WIKA HIRSCHMANN MCS qSCALE maestro User manual

HIRSCHMANN MCS
qSCALE
maestro
PLC v01.00.00
Contents
Safety instructions
1
Product description
2
Operating Mode Selection
3
Operation
4
Service and Maintenance
5
Appendix
6
7
Operators Manual
Issue K –08/2018
HMI v01.00.00
This document has the order number:
MAN-QSCA-O-0008

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qSCALE maestro (PLC v01.00.00) Operators Manual / Issue K (HMI v1.0.0) 08/2018 / rbm.
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TABLE OF CONTENTS
1Safety Instructions...........................................................................................6
1.1 EC Conformity Declaration........................................................................6
2Product Description .........................................................................................7
2.1 Product Identification .................................................................................8
2.2 Overview of Console Elements .................................................................9
2.3 Overview Feedback Elements.................................................................10
3Operating Mode Selection.............................................................................11
3.1 Switching Device On and Off...................................................................11
3.2 Setting the Operation Mode.....................................................................13
4Operation.........................................................................................................16
4.1 Main Working Screen ..............................................................................17
4.1.1Warning Lights / Audible Alarm ...........................................................18
4.2 Work Area Limitations..............................................................................19
4.2.1 Height Monitoring.................................................................................21
4.2.2Radius Monitoring................................................................................22
4.2.3 Boom Angle Monitoring .......................................................................23
4.2.4 Wind Speed Monitoring .......................................................................24
4.3 Tare Weight .............................................................................................26
4.4 Switching Off Audible Alarm....................................................................26
4.5 Error Events.............................................................................................27
4.6 Camera....................................................................................................29
5Service and Maintenance ..............................................................................30
5.1 Settings Menu..........................................................................................30
5.2 Machine Information................................................................................31
5.2.1 System Version Information.................................................................31
5.2.2 Status of Digital Outputs......................................................................32
5.2.3 Status of Digital Inputs.........................................................................33
5.2.4 Readings of Analog Sensors...............................................................34
5.3 User Screen.............................................................................................35
5.3.1 LCD Brightness....................................................................................36
5.3.2 Key Brightness.....................................................................................37
5.3.3 Unit Selection.......................................................................................38
5.4 Sensor Calibration ...................................................................................39

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5.5 System Information..................................................................................40
5.6 Screen Capture........................................................................................41
5.6.1 Taking Screen Captures......................................................................41
5.6.2 Saving Screen Captures......................................................................41
5.7 Maintenance and Repair..........................................................................42
6Appendix .........................................................................................................43
6.1 Technical Data.........................................................................................43
6.2 Password Entry........................................................................................44
6.3 Error Codes Table ...................................................................................45
VERSION OVERVIEW
Issue
Date
Description
Editor
A
10/2017
Initial Release (HMI v01.00.00)
RBM
B
11/2017
Replaced Cover Image and added references to
vSCALE D2 Console
RBM
C
11/2017
Added error code 1F01 handling information to section
3.1 Section 5.5 changed system information icon.
RBM
D
11/2017
Section 5.5 changed system information icon.
RBM
E
11/2017
Added Error Code List
RBM
F
11/2017
Tweaked grammar, wording and formatting throughout
manual.
RBM
G
12/2017
Corrected wording and moved Alarm Volume section
to the Service Manual.
RBM
H
1/2018
Changed override alarm behavior.
RBM
J
3/2018
Changed numerical entry instructions.
RBM
K
8/2018
Removed references to D3 console
RBM

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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 certain
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 con-
strued to mean that such names, even without special identification, are free in the sense of trademark
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 inappro-
priate or impermissible use. This device / system may only be used if it is in perfect technical condition.
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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Marking of Notices
Dangers and other important notices are marked as follows in this user 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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1 Safety Instructions
WARNING
Imminent threat of personal injury and damage to property due to incorrect system 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!
1.1 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.

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2 Product Description
The vSCALE D2 maestro console is the interface of the Rated Capacity Limiter system (RCL).
The RCL monitors the sensors and detects a machine overload status depending on various parameters.
The machine driver is warned before the onset of an overload status via visual and audible warning signals.
The RCL comprises:
qSCALE S6 maestro central control unit
vSCALE D2 maestro console
various sensors for detection of machine status and environmental conditions
The vSCALE D2 maestro console is used for:
programming and inputting operating parameters
displaying the current machine operating data
NOTE
This user manual contains information about the vSCALE D2 maestro console,
mode selection, operation, sensor calibration and maintenance.
WARNING
Although the system incorporates functions for monitoring adjustable geometrical 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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2.1 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.
Type plate
(Example for D2)

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2.2 Overview of Console Elements
Function Keys F1 to F8: 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 2.3)
Function Keys F1-F8
Function Varies by screen
USB 2.0 interface
(used for service purposes)

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2.3 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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3 Operating Mode Selection
This chapter contains information, advice and instructions for choosing an operating mode.
3.1 Switching Device On and Off
The load limiting device has no on/off switch. The console automatically switches on with PTO power.
After boot-up, the following appears on the display:
Operating Mode Selection Screen
If the machine configuration has not changed, check
displayed configurations. If OK, press
Then check outriggers and confirm with
The Main Working Screen is then displayed.
If the machine configuration has changed see Setting
Operation Mode in Section 3.2
Initial Display After
Boot-Up:

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In the event of a system malfunction an error code is displayed in the bottom right of the display:
The error codes and what they mean are explained in the error codes table in Section 6.3.
The device is not ready for operation until all faults have been rectified and no error codes are displayed. The
error codes are displayed in red color. The warning codes are displayed in yellow color.
When confirming the operating mode, if the vSCALE D2 maestro console does not have a working Ethernet
connection to the qSCALE S6 maestro central control unit, the operating mode will default to 0000 and error
code 1F01 will be displayed.
The vSCALE D2 maestro console must be properly connected to the qSCALE S6 maestro central control
unit, before confirming the operating mode. See the Service Manual for details.
System Malfunction?
Error code

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Operating
Mode Code
3.2 Setting the Operation Mode
SETUP Procedure
The RCL must be adjusted to the current machine setup status by completing the full SETUP
procedure after start-up and after any change to the machine configuration.
The system is not ready to operate until the full SETUP procedure has been completed.
WARNING
Imminent threat of personal injury and damage to property due to incorrect system settings!
The correct adjustment of the RCL to the current set-up status is essential for the correct func-
tion 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 opera-
tion and functions of the machine and the RCL.
The correctness of these settings must be guaranteed before operating the machine!
Operating Mode
Depending on the inputs during the SETUP procedure and on various sensor values, the deter-
mines the corresponding operating mode with the associated lifting capacity table. The operating
mode used by the system at any given time is displayed as a code in the status row:
Process
The process for setting the RCL to the current machine status (SETUP procedure) includes the
following steps:
Entering Operating Mode selection screen from the Main Working Screen or automatically after the console is pow-
ered on.
Entering the number of rope reeving.
Selection of the hoist used.
Selecting the operating mode that matches the current outrigger and jib status.
Overview of inputs
NOTE
The process for setting the RCL to the current set-up status (SETUP procedure) will vary by
machine model. The following is an example machine.

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Selection
Selection is with the rotary control:
Optionally press “up arrow” or “down arrow” function keys to select options.
Start SETUP
Operating Mode Setup can be called from the main RCL operating menu by pressing the
function key.
Select Reeving
Selection:
Press the button to enter the Select Reeving
Menu.
When the Reeving Button turns green you can
adjust the Reeving value.
Use rotary knob or up and down arrows to select
reeving amount.
Select Hoist
Selection:
Press the button to enter the Select Hoist Menu.
When the Hoist Button turns green you can
adjust the Hoist option.
Use rotary knob or up and down arrows to select Hoist.

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Select Operating
Mode
Selection:
Press the button to enter the Operatig Mode
Menu.
When the Operating Mode Button turns green
you can adjust the Operating Mode number.
Use rotary knob or up and down arrows to select the
operating mode that corresponds to the current
machine setup. Ensuring that the Jib and Outriggers
match the description shown on the right.
Confirm Selections
After selecting the appropriate modes
press or to set the selected operating mode.
Check that the outriggers are in the cor-rect position for the
selected mode and that the machine is stable
and press or .
The selected mode, reeving and hoist will be displayed.
Press or again to confirm the settings are
accurate and return to the Main Working Screen using the
newly selected operating mode.

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4 Operation
After the operating mode is set, the RCL is ready to use.
The machine operator must be familiar with all operating elements of the RCL before operating the
machine.
All settings must be checked by hoisting a known load and comparing the information with that displayed by the
RCL.
WARNING
Imminent threat of personal injury and damage to property due to incorrect system settings!
The correct adjustment of the RCL to the current set-up status is essential for the correct func-
tion of the system.
The correctness of these settings must be guaranteed before operating the machine!

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4.1 Main Working Screen
The RCL Main Working Screen is the central operating image during machine operation and the start-
ing point for the selection of various functions. You can return to this screen from any other screen by
pressing the “Home” button.
Other indicators such as Jib Length and Jib Angle may be displayed on the Main Operating Screen and
can be set up in the Settings Menu.
Settings
(see Section 5.1)
Set or Disable Tare
(see Section 4.3)
Camera
(see Section 4.6)
Set Operating Mode
(see Section 3.2)
Work Area Limitations
(see Section 4.2)
Temporarily Mute Alarm (And after
muting, display warnings. See
Section 4.4)
Function keys with no assigned symbol are not active:
Function
Keys
Load Capacity
Utilization (Bar Chart)
Angle of Boom
Error Code,
Displayed as required
(See Section 4.5)
Rope Reeving
Current Load
Radius of Boom
Calculated Height of boom tip
Maximum Lifting
Capacity
Operating Mode
The Information Bar shows current
wind speed on the main screen
and maximum/current load on any
other screen.
Load Capacity
Utilization %
Length of Boom
Warning Lights
(See Section 4.1.1)

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4.1.1 Warning Lights / Audible Alarm
Various warning symbols are shown in the information bar as required and are visible from any screen:
Depending on the cause of the warning the following also occurs:
audible alarm is activated
error code is displayed (see error table in appendix)
status is recorded in the data logger
The audible alarm can be suppressed for a short period by pressing the function key. See Section
4.4 for more detail.
Early overload warning
This yellow symbol flashes to indicate that the machine load is or has already exceeded 90% of the safe
working load. An overload status may be imminent!
Overload/Error
This red symbol is lit to indicate that an error has occurred such as the maximum machine load has been
reached or exceeded.
The audible alarm sounds an uninterrupted tone.
RCL bypass
These red symbols flash on and off during the manual override of the power-off function of the safe load
indicator. This status is recorded in the data logger. An audible alarm will be triggered and may be muted by
the function key. (See Section 4.4 for more detail.)
Stroke End (A2B)
This red symbol lights up to indicate that a two-block event has occurred.
A stroke end status is recorded if the load block comes into contact with the boom head. There is a danger in
this case that the lifting rope will break and the load will drop. A stroke end state can be caused by the load
being pulled against the boom head or the boom being extended or raised without playing out the lifting rope.
The audible alarm sounds an uninterrupted tone.
Example
Acknowledging
Alarm
Error Code
Warning Symbols

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4.2 Work Area Limitations
The RCL system has programmable functions for monitoring geometrical limits of the working area:
Height Monitoring > See Section 4.2.1
Radius Monitoring > See Section 4.2.2
Boom Angle Monitoring > See Section 4.2.3
Wind Speed Monitoring > See Section 4.2.4
Programming is carried out via an interactive menu.
The functions can be set individually or in combination. Active limit values are indicated by the display of color-
highlighted symbols.
Exceeding a programmed limit value causes a corresponding color change in the limit symbol on the main
menu to be displayed and an audible alarm warning to be sounded.
Blue
No Limits Set
Green
Within Valid Limits
Yellow
Warning Condition / Approaching Limit
Red
Outside Limit
Color Meanings

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CAUTION
Machine movements are not switched off when limit values are exceeded.
Angle Limit
(see Section 4.2.3)
Wind Speed Limit
(see Section 4.2.4)
Radius Limit
(see Section 4.2.2)
Deactivate all Limits
Height Monitoring
(see Section 4.2.1)
The colors of the function buttons and symbols will change depending on the state of the limit.
Function
Keys
Radius Limit
Angle Limit
Color Meanings:
Limit inactive or not
programmed
Limit active
Limit Nearing
Maximum Value
Limit value reached
or exceeded
Height Limit
Wind Speed
Limit