.3)
The operation for enter the actual reeving is the same with OM setting.
2.2.3 Setting time
Only manufacture has this right.
2.3 ALARM STOP
The HC3936 system’s warning buzzer will sound alarm under the following conditions:
— reach max. of rated capacity
— the hook reach to height limit
— exceed the permitted movement radius of the crane
— load moment indicator malfunction
SkyAzúl, Equipment Solutions
www.skyazul.com
5
301-371-6126

— Error operation
Press the key in the main interface and the audible alarm will be silenced till above condition
happen again.
2.4 DESCRIPTION OF INDICATION LIGHT
2.4.1 A2B indication light
The red warning light will light up
as soon as the anti-two-block limit
Switch contact open, indicating that a two-blocking condition is approaching. At the same time the
audible alarm will sound.
The following crane movements will be stopped subsequently: hoist up, telescope out, boom down.
In order to avoid any injury to people or crane, please check the A2B system before operating the
crane in the following procedure:
a. Manually lifting the weight attached to the anti two-block switches, then the audible alarm sound
and the anti two-block alarm light will light.
b. Slowly raise the hook or lower the boom or extend(telescope) the boom to create a potential
two-block condition, when the hook lifts the weight, the audible alarm sound, the anti two-block alarm
light will light and the crane movement such as hoist up, luffing down, telescopic out will be stopped.
c. If the light and audible alarm do not function as described and the crane movements are not
stopped, the system is not working properly. The malfunction shall be corrected before operating the
crane.
2.4.2 Pre-warning light
The yellow load moment pre-warning
Light will light up when the load on the
crane reaches the defined pre-warning area 90%～100% of the rated capacity, thus indicating that an
overload condition is approaching.
This means for the operator to continue his crane operation with extreme caution.
2.4.3 Overload alarm light
The red warning light will light up
when the load on the crane reaches
the defined overload capacity of 100%(or 102%,according to country standard) rated capacity,
STOP
SkyAzúl, Equipment Solutions
www.skyazul.com
6
301-371-6126

2.5 SETTING OF UPPER AND LOWER LIMIT
The LMI system function for the limitation of the boom angle to warn the operator of extreme
caution under dangerous condition: buildings, bridges, high-voltage wire.
WARNING
This limit function is only of warning use but without control function. For each time reset
the LMI system you need to reset the limit value.
2.5.1 Setting of upper limit angle
Luff up the boom to max. safe position and then press the key to set present boom angle as
upper limit. When this limit value is exceeded the
STOP
indication light will
light up and audible alarm sound to warn the operator to take extremely operate.
2.5.2 Setting of lower limit angle
Luff down the boom to min. safe position and then press the key to set present boom angle as
lower limit. When the angle is lower than this limit value the
STOP
indication light will light up and audible
alarm sound to warn the operator to take extremely operate.
2.5.3 Delete of angle limit
Simultaneously press the number key“0”then the set limits are deleted.
Select language interface
When it is need to select language, please press the button under the Function interface(see
pic.1), you should press the button
SkyAzúl, Equipment Solutions
www.skyazul.com
7
301-371-6126

3 HC3936 SYSTEM FUNCTIONS
1. Warning
— overload
— 2 block condition
— malfunction
Any above condition happens the HC3936 system will light up and sound alarm for warning.
2. Prohibited
Cooperating with crane electrics system the system will send alarm warning and any of the
following crane’s movements will be prohibited:
— boom luffing down
— telescopic out
— hoist up
At this moment only the movements toward safety direction is allowed:
— boom luffing up
— boom retract
— hoist down
SkyAzúl, Equipment Solutions
www.skyazul.com
8
301-371-6126

The LMI system has this cut-off function however the operation toward dangerous direction is not
allowed when overload or 2 block condition happens. Because this cut-off device is a interacted system,
in case of any error it may cause big danger.
NOTICE
When the cut-off device is activated this cut-off signal will always keep be out. Functions such
as “dangerous direction operation is not allowed”, “only safe direction operation is allowed” is
realized by cooperating with the crane’s electronics system which including “ safe direction inspect
switch”, “ safe overflow solenoid valve” etc. The LMI system cannot judge the operation is safe or
dangerous itself.
4 SERVICE AND MAINTENANCE
4.1 CONTENT OF MAINTENANCE
a. Check all cable connections of the system. Damaged cables are to be replaced immediately.
b. Check the isolation of the length sensor and A2B switch cable and the cable guides. Worm
isolations and damaged cable guides have to be replaced.
c. Inspection of the anti-two block switch as to easy running
d. Check of the cable reel as to sufficient tight.
e. Check of the pressure transducers at the hoist cylinders and the connection hoses as to oil
leakage.
4.2 LENGTH SENSOR ADJUSTMENT
When the displayed boom length is not correct (exceed the permitted error range) , please adjust it:
Retract the boom to the basic boom condition and check the pre-stressing force of the cable
reel( cable must be tight)and then open the cover of the length/angle sensor and turn the axle of the
length potentiometer slowly( see arrow mark) till the displayed value to be the same with the actual
length.
Length sensor adjustment (see above arrow)
4.3 ADJUSTMENT FOR ANGLE SENSOR
The angle sensor is installed in the same house with the length sensor.
First, retract the boom to the basic length condition and make sure the displayed value accord with
the actual length. Use the angle instrument to measure when the actual angle is between 10°and
SkyAzúl, Equipment Solutions
www.skyazul.com
9
301-371-6126

70°whether the displayed vale is the same or use the tape to measure the working radius. If the
displayed value or radius is not the same with the actual value, you should adjust the angle sensor.
Please lose the three bolts (see the following pic.). Slowly turn the angle sensor till the displayed value
accord with the actual value. And then tight the bolts again.
4.4 THE REASON FOR BUZZER KEEPING SOUND ALARM
After start the system it displays without any malfunction or error code but the buzzer keep sound
alarm, in this case please check if any disconnection or water falls in the connection between length
cable and A2B switch.
4.5 CABLE RETRACT NOT SMOOTHLY
Sometimes when retract the boom it happens that the length cable cannot return to the original
position naturally or retract not smoothly. It is because of the coil-spring’s pre-tight is too low or the length
cable in the cable reel fall off.
Please pre-tighten the length cable several circles to solve the problem:
1. Retract the boom and put it on the rack
2. Draw back the tip of the cable from the tip of the boom and retract to the cable reel
3. Pre-tight the cable reel 3 to 5 circles, to make the cable can be pulled out and retracted smoothly.
4. Pull out the cable and fix it on the tip of the boom again
5. After pre-tight the cable reel the display of the boom length will be affected, so at this moment
please adjust the length sensor till the displayed value the same with the actual length.
SkyAzúl, Equipment Solutions
www.skyazul.com
10
301-371-6126

5 TROUBLE SHOOTING
5.1 LENGTH SENSOR
SkyAzúl, Equipment Solutions
www.skyazul.com
11
301-371-6126

5.2 ANGLE SENSOR
SkyAzúl, Equipment Solutions
www.skyazul.com
12
301-371-6126

5.3 PRESSURE TRANSDUCER
SkyAzúl, Equipment Solutions
www.skyazul.com
13
301-371-6126

5.4 A2B
SkyAzúl, Equipment Solutions
www.skyazul.com
14
301-371-6126