Installation and User Manual
Contents
1. The name of the bound HoistNet device will be shown on the Load screen The connection status will also be shown NB You will need to ensure that the originating HoistNet load signal has been calibrated correctly Whiting Passport 2013 General Load Overload Input rv md C G Link Frequency HoistWet oo Control Pro HoistNet ls Tex Selecta Device to bind to General Load Overload Input mm G Link TrafhicLite T rafficlite Frequency Hoisthet Control Pro 16 Page Y A UA Whiting A Passport l p To unbind a MaxOut from a HoistNet device or to change the bound device press the lt Bind gt button on the Load screen and then select lt Unbind gt on the popup box 4 5 3 Using the MaxOut with a ControlPro If your MaxOut device is connected to a Konecranes ControlPro and you want to use the calibration settings stored on the ControlPro rather than calibrating with test weights press the lt Control Pro gt button A dialog box will appear asking you to confirm this action Press lt OK gt to confirm Another dialog box will appear Hoist capacity Rated capacity of this hoist in tons eg 6 5 Enter the capacity of the hoist in tonnes and press lt OK gt Your device is now calibrated and you will not need to zero or calibrate this hoist in order to use this Liftlog NB You need to have selected the lt mV mA V gt2. WA Whiting A Passport 2 240VAC 32 240V ACO 1 OVAC Figure 6 Connection to an ABUS LIS using a Q Link Q Output NB Output pins 13 14 are Normally Closed and rated for 250V AC 4A They can be reconfigured to Normally Open using the FSU software 3 2 6 Installation with a F Link Output ABUS LIS 2 240VAC 32 240V ACO 1 OVAC Figure 7 Connecting to an ABUS LIS using the Q Link Frequency F1 F2 Output NB Output pins 13 14 are Normally Closed and rated for 250V AC 4A They can be reconfigured to Normally Open using the FSU software O Whiting Passport 2013 11 Page y VA Whiting A Passport rasspUit 4 COMMISSIONING DETAILS MaxOut is designed to be commissioned using a laptop computer You will need a CASWA LINK 2 Bluetooth Modem and the Field Service Utility FSU software application loaded on a laptop 4 1 Installing and Launching the FSU Application 4 1 1 FSU Program Installation Ensure that your computer is switched on connected to the internet and that the minimum required software versions are installed see Appendix B for minimum system requirements Ensure that the LINK 2 modem is installed and that the drivers have loaded 4 1 2 Installing the FSU application The latest LINK 2 FSU software Link 2_ FSU can be downloaded from http www soledigital com au Link2 html You should check this location periodically for updat
3. MAXOUT LOAD LIMITER Model MX10x Version 1 V1 1 3 10 2013 Whiting Passport 2013 y Whiting A Kr Pe 7 Passport 4 gt CONTENTS AAA In o eee an uen anna etes en 4 2 SPECIFICATIONS ne de ann en ane sc ete otre 5 Dede PAVSICA IS Dee NOA rd 5 2 2 Electrical Species een ane eee unes et 6 2 3 Communication SDECITICATIONS sisas aerea roca 6 3 INSTALLATION D PASSE eds NAAR ess see sed cas abia 57 co nn P o O 7 BZ e US E LO E de do ai 7 3 2 1 Installation with an existing load display 7 3 2 2 Installation with a Dedicated Load Cell 8 3 2 3 Installation with a 4 20mA Load Output 9 3 2 4 Installation with a 0 10V Load Output 10 3 2 5 Installation with a Q Link Output ABUS LIS RL 11 3 2 6 Installation with a F Link Output ABUS LIS ee eeeeccceeeseseeceeeeeeeeeseeeeeees 11 4 COMMISSIONING DETAILS 28 40 s semeess cdihe caresses see 12 4 1 Installing and Launching the FSU Application ss 12 Mil FSU Program installatiON iio 12 4 1 2 Installing the FSU application ss 12 41 3 Launching the application scocitan ninia iii 12 12 COnnectne to the DEVICE ria 13 ds Checking 10r FMW C C osa A A 13 44 MaxOut Configuration SCPE CN isaac 14 aA L Sene TOS Cl Ve WD a E 14 15 Calbratine tie IM KO E N 15 4 5 1 Setting the Input TYPE ooccccccnccnnonaccnnnnccnncnononnnonocnnnnncnnonncnnnonnrnnnnonncnnnnnonnnononnnonanons 15 4 5 2 Using Removing a HoistNet Inpu
4. input type Whiting Passport 2013 17 Page p s 4 y y Whiting A Passport 4 5 4 Checking the Gain A bar underneath the load display indicates the signal General Load Overload strength Input It is important that the highlighted section of the bar Comma C Qlik Frequency HoistNet moves to the right as load is increased and moves to a the left as load is decreased If the bar does not change at all check your wiring from the load cell Also check that you have selected mV mA V input type A small change in the bar across a wide range of loads e g zero to full load indicates that the load signal requires more gain Conversely if the bar moves past the end of the scale then you have too much gain The signal from the General Load Overload load cell is being clipped and load readings will be incorrect The red box around the bar alerts you to eee _ f mima C Blink Frequency Ho istMet this clipping If this occurs you need to reduce the gain in the MaxOut See section 4 8 for instructions on changing the gain NB You will need to recalibrate the MaxOut after changing the gain O Whiting Passport 2013 18 Page Passport 4 5 5 Setting the Zero Value With no load on the hook or the crane load display reading 0 00t click on the lt Zero gt button Within a few seconds the display will change to 0 0t 4 5 6 Calibrating the MaxOut Lift a
5. 2013 R W Read Read Read Write Read Read Write Read Write Read Write Read Write Read Write Write Description Query the firmware version number Display a summary of all settings Query the input mode O Analog 1 0 Link 2 Frequency Set the input mode Query the raw loadpin reading The lifted load may be computed from this value as Raw Zero Cal See the C command Query the device ID Set the device ID Device ID s are limited to 18 characters Query the zero parameter The zero value is used to calculate the actual load See the C MI r and commands Set the zero parameter Query the cal parameter The cal parameter is used to calculate the actual load See the C and r commands Set the cal parameter In normal operation the cal parameter would be set as follows Send the r command to get the raw reading from the load pin in it s unloaded state Send the Z command to set the zero parameter Apply a known load to the pin Send the r command to get the raw reading from the load pin Sent the C command to set the calibration value to Rawunloaded zero Known_Load in 100Kg units Query the overload setpoint parameter This parameter is stored in 100Kg units eg 3 5mt is expressed as 35 It is used by the device to determine when an overload occurs Set the overload parameter ES so so EP EP en gt o a gt Q
6. 9 of the FSU application To initiate Checklt Diagnostics go to the General Tab and click on the check box in the lower left corner of the tab A new window will appear and Checklt Diagnostics will be initiated During this process you may be asked to enter parameters e g rated capacity of the hoist to verify that critical settings have been entered and have saved correctly Any potential issues or irregularities will be described in the Checklt Diagnostics window Press lt Close gt to return to the main FSU screen O Whiting Passport 2013 23 Page Whiting 4 Fr ass D or A 9 ROUTINE MAINTENANCE There is no routine maintenance for this device Whiting Passport 2013 24 Page Whiting Passport 6 TROUBLESHOOTING Fault Cause Fix Load display indicates a Logger is affecting load Check power to the logger fault pin voltages Disconnect pins 10 and 11 to verify that the logger is causing the fault Check logger LED is operational solid red or green Check that the voltage from pins 11 and 12 is between 4 and 6 volts If these voltages are out check the connection between logger GND and load pin GND Unable to connect to Logger or FSU are busy Power cycle the crane logger from FSU Incorrect wiring Check that wiring is as per section 3 2 Check that removable terminals have been reinserted into their correct positions as shown in Figure 2 Pluggable termina
7. 7 Control Pro 4 5 1 Setting the Input Type Make sure that the Input is set to the type of MaxOut input By default the mV mA V input will be selected This is applicable for MaxOut devices that have a strain gauge 4 20mA and 0 10V DC input If you have a Q Link or Frequency MaxOut i e connected to an ABUS LIS unit then you will need to change this selection If you intend to use the MaxOut with a Konecranes ControlPRO make sure that you have selected the lt mV mA V gt input O Whiting Passport 2013 15 Page i P N t A pS Y 4 d Y A A Whiting Dire e Passport 4 4 5 2 Using Removing a HoistNet Input MaxOut devices are now compatible with CASWA HoistNet This means that they can obtain their load signal wirelessly from any other HoistNet enabled device eliminating the need for long cable runs between the load cell and data logger To receive a load signal via HoistNet select the HoistNet input and then press the lt Bind gt button NB HoistNet was first enabled in FSU version 10 7 If you do not see the HoistNet option then you are running an old FSU version Download and reinstall the lastest version of CASWA FSU You may also need to update the firmware on your MaxOut box will appear asking you which HoistNet enabled device you want to connect to Select the device that has the load signal to be used and press lt OK gt The popup box will close
8. SU software It is very important not to connect pin 15 16 to the chassis earth 3 2 2 1 Connecting the negative reference The MaxOut input circuit is connected to the chassis ground When installing against an existing load Indicating system ensure that its inputs are floating It is important that the voltage on pins 10 and 11 do not exceed 3 3V with respect to pin 12 O Whiting Passport 2013 y Wea Whiting Passport FaSspOrl Dr gt a 3 2 3 Installation with a 4 20mA Load Output To existing control circuit MAXOUT Load limit 250VAC 4A O O 10 mA IN 4 20mA Signal O O 12 GND UP CONTACTOR O 2 240VAC 32 240V ACO 1 OVAC OV Figure 4 Connecting a 4 20mA load signal NB Output pins 13 14 are Normally Closed and rated for 250V AC 4A They can be reconfigured to Normally Open using the FSU software O Whiting Passport 2013 y Wea Whiting Passport Er gt a 3 2 4 Installation with a 0 10V Load Output To existing control circuit MAXOUT Yes Load limit 250VAC 4A o O 10 VIN 0 10V Signal o O 12 GND UP CONTACTOR O 2 240VAC 32 240V AC CY O 1 OVAC OV Figure 5 Connecting to a 0 10V Load Signal NB Output pins 13 14 are Normally Closed and rated for 250V AC 4A They can be reconfigured to Normally Open using the FSU software Whiting Passport 2013 10 Page y
9. ation b the case is not damaged and fits together securely c terminals are secure d terminal numbering is as per the following diagram L Red 0 L Flash Liftimg O 8 4 9 G OO O O 121110 9 OO O 16 15 14 13 vee Figure 2 Terminal Positions NB As each block of 4 terminals can be removed for installation it is important that they be reinstalled in the positions shown 3 2 Wiring Diagrams 3 2 1 Installation with an existing load display The recommended method for connecting a MaxOut to an existing load display is to use a 4 20mA output from the display to a 4 20mA configured MaxOut or to insert a 4 20mA MaxOut into an existing current loop Where this is not an option it may be possible to piggyback the MaxOut onto the strain gauge inputs of the load display Whiting Passport 2013 Y i N Wea Whiting A Passport 3 2 2 Installation with a Dedicated Load Cell To existing control circuit MAXOUT Load limit 14 250VAC 4A Red 9 XCite 10 Sense Green i 11 Sense White 12 XCite UP l CONTACTOR Biak ale O 2 240VAC 32 240V ACC OV Figure 3 Connecting a dedicated load cell NB Output pins 13 14 are Normally Closed and rated for 250V AC 4A They can be reconfigured to Normally Open using the F
10. ecoverable state Alternatively press lt Not now gt to update firmware at a later time NB If you did not see this window then your device already has the most current firmware 4 4 Max0ut Configuration Screen Once the firmware version has been verified the following screen will appear This screen shows the Crane ID see section 4 4 1 for configuring this is Current firmware version operating on the device It also contains a button checkbox in lower left corner to initiate Checklt diagnostics This is described in Section 4 9 4 4 1 Setting the Crane ID To set the crane ID click on the lt General gt button to return to the first screen Type in the desired Crane identification in the ID field This must be 18 characters or less O Whiting Passport 2013 14 Page Whiting A Passport gt 4 5 Calibrating the MaxOut If your MaxOut device has been preconfigured only available with Q Link inputs or you are using a HoistNet load signal which is calibrated then you will not need to calibrate the MaxOut All other types of MaxOut must be calibrated Unless you are connecting the device to a Konecranes ControlPro and elect to use the already calibrated ControlPro settings this process will require test weights Click on the Load tab to bring up the load settings screen General Load Overload Input fom G Link Frequency HoistMet Zero ul q A2 a
11. es 4 1 3 Launching the application Double click on the FSU program icon a Whiting Passport 2013 12 Page A Whiting A Passport gt 4 2 Connecting to the Device The FSU will scan for Bluetooth enabled devices This process takes approximately 10 seconds when complete a list of all Sole Digital devices within range will be displayed caswa Fsu 109 H f E unconfigured ritest2 unconfigured roladoor Look again If a particular MaxOut unit is not found ensure it is powered up and press lt Look again gt to repeat the search NB The Bluetooth link between the Laptop using a Link 2 and a MaxOut has a range of approximately 200m Select the MaxOut you wish to configure and press lt Connect gt 4 3 Checking for Firmware An update for this devices After you have selected your desired MaxOut a connection will Sofa DRE Vol be made and the software will check if the device has the current you like to upgrade this firmware If anew firmware version is available the following ee Current firmware version 10 9 window will pop up New firmware version 110 O Whiting Passport 2013 13 Page A Whiting A Passport Press lt Update gt to update the MaxOut to the latest available firmware version recommended The new firmware will be installed on the device DO NOT switch off the computer or remove the LINK2 modem until this is complete doing so may leave the MaxOut in an unr
12. his can be in 0 1t increments E g 9 4 4 7 2 Overload Sensitivity The overload sensitivity is controlled by a slider that changes how sensitive the overload is to short overloads caused by signal noise Moving the slider to the right will make it less sensitive so that it will effectively take longer to respond to a real overload event Moving it to the left will make the logger respond quicker to real overloads but also make it more susceptible spurious trips You should set this slider as far to the left as possible without the overload tripping during normal operation A text warning will display if this is set too high O Whiting Passport 2013 20 Page Whiting A Passport 4 7 3 Invert Output The fault output on the MaxOut is a pair of normally closed contacts Checking the lt Output N O gt box will change the normally closed fault output to normally open You may need to do this If there is an interposing relay between the MaxOut and the up contactor 0 You want the MaxOut to operate in a fail functional rather than a fail safe mode You are using the MaxOut for slack rope detection 4 8 Changing the Gain When using a strain gauge load cell MaxOut can be configured to one of 3 gain settings by moving an internal jumper To change the gain remove the internal board from the case To do this gently press the tabs on each side of the MaxOut and separate the end with the terminals fro
13. load minimum 80 of rated capacity and click the lt Cal gt button Enter the mass shown on the load display when prompted and press lt OK gt NB If the fault output of the logger is used as an overload you may need to go to the Overload screen and set a large overload limit e g 3000 to allow the load to be lifted See section O for details Tap the lt OK gt button and the main screen will now display the load on the hook NB An overload will probably be shown box becomes red as the maximum load has not yet been k 5 0t Whiting Passport 2013 19 Page Whiting A Passport gt 4 6 Erasing the Calibration Under some circumstances it may be necessary to erase the calibration of a hoist Warning IF YOU ERASE THE CALIBRATION THEN YOU WILL NEED A TEST WEIGHT TO SET IT AGAIN unless you are connected to an LIS via Q Link or ControlPro To reset the calibration for a hoist tap the lt gt button NB Resetting the calibration of one hoist main or aux does not affect the calibration of the other 4 7 Configuring the Overload This option is not available for loggers using an ABUS Frequency or Q Link input settings will be ignored To set the overloads and or to invert the output signal press the Overload tab to bring up the following screen General Load Overload Limit No Output N 0 Sensitivity 4 7 1 Set Overload Enter the desired overload T
14. ls Replace pluggable terminal and rewire the associated not seating correctly terminals Limit cuts out Magnetic interference Check that MaxOut is at least 15mm from any large prematurely on hoisting causing MaxOut to contactor and adjusting sensitivity reset has no effect Adding MaxOut to a 4 MaxOut is pulling the Ensure the MaxOut is the lowest potential device in the 20mA current loop causes loop to GND loop or contact CASWA to order a 4 20mA isolator a fault Whiting Passport 2013 25 Page AY AWhiting A Passport gt APPENDIX A COMMUNICATION PROTOCOL The host sends single character commands to the device to write or query parameters Each command must be followed by a carriage return lt CR gt ASCII 13 Where the command is a query command no arguments are sent and the device will respond with a single line except for the u and E commands the requested value in ASCI text followed by a lt CR gt Where the command is a set command an argument may be included between the command and the lt CR gt Where numbers are sent or received they are sent as clear text eg 1234 Where a number represents a load eg the o and 0 it is expressed in 100Kg units Eg 3 5mt would be sent and received as 35 O Whiting Passport 2013 26 Page Whiting A Tt N 7 S PASST Va Passport Communication commands Command v on On Whiting Passport
15. m the main body The board will be attached to the terminals If you have already wired in the MaxOut remove the four terminal blocks first Place the jumper into one of the following 3 positions A Position 1 No jumper or jumper off to one side In this position gain is set to the lowest setting Lowest gain Remove suitable for a 3mV V load cell at full span jumper or move to one side O Whiting Passport 2013 21 Page B Position 2 Jumper bridges lower two terminals 7 a Medium gain Bridge In this position gain is set to the medium setting lower two pins with suitable for a 2mV V load cell at full span l jumper C Position 3 Jumper bridges upper two terminals ON a In this position gain is set to the maximum setting suitable for a 1mV V load cell at full span Max gain Bridge upper two pins with jumper Reinsert the board into the case If you removed the terminals replace these too See section 3 1 for their correct positions You will need to recalibrate the MaxOut device after changing the gain O Whiting Passport 2013 22 Page Y N Wea Whiting A Y Passport 4 9 Running Checkit Diagnostics To confirm whether critical settings and parameters have been set sensibly after completing the setup and commissioning of the MaxOut device it is strongly recommended that you run Checklt diagnostics first introduced in version 11
16. on only the source MaxOut device wired to the load cell needs to be calibrated O Whiting Passport 2013 2 SPECIFICATIONS 21 Physical Specifications Overall length mm 115 Overall width mm 100 Overall height mm 23 Weight kg 0 12 Mounting 30mm DIN Rail Figure 1 Case Dimensions O Whiting Passport 2013 y Passport N 2 2 Electrical Specifications Parameter Description Min Typ Max Units Vin Supply voltage 32 250 VAC lin Supply current 7 8 12 mA E Maximum voltage on a load sensing pin with 7 V respect to device gnd Lis Load pin differential input for full scale reading 20 23 25 mV Veault Max voltage for fault output 250 V AC laut Max current sink by fault output 4 A Pfault Max contactor inrush rating at 48V 200 W Allowable operating temperature 40 gore C Notel Extended operation at maximum temperature will reduce the life the device 2 3 Communication Specifications Communications between the device and a host is usually via a Bluetooth radio link The Bluetooth device name will be set to the Crane ID the PIN is 0000 For more details on the communication protocol used to communicate with the MaxOut see Appendix A Whiting Passport 2013 3 INSTALLATION DETAILS 3 1 Prior to Installation Before installing your MaxOut device visually inspect the device and check that a the type of input marked on the front of the device is appropriate for your applic
17. t oononnnccncnnnnnnnnnnnanananccnnnnnnnnonononananononinanananonos 16 4 5 3 Using the MaxOut with a ControlPro ss 17 Mod RECRE AE G a ee O 18 SS a A 19 O Whiting Passport 2013 y VA Whiting A Passport rasspUit 456 Calibrating th MORE eee neon ene ee ener eee reece 19 do ETS Be tae CDr CONN nino 20 47 Conneurnne the OVER ios 20 AJE OE e de e E EEE A 20 47 2 Overload Sensitivity scott lo ue 20 Bla ANVer OU rides 21 4 8 Changing the GAlisssnsiart errata 21 4 9 Running Checklt Diagnostics oocccccooccncnnncnnnnaconnonanonnnnacnnnononnnonarnnonnronnnnnncnnnnornnenanoncnnanononas 23 5 ROUTINE MAINTENANCE di css des cases ane annees ninio 24 6 TROUBLESHOOTING sea none de an sn te ae ess cenas 25 APPENDIX A COMMUNICATION PROTOCOL ssccssccssccsssccsscnsscnssccssscnssesccsssessscsssosssoessonees 26 APPENDIX B FSU SYSTEM REQUIREMENTS ssssosssssossossesessecsscsecsecossossossosecsecssecssossossoseosseeeeoe 28 O Whiting Passport 2013 Whiting A Passport 1 OVERVIEW MaxOut is an inexpensive electronic load limiter for a single hoist that also wirelessly transmits the load signal using Sole Digital s HoistNet technology In addition to performing its load limiting function MaxOut is a HoistNet compatible device that can act as a wireless source of load data for displays data loggers and load summation units When used in this configurati
18. uery the inverted status of a setpoint output A return value of 1 means the output is normally open Set the inverted status of a setpoint output Reboot the device This command is usually only used to load new firmware onto the device Example Send v lt CR gt Rev 1 02b lt CR gt Send h lt CR gt Rcv 2 lt CR gt Send HO lt CR gt Send r lt CR gt Rcv 354 lt CR gt Send i lt CR gt Rev crane34 lt CR gt Send Icrane45 lt CR gt Send z lt CR gt Rev 34 lt CR gt Send Z23 lt CR gt Send c lt CR gt Rev 11 lt CR gt Send C9 lt CR gt Send 01 lt CR gt Rev 35 lt CR gt Send 0140 lt CR gt Send w2 lt CR gt Rev 1 lt CR gt Send W20 lt CR gt Send lt CR gt Y il A f j a Whiting A Passport T APPENDIX B FSU SYSTEM REQUIREMENTS The minimum requirements for operating CASWA s Field Service Utility FSU and Link 2 Bluetooth modem are Laptop computer running Windows XP SP3 or later One Spare USB port Microsoft NET framework 3 5 Whiting Passport 2013 28 Page
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